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SAP ECC 6.

00
January 2008
English

PP07-Material Quantity
Calculation in Blending Stage
Business Process Procedure

OBT Global Inc.


(A Subsidiary Zensar
Technologies Inc)
103,College Road East
2nd Floor, Princeton, NJ
08820, U.S.A

OBT Pharma

PP07 - Material Quantity Calculation in Blending Stage - BPP

Process Flow Legend

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OBT Pharma

PP07 - Material Quantity Calculation in Blending Stage - BPP

Contents
1 Purpose.................................................................................................................................................... 4
2 Prerequisites............................................................................................................................................. 5
2.1 Master Data........................................................................................................................................ 5
2.1.1 Create Class Characteristics.......................................................................................................... 5
2.1.2 Create Class................................................................................................................................... 5
2.1.3 Create Active Material (API)........................................................................................................... 6
2.1.4 Create Master Inspection Characteristics.......................................................................................7
2.1.5 Create Inspection Plan................................................................................................................... 8
2.1.6 Create Blended Material (ZBLK).................................................................................................... 8
2.1.7 Create Filler Material (ROH)......................................................................................................... 9
2.1.8 Create a Bill of Material.................................................................................................................. 9
2.1.9 Create a Master recipe................................................................................................................. 10
2.1.10 Create Batch search strategy..................................................................................................... 11
3 Process Steps......................................................................................................................................... 13
3.1 Process Flow Diagram..................................................................................................................... 13
3.2 Process Overview Table.................................................................................................................. 14
4 Scenario................................................................................................................................................. 15
4.1 Create a Purchase order ................................................................................................................ 15
4.2 Goods Receipt from Purchase order..............................................................................................15
4.3 Check for the Inspection Lot............................................................................................................ 16
4.4 Result Recording ............................................................................................................................ 16
4.5 Usage Decision............................................................................................................................... 17
4.6 Create a Process order .................................................................................................................. 17
4.7 Change Process order................................................................................................................... 18
4.8 Goods issue to the order................................................................................................................. 18
4.9 Completion Confirmation................................................................................................................. 19
4.10 Goods receipt from the Order........................................................................................................ 19
4.11 Technical completion..................................................................................................................... 20

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OBT Pharma

PP07 - Material Quantity Calculation in Blending Stage - BPP

Material Quantity Calculation


1 Purpose
If we use materials that are subject to batch management, you may need to take quantities and properties
of specific batches into account when you perform material quantity calculations in the process order.
Depending on the active ingredient concentration of a component batch, you may need, for example,
different quantities of another component that is used as a filling material.
Since no batches are assigned in the master recipe, you must use the values planned in the material item
when you perform calculations there. In the process order, however, you must perform the same
calculation again after you have carried out batch determination due to the values of one, or in case of a
batch split, several batches selected.
We use this function for a process order to visually reproduce the dependencies between the following
values:

Quantity and properties of a product, such as the active ingredient proportion

Quantity and properties of material components, that is, material items and their batches

You need this function to adjust the quantities defined in the bill of material (BOM), master recipe, or
process order in the following cases:

To calculate the component quantities if they are not proportional to the product quantity or if
different active ingredient concentrations of batches must be taken into account

To calculate the product quantity, that is, the base quantity of the master recipe or the order
quantity if it must be adjusted to modified component quantities. This may be the case if, for
example, a batch of a component is always used up completely.

For this purpose we have to use both Batch specific unit of measure and Material quantity calculation
through Master Recipe.
Using Batch specific unit of measure we can calculate the Active ingredient quantity in the Active material
depending upon the Active ingredient percentage in that particular Batch. And using Material quantity
calculation formulae defined in the Master Recipe, we can calculate the Filler material quantity in the
Process order after determining the Batches of Active ingredient material.
System will subtract the quantity of the Active ingredient material from the total Ordered quantity and
proposes the quantity of the Filler material which is the Excepient.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

2 Prerequisites
2.1 Master Data
2.1.1 Create Class Characteristics
Use
In this activity we create Class characteristics.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Cross Application components > Classification system >


Master data > Characteristics

Transaction code

CT04

Create three Class characteristics for Assay, LOD and Active Ingredient Percentage.
While creating Characteristics make sure that the following details are entered.

Single value

Intervals not allowed

Negative values not allowed.

Restrictions 023 (Batch class)

Create the following Characteristics.

