2.0 Business Process

MRP:

The main function of the Material Requirement Planning (MRP) is to guarantee the availability of the finished product, this means calculating the components needed (semi-finished / packaging / raw material) to make a product. It consists of several steps : taking inventory of the materials and components on hand, identifying which additional ones are needed and then scheduling their production or procurement.

The Material Requirement Planning tries to conciliate as much as possible the 3 following objectives 

• Optimize the Service Level rate by delivering On Time In Full (OTIF) 
• Optimize inventory 
• Improve day-to-day operational efficiency 

Site Planner Role:

The Site planner is a local leader for the planning activities, an efficient scheduling process can ensure quick respond to changes in demand, supply while taking into consideration of available resources. A skilled site planner plays a key role in optimizing performance at the site

Planner Workflow

3.0 Application Feature Overview

Information about the existent Workbooks and the respective BW queries.

Reporting

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Reporting

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4.0 Functional Specification

4.1 General Data/Calculations 

This section will approach the concepts/definitions that will be used in all the reports and required to understand the data from the reports.

Could be specific fields, closing activities, additional information to work and understand the reports.

4.2 Process Detail 

4.2.1.  Report/Process Definition 

This section represents the process with detail information for the application. Can include specific or special cases, complex logics , calculations, flows, among others.

Capacity Planning

Purpose of this query

This report  in BW is showing in a period until 5 years the load of production resources depending on their working hours, and on the production plan (planned orders & process orders) in place. The load is expressed in hours and % and Qty Produced is based on phase in Recipe. 

Monthly view :

Weekly View

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Context

There are two transactions in SAP that can be used for capacity analysis:

• CM01 – shows capacity planning for active planning version
• CM38 - shows capacity planning for any planning version

In each case,

• You can look at capacity by week, month, qtr, etc.
• You can view hours and quantity

However,

• If a planned order starts in one period and ends in another, qty is shown in both periods
• The quantity displayed is based on the planned order quantity, NOT the quantity on the phase of recipe
• Difficult to work with

Two Capacity Planning reports were developed in BW:

• BW - Capacity planning - Monthly (Core Query)
• BW - Capacity planning - Weekly(Core Query)

Benefits: Reliability

• Source of information comes right from SAP ECC
• Available capacity based on intervals defined on the resource master
• Information is updated daily (during night)

Functionalities comparison with SAP reports

Further considerations

• BW capacity report displays total plant throughput and hours by reactor
• BW capacity report may not agree with the standard SAP reporting or ZWPP31A

Variables screen

Enter a Unit of Measure, plant and Date range

• The standard planning scenario is #
• Other Long Term Planning Scenarios could also be selected

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Filters

Characteristics

Key Figures

Unit Conversion

Unit : Variable

The full explanation on how the quantity conversion works can be found in the Quantity Unit Conversion page.

FAQ

Question : How Data Gets Populated into this query?

Each night AFTER MRP completes, a job runs to extract the MRP results. These jobs are linked

MRP Jobs here

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Data Extract Jobs here

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Material Production

Basic Information

• Basic Information
• Purpose of this query
  • Context
• Variables screen
• Filters
• Characteristics
• Key Figures
  • Specific cases
  • Example
• Unit Conversion
• FAQ
  • Question : How Data Gets Populated into this query?
  • Question : Why there's no data for my plant ?

Purpose of this query

This report is comparing week after weeks the actual production versus the planned production at the beginning of the week.

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Context

This query was developed by the GBUs looking for a simplified calculation to measure a scheduling adherence.

It allows to analyse the actual production against the scheduled plan week by week.

A snapshot of the scheduled plan is saved every Friday, through the transaction ZWPP31B. Then, during the week, the confirmations of production are done in SAP and updated in BW every night. The analysis is done by material code and then, depending of your selection, a sum is done by commercial product, resource, and so on...

Variables screen

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Filters

Characteristics

Key Figures

Specific cases

- if Actual Production = 0, then SP = 0 %
- if Planned Production = 0, then SP = 0 %

Difference with the schedule adherence : the calculation for the schedule adherence allows getting negative results.

