Access ADM and WebDP from your web browser of choice with this link: http://alphdb05.eua.solvay.com/ADMPrd/
If it gives you this screen, just hit 'cancel'.
Before you get started, check out a few tips and tricks about navigation in ADM here.
Master Data
Material table
Picaso materials are not package specific. They match the SAP concept of a Material group.
The material fields are to be populated as below:
| Field | Mandatory/Optional | Rule | Comment |
|---|---|---|---|
| Material | Mandatory | Once created, cannot be changed. Picaso materials are not package specific. They match the SAP concept of a Material group. For Finished goods and intermediates : Aromatics start with T and the second letter identifies the Product family . Aromatics is 4 - 6 digits of letters and numbers . For new products in STARS , STARS creates a 4 digit code and the interface to PICASO adds the T and product family in front( i.e. TF0J04 ). For FP, it is 14 character Short Description. | |
| Nome Code | Mandatory | Same as Material | Must equal Material |
| Manager | Mandatory | Whomever is in charge. Usually the GP or the PM. | |
| Material Type | Mandatory | Material Type | see below for different material types |
| Description | Mandatory | Free text | Long description |
| Lot Site | |||
| Unit of Measure | Mandatory | as fit | Kilograms or Metric Tons : all other tables refer to that one. Example: production rates in production standards. Once set, better not change it. |
| Search Code | Mandatory | Material Search Code | See below critical for EP separation of Aromatics & FP; Not to be mistaken with the Inventory target search code. |
| Quality Test Lag | Optional | Important for ATP | Production end date + QC test lag = product availability : consider the effect of the Quality test lag on the grid and on the SAP Planned orders. |
| Bulk Density | |||
| Box Liner Code | |||
| Box Shroud Code | |||
| Cust Tier | |||
| Margin | |||
| Inv Cost | Mandatory | default with 40000 | used by EP: Additives = 10,000; Resins & intermediates = 20,000 ; Finished goods = 40,000 |
| Bag Size Code | = 1 for Abacus products | ||
| Material Field 1 | was used for Stock or MTO but Inventory targets Search Code manages that now | ||
Material Field 2 | 5 character | Product family : critical since used in many reports to separate product family | |
| Material Field 3 | Business | ||
| Material Field 4 | Product family full description | ||
| Material Field 5 | Product family subgroups used in variety of ways | ||
| Material Field 6 | Product family subgroups used in variety of ways | ||
| Material Field 7 | Product family subgroups used in variety of ways | ||
| Material Field 8 | Used to be H4 before H4 field was added | ||
| Material Field 9 | |||
| Material Group | Mandatory | as per SAP | |
| H4 | Mandatory | as per SAP | For it to work, you want to update the Product Family / Business Unit table. Once this table is updated, the fields will auto populate. H4: SPP H4 mapping |
| Business Unit | Mandatory | ||
| Finance Material Type | Mandatory | ||
| Archetype | still used? | ||
| Material Field 15 | |||
| Material Field 16 | |||
| Material Field 17 | |||
| Material Field 18 | Optional | X if product is under allocation |
Material types
| Material types | Identifier | What for |
|---|---|---|
| Finished Goods | P | Finished goods |
| Additives | A | Raw Materials / Additives |
| Intermediates | I | Bulk, polymers |
| Package Materials | P | Package Materials |
| Resins | R | Resins |
| sfm | M | monomers (TFEM, Sulfones, VF2,...) |
| wide spec | wide spec or substandard |
Material Search Codes
| Search code | What for |
|---|---|
| 900 | Obsolete |
| 999 | New products (interfaced) |
| 1 | Aromatics |
| 2 | FluoroPolymers |
| 4 | PVDC |
| 7 | FP intermediates |
Location Dependent Quality Test Lag
The material shows a global Quality test lag:
What if the QC time is not the same in the two (or more) production plants that this product is manufactured?
The Location dependent Quality test lag let you deal with locations where the Quality test lag differs from the material default.
Effect of the Quality Test Lag on:
- the production schedule: none
- the grid: it offsets the availability of the output product of a run
- the SAP Planned order: it offsets the end date of the planned order corresponding to a run.
In order to avoid duplicating QC times when one is maintained in SAP, you want to use the Schedule Upload Lag Adjustment Table.
