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Manufacturing VC query (QV_BW_QRY_CPCOPC04_0001) is one of the components to calculate the FL-ICM (Forward-Looking Integrated Contribution Margin).The brings the Variable Cost (VC) of a product is the (sum of Raw Materials + Packaging + Tolling + Utilities costs).

We bring the these detailed costs from SAP from the BOM (Bill of Material).

The BOM brings, for a given Finished Product/Plant/Month, the detailed list of components (raw material/activity type) with with the corresponding quantities and costs.

In the query, we calculate theFL Variable Cost for projected months, using the forecasted prices for Raw Material and Energy (input by the users in IP workbooks) and multiply them by the quantities from the BOM. If no forecast is found, then we extrapolate last Actual price to the future months.

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Dataflow overview

Manufacturing Cost is available in Composite Provider CPCOPC04

ADSOs ABCOPC06 (WP1) and ABCOP06B (PF1) stage the data, which combines BOM (Actuals) + Forecast data.

(FL ICM - Manufacturing Unit Cost) contains 2 DSOs:

• ABCOPC06 - WP1 
• ABCOP06B - PF1

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The BOM data from both ERPs is harmonized in CV_FMCO_BOM to be consumed by the Manufacturing Cost CVs.Image Removed

BOM data flow

First step to calculate Manufacturing Cost is to load the BOM.

It is loaded from WP1 and PF1 in different data flows.

Then BOM data from both ERPs is harmonized in CV_FMCO_BOM 

WP1 flow

2 datasources are used to define the BOM scope 

• DTS_PU_RM01: to get from P&L (MVCOPA01) all materials sold in the past 24 months
• ABCOPC07: to get materials with Sales Forecast (eventually new materials with Sales Forecast but no actual sales yet)

Then, in the Transformations, for each plant/finished material, we call table function ZCDS_BOM_ALL, which is implemented with method GET_BOM_ALL (class ZCL_BOM_ALL.)

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This method GET_BOM_ALL does the BOM explosion via lookup in ODS_PCP1 with a recursive logic.

Each subsequent level is built by taking the component and reading again ODS_PCP1 using the component as "father", to check if it explodes further (if it's an intermediate product).

For example: when building level 2, the component (COMPNT) of level 1 is used as material (MATNR) of level 2 and so on up to level 10.

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After the explosion of the BOM, the calculated quantity of each component in each level is stored in ABPURM02 in field K_MENGECK.

Then ABPURM02 is used in CV_ALL_BOMLEVELS_N2 where we calculate the cost, getting Raw Material prices from ODS_PCP3 and Utilities prices from ODS_PCP8.

Then CV_ALL_BOMLEVELS_N1 is on top of CV_ALL_BOMLEVELS_N2 just for currency conversion purposes.

PF1 flow

Data is loaded from table ZCO_PRICE_RM in PF1 (this table is generated with program ZCO_PRICE_SIMULATION in PF1).

The logic of the BOM explosion resides in PF1 and it goes straight-forward to BW.

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Then calculation view CV_FMCO_BOM joins BOM data from both ERP

PF1 - from CPCOBOM2

WP1 - from ABCOCP05

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ABCOPC05 is an intermediate DSO (used only for WP1 data) for the correct aggregation of data (exception aggregation on price KF) as we remove some characteristics (level and intermediate product) to send to Manufacturing Cost CV. 

BOM overall dataflow

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There are 2 different BOM queries (not used directly in Pricing dashboard, but can be used to check the BOM data with all the available granularity)

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Granularity of the BOM

From WP1, each record in the BOM is an individual component, which is either a Raw Material (C_BOMCPT) or an Activity Type (0ACTTYPE).

From PF1, we don't have the same granularity. Only the critical raw materials are detailed (with quantity and price). This is what we call "Simple" version (VERSION = 'S').

Then we have some "buckets" that aggregate the costs as follows:

• OTHER_RM - Sum of the costs of the non-critical raw materials
• OTHER_PK - Sum of the cost of Packaging Materials
• OTHER_UTI - Sum of the cost of Utilities
• OTHER_TOLL - Sum of the cost of Tolling

Raw Material Forecast Integration (Novecare)

DSO ABCOPC01 stores Raw Material forecast prices (saved by the users in the workbook). 

