Chapter 1

Introduction
Integrated information systems in firms using discrete manufacturing practices have been in use for quite some time. In the logistics chain, this spans a
range of applications going from sales processing up to automated production plants.

Integrated Information
Processing

In process industry plants, however, this degree of integration has not yet
been reached. Instead, higher-level planning systems exist, which however
are not used conjointly with the lower-level process-related control systems.
Integration is usually achieved if customers individually program interfaces
between the higher and lower levels, but hardly any standard software solutions exist on the market.
The component PP-PI was developed by a team made up of SAP AG and
IDS Prof. Scheer GmbH. In this way, the development of business and
logistics applications is closely linked with the knowledge of experts in the
area of process and control systems. The requirements made by processoriented firms on PP-PI range from the representation of individual
synthesis and formulation problems to entire single and multi-way plants or
single and multi-product processes. Some are largely automated, using
process control systems, whereas others are run largely manually. All have
vendor and buyer relationships with each other, meaning that the intra-plant
coordination forms part of the planning process.
The component PP-PI was developed to cover all of the above requirements.
In parallel to the development work, contact with further potential
customers was made during the course of seminars, workshops, talks and
presentations. In this way, development was able to obtain feedback and
suggestions from firms coming from various lines of industry.

Pilot sites

Furthermore, a group of pilot customers was selected in mid-1994 to test and

verify the functionality developed until then. These are pilot sites coming
from various lines of industry in Europe and America. The functionality of
the first version of PP-PI (Release 3.0) was greatly influenced by these firms.
This way of proceeding had the decisive advantage of having had the
functionality tested by seven large firms before its release, as well as
providing important input for the further development of PP-PI.
This brochure contains an overview of the functions in the application PP-PI.
The requirements placed on an integrated batch processing system that has
links to all levels of a company also affect other R/3 modules. The modules
whose development was most affected were materials management and
material requirements planning. With PP and PP-PI, the R/3 System will be
supporting our customers in industrial plants using discrete manufacturing
as well as those carrying out process manufacturing.

1-1

Chapter 2

Product Positioning
The area in which PP-PI will be used is the production plant carrying out
batch manufacturing processes. With the help of PP-PI it will be possible to
carry out integrated planning of the production, transport and waste disposal data flows of a plant. Furthermore, PP-PI will support the integration
of all plants in an enterprise over the entire logistics chain: vertically by
means of an integrated information flow, ranging from central business
applications down to process control on the shop floor. Horizontally, this
integration is supported by the coordination of planning between production
plants, as well as with the recycling and waste disposal facilities and the
production laboratory.

Vertical and Horizontal

Integration

The ideal plant for PP-PI is found in the chemical, pharmaceutical or food
and beverages industries. The following are some of the features characterizing such a plant:

Characteristics of
Process Industries

It has a relatively large degree of planning autonomy with regard to its
resources.
It carries out non-continuous forms of manufacturing and the batches
are often grouped together in production campaigns.
The production plant is designed as a multi-way plant and can be used
in various ways.
The product sequences must be planned carefully, in order to avoid
unnecessary cleanout operations and changeovers.
The various production steps lead to the creation of finished products,
by-products and remaining materials.
Process control involves various parameters which vary from batch to
batch, because the quality of the ingredients used or the environmental
conditions may vary.
The control of the product quality requires a close coordination with the
production laboratory allocated to the production process.
The production plant is partially automated; some of the operating
instructions must therefore be in natural language and others in a language understandable to the automated process control system.
For each batch, the corresponding recipe and its production order must
be archived, together with the actual data on the process. This data must
be available for evaluations of all types.

2-1

Product Positioning

Furthermore, all messages sent during a process, whether they are used
in a process control system or have been entered by a plant operator,
must be processed in a uniform manner. These messages may provide
status information on a batch just produced, or on the resources used to
produce it. A message may deal with material consumption or production yields, which must be posted immediately as stock movements. Or,
a message may deal with a process event or quality data, which must be
archived according to GMP (Good Manufacturing Practices).
These features roughly describe process-oriented production as it is carried
out in modern plants today.