Class Characteristic

Description

ZASSAY

ASSAY

ZLOD

LOSS ON DRYING

ZACT_ING

ACTIVE INGREDIENT PERCENTAGE

Result
Three Class characteristics are created.

2.1.2 Create Class


Use
In this activity we create a Class.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Cross Application components > Classification system >

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Master data > Classes


CL02

Transaction code

Create a Class ZAPI_CLASS with Class type 023 and assign the following Class Characteristics.

Class Characteristic

Description

ZASSAY

ASSAY

ZLOD

LOSS ON DRYING

ZACT_ING

ACTIVE INGREDIENT PERCENTAGE

LOBM_VFDAT

SHELF LIFE

LOBM_HSDAT

DATE OF PRODUCTION

While creating the Class, in the Basic data screen, in the field for Organisational area, using F4 enter the
value S Substance / Steel.
While assigning the Class characteristics, in the field for Organisational area against the Class
characteristics ACT_INGR, using F4 enter the value S Substance / Steel.
Save the Class.

Result
The Class is created and the Characteristics are assigned.

2.1.3 Create Active Material (API)


Use
In this activity we create Active pharmaceutical ingredient.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics Materials Management Material Master


Material Create (General) Immediately

Transaction code

MM01

On the initial screen, enter the following values and choose Enter:
Field

Description

Values

Material

FCIP00-00

Industry sector

P Pharmaceuticals

Material type

ZAPI

Comment

In the Classification view assign the above created Class (ZAPI_CLASS).

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Click on Additional data tab and go to Proportion unit screen.


Enter the following details.
Field

Values

Unit of measure usage

A Proportion unit

Characteristic

ZACT_ING

Plan value

100 %

Batch specific unit of measure

KAI (Kilogram Active Ingredient)

Leading unit of measure

Select

Valuation relevant unit of measure

Select

In the Quality management view activate 01 Inspection type.


Save the Material.

Result
Active material is created.

2.1.4 Create Master Inspection Characteristics


Use
In this activity we create Master Inspection Characteristics.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics Quality Management Quality Planning


Basic data Inspection characteristics Create

Transaction code

QS21

Create three Master Inspection characteristics for Assay, LOD and Active ingredient percentage with
reference to the Class characteristics created earlier.

Master Inspection Characteristic

Reference Class characteristics

ASSAY

ZASSAY

LOD

ZLOD

ACT_INGR

ZACT_INGR

While creating the third Master Inspection Characteristic ZACT_INGR, in control indicators, in the
Formula area, select the radio button Calc.Charac.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Result
Master Inspection characteristics are created with reference to the Class characteristics.

2.1.5 Create Inspection Plan


Use
In this activity we create an Inspection plan for the Active material.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics Quality management Quality planning


Inspection planning Inspection plan Create

Transaction code

QP01

Create Inspection plan for the Active material and assign the three MICs which are created above.
For the third Master Inspection characteristic ACT_INGR, in the quantitative data enter the following
formula.

C00010 - (100 / (100 - C00020))

This formula represents the following actual formula.

ASSAY (100 / (100 LOD))

Save the Inspection plan.

Result
Inspection plan for the Active material is created.

2.1.6 Create Blended Material (ZBLK)


Use
A new semi finished material is needed.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics Materials Management Material Master


Material Create (General) Immediately

Transaction code

MM01

On the initial screen, enter the following values and choose Enter:
Field
Material

Description

Values

Comment

BCIP00101

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Industry sector

P Pharmaceuticals

Material type

ZBLK

In classification view assign a Class which contains Production date and Shelf life as Class
characteristics.

2.1.7 Create Filler Material (ROH)


Use
Filler material (Excepient) is created.

Procedure
1. Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics Materials Management Material Master


Material Create (General) Immediately

Transaction code

MM01

On the initial screen, enter the following values and choose Enter:
Field

Description

Values

Material

RASP0002

Industry sector

P Pharmaceuticals

Material type

ZRAW

Comment

In the Classification view assign a Class with class type 023 which contains Class characteristics for
SHELF LIFE & PRODUCTION DATE.

Result
Filler material (Excepient) is created.

2.1.8 Create a Bill of Material


Use
In this activity we create new Bill of Material for the Blended material.

Procedure
Access the transaction using:
Menu

Logistics > Production >Master data > Bill of Material> Bill of


material > Material BOM > Create

Transaction code

CS01

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PP07 - Material Quantity Calculation in Blending Stage - BPP

In the initial screen enter the following details.


