Access ADM and WebDP from your web browser of choice with this link: http://alphdb05.eua.solvay.com/ADMPrd/
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A couple of tricks:
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| Mass change in ADM |
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| Export into an Excel spreadsheet |
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 | Optional | For Tavaux: A material with a flag in this field will be factored in with the optimizer. | |
| 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 )
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).
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)
| Formulas numbers | are generated automatically in Picaso as per another ADM table. These numbers will be used in Production Standards Effectivity. Formula 9 are created in Picaso (i.e. not from SAP or STARS interface) |
| Formula descriptions | are named after the SAP Production version they are created from. Therefore, a BOM not associated to a Production Version will not load in Picaso. Nomenclature: <Production version number> - <Plant> - <Package code> - <Production version description> |
| I/O Type | Continuous / Ending / Begining → how does the output product of a run affects projected inventory |
| I/O Lag (hours) | 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)
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).
| Materials | Output product |
| Element | Input product (i.e. component) |
| Package | Package code of the component |
| In/Out | Input for all components of the formula |
| Units | either % for variable quantity or absolute amount for fixed quantity |
| I/O Type | Beginning / Continuous / Ending |
| IO Lag (Hours) | TBC |
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 %) |
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.
| Standard Rate | Run duration for a 10 t run | Up Time = 100 % | Up Time = 90 % | Up Time = 50 % | Comment |
|---|---|---|---|---|---|
| 0.5 MT / h | 20 h (= 10 MT / (0.5 MT/h) | 20 h (= 20h / 1) | 22h13 (= 20h / 0.9) | 40h (= 20h / 0.5) | Up time affects the run duration. It does not affect consumption nor production rate |
Find an example of how Up Time affects a run here
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.
| What if affects | Standard output/input rate or run duration | Run with Yield = 100 % | Run with Yield = 90 % | Run with Yield = 50 % |
|---|---|---|---|---|
| Output product | 1500 kg | 1500 kg | 1500 kg / 0.9 = 1666.7 kg | 1500 kg / 0.5 = 3000 kg |
| Input Product A | 400 kg | 400 kg | 400 kg / 0.9 = 444.4 kg | 400 kg / 0.5 = 800 kg |
| Input Product B | 100 kg | 100 kg | 100 kg / 0.9 = 111.1 kg | 100 kg / 0.5 = 200 kg |
| Input Product C | 1000 kg | 1000 kg | 1000 kg / 0.9 = 1111.1 kg | 1000 kg / 0.5 = 2000 kg |
| Run duration | 24 h (for 1500 kg of output product) | 24 h | 24 h / 0.9 = 26 h 40min | 24 h / 0.5 = 48 h |
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.
| What if affects | Standard output/input rate or run duration | Run with Yield = 90 % and Up Time = 80 % |
|---|---|---|
| Output product | 1500 kg | 1500 kg / 0.9 = 1666.7 kg |
| Input Product A | 400 kg | 400 kg / 0.9 = 444.4 kg |
| Input Product B | 100 kg | 100 kg / 0.9 = 111.1 kg |
| Input Product C | 1000 kg | 1000 kg / 0.9 = 1111.1 kg |
| Run duration | 24 h (for 1500 kg of output product) | 24 h / 0.9 / 0.8= 33 h 20 min |
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). 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 | |
| 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. |
| Material types | Identifier | What for |
|---|---|---|
| Plant | P | Manufacturing facility |
| Warehouse | Storage facility | |
| Vendor | Vendor |
Applies to DRP Records and SAP STO's.
Transition tables drive automated changeover time calculation between runs. Find here how they are used by the Production Schedule
| Field | Mandatory/Optional | Rule | Comment |
|---|---|---|---|
| Matrix Code | Mandatory | automatically generated | Sequential number identifying a transition matrix |
| Description | Mandatory | N/A | Name of the transition matrix |
| Default Transition (mins) | |||
| Product Class | |||
| Use Default | optional | if active, all default values are in use (unless ...tbc) | |
| Default Transition Material | Optional | TBC | |
| Default Transition Qty | Optional | TBC | TBC |
| Default Down Time (mins) | Optional | TBC | default downtime after a run |
| Default Cost | Optional | TBC | unused |
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.
| Field | Mandatory/Optional | Rule | Comment |
|---|---|---|---|
| Matrix Code | Mandatory | N/A | Sequential number identifying a transition matrix |
| Initial Material | Mandatory | ||
| Final Material | Mandatory | ||
| Transition Material | Optional | TBC | |
| Allow Seq | Optional | TBC | |
| Down Time | Optional | TBC | Downtime after a run |
| Transition Time (mins) | Optional | TBC | Downtime Before(?) a run |
| Transition Qty | Optional | TBC | TBC |
| Transition Cost | Optional | TBC | TBC |
Another, less labor intensive way to manage transition:
|
The group level transition views are not turned on by default because there are some limitations to its use. Below are some guidelines for using group transitions: 1) The transition matrix size is dependent on the number of equipment lines that a transition matrix is assigned to. It is good to assign a transition matrix to as few equipment units as possible. This helps avoid a situation where the derived transition matrix produces many invalid transitions. Assign each group of products to a transition matrix and only use that matrix on the equipment lines that make the given group of products. 2) Limit the number of production standards on an equipment line. Reducing this number isn't always an option. But it is good to make sure unused production standards are deleted or archived if using group transition functionality. 3) One other thing to be aware of is the way transition groups are configured. There is an increased risk of a conflict when enumerating the transitions and the same product(s) is included in several different groups. 4) By reviewing any one matrix and squaring the total number of products in that matrix, the total rows expected in the derived view can be determined. When the total rows starts getting towards 100 thousand, there will likely be a slowdown in performance. |
Package code definition.
Drives:
| Use 0001 or production version override | self-explanatory |
| JCODES for AUA | IDK |
| CL_FormulationCrossRef Table | Production version driven by formula assigned to the run |
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.
there are limitations and good practices to using transition by groups