With Release 3.0 of PP-PI, SAP is providing the first version of its system for
production planning and control of process-oriented lines of industry.
For which type of production is PP-PI primarily suited?
PP-PI is suited primarily for process-oriented plants, and can support central
as well as local applications. The main lines of industry for which the functionality of PP-PI was developed are the chemical and pharmaceutical industries, as well as food and beverages and the process-oriented electronics
industry.

2-2

Chapter 3

Overview of Functions
In daily plant use, PP-PI is located between the business applications on
higher levels and the technical operations on lower levels.
PP-PI is made up of the following groups of functions:
Resources
Master recipes
Process orders
Campaign and process planning (capacity planning)
Process management
Integration with laboratory information systems (LIMS)
and R/3-QM (Quality Management)
Integration with higher-level systems
Production documentation and evaluation
Non-SAP
system

R/2

R/3-MPS

Master data

External
requirements

R/3- MRP
Materials

Campaign
planning

Process
order
planning
Quality
management
Process
management

Ressources

Process data
documentation
dokumentation

Master receipes

Process data
evaluation

LIMS

Automatic

Manual

Laboratory

(PCS)

PI sheet

Fig. 3-1: The main functions of PP-PI

3-1

Overview of Functions

Resources

The resource management component describes all resources necessary to

the production of output in the chemical industry. These can be labor resources, plant equipment used, transport facilities, or recycling and waste
disposal facilities. These are considered not only with respect to their productive use in a plant, but also with respect to product quality, work safety
and environmental protection.
It is possible to create a network-like structure to display the sequence and
relationships of resources, as well as resource hierarchies to show the dependencies.

Master Recipes

Materials and resources are maintained in the recipe management component, in order to describe the steps involved in a specific manufacturing
process. Recipes also contain information on all resources required and how
they are related to each other in the production process, i.e. the resources are
networked. For PP-PI, recipes combine all the main information on which
planning, control and documentation of manufacturing processes are based.
The starting point for recipe management was provided by the proposals
made by NAMUR (norms working committee for measuring and control
techniques in the chemical industry). The proposals made by NAMUR for
defining the structure of basic and control recipes were developed for process control procedures and will be expanded accordingly in PP-PI.
Master recipes are regarded from the planning as well as from the control
aspect. In the planning phase, the user has to define the operations and
phases of a master recipe, to classify the materials or substances used, to
calculate the target quantities and define the inspection characteristics to be
used in the quality inspection. User-defined relationships between the
operations and phases can be maintained and viewed in the graphic editor.

Process Orders

Process orders describe the specific production steps involved in creating

one or several products, substances or batches. The basis for this is the information stored in the master recipe, which now contains dates and specific
quantities. When an order or individual operations of an order are released,
control recipes are generated, which are passed on to the process
management component.

Capacity Planning
and Leveling

Capacity planning and leveling refers to the planning of campaigns (roughcut scheduling) and the planning and scheduling of orders (detailed scheduling).
Within the framework of campaign planning, rough-cut scheduling (to
the day) is carried out for production campaigns, resources are allocated, and the availability of the allocated resources is checked.
Process plannings main functions are to schedule and release operations in process orders, as well as to check material and resource availability.
Campaign planning will be available after Release 3.0.

3-2

Overview of Functions

The process management component coordinates the data exchange between

PP-PI and the systems involved in process control and quality assurance.
Due to its flexible architecture, process management can link up to automated, partially automated and manually operated plants.

Process Management

The data exchange takes place via control recipes sent to the corresponding
control systems. In the reverse direction, process-related data is collected in
the form of process messages and passed back to process management.
Process messages provide information on the current status of a process, on
the committed resources, material consumptions and other selected events.
By distributing process messages to predefined recipients, process management ensures that information also flows to other PP-PI functions. Process
messages are a prerequisite for process documentation.
The exchange of information between production plant and lab is the task of
the laboratory integration component. In this way, the quality of products
coming out of the production process is ensured. There are the following
two types of control or inspection runs:

Integration with
the Laboratory

In-process control, which records process events directly during the

production process.
Post-process control, in which inspection results are recorded after the
production run and then passed on to the laboratory.
The results of both methods are then written to the batch record.
There is no difference as to whether you use an external LIMS system or the
R/3 QM System.
The documentation and evaluation of processes closes the cycle of data
used. Production specifications from process orders are compared with
actual values from production and, together with process events and analysis results, used to create batch and production records. This data forms the
basis of the technical and business-related optimization of the process, as
well as of the fulfillment of legal requirements coming from work safety and
environmental protection regulations, such as the Good Manufacturing
Practice of the US Food and Drug Administration.

