ADM Navigation

Access ADM and WebDP from your web browser of choice with this link: http://usalpdb05.eua.syensqo.com/ADMPrd/

(if you need to access ADM, or WebDP in the dev system: http://usalpdb06.eua.syensqo.com/ADMDev/)

A couple of tricks:

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:

Material types

Material Search Codes

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?

Hit the key. It takes you to the Location Dependent Quality Test Lag Table.

The Location dependent Quality test lag let you deal with locations where the Quality test lag differs from the material default.

Note: you may access the Location Dependent Quality Test Lag directly from there:

Effect of the Quality Test Lag on:

• the production schedule: none
• the grid: it offsets the availability of the output product of a run. See below
• 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 (Quality Test Lag and Schedule Upload Lag Adjustment). 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

What is going on? This:

The Quality Test Lag adds to the SAP Planned order End Date:

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

Used by DRP, DS, EP, the grids, and inventory targeting reports.

Note: for RM, we use inventory targets for EP (Replenishment type must be "Purchased" and Supplier must be "000124143" so that it doesn't generate an unassigned supply).

Used by the Forecast adjustment program (for the "Lead Time" field).

The material fields are to be populated as below:

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. Other formulas are created from STARS.

(automatic refresh if BOM modified? TBC)

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 indicates otherwise (two main options: always use production version 0001 or production version is determined by the formula)

Formula Details

Select a formula, hit the key. The formula details is the actual list of components of a formula.

This formula has only one component (it is a repackaging formula).

Production Standards

Similarly to an SAP Production version, the Production standard indicates which products/packages are qualified on which lines.

Up Time

Equivalent (however NOT identical) to OEE.

OEE is a line efficiency indicator that factors in planned downtimes, unfavorable production rates, times when lines do not run due to no demand, etc.

Up Time does not account for these aforementioned factors, because they are already accounted for on the production schedule as separated events (downtimes, for examples, are captured on the production schedule, therefore they not need being incorporated in the Up Time)

Up Time indicates how real life events will affect standard production rates.

Up time affects run duration.

Find an example of how Up Time affects a run here

Yield

Equivalent to SAP assembly scrap.

Affects component consumption quantity of runs using that production standard.

Also affects output gross quantity (not the net quantity). Net quantity is affecting the output product grid. This is the effective quantity of in-spec product we expect to get. Add the losses to this to get to the gross quantity.

And, finally, affects run duration.

Yield and Up Time have a cumulative effect. In other words, the duration of a run will be affected by both Up Time and Yield. 

Production Standards Effectivity

Ties together a Production Standard 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:

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:

Still not adding up.

But, there is a QC Lag Adjustment record for TFWC in AUA

Now, it does add up:

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). Transition tables are configured separately and assigned to equipments.
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 / Packaging Lines / Reactors	Selection / grouping field.
Exportable	Optional		if active, runs on that equipment are uploaded to SAP. Runs themselves will show this exportable checkbox as active. More about Production schedule interface here
Calendar	Mandatory		Assign an existing calendar (see Equipment Calendars)
Unit Position	Optional		position of the line on the production schedule.
Schedule by	Mandatory	Qty / Lot size / Package	(Qty is default). Default unit of measure when creating a new run.

Equipment Calendars

See here how they affect the available/unavailable time of an equipment on the Production schedule.

Equipment Calendar Events

For fixed downtimes. See here how they are used on the Production schedule.

Locations

Merged Locations

Location types

Transit Times

Applies to DRP Records and SAP STO's.

Location Formula Number Map

Transitions

Transition tables drive automated changeover time calculation between runs. Find here how they are used by the Production Schedule & Dynamic Scheduling

Transition Matrix and Default values

Default Transitions

This is the default transitions between runs on a Line . The Transition matrix is inserted in the Equipment master data . This is also used for transitions within a group.

=====> this section below, and until the next divider seems not to be available with version 11.7 (our current version as of Aug 2023).

Product to product specific transitions

Select a matrix, then hit the . It takes you to the list of product-to-product transition rules.

Use the Edit/Add/Copy/Delete keys to update the list of transitions.

=========================================================================> end of obsolete section.

Transition by Groups

Another, less labor intensive way to manage transition:

1. assign materials to groups (groups to be defined in the classification table)
2. define transitions between groups instead of between materials.  Always check the Allow Seq flag or it will not work. Input the transition in the Down time field

After making updates to transition  by groups , always "Apply Transitions" 

After Apply Transitions is completed , exit PICASO and open PICASO to see the impacts

This is all the transitions from Product to Product either created  from the Default transitions table for a line or the Transitions by group . This is a view only table 

Add a new transition by groups

Then Save and Apply transitions. We should wait for the night job to see the change.

In effective Transitions, with filter " group to group", we find all member products affected to the same group with the same down time. 

In the example mentioned above, we have setup a transfer from group (white products) to group (blue products). See detail of classification below:

After the creation of transition group, from any white product to anly blue product, we have the same down time. 

When we've got the same down time between 2 groups of products, it's practical to configure this way, when down time changes, we only need to make one modification.

Classification

Classifications or groups of materials are effectively used for GRID selections and for transitions for Groups

If it is for Transitions by Groups , make sure the Transition group flag is Checked

Classifications start with a CLASS then a GROUP then members in a Group

I recommend making the Class  code and the Group  code the same . It makes it easier to find later. In GRID Selections , input the Group code 

Class

Group

Once the class is created, open the follower window (), and create the corresponding group:

Material assignment to group:

Hit the follower window key (), this time, from the Group section:

It opens the Material/Group Mapping.

It pulls in all materials defined in ADM. Use the filter to narrow that list down.

Assign materials to the group as below (with the checkbox).

Schedule colors

Package

Package code definition.

Troubleshoot

PF1 Schedule Interface Management

Schedule Upload Unit Parameters

Schedule Upload Configuration 

For the overnight program to upload the schedule for a location  then USER MSAUSALP must added to the table for that location

Drives:

• conversion of planned orders into process orders in SAP: e.g. 3 days means that planned orders with an end date (TBC) within 3 days will be converted.
• how SAP production versions are selected in SAP when creating planned orders: 

  
  

  Use 0001 or production version override	self-explanatory
  JCODES for AUA	IDK
  CL_FormulationCrossRef Table	Production version driven by formula assigned to the run

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.

WP1 Interface Management

Picaso is also interfaced with WP1.

This is a one way interface, that brings: orders and stocks from WP1 to Picaso.

There is no Picaso→WP1 interface: no schedule upload, no forecast upload.

Historically developed for a few locations in Brazil (hence the name of the hereafter tables), this interface and the aforementioned table work for any location / product in WP1.

The overnight program brings the WP1 data ( Inventory , customer orders , Stock transfers, etc ) and converts them to PF1 codes .

Brazil Location Map

Fields to be populated as below:

Brazil Material Map

Fields to be populated as below:

User Management