Field K_AMT_EUR is the final confirmed price (in EUR/1000 KG), used to integrate in Manuf. query

This DSO is integrated in CV_FMCO_MAN_COST_RCS with the following logic:

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A dynamic month lag is applied by GBU, which is stored as a parameter LAG_xx (xx = GBU) in the Global Filter Master Data C_GLBFILT.
If no lag is set in the Master Data, the default one is 1 month applied to the relevant GBU.
The Forecast months included in this lag period are excluded, and then the Standard cost is displayed instead during this lag.

CC_TYPE = 1 (Forecast) ==> Value Component 009 (Raw Material Forecast)

CC_TYPE = 2 (Actual) ==> Value Component 004 (Raw Material Actual)

"Buy & Sell" products (Novecare)

These are products that the GBU buy and re-sell, and they have no BOM in SAP.

They are identified via in Critical Raw Material Master Data C_FLRMAT, where with “Critical flag” (C_FLRMATF) =  “B” “B” (No BOM)

We create a "virtual" BOM in BW assigning the same material code as both Finished Product and Raw Material, and with the whole quantity is 100% of the lot size (1000 KG).

The forecast price for these materials is collected in the workbook and saved in ABCOPC01 as the other critical raw materials.

This is done with 2 different Transformations into ABCOPC06 (WP1 only):

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• TRSF: ABCOPC01 -> ABCOPC06

Here we get from ABCOPC01 the forecast prices for Buy & Sell products.

• TRSF: ODS_PCP9 -> ABCOPC06 

Here we get the actual price The actual price in this case comes from P&L. query query QVSBS_QRY_MVCOPA06_0001 . (technically we take data directly from ODS_PCP9 field C_MVR_CP).

We adjust the price to a lot size of 1000 KG and also convert the price to EUR using CAR3 exchange rate.

Also in this transformation, we extrapolate Actual price for the future 12 months, in case no forecast exists in ABCOPC01. 

"Make or Buy" products (SpP)

The relevant raw materials for "Make or Buy" process are marked in Critical Raw Material Master Data C_FLRMAT, with “Critical flag” (C_FLRMATF) = “I” for internal and “E” for external.

In ABCOPC20 we find the Usage Factor (K_USGFACT) to replace the quantity from the BOM.

This Usage Factor is filled in the corresponding workbook by Material Group / Finished Material / Raw Material / Quarter.

Forecast data

It comes from the following ADSOs:

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In CV_FMCO_MAN_COST we read data from ABCOPC20 joining with CALMONTH  to extrapolate the months in each quarter and copy the Usage Factor.

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CC_MORB_QTY = K_USGFACT * 1000

CC_MORB_AMOUNT = CC_MORB_QTY * Forecast Price

Then in TRSF: DTS_CV_FMCO_BOM_FORECAST -> ABCOP06B we take the "Make or Buy cost" if it exists.

The Usage Factor can be seen in Manufacturing query but it's hidden by default.

BOM Reloading

In case of any period reloading, a Global Parameter is set in C_GLBFILT to condition the code in the relevant Transformations : 

TRSF: DTS_CV_FMCO_BOM_FORECAST WBD_HANAIV -> ABCOP06B

TRSF: DTS_CV_FMCO_MAN_COST_RCS WBD_HANAIV -> ADSO ABCOPC06

TRSF: ODS_PCP9 -> ABCOPC06

TRSF: DTS_CV_FMCO_BOM_FORECAST WBD_HANAIV -> ABCOP06

The RULE = 'BOM_RELOAD' allows to change the loading logic in these Transformations, to keep only Actuals in case of period reloading.

Field C_LOW must be changed to 'Y' in case of reloading.

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You can find FL-ICM overall architecture here:

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Note that for Novecare (WP1), there is a month lag in the RM Forecast price for the projected months (for example Forecast for April uses , April Forecast is calculated with the price from March).In Manufacturing Cost calculation view, BOM (Actuals) is combined with Forecast data.

2 different calculation views were created as we can only filter a single period to read BOM data, so in each CV, Run Period is calculated differently:

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RUNPER = FISCPER from DTP +1

For example: to generate RUNPER 03/2022

DTP from WP1 with  FISCPER = 03/2022 (to extract BOM data from 03/2022)

CV will generate RUNPER 03/2022.