Process Documentation
and Evaluation

Using the functionality of batch management, you can manage subsets of

materials subject to handling in batches throughout the entire logistics chain,
from procurement over production up to final delivery. This is of particular
importance in process industries, in which manufacturing is often carried
out in batches.

Integration with
R/3 Batch Management

In this way you can define and locate warehouse batches with unique specifications which are required for the production of a particular product or
intermediate. Furthermore, you can trace the individual batch throughout
the entire production process and in this way comply with legal requirements placed on product liability.

3-3

Overview of Functions

Integration with
Higher-level Systems

PP-PI is integrated with all other R/3 modules, i.e. plant data is directly
linked with application data on the company management level. The use of
company-wide data by the plant, the integrity of central and distributed
data, and the data flow between these levels are all functions carried out by
PP-PI.

The module PP-PI contains all the necessary functions for the planning and
control of processes and is fully integrated with all other R/3 modules.
What ar the main functions of PP-PI?
PP-PI contains functions for resources, master recipes, process orders, campaign and process planning (capacity planning) and process management,
i.e. down to the process control level.

What links exist from PP-PI to other systems?

There is an integration with laboratory information management systems
(LIMS) and to the R/3 Quality Management System (QM), to higher-level
and external systems (for example, R/2), as well as to process data documentation and evaluation.

3-4

Chapter 4

Resources
In the strict sense of the word, the term "resource" refers to all materials,
work centers, plants, plant lines and processing units, capacities, production
resources, tools and documents to be maintained.

Definition of the
PP-PI Resource

Since however in the R/3 System the term "material" plays a central role - via
the material master - it does not make sense to manage materials a second
time in the form of resources. In the R/3 System, materials themselves refer
to any number of things, from finished products, assemblies, to raw materials, batches and even services.
In the area of PP-PI, the term resource refers to all user-defined production,
waste disposal or recycling facilities and the persons working within them,
as well as, for example, transport or storage facilities and energy sources.
The resource can be regarded as a planning-related type of organizational
unit within a company, describing the tasks of planning, control and execution of production processes. The organizational unit "resource" serves to
structure production in a plant in detail, since it is a main element of shop
floor planning as well as of capacity planning. For purposes of capacity
aggregation, you can create your own hierarchical resource structures. Different aggregation structures via a number of user-defined resource hierarchies can be represented via any number of parallel resource hierarchies for
simulation purposes.

The Resource as an
Organizational Unit

Waste
disposal
facility

Train/Line

Labor

Transport

Energy

Fig. 4-1: Possible types of user-defined resources

4-1

Resources

Resource Categories

The user himself can define the different resource categories used in a plant.
Here are some examples:
Line

This is the line in the production plant, as defined by

NAMUR and ISA/SP88, which contains one or several
processing units. It can be a one-way or multi-way plant
and can produce a complete batch. It makes no difference
whether the goal is to manufacture a product, recycle remaining materials or dispose of wastes.
The production line or plant can be regarded as the root
of a resource hierarchy containing several processing
units.

Processing unit

This is the smallest logistic unit at which a batch can be

manufactured. For example, this could be a mixing vessel, in which different process operations, such as charging, mixing, or heating, can be carried out.

Labor

The shift foreman, plant or line operator, etc. can be

represented as a group whose members have the same
qualifications, but also as individual persons.

Transport

This can be transport facilities, such as pipes or tanks,

which are used to carry out the inner-plant transport runs
between warehouse and plant line.

