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 quality inspection.
In addition, it allows SAP (and especially ATP) to determine if a specific lot can ship at a given date, while still being under quality inspection.
In order to achieve this, the Lab reviews their statistics and establishes the expected completion time of a given product (or family of products), which goes into SAP.
Both Picaso and SAP have to be kept in synchronization when accounting for time the Lab needs to complete quality control. We will call this time: Lab Time. (Lab Time: from receiving sample, to registering results of tests and analysis).
Step-by-step guide
Now, in order to determine the SAP QC Time, SAP Average Inspection Time, SAP Goods Receipt Processing Time, SAP Planned Delivery 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)
- Special scenarios, when there is no external scheduling system:
- Scenario A-bis (same as A, no external scheduling system)
- Scenario B-bis (----------B,----------------------------------)
- Scenario C-bis (----------C,----------------------------------)
Tips: The SAP QC Time, SAP Average Inspection Time, Goods Receipt Processing Time, Planned Delivery time, Picaso QC Lag, and Picaso QC Lag Adjustment apply during specific events of the life of a lot:
Applies before the lot is received in inventory | Applies once the lot has been received in inventory and the QM Lot has been generated |
|---|---|
Picaso QC Lag Picaso Schedule Upload Lag Adjustment Goods Receipt Processing Time Planned Delivery Time | Average Inspection Duration |
Material flows:
| Phase | Scenario A |
|---|---|
Production run time: 6 days Lab time = 4 days | |
Before Goods Receipt from Production in the manufacturing plant (why the interface created a 10 days planned order in SAP when the original Picaso run is 6 days? Find the answer here) |
|
| After Goods Receipt from Production in the manufacturing plant |
|
| After QC Release |
|
| Master Data: | Picaso: QC Lag = Lab Time (4 days) SAP (at the plant)
|
| Phase | Scenario B |
|---|---|
Production run time: 6 days Lab time = 4 days Transfer time between manufacturing plant and warehouse = 1 day Lot moved to the warehouse after QC release | |
Before Goods Receipt (why the interface created a 10 days planned order in SAP when the original Picaso run is 6 days? Find the answer here) |
|
After Goods Receipt from Production in the manufacturing plant |
|
After QC Release |
|
After Goods Receipt from Transfer in the warehouse |
|
| Master Data: | Picaso:
SAP (at the plant)
SAP (at the warehouse)
|
| Phase | Scenario C |
|---|---|
Production run time: 6 days Lab time = 4 days Transfer time between manufacturing plant and warehouse = 1 day Lot moved to the warehouse during QC | |
Before Goods Receipt from Production |
|
After Goods Receipt from Production in the manufacturing plant |
|
After Goods Receipt from Transfer in the warehouse |
|
After QC Release |  |
| Master Data: | Picaso:
SAP (at the plant)
SAP (at the warehouse)
|
| Phase | Scenario A bis |
|---|---|
Production run time: 6 days Lab time = 4 days | |
Before Goods Receipt from Production in the manufacturing plant |
|
| After Goods Receipt from Production in the manufacturing plant |
|
| After QC Release |
|
| Master Data: | SAP (at the plant)
|
| Phase | Scenario B bis |
|---|---|
Production run time: 6 days Lab time = 4 days Transfer time between manufacturing plant and warehouse = 1 day Lot moved to the warehouse after QC release | |
Before Goods Receipt |
|
After Goods Receipt from Production in the manufacturing plant |
|
After QC Release |
|
After Goods Receipt from Transfer in the warehouse |
|
| Master Data: | SAP (at the plant)
SAP (at the warehouse)
|
| Phase | Scenario C-bis |
|---|---|
Production run time: 6 days Lab time = 4 days Transfer time between manufacturing plant and warehouse = 1 day Lot moved to the warehouse during QC | |
Before Goods Receipt from Production |
|
After Goods Receipt from Production in the manufacturing plant |
|
After Goods Receipt from Transfer in the warehouse |
|
After QC Release |  |
| Master Data: | SAP (at the plant)
SAP (at the warehouse)
|
Recap:
| Scenario | Master Data Picaso | Master Data SAP |
|---|---|---|
| A | QC Lag = Lab Time Schedule Upload Lag Adjustment = 0 (or none) | @the plant Av.Ins.Duration = Lab Time Planned Delivery Time = 0 Goods Receipt Processing Time = 0 |
| B | QC Lag = Lab Time + transfer to the warehouse, including handling Schedule Upload Lag Adjustment = - transfer time | @the plant Av.Ins.Duration = Lab Time Planned Delivery Time = 0 Goods Receipt Processing Time = 0 @the warehouse Planned Delivery Time = Transfer time Av.Ins.Duration = 0 Goods Receipt Processing Time = 0 |
| C | QC Lag = max of (Lab Time // transfer time) Schedule Upload Lag Adjustment = - QC Lag | @the plant Av.Ins.Duration = 0 Planned Delivery Time = 0 Goods Receipt Processing Time = 0 @the warehouse Planned Delivery Time = Transfer time GRPT = Lab Time - Transfer time Av.Ins.Duration = Lab Time - Transfer time |
| A-bis | N/A | @the plant Av.Ins.Duration = Lab Time Goods Receipt Processing Time = Lab Time Planned Delivery Time = 0 |
| B-bis | N/A | @the plant Av.Ins.Duration = Lab Time Goods Receipt Processing Time = Lab Time Planned Delivery Time = 0 @the warehouse Planned Delivery Time = Transfer time Av.Ins.Duration = 0 Goods Receipt Processing Time = 0 |
| C-bis | N/A | @the plant Av.Ins.Duration = 0 Planned Delivery Time = 0 Goods Receipt Processing Time = 0 @the warehouse Planned Delivery Time = Transfer time GRPT = Lab Time - Transfer time Av.Ins.Duration = Lab Time - Transfer time |
Use this file to help calculate the data en masse.
Maintain the QC Lag and the Schedule Upload Lag Adjustment in their respective tables in ADM.
Maintain