Keep in mind that the Picaso → SAP interface always uses these two factors. This is hardcoded in the interface.
Effect of the Quality Test Lag on the availability of the output product of a run:
Consider this run. Its attributes:
- Product: PVDC PV910
- Package: BB5
- Line: SUSP PKG
- Formula 80 (from possible formulas for that line, determined by Production Standard and Production Standard Effectivity)
- Quantity 176 MT
- Start Date: Dec 02 2022
- End Date: Dec 04 2022 - 12:00 (determined by quantity and rate. Rate from Production Standard Effectivity)
- Customer Order: SAP Planned Order number. This Run has already been interfaced with SAP.
The effect of the plot of a 2 days QC Lag:
- despite the run starting Dec 02, it will start affecting (increasing) the projected inventory Dec 04
- the run ends on Dec 04, but the projected inventory will continue to increase until Dec 06
Effect of the Quality Test Lag on the end date of the corresponding SAP Planned order:
Consider the dates of this run:
- Start Date: Nov 07 2022 - 15:26
- End Date: Nov 08 2022 - 12:04
- Customer Order: 1079448688 (SAP Planned Order number).
And the dates of its corresponding SAP Planned Order:
- Start Date: Nov 07 2022
- End Date: Nov 15 2022
| Picaso Run | SAP Planned Order | Difference | |
|---|---|---|---|
| Start Date | Nov 07 2022 | Nov 07 2022 | same |
| End Date | Nov 8 2022 | Nov 15 2022 | 7 day |
What is going on? This:
The Quality Test Lag adds to the SAP Planned order End Date:
| Picaso Run | SAP Planned Order | Difference | |
|---|---|---|---|
| Start Date | Nov 07 2022 | Nov 07 2022 | same |
| End Date | Nov 8 2022 | Nov 15 2022 | = Picaso End Date + QC Lag |
Why this? Because the QC Lag affects the availability of the output product in Picaso, and in order to achieve the same in SAP, the interface offsets the End date of the Planned order accordingly.
This results in the availability date of the output product in Picaso and SAP to (better) match. See below:
Picaso plot (TFPD / C5 in AQS)
SAP MD04 (66328 / AQS)
In Plants where the QM module is operational, Lab time is also maintained in SAP. In order to avoid duplicating Lab times (in Picaso and SAP0, you want to maintain the Schedule Upload Lag Adjustment table.
SKU Mapping
SAP code added to SKU Code mappings (SKU code is 7 digits with leading 0’s )
Inventory Targets and Preferences
- Time fence = 0
- stockout allowed = 7 (to start with, you may adjust later)
- forecast ignored = 7
- SKU responsible = MTO or STK
- search code = 1 (if MTO) or 0 (if STK)
- service level target = 95
- other necessary fields:
- safety stock / high target / min order qty (use inv. unit)
- Source location (if same as destination, PICASO understands this is a production location) & source packaging
- lead time (for forecast adjustment algorithm)
Formula
A formula is a list of ingredients. It is our SAP Bill of Materials.
Most formulas are created in Picaso by uploading SAP BOM's.
(automatic refresh if BOM modified? TBC)
Picaso formulas are named after the SAP Production version they are selected from. Therefore, a BOM not associated to a Production Version will not load in Picaso.
Formulas numbers are generated automatically in Picaso. These numbers will be used in Production Standards Effectivity.
When creating a run in the Picaso Scheduler, specify the formula (or keep the default). This formula will determine the production version used when creating the Planned order in SAP. Unless, the Schedule Upload Unit Parameter drives whether SAP Planned orders always use production version 0001 or if the production version is determined by the formula.
Production Standards
Similarly to an SAP Production version, the Production standard indicates which products/packages are qualified on which lines.
| Field | Mandatory/Optional | Rule | Comment |
|---|---|---|---|
| Unit | Mandatory | ||
| Material | Mandatory | ||
| Package | Mandatory | ||
| Lot size | Optional | see Dynamic Scheduling |
Production Standards Effectivity
Ties together a production line (or equipment), a product/package and a formula. Also the Production Standard Effectivity is where the production rate is maintained. The unit of the production rate (e.g. kg/h) does not show on this ADM view.