In-process storage These can be storage facilities in which materials are

stored between production steps.
The resource category controls the screens and fields which are displayed by
the system for user maintenance. In the chemical industry, for example, this
would be at least the basic data, the scheduling and capacity data of the resource.

Default Resource

It is also possible to maintain a default resource via Customing, in order to

include default values when creating resources. These default values are
maintained for a combination of resource category and plant. When a resource of this type and in this plant is created, the default values will be
transferred to this resource. This is time-saving if you have to maintain many
resources of the same type, for example, many vessels distributed over
several buildings.

Commitment and
Allocation of Resources

The primary resource is the part of a plant or processing unit on or at which

an operation is carried out. It is occupied or "committed" for the duration of
the operation, and all phases within this operation are scheduled for this
time period, since they automatically have the same primary resource.

4-2

Resources

Besides the primary resource, you can allocate other required resources to an
operation or to a phase. These are called secondary resources. This allocation
can be flexible, meaning that you can define a variable start and finish time
which is relative to the start or finish time of the operation or phase to which
the secondary resource is allocated.

Resource commitment times

Operation
Mixing

Activities
Phase:
Filling

Primary resource

Phase:
Stirring

Phase:
Emptying

Vessel 37
Line operator

Allocation of
secondary resources
var.
Start

var.
Finish

Transport
container

time

Fig. 4-2: Allocation of secondary resources

If resources have the same attributes with respect to their usage in a process,
it is possible to group them into a class via the classification system. This is
useful, for example, when maintaining a recipe, since you do not have to
allocate all the possible alternative processing units to the operations of the
recipe. Instead, you can classify the operation with the same class as the resource (for example, operation "mixing" is carried out via the resource class
"mixers"). The characteristics of the class (see Fig. 4-3) are then the selection
conditions for the resource in the process order. In this way, you can select a
processing unit shortly before production, i.e. when releasing a process order.

Grouping within
Resource Classes

Class: Mixing vessels

Object

Mixing vessel 37

Characteristics
Values:
RPM.:
Volume:
Maximum temp.:

150
300 l
70 C

Fig. 4-3: Classification of resources

4-3

Resources

Aggregation of Resource
Data via Hierarchy

The resource hierarchy serves to aggregate available capacity and requirements data at a resource (for example, the plant) on a higher level. In particular, rough-cut capacity planning and medium-term planning need to
have aggregated available and required capacity data. An allocation of new
resources to a hierarchy is possible at any time. You can display and maintain the hierarchy in the R/3 graphic editor (Fig. 4-4), with the results being
written back to the resource record.

Fig. 4-4: Resource hierarchy

Resource Networks

Processing units can often not be used in any sequence. If a batch was started
in a particular mixing vessel, it can only be continued in vessels which are
available and to which, for example, there is a pipeline. The possible resources with their predecessor/successor relationships are created as resource
networks in the system (see Fig. 4-5).
During process planning, resource networks can then help you find the possible paths which a process order can take through a plant. The resource
network is thus accessible when individual resources are specified for
operations.

4-4

Resources

Fig. 4-5: Networking of resources

You can link resources with the following objects:

Links

with a cost center

with a person
with a position in personnel administration (PA)
with a specific qualification or a qualification/requirements profile
Every resource is allocated to a cost center. In this way, product or order
costing provides a link between CO and PP. More information on this topic
can be found under Costing data further on in this chapter.

Link between Resource

and Cost Center

The link of a resource with a person is used in order to find out who is
working at which resource, for example.

Integration with Personnel

Administration (PA)

If the Personnel Administration system is not active, you can define a
person responsible for the resource. This can later be used as a search
field.
If the Personnel Administration system is active, the resource data is
made available to PP-PI.
Furthermore, when creating a personnel resource, you can refer to a work
center maintained in the Personnel Administration system. In this way, the
R/3 System ensures that personnel data for an employee is unique.

4-5

Resources

Link to Positions

Allocation of
Qualifications

Positions in the PA system are planned and approved jobs. The link of a
personnel resource with a position enables you to find out which position
this resource belongs to.
Qualifications serve to more closely describe personnel resources.
If the Personnel Administration system is not active, you can define a
qualification in the form of a suitability necessary for a person to carry
out a specific task or operation at this resource. For this, the R/3 classification system is used.
If the Personnel Administration System is active, you can define several
qualifications for employees, which can then be grouped into a qualifications profile.