Example

Material 88888
Planned production for the week 41 : 25 000 KG (2 planned orders : one fixed of 15 000 KG and one not fixed of 10 000 KG)
Confirmed Production for the week 41 : 28 000 KG

SP = 28 000 / 25 000 = 112 %
SP fixed = 28 000 / 15 000 = 187 %

Unit Conversion

Unit : Variable

The full explanation on how the quantity conversion works can be found in the Quantity Unit Conversion page.

BW - Stock and Planning Month Snapshot (Core query)

Purpose of this query

This reports is providing a synthesis of the stock and planning elements.

You can find Actual from past inventory movements :

• Production
• Consumption
• Procurement
• Sales
• inventory 

and Future planning from MRP elements :

• Planned Production
• Planned Consumption
• Planned Procurement
• Future Demand : Sales Orders + remaining Sales Forecast
• Projected Stock

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Link to MD04:

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Selection Screen

Example:

1. Company Code (due to authorization)
2. Calendar Year/Month will always be the current month (by default)
3. Other prompts are optional.

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Characteristics and Key Figures available for Display and Drilldown

Characteristics

Future Key Figures (Planned)

Actual (from Stock Movements)

Key Figures : Production

Name	Description
Production	Internal Production + Sub Contacting Production + Co-product Production + By-product Production
Principale Production	Image Added
Co-product Production	Image Added
By-product Production	Image Added
Sub contracting production	Sub contractor Production MM + Sub contractor Production PP + Sub contractor Co product Production + Sub contractor By-product Production
Sub contractor Production MM	Image Added
Sub contractor Production PP	Image Added
Sub contractor Co product Production	Image Added
Sub contractor By-product Production	Image Added

Key Figures : Other Flows

Name	Description
Transfert Debit	Image Added
Transfert Credit	Image Added

Key Figures : Consumption

Name	Description
Global consumption	Internal consumption + Sub contracting consumption
Internal consumption	Image Added
Sub contracting consumption	Image Added

Key Figures : Procurement

Name	Description
Global procurement	Procurement External + Procurement Inter Company + Procurement Intraco + Procurement Consignment
Procurement External	Procurement External ( + ) - Procurement External ( - )
Procurement External ( + )	Image Added
Procurement External ( - )	Image Added
Procurement Inter Company	Procurement Inter Company ( + ) - Procurement Inter Company ( - )
Procurement Inter Company ( + )	Image Added
Procurement Inter Company ( - )	Image Added
Procurement Intraco	Procurement Intraco ( + ) - Procurement Intraco ( - )
Procurement Intraco ( + )	Image Added
Procurement Intraco ( - )	Image Added
Procurement Consignment	Procurement Consignment (without order) + Procurement Consignment (with order)
Procurement Consignment (without order)	Image Added
Procurement Consignment (with order)	Image Added

Key Figures : Sales

Name	Description
Global Sales	Sales External + Sales Inter Company + Sales Intraco + Sales Consignment
Sales External	Sales External ( + ) - Sales External ( - )
Sales External ( + )	Image Added
Sales External ( - )	Image Added
Sales Inter Company	Sales Inter Company ( + ) - Sales Inter Company ( - )
Sales Inter Company ( + )	Image Added
Sales Inter Company ( - )	Image Added
Sales Intraco	Sales Intraco ( + ) - Sales Intraco ( - )
Sales Intraco ( + )	Image Added
Sales Intraco ( - )	Image Added
Sales Consignment	Sales Consignment ( + ) - Sales Consignment ( - )
Sales Consignment ( + )	Image Added
Sales Consignment ( - )	Image Added

Key Figures : Total Stock

Name	Description
0TOTALSTCK	Quantity Total Stock
Unrestr.-use stock (Unrestr + Quality Inspection)	Image Added
Unrestr.-use stock	Image Added
0QMSTOCK	Stock in Quality Inspection
0BLOCKEDSTK	Blocked Stock

Related Queries

BW - Stock Movement Production (Core Query)

Purpose of this query

This query allows to follow the past inventory movements with a supply chain view, to follow monthly, weekly or daily evolution of :

• Production
• Consumption
• Procurement
• Sales
• inventory (Qty, Value)

Neutralisation – How does it work ?

What is neutralisation

• Neutralisation is a calculation which avoids to aggregate some key figures for which a simple sum is not relevant

Why do we neutralise

• Neutralisation is required when a process order produces and consumes material which belong to the same group of material.
  