The volume (e.g. kg) derives from the material master. The time (e.g. hours) derives from the equipment definition.
The Default flag drives which production standard effectivity auto-populates when creating a run. There should only be one default per production standard.
Product Family / Business Unit
The Material groups are interfaced from SAP into Picaso.
However, in order for the Picaso Material table to autopopulate the H4, Business Unit, and Finance Material Type field, you want to assign these three attributes to their corresponding material group in this table.
Schedule Upload Lag Adjustment
The schedule upload lag adjustment has no effect in Picaso (neither on the grid, no anywhere else). It only affects the interface to SAP for planned orders.
Used when the GRPT / QM Module with Average Inspection Duration are used in SAP.
The lag adjustment prevents QC Times to be counted twice when they are maintained both in SAP and Picaso.
The Schedule Upload Lag Adjustment affects the SAP Planned order end date as below. Consider this Picaso run in plant AUA (Oudenaarde):
... and its corresponding SAP Planned order:
Recap:
| Picaso Run | SAP Planned Order | |
|---|---|---|
| Start Date | Nov 24 2022 | Nov 24 2022 |
| End Date | Nov 27 2022 | Nov 28 2022 |
Why such a difference? Consider the QC Lag: 5 days for TFWC in Oudenaarde
Based on QC Lag only, this is what should have happened:
| Picaso Run | SAP Planned Order | Effect of the QC Lag | |
|---|---|---|---|
| Start Date | Nov 24 2022 | Nov 24 2022 | none |
| End Date | Nov 27 2022 | Dec 2 2022 | = Picaso End Date + QC Lag = Nov 27 2022 + 5 = Dec 2 2022 |
Still not adding up.
But, there is a QC Lag Adjustment record for TFWC in AUA
Now, it does add up:
| Picaso Run | SAP Planned Order | Effect of the QC Lag | Effect of the Adjustment | |
|---|---|---|---|---|
| Start Date | Nov 24 2022 | Nov 24 2022 | none | none |
| End Date | Nov 27 2022 | Nov 28 2022 | Dec 2 2022 | = Dec 2 2022 + (-4) = Nov 28 2022 |
Learn more about this: Determine QC Time, GRPT, Average Inspection Time, QC Lag Adjustment
Material Equivalents
Equipment
Equipment typically represent a production line.
| Field | Mandatory/Optional | Rule | Comment |
|---|---|---|---|
| Unit Name | Mandatory | ||
| Location | Mandatory | ||
| Area Code | Mandatory | PP-PI or PP-REM | |
| Facility | Mandatory | same as unit name  | |
| Default Rate | Optional | auto-populates if production standard effectivity rate is empty | |
| Standard Rate Unit | Mandatory | is the time unit of measure used for rates with production standard effectivity | |
| Operation mode | |||
| Up rate (%) | Optional | default if production standard Up Rate is empty | |
| Hit Rate (%) | Optional | default if production standard Yield rate is empty | |
| Transition matrix | Optional | drives automated transition times for that line (e.g. 8h transition between product A and product B) | |
| Cycle length | Mandatory | 30 days for monthly production wheels 60 for bi-weekly production wheels etc. | used for inventory targeting and Dynamic Scheduling. |
| Class | Mandatory | Finishing line / | Selection field. |
Locations
Location types
| Material types | Identifier | What for |
|---|---|---|
| Plant | P | Manufacturing facility |
| Warehouse | Storage facility | |
| Vendor | Vendor |
Transit Times
Applies to DRP Records and SAP STO's.
Transitions
Schedule colors
Package
Troubleshoot
Interface Management
Schedule Upload Unit Parameters
Drives:
- conversion of planned orders into process orders in SAP: e.g. 3 days means that planned orders with a start date (TBC) within 3 days will be converted.
- how SAP production versions are selected in SAP when creating planned orders: always 0001, or as per the formulation table.
Production Schedule Monitoring
Logs production schedule interface runs.
Push Button Management
Configure who can run the on-demand production schedule interface.
This table let one user run the interface for either one (or multiple) location, or for a set of equipment (production lines) within that location.
For a unit-specific on-demand upload, insert a check-mark in the Unit-Specific checkbox, and hit the 
key.
This takes you to the units list assigned to that user. For that user, the on-demand will only upload the production schedule related to these production units.