Requirements Profile

Furthermore, you can define requirements for every resource, such as requiring that a specific operation be carried out by someone with a certain level
of experience or training.

Resources and Capacities

Link between
Capacity and Resource

The term capacity refers to the ability of a resource to perform a specific

task, i.e. the available work of people, machines, processing units and other
resources within a particular period of time. Capacities are differentiated
according to capacity category (like resources and resource categories).
You can allocate any number of capacities to each capacity category. The
capacities used during a production process do not need to be allocated individually, since when selecting a resource, the capacity categories are
automatically linked to the resource.
These capacities form the basis of scheduling for process orders, as well as of
capacity planning and shop floor control.

Energy

Resource

Resource

Process unit 1

Process unit 2

Volume

Available
time

Pooled
capacity

Heating
capacities
Line operator

Fig. 4-6: Capacity categories for resources

4-6

e.g. Cleanout
personnel

Resources

A capacity category classifies a capacity of a resource. It can only exist once

for each resource; however, capacities defined for different resources can
belong to the same capacity category. Via an internal conversion factor, the
capacities not maintainable in hours can be maintained, for example, in liters
or kilowatt.

Capacity Categories

A pooled capacity refers to a capacity whose availability is used conjointly

by several resources. An example of a pooled capacity is the cleanout team,
whose members work together at several different plant lines, for example.

Pooled Capacity

Capacity commitment can be exclusive or non-exclusive. For example, the

capacity of a mixing vessel described in cubic meters can be completely used
up, even if a batch occupies only half of the vessel space available. In another
case, one capacity might be allocated to several operations of the process
order, or even several orders.

Exclusive/Non-exclusive
Use of Capacities

In Fig. 4-7 below, for example, the capacity of a flare conduit can be used
fully, since the operations of several process orders can send their gaseous
wastes to it.

not
le
availab
le
availab

occupied
Batch 01

occupied

Exclusive use of capacity

Waste
Order 1

Waste
Order 2

Non-exclusive use of capacity

Fig. 4-7: Commitment and allocation of capacities

In order to carry out detailed resource planning (for example, committing

resources for specific periods of time), capacities can be subdivided into
individual capacities (for example, individual vessels), for which you can
maintain availability data. The requirements can be allocated to these individual capacities in the planning table.

Subdivisions into
Individual Capacities

Furthermore, you can allocate a capacity to persons working at a particular

resource, as well as allocating qualifications to such persons. Via the allocation of a capacity to a PA position, the system will enable you to select the
most suitable person to carry out the work.
The capacity category determines the objects to which you can link a capacity.

4-7

Resources

Maintaining Resource Data

Default Values for
Operations

In order to simplify the maintenance of operations in recipes, you can enter

default values for an operation to be carried out at a resource. This information is copied or referenced in the operation by the system. In this way, for
example, the standard texts stored for a resource simplify the maintenance of
operation texts in the recipe. Other default values are, for example, the control key of the operation to be carried out at this resource or the wage group
of the employee at this personnel resource.

Standard Values

Standard values enable planners to specify values (for activities such as

mixing or charging) to be maintained for an operation at a particular
resource. In this way, complex calculations of costs, durations or capacity
requirements for a resource can be carried out. The user specifies whether a
standard value must be verified, for example, or is required/optional.

Standard
value

Unit

Rule for
maintenance

Charging

Liter

required

Mixing

Time

optional

Heating

-- (none)

Fig. 4-8: Standard operation values used in the resource (example)

Formulas

Formulas defined for a resource are used within costing, scheduling and
capacity planning. You can define formulas specific to your firm, in order to
carry out calculations for execution times, costing, and capacity requirements for a process order.
Via the formulas for the calculation of the execution times, the scheduling
functions enable you to schedule the duration of operations (see Fig.
4-9).
Formulas for the calculation of costs enable you to cost operations being
carried out at a particular resource. They specify how costing is to be
carried out.
Every capacity defined for a resource can have a formula for the calculation of capacity requirements in the operations of a process order allocated
to it.