  
• Example : group of material = LIP00, where LIP00 is a code which defines the chemical product of a material

• • Packaging process orders
  • Unpacking process orders (Silica « Craquage », Salicylic acid in Roussillon)
  • Recycling or Rework process orders (only net qty needs to be counted)
  • Relotification process order

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How do we neutralise ?

• First: Neutralized consumption = consumption into a material of another group
• Second: Neutralized production = Production – Consumption + Neutralized consumption

Selection Screen

Example:

1. Calendar Year/Month is mandatory (MM.YYYY) as well as Company Code (due to authorization)
2. Other prompts are optional.
   
   

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Characteristics and Key Figures available for Display and Drilldown

Characteristics

Key Figures : Production

Name	Description
Global Production	Internal Production + Sub Contacting Production
Internal Production	Principale Production + Co-product Production + By-product Production
Principale Production	Image Added
Co-product Production	Image Added
By-product Production	Image Added
Sub contracting production	Sub contractor Production MM + Sub contractor Production PP + Sub contractor Co product Production + Sub contractor By-product Production
Sub contractor Production MM	Image Added
Sub contractor Production PP	Image Added
Sub contractor Co product Production	Image Added
Sub contractor By-product Production	Image Added

Key Figures : Transfert

Name	Description
Transfert Debit	Image Added
Transfert Credit	Image Added

Key Figures : Consumption

Name	Description
Global consumption	Internal consumption + Sub contracting consumption
Internal consumption	Image Added
Sub contracting consumption	Image Added

Key Figures : Neutralized Production and Consumption

Name	Description
Neutralized production (LIP00)	Principale Production + Co-product Production + By-product Production + Sub contractor Production PP + Sub contractor Co product Production + Sub contractor By-product Production - (Internal consumption + Sub contracting consumption) + Neutralized consumption (LIP00)
Neutralized consumption (LIP00)	Image Added

Key Figures : Procurement

Name	Description
Global procurement	Procurement External + Procurement Inter Company + Procurement Intraco + Procurement Consignment
Procurement External	Procurement External ( + ) - Procurement External ( - )
Procurement External ( + )	Image Added
Procurement External ( - )	Image Added
Procurement Inter Company	Procurement Inter Company ( + ) - Procurement Inter Company ( - )
Procurement Inter Company ( + )	Image Added
Procurement Inter Company ( - )	Image Added
Procurement Intraco	Procurement Intraco ( + ) - Procurement Intraco ( - )
Procurement Intraco ( + )	Image Added
Procurement Intraco ( - )	Image Added
Procurement Consignment	Procurement Consignment (without order) + Procurement Consignment (with order)
Procurement Consignment (without order)	Image Added
Procurement Consignment (with order)	Image Added

Key Figures : Sales

Name	Description
Global Sales	Sales External + Sales Inter Company + Sales Intraco + Sales Consignment
Sales External	Sales External ( + ) - Sales External ( - )
Sales External ( + )	Image Added
Sales External ( - )	Image Added
Sales Inter Company	Sales Inter Company ( + ) - Sales Inter Company ( - )
Sales Inter Company ( + )	Image Added
Sales Inter Company ( - )	Image Added
Sales Intraco	Sales Intraco ( + ) - Sales Intraco ( - )
Sales Intraco ( + )	Image Added
Sales Intraco ( - )	Image Added
Sales Consignment	Sales Consignment ( + ) - Sales Consignment ( - )
Sales Consignment ( + )	Image Added
Sales Consignment ( - )	Image Added

Key Figures : Quantity and Valuation Total Stock

Name	Description
0TOTALSTCK	Quantity Total Stock
Unrestr.-use stock (Unrestr + Quality Inspection)	Image Added
Unrestr.-use stock	Image Added
0QMSTOCK	Stock in Quality Inspection
0BLOCKEDSTK	Blocked Stock
0VALSTCKVAL	Valorised Stock Value
Unrestr.-use stock (Unrestr + Quality Inspection) (Value)	Unrestr.-use stock (value) + Q stock (value)
Unrestr.-use stock (value)	Valorised Stock Value * Unrestr.-use stock / Quantity Total Stock
Q stock (value)	Valorised Stock Value * Stock in Quality Inspection / Quantity Total Stock
Blocked stock (Value)	Valorised Stock Value * Blocked Stock / Quantity Total Stock

Related Queries

4.0 Functional Specification

4.1 General Data/Calculations 

This section will approach the concepts/definitions that will be used in all the reports and required to understand the data from the reports.

