Once a plant starts using the SAP QM Module, the next step is to leverage on the new capability to determine when each new lot will be available (=released from QC).
This also allows SAP (and especially ATP) to prevent a lot to ship while it is in QI.
It furthermore allows SAP (and especially ATP) to determine if a specific lot can ship at a given date.
In order to achieve this, the Lab reviews their statistics and establishes the expected QC completion duration, which goes into SAP.
Both Picaso and SAP have to be kept in synchronization when accounting for QC Lab time factor.
Now, in order to determine the SAP QC Time, SAP Average Inspection Time, Picaso QC Lag, and Picaso QC Lag Adjustment, first determine what material flow applies:
- Scenario A: Lot is received in inventory at the manufacturing plant, then ships from the plant to final customer. All happening from within the production plant.
- Scenario B: Lot is received in inventory at the manufacturing plant, then is pushed to the warehouse once released from QC. Once it arrives at the warehouse, it can ship to final customers.
- Scenario C: Lot is received in inventory at the manufacturing plant, then is pushed to the warehouse right away, that is, before QC release. It is received at the warehouse in QC status. It will ship to final customers once released from QC.
- Scenario D: Same as C, with lots being received in SAP, and QC starting, while campaign still in progress. Even more complex, therefore only if adds value (to be continued)
Tips: The SAP QC Time, SAP Average Inspection Time, Picaso QC Lag, and Picaso QC Lag Adjustment apply during specific events of the life of a lot:
Applies before the lot is produced (aka Planning Phase) | Applies after goods receipt in inventory, and while the lot is in Quality Inspection (aka ) |
|---|---|
Picaso QC Lag (and Lag Adjustment) GRPT | Average Inspection Duration |
Material flows:
| Phase | Scenario A |
|---|---|
Production run time: 6 days Expected QC completion time = 4 days | |
| Before Goods Receipt (aka Planning phase) | |
| After Goods Receipt (aka QC Phase) | |
| After Release | |
| Master Data: | Picaso: QC Lag = expected QC duration (4 days) SAP: nothing. |
| Phase | Scenario B |
|---|---|
Production run time: 6 days Expected QC completion time = 4 days Transfer time between manufacturing plant and warehouse = 1 day Lot moved to the warehouse after QC release | |
Before Goods Receipt (aka Planning phase) | |
After Goods Receipt in the manufacturing plant (aka Goods Receipt from Production phase) | |
After Release | |
After Goods Receipt in the warehouse (aka Goods Receipt from Transfer) | |
| Master Data: | Picaso:
SAP:
|
| Phase | Scenario C |
|---|---|
Production run time: 6 days Expected QC completion time = 4 days Transfer time between manufacturing plant and warehouse = 1 day Lot moved to the warehouse during QC release | |
Before Goods Receipt (aka Planning phase) | |
After Goods Receipt in the manufacturing plant (aka Goods Receipt from Production phase) | |
After Goods Receipt in the warehouse (aka Goods Receipt from Transfer) | |
| After Release | |
| Master Data: | Picaso:
SAP:
|
Recap:
| Scenario | Master Data Picaso | Master Data SAP |
|---|---|---|
| A | QC Lag = expected QC duration | N/A |
| B | QC Lag = expected QC duration + transfer to the warehouse, including handling Schedule Upload Lag Adjustment = - QC Lag + transfer time | Av.Ins.Duration = expected QC duration |
| C | QC Lag = max of (expected QC duration // transfer time) Schedule Upload Lag Adjustment = - QC Lag | GRPT = QC duration - Transfer time Av.Ins.Duration = GRPT |
Step-by-step guide
Now, in order to determine the QC Time, Average Inspection Time, and QC Lag Adjustment, first determine what material flow applies:
Average Inspection Duration GRPT Picaso QC Lag Picaso Schedule Upload Lag Adjustment any additional step? Scenario A as per Lab determination N/A Same as Av.Ins.Duration N/A nope, you're good to go. Scenario C see below yes, see below - Scenario A:
- Scenario B: Lot is received in inventory, then is pushed to the warehouse once released from QC. Once it arrives at the warehouse, it can ship to final customers (usually not efficient, therefore will not be documented here)
- Scenario C: Lot is received in inventory, then is pushed to the warehouse right away, that is, before QC release. It is received at the warehouse in QC status. It will ship to final customers once released from QC.