Field name

Description

User action and values

Material

BCIP00101

Plant

1100

BOM usage

Alternative BOM

Comment

In the General Item overview screen enter the components which are required to produce the finished /
semi finished material along with quantities.
Item category

Component

Quantity

Unit of measure

FCIP00-00

50

KAI

RASP0002

100

KG

For the Active material enter Unit of measure as KAI.


Select the Active material, go to Extras in the main menu and click on Batch classification.
In the Batch classification screen, against the Characteristic ACT_INGR, enter the value 100%.
Go to header details and give Base quantity as 100 kg.
Click on Save button.

Result
Material BOM is created.

2.1.9 Create a Master recipe


Use
In this activity we create new Master Recipe and Production version.

Procedure
Access the transaction using:
Menu

Logistics > Production Process >Master data > Master Recipe >
Recipe and Material list > Create

Transaction code

C201

Create the Master Recipe and Production version.


Save the Master Recipe.
Go to Change Master Recipe.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Go to Materials screen and click on Material Quantity Calculation button.


In the MQC screen, select the cell for Active ingredient quantity and click on Select Formula button.
In the formula definition field, enter the following formula.

CQSM(004;002)

This formula will calculate the Active ingredient percentage in the specified Batch.
Select the cell for the Filler material quantity and click on Select Formula button.
In the formula definition field, enter the following formula.

[001,001] - [004,001]

This formula will subtract the Active material quantity from the Ordered quantity and proposes the Filler
material quantity.
Click on Execute button.
Save the Master Recipe.

Result
Master Recipe and Production version are created and formulae are defined.

2.1.10 Create Batch search strategy


Use
In this activity Search strategy for the Active material is created.
Access the transaction using
Menu

Logistics > Central functions > Batch management > Batch


Determination > Batch search strategy > For Process order > Create

Transaction code

COB1

In the initial screen enter the Strategy type as CO01. Select Enter.
Choose Order type / Plant / Component. Press Enter.
Enter the Order type (ZP10) and Active material (ACT001) and press Enter.
Select the line and click on Details.
Enter the following details.
FIELD

VALUE

Number of Batch splits

999

Changes allowed

Select

Over delivery allowed

Select

Quantity proposal

Display Unit of measure

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Select the Material line and click on Selection criteria.


Enter the same class (ZAPI_CLASS) which has been assigned to the Active material.
Click on SORT button.
Enter the Sort rule FEFO_RULE.
Click on Save button.

Result
Batch Search strategy is created.
Similarly create Batch Search strategy for the Filler material and assign FEFO rule.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

3 Process Steps
3.1 Process Flow Diagram

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3.2 Process Overview Table


Step

Step Name

Role

Transaction
Code

Expected Results

4.1

Create a Purchase order

Inventory

ME21N

Purchase order is created

4.2

Goods Receipt from Purchase


order

Inventory

MIGO

Goods are received from


Purchase order

4.3

Check for the Inspection lot

Quality control

QA32

Inspection lot is created

4.4

Result recording

Quality control

QE51N

Result recording

4.5

Usage Decision

Quality control

QA11

Usage decision

4.6

Create a Process order

Manufacturing

COR1

Process Order is created


for the Material.

4.7

Change Process order

Manufacturing

COR2

Active and filler materials


quantities are calculated.

4.8

Do Goods issue to the order

Inventory Clerk

MB1A

Goods are issued for the


Process order

4.9

Confirm the Order

Manufacturing

CORK

Confirmation of the
Process order is done.

4.10

Goods receipt from the Order

Inventory Clerk

MB31

Goods receipt from


production is done.

4.11

Technical completion of Order

Manufacturing

COR2

Process order is
technically completed

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PP07 - Material Quantity Calculation in Blending Stage - BPP

4 Scenario
4.1 Create a Purchase order
Use
To create a Purchase order for the Active Material.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Materials Management > Purchase Order >


Create

Transaction code

ME21N

Enter the material, quantity and plant.


Enter Purchase organization, Purchase group and vendor.
Press Enter.
Save the transaction.
Make a note of the Purchase order number.

Result
The Purchase Order is created for the Material.

4.2 Goods Receipt from Purchase order


Use
To receive the goods against a Purchase order.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Materials Management > Goods Movement >


Goods Movement

Transaction code

MIGO

Enter the Purchase order number and Delivery note and press Enter.
Enter the Number of containers, Batch number and manufacturing date and Post the transaction.