Could be specific fields, closing activities, additional information to work and understand the reports.

4.2 Process Detail 

4.2.1.  Report/Process Definition 

<insert link>

This section represents the process with detail information for the application. Can include specific or special cases, complex logics , calculations, flows, among others.

5.0 Non-functional Descriptions 

5.1 Usability

Usability is about the ease with which a User can learn to start using the solution and the ease with which they can use the system.  In addition to ease of learning and ease of use, usability also includes areas such as ease of recall, error avoidance and handling, accessibility among others e.g., 99% of metadata entry Users who have use the Maintenance Dashboard should be able to change filters, extract etc., when required.  Maintenance data will be centrally stored in the Google Cloud platform, which will be available to other applications e.g., and Dashboards if needed.

5.2 Regulatory Compliance

Software systems must comply with legal and regulatory e.g., GDPR requirements, this can change depending on country, organisation industry and / or region.  The software systems must be secure from unauthorized access.  The Maintenance Dashboard will comply with Solvay’s regulations and compliance e.g., access only granted to authorized Users.

5.3 Security

Security refers to essential aspects that assure a solution and its components will be protected against unauthorized access or malware attacks.  Important considerations related to security aspects of a system are User authentication, User authorization or User access privileges, data theft, malware attacks, data encryption, and maintaining audit trails, e.g., only Users with administrator access shall be able to create new accounts and assign data access privileges to the new accounts e.g.,

• All data will be encrypted in the dashboard
• Only authorised Users / Administrative Users will be able to access data.
• Maintenance data will be split between either SCO or ECO, and Users will only have authority to one Entity data.

5.4 Performance

Performance defines how fast a software system or a particular section of it responds to certain User actions under a certain workload.  In most cases, this metric explains how long a User must wait before the target operation happens e.g., the page renders, a transaction is processed, etc., given the overall number of Users now.  Performance requirements may describe background processes invisible to Users, e.g., backup and speed of data transfers. 

5.5 Reliability

Reliability is the ability of a solution or its component to perform its required functions without failure under predefined conditions for a specified time / period.  Reliability can possibly be specified in terms of average time system runs before failure occurs, percentage of operations completed successfully within a time / period, maximum acceptable failure probability, or number of failures within a period.  Reliability aspects are in reference to (but not limited to) evaluation of the system to be considered as reliable, classification of reliability defining failures vs. regular failures, and the impact of failure on business operations.  The Maintenance Dashboard will display data from the previous refresh of data.   

5.6 Scalability

Scalability refers to the degree to which a solution can evolve to handle increased amounts of work.  The increased amount of work could be in terms of the user base, transactions, data, network traffic, or other factors e.g., the system should be able to handle an additional load of a maximum of 5,000 Users every month for the next 6 months without any noticeable performance impacts.  

5.7 Compatibility

Interoperability is the degree to which the solution is compatible with other components.  It is a measure of how effectively the system interoperates with other software systems and how easily it integrates with external hardware devices.

Interoperability aspects to be discussed during elicitation are in reference to (but not limited to) software systems to be interfaced with along with data / messages to be exchanged and any standard data formats, hardware components to be integrated with, and any standard communication protocols to be followed e.g., Order Management system will push the order file into a secured file transfer protocol server from where it will be loaded into the system through a daily job.  To guarantee between Google Cloud platform and SAP BW Queries e.g., BW_QRY_MVPMOR01_0002, Solvay has introduced a new tool called Xtract (Xtract).

5.8 Availability

Availability is the degree to which the solution is operable and accessible when required. It is a measure of time during which the system is fully operational e.g., available for use and sometimes included as a Service Level Agreement (SLA) considering its criticality to the business, e.g., the system shall be at least 99% available on weekdays between 09:00 to 18:30 Central European Time (CET).

5.9 Refresh of the Data

Frequency, data, and time of the data refresh in the data product.