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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 | 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 |
| Search code | What for |
|---|---|
| 900 | Obsolete |
| 999 | New products (interfaced) |
| 1 | Aromatics |
| 2 | FluoroPolymers |
| 4 | PVDC |
| 7 | FP intermediates |
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:
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.
Consider this run. Its attributes:
The effect of the plot of a 2 days QC Lag:
Consider the dates of this run:
And the dates of its corresponding SAP Planned Order:
| 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.
SAP code added to SKU Code mappings (SKU code is 7 digits with leading 0’s )
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.
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 | Mandatory | see Dynamic Scheduling | in combination with Min Run, it is used by DS to determine automatically generated run quantity |
| Min Run | Mandatory | see Dynamic Scheduling | in combination with Min Run, it is used by DS to determine automatically generated run quantity. Also used to calculate Inventory targets in production locations. |
| Default | Optional | one default production standard per product/package/location | Used by EP & Inventory targeting to determine the preferred mode of production. |
| Yield | Mandatory | between 0 and 100 | percentage of component loss (see below) |
| Up Time | Mandatory | between 0 and 100 | efficiency loss (see below) |
| Bath Res Time | Mandatory | set to 0 | no idea what this stuff does |
| Setup Time | Mandatory | set to 0 | no idea what this stuff does |
| Cycle position | Mandatory | see Dynamic Scheduling | position on the production wheel. Sequence in which DS will schedule a run. |
| Cycle frequency | Mandatory | see Dynamic Scheduling | in combination with equipment cycle length, determine how many times per cycle length is DS going to create a run. e.g. if cycle length is 30 days and Cycle frequency is 2, then DS will generate two runs per month. |
| Allow skip | Optional | leave blank | no idea what this stuff does |
| Qty increment | Mandatory | set to 0 | no idea what this stuff does |
| Pct to Tot | Mandatory | set to 0 or 100 | used by EP to calculate production penalty (in combination with Swing %) |
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.
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.
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
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. |
| Material types | Identifier | What for |
|---|---|---|
| Plant | P | Manufacturing facility |
| Warehouse | Storage facility | |
| Vendor | Vendor |
Applies to DRP Records and SAP STO's.
Drives:
Logs production schedule interface runs.
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.