Result
Goods are received against the Purchase order.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

4.3 Check for the Inspection Lot


Use
Check whether the Inspection lot is created.
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Quality Management > Quality Inspection > Work list
> inspection > Change data

Transaction code

QA32

On the inspection Lot Selection screen, enter the necessary data, and then choose Execute.
Field name

Description

User action and values

Plant

1100

Inspection lot
origin

01

Material

FCIP00-00

Comment

The List shows all lots for this material. Choose the appropriate Inspection lot for the material.

Result
Inspection lot for the Active material is created.

4.4 Result Recording


Use
In this activity we record the results of the Inspection lot.
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Quality Management > Quality Inspection > Inspection


Results > Result recording

Transaction code

QE51N

On the inspection Lot Selection screen, enter the necessary data, and then choose Execute.
Field name

Description

User action and values

Plant

1100

Inspection lot
origin

01

Material

FCIP00-00

Comment

Enter the Results in the required field for the first two chars ASSAY& LOD and valuate them.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Go to Extras in the Main menu, go to Formula and click on Calculate Formula.


According to the Formula we have entered in the Inspection plan, based on the ASSAY and LOD
values, the Active Ingredient percentage will be calculated and results are displayed.
Valuate the results and Save the Results recording.

Result
Results are recorded for the inspection lot.

4.5 Usage Decision


Use
In this activity we will make Usage decision
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Quality Management > Quality Inspection > Inspection


Lot > Usage decision > Record

Transaction code

QA11

On the initial screen enter the Inspection lot number.


Enter the UD code (Accepted).
Save the transaction.
After saving the UD, Batch classification will be updated and the values for all the three chars will be
displayed in Batch classification data.

Result
Usage decision is made for the inspection lot.

4.6 Create a Process order


Use
To create a Process order for the Blended Material.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Production Process > Process Order >Process


Order > Create > With Material

Transaction code

COR1

Enter the Blended material number, Plant and Order type and press Enter.
Enter the quantity and schedule the process order.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Assign a Batch number to the Blended material.


Release the Process order and Save it.

Result
The Process Order is created for the Blended Material.

4.7 Change Process order


Use
This activity is to change the Process order for the Material.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Production Process > Process Order >Process


Order > Change

Transaction code

COR2

Go to Materials overview, select the Active material and click on Batch determination tab.
As per the Active ingredient percentage values of the batches, the system will calculate and propose
the changed quantity of the Active material batch.
Copy the Batches for the Active material.
Now after determining the Active material batches, in the Material overview screen, click on Material
Quantity calculation button.
According to the Formulae entered in the Mater Recipe, the Active material quantity will be
subtracted from the Total Ordered quantity and the Filler material quantity will be proposed.
Click on Execute button.
Now determine the Batches of Filler material.
Copy the Batches for the Filler material.
Save the Process order.
If the Active ingredient material quantity is increased according to the calculation, the system will
decrease the quantity of Filler material.

Result
Process order is changed, Material quantities are calculated and Batches are determined.

4.8 Goods issue to the order


Use
In this activity Goods will be issued to the Process Order.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Access the transaction choosing one of the following navigation options:


SAP ECC Menu

Logistics > Material management > Inventory management


>Goods movement >Goods Issue

Transaction code

MB1A

Enter the movement type 261 and click on To Order button.


Enter the Process order number and click on Adapt + Details button.
While issuing goods to the Process order, the Active material will be displayed in both KG and KAI
units of measure.

Result
Goods are issued to the Process Order.

4.9 Completion Confirmation


Use
In this activity we confirm the completion of the Process order.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Production Process > Process Order


>Confirmation > Enter for Order

Transaction code

CORK

Enter the Process order number and press Enter.


Enter the yield and Save the transaction.

Result
Process Order completion is confirmed.

4.10 Goods receipt from the Order


Use
Produced goods will be received from the Process order.
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Material management > Inventory management


>Goods movement >Goods Receipt > For Order

Transaction code

MB31

Enter the movement type 101, Process order number and click on Adapt + Details.

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PP07 - Material Quantity Calculation in Blending Stage - BPP

Save the Transaction.

Result
Goods are received from production against the Process order.

4.11 Technical completion


Use
To complete the Process order technically.

Procedure
Access the transaction choosing one of the following navigation options:
SAP ECC Menu

Logistics > Production Process > Process Order >Process


Order > Change

Transaction code

COR2

In the main menu go to Process order Functions Restrict processing Technically complete
Choose

Save.

Result
The Process order is Technically completed.

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