CEMENT INDUSTRY & SAP

MANUFACTURING OF CEMENT

SAP SOLUTIONS FOR CEMENT INDUSTRIES

SAP SOLUTIONS FOR CEMENT INDUSTRIES

INTEGRATED PROCESS FLOW FOR A CEMENT

PLANT

HOW SAP INTEGRATE THE PROCESS FLOW

PRODUCTION PLANNING & CONTROLING

PRODUCTION PLANNING :
Sales & Operational Planning (SOP)

Demand Planning (DP)

Demand Management (DM)

Planned Independent
Requirement (PIR)

Customer Requirement (CR)

Material Requirement Planning
(MRP)

Capacity Requirement Planning

(MRP)

PRODUCTION PLANNING MASTER DATA:

Material Master

Bill of Materials (BoM)

Resource
Master Recipes
Production Version
Process Order
Goods Received
Goods Issue

PRODUCTION PLANNING MASTER DATA:

Terms

Material Master

Bill of Materials

Resource

Master Recipe

Definition

Example

Contains descriptions of the

materials a company procures,
produces, and stores. The material Limestone, Cement stone, Gypsum
master is the central repository of etc.
material information (such as stock
levels) for the company.
A bill of materials (BoM) is a list of
the parts or components that are
Which material and how much
required to build a product. The
quantity is required to produce OPC
BoM provides the manufacturer's
cement
part number (MPN) and the quantity
needed for each component.
An organizational unit that defines
where and when an operation must
be performed. The resource has an
Machine , labor etc. can be treated as
available capacity. The activities
resource.
performed at or by the resources
are valuated by charge rates, that
are determined by cost centers and
activity types.
is the description of an enterpriseCrusing, Burning, Grinding, Packaging
specific process in process
industries, that does not relate to a etc.
specific order.

PRODUCTION PLANNING MASTER DATA:

Terms

Production Version

Process order

Definition
A production version determines
which alternative BOM is used
together with which task list/master
recipe to produce a material or
create a master production
schedule.
For one material, you can have
several production versions for
various validity periods and lot-size
ranges
Process orders are the main
element used for the detailed
planning and execution of process
manufacturing.
A process order describes the
production of batches (materials) in
a production run or the rendering of
services. It is generated from the
master recipe and contains all the
information specified during
process planning.

Example

PRODUCTION PLANNING MASTER DATA:

Terms

Goods receipt

Goods issue

Definition
When a material has been produced
in a process, a goods receipt for the
order must be posted. Whether and
how you can trigger the goods
receipt posting using a process
message depends on the type of
material produced:
Goods Issue is basically movement
of material within the plant for
consumption/manufacturing or
outside the plant as delivery to
Customer.

Example

QUALITY CONTROL:
Quality Control enables recording, tracking and analysis of
product and process characteristics to ensure quality
compliance.
Key Benefits:
Supports automatic or manual triggered inspection lots.
Integrated tightly with the complete supply chain (e.g. inventory,
batch, purchasing).
Enables statistical process control (SPC) to monitor critical
product and process characteristics in the manufacturing
process and allows instantaneous intervention.
Documents product quality to achieve regulatory compliance.
Includes integrated problem management .

QUALITY CONTROL:
Key Functionalities:

Quality Inspections
Laboratory Integration
Test equipment Interfacing
Usage Decision / Release
Certificate of Analysis
Statistical Process Control
Problem Management
Test Equipment Calibration
Quality Information System

QUALITY INSPECTIONS

Comprehensive inspection processing

Goods receipt inspection .
In-process control
Post-process control
Inspections at goods issue
Recurring inspections
Test equipment interfacing
Statistical process control (SPC) with integrated problem
management
Results recording - mobile or Web-based
Functions integrated in logistics (e.g. inventory management)

QUALITY INSPECTION DASHBOARD