DTP from PF1 with FISCPER = 02/2022 (to extract BOM data from 02/2022)

CV will generate RUNPER 03/2022.

Dependencies with other applications

Data loadings

Info providers and objects loaded

Process chain PC_COPC_10 scheduled monthly on CD7

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Loading frequency

Dependencies with other applications

Data loadings

Info providers and objects loaded

Process chain PC_COPC_10 scheduled monthly on the 6th at 03:00 AM CET → //\\ BOM loadings constraints to consider before changing scheduling → Loading frequency //\\

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Process chain PC_COPC_20 scheduled monthly from the 7th to 14th at 03:00 AM CET → No BOM loading → No scheduling impact

This process chain reloads Manufacturing Cost into ABCOPC06 to take into account potential changes in the forecast prices done by the users in the workbooks.

It is not necessary to reload the BOM from SAP, since there are no changes after the costs are released in WP1.

It contains a step (with an ABAP program) to delete from ABCOPC06 the requests from the same Run Period before reloading, to avoid duplication.

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Loading frequency

//\\ Dependencies to consider before changing PC scheduling //\\

We need all the below objects to be properly loaded at the time of the FLICM Manufacturing loading process.

ABCOPC07  Sales Revenues Forecast Snapshot
MVCOPA01   Profitability Analysis: COPA - P&L -> 25 Infoproviders
ODS_PCP1   CCR: Product Cost Items
ODS_PCP3   CCR: released costs estimates
ODS_PCP8   Resource's Unit Price

The FLICM Manufacturing process is first dealing with the loading of ABPURM02 BOM explosion (WP1), using all dependent objects above.
The loading time restrictions for each are as follow : 

MVCOPA01   Profitability Analysis: COPA - P&L -> 25 Infoproviders
   PC_COPA_PL_GLOBAL    COPA: PL Global Process Chain - Daily 1:00 AM

ODS_PCP1 - CCR: Product Cost Items
   DTP: DTS_KEKO_CKIS (WP1) -> ODS_PCP1 - Delta   
   RSP_COPCP_MONTHLY   Integ Margin : 2 workdays from start of month (FR calendar) - 11:30 PM
   RSP_PVELOCITY    PVelocity : 3 workdays from start of month (BE calendar) - 10:00 AM
   DTP: ABDSOPCP1 -> ODS_PCP1 - PC_FILE - full
   PC_INT_MARGIN      Integ Margin : 3 days from start of month (no Sunday) - 00:30 AM

ABCOPC07 - Sales Forecasts
   PC_COPC_16   COPC: TD - M - Sales Loadings : Daily 3:00 AM + 03:00 PM - not on Sundays nor bank holidays

ODS_PCP3   CCR: released costs estimates
   RPC_CCR_PCP1_MTHLY_CHAIN    CCR Monthly Process Chain : 1 workday from start of month (FR calendar) - 11:30 PM

ODS_PCP8   Resource's Unit Price
    RSP_COPCP_MONTHLY    Integ Margin : 2 workdays from start of month (FR calendar) - 11:30 PM
    RSP_PVELOCITY    PVelocity : 3 workdays from start of month (BE calendar) - 10:00 AM

We must take the worst restriction above as the time to consider before starting the FLICM Manufacturing loading process.

If we consider the second monthly Delta loading of ODS_PCP1, it is 3 workdays from the start of month (BE calendar) - 10:00 AM
This object is the BOM structure used to explode each Material with recursive logic (WP1 source : ZBW_KEKO_CKIS (Extraction of cost items)).

Therefore, if the 1st day of the month is a public holiday on Friday (New Year's Day or All Saints' Day in FR or BE calendar), the worst time of BOM loading will be the 6th at 10:00 AM.
We can optimize the FLICM Manufacturing loading on the same day at 10:00 PM

If we consider the first monthly Delta loading of ODS_PCP1, it is 2 workdays from start of month (FR calendar) - 11:30 PM

If the 1st day of the month is a public holiday on Friday (New Year's Day or All Saints' Day in FR or BE calendar), the worst time of BOM loading will be the 5th at  11:30 PM.
We could schedule the FLICM Manufacturing loading on the next day the 6th at 03:00 AM.Monthly on Day + 7

Average performance

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Variable Sequence

Filters

Key figures

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Characteristics

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Broadcast