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    Cement Updated

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    Koushik Goswamy
    This document discusses SAP solutions for cement industries. It describes the integrated production process flow for a cement plant and how SAP can integrate this. It covers production planning and control, including sales and operations planning, demand planning, material requirements planning, and capacity requirements planning. It also discusses the relevant master data used in production planning like materials, bills of materials, resources, recipes, and process orders. Finally, it covers quality control in cement production, including quality inspections, statistical process control, and problem management to ensure quality compliance.

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    © All Rights Reserved
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    Cement Updated

    Uploaded by

    Koushik Goswamy
    143 views16 pages
    This document discusses SAP solutions for cement industries. It describes the integrated production process flow for a cement plant and how SAP can integrate this. It covers production planning and control, including sales and operations planning, demand planning, material requirements planning, and capacity requirements planning. It also discusses the relevant master data used in production planning like materials, bills of materials, resources, recipes, and process orders. Finally, it covers quality control in cement production, including quality inspections, statistical process control, and problem management to ensure quality compliance.

    Original Description:

    Basic Scenario of Cement Industry in SAP

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    This document discusses SAP solutions for cement industries. It describes the integrated production process flow for a cement plant and how SAP can integrate this. It covers production planning and control, including sales and operations planning, demand planning, material requirements planning, and capacity requirements planning. It also discusses the relevant master data used in production planning like materials, bills of materials, resources, recipes, and process orders. Finally, it covers quality control in cement production, including quality inspections, statistical process control, and problem management to ensure quality compliance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    143 views16 pages

    Cement Updated

    Uploaded by

    Koushik Goswamy
    This document discusses SAP solutions for cement industries. It describes the integrated production process flow for a cement plant and how SAP can integrate this. It covers production planning and control, including sales and operations planning, demand planning, material requirements planning, and capacity requirements planning. It also discusses the relevant master data used in production planning like materials, bills of materials, resources, recipes, and process orders. Finally, it covers quality control in cement production, including quality inspections, statistical process control, and problem management to ensure quality compliance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 16

    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

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