Issue

In Syensqo Composite Materials, batch is used to manage/track & trace the individual material items in some business scenarios. This KDD is to assess the option of using SAP serial number to handle the relevant scenarios. 

Decision

Introduce Serial Number (SN) concept and use SN to manage, track and trace the material at the individual item level rather than using batch number to handle the same. 

Background & Context

1). Sublot Scenario

In Composite GBU, especially Aerospace Materials business, there are some special requirements regarding track and trace materials. Syensqo manufactures rolled goods (eg. prepreg rolls, resin film rolls and carbon fiber spools); In most cases the source of these multiple rolls is a batch of chemicals (typically the resin mix). The business requirement is to not only keep track of the batch of chemicals (sometimes referred to as the ‘original batch’), but also each individual roll that was manufactured from this batch and its sequence in the manufacturing run.

This requirement is currently managed by SAP batch and sub-batch numbers.

For example, a Process Order is created in SAP to make the Master Roll, which is a piece of carbon fabric of 1 meter wide x 100 meters long. A SAP batch number, for example MROLL1, is generated and assigned to the Master Roll. Later, another Process Order is created to consume Master Roll (MROLL1) and produce 5 separate pieces. Each is 20 CM wide and 100 meters long. Then another 5 SAP batch numbers are generated to represent sublot rolls as shown below to identify each of the sublots.

2). Non-Sublot Scenario 

In another case, for example, 500 liters of a liquid adhesive is produced with SAP batch BATCH1. It's been packed in 5 liter cans. In total, there are 100 cans of  the adhesive in BATCH1. Business may number each individual cans by using unique numbers related to adhesive BATCH1, eg. BATCH1001 for can#1, BATCH1002 for can#2, etc. Those unique numbers look like sub-batch numbers, but they will only be used for physically identify the cans. They are not SAP batch numbers and are not stored in SAP currently. So those sub-batch numbers cannot be used for tracking or tracing. In other words, business can't track & trace each individual cans in SAP at the moment.

Business will print the Master and/or Sub Batch depending on the requirement. Batch numbers are limited to 10 characters. Most are 6+4 or 6+3, but other schemes are also possible.

Assumptions

1. Business needs to track & trace the relevant materials at the individual item level.
2. Master Roll and Sublot Rolls use different material numbers.
3. Bulk finished goods and related packed finished goods use different material numbers. 

Constraints

1. SAP Standard serialization numbering doesn't have straightforward connection with the relevant Batch number. 
2. May have constraints on standard Fiori Apps. => Version to be checked. Alternative: use Fiori GUI transactions such as MIGO to perform goods receipt instead of Fiori Apps such as F3110 - Post Goods Receipt for Production Order (Refer to SAP Notes# 3459964)

   https://userapps.support.sap.com/sap/support/knowledge/en/3459964

Impacts

1. Impacts on Processes

   1). Sublot Scenario

- In addition to batch numbers, business will also need to generate and record serial numbers when performing relevant transaction.

- The numbering of Serial numbers (SNs) will not reflect the connections of master batch numbers. (But SNs will always be associated with relevant master batch numbers).

    2). Non-Sublot Scenarios

- It will be mandatory to record Serial numbers for each individual item (eg. each liquid adhesive cans) when performing any of the material movement transactions, for example goods receipt from the production, stock transfer and stock take etc.

- The numbering of Serial numbers (SNs) will not reflect the connections of master batch numbers. (But SNs will always be associated with relevant master batch numbers). 

2. Impacts on Other Domains

    1). WM/EWM

    2). TM

Impacts on Data and Migration

    1). New data object: Serial Number

    2). Stock on Hand: Serial Numbers need to be added to all the relevant batch stocks when uploading the stock from legacy SAP ECC systems.      

    3). If any legacy transactional data related to serialized material is required to migrate to new SAP S4/HANA system(s), SNs will need to be specified. 

3. Impacts on Developments

    1). TB Confirmed: factor current numbering logic between Master Batch and Sub-Batches.

    2). TB Confirmed: enhance standard Fiori Apps to support the SN functions.

4. Impacts on Interfaces & TPAs

Serial number information will need to be included to the current interfaces between SAP and other applications or passed to relevant TPAs, if relevant serialized materials are involved. Below are the potential interfaces and TPAs may get impacted.    

    1). 3PL (Third Party Logistics) Sites/Plants

    2). TPAs (Third Party Applications)

- Neptune

- Labelling Tools

- Weighbridge (TB Confirmed)

5. Impacts on Change Management

   1). Trainings are required for serial number management 

Business Rules

Potential business rule if adopt Serial Number management:

- Serial number will be activated for the materials requiring track and trace at individual item level.

Options considered

Option A: Introduce Serial Number with Batch Management

Serial Number activate + SN Profile + SN in HU/SU => TB Added

With this option, during goods receipts from production, relevant SNs will be generated and assigned to each of the material. SN and relevant Batch number should be printed on the label with the scannable barcode to streamline the downstream transactions such as stock transfer, stock take, picking/packing, goods issue etc.  

1. Sublot Scenario

Serial number will be generated for each of individual Sublot Rolls with the same batch number as the Master Roll. 

In the above Master Roll example:

2. Non-Sublot Scenario 

Serial number will be generated for each of the packed FG (eg. 5L cans) with the same batch number as the bulk FG (eg. 500L adhesives).

In the above liquid adhesive example:

Option B: Replicate AS-IS Batch Logic 

With this option, a batch number will be created for the original material, eg. master roll or bulk liquid adhesive etc. Different batch numbers will be created for each of the manufactured products, eg. sublot rolls or packed liquid adhesive cans. The link between original batch and sub-batches is via batch numbering rule.

1. Sublot Scenario

For the above Master Roll example:

2. Non-Sublot Scenario 

For the above liquid adhesive example:

Evaluation

Pro's and Con's 

	Option A (SN + Batch)	Option B (Batch Only)
Standardization	Pro's: In standard SAP, serial number is used to mange stock at the individual material level. By using the SN, business can track and trace each of the material where the material is used and what's the operations been done. In the meanwhile, SN can be associated with batch number to show the relationship with the original material, either Mater Roll or Bulk Liquid Adhesive.    Con's:	Pro Pro
Traceability	Pro Con	Con
Change Management	Pro	Con
Future Proof

See also

Change log

Workflow history