4-8

Resources

Standard values

Formular

Operation qty.
Base qty.
Charging
Processing
Emptying

200 l
100 l
20 min
60 min
10 min

(Charging + Processing + Emptying)

x Operation qty.
Total time =

Total time =

Results

:
:
:
:
:

Base qty.

(20 min + 60 min + 10 min)

x 200 l / 100 l
= 180 min

Fig. 4-9: Standard values for formulas and calculation results

Via the scheduling functions, the start and finish dates for operations are
calculated. For this, the system needs to calculate the execution times and
relate them to the operating times of the resources.

Scheduling Data

Using the costing data, the production costs of an operation can be calculated. Costing has the goal of allocating individual costs to the cost objects
(material, order, etc.) involved.

Costing Data

If a resource is used in a recipe, standard values can be entered for the

activity types defined for this resource. Using these activity types, you can
specify how the standard values are to be costed. The valuation of in-house
activities uses the cost rates defined for these activities in the cost center.

Further Resource Functionality

Capacity requirements are calculated on the basis of the standard values and
quantities stored in the operations themselves. These in turn stem from formulas stored for the resources. During CRP, the capacity requirements of the
operations in an order are calculated and compared with the available
capacity defined for the resources. This results in a so-called capacity load
analysis.

Capacity Requirements
Planning

You can use the interactive graphic planning table to dispatch operations to
resources and to carry out capacity leveling. More information on this subject can be found in Chapter 7.
Via an interactive interface, you can then transfer the results of the load
analysis to MS-EXCEL. In this way, load profiles can be processed further
with MS-EXCEL, or placed in word processing systems. Planners and schedulers can obtain a clear picture of the load situation of the capacities in their
plant or company.

Interface to MS-EXCEL

4-9

Resources

Capacity Availability at
Time of Order Dispatch

Using availability checks, the available capacity of a process order or for

entire order structures can be checked and monitored in every stage of planning.
For every operation of a process order, the system checks to see if there is
available capacity at the specified resource. If there is not enough capacity,
the system will propose a date to the planner at which the process order can
be carried out without bottlenecks.

Evaluations for Resources

You can carry out many different types of evaluations for the resources
maintained in your plant, such as:
Which resources are available?
Which cost centers are allocated to them?
Which capacities have been defined for the resources; at which
resources is a capacity being used?
What resource hierarchies exist?
In which recipes or for which materials is a resource being used?
Note:
You can find further information on the topic of capacity planning and leveling in Chapter 8 Capacity planning and leveling.

User-defined resources with any number of allocated capacities, grouped into

capacity categories, ensure that a firm can precisely control and monitor the
availability and the costs of its resources.
What types of resources can be maintained in PP-PI?
In PP-PI, you can define plants with individual processing units (for example, reaction vessels), labor, transport facilities, storage tanks and many
other types of resources.
How are the capacities of resources used in PP-PI?
User-defined resource categories, factory calendars, shift schedules, and
resource hierarchies make it possible to realistically represent the capacity of
any type of resource. Furthermore, you can define single and multiple allocation of capacities, as well as the exclusive use of a capacity for a resource.

4-10

Chapter 5

Master Recipes
The master recipe describes the production of one or several materials in a
production run. It contains master data and details the plant-specific use of a
process. It is used in MRP runs and in campaign planning, as well as in process planning and control.
Process
Planning

Introduction

Control

EBF/S88/Namur

Resource
Requirements

Header
Recipe

Procedure

Materials
Safety and
Compliance
Information

Fig. 5-1: Master recipes in PP-PI

The master recipe was designed in close conformity with the norms and
guidelines of the following institutions:

Conformity to Norms

ISA (Instrument Society of America) with the norm S88

NAMUR (Norms working committee for measuring and control techniques in the chemical industry): For the requirements of process planning, PP-PI has included some enhancements over and above the
NAMUR requirements.
European Batch Forum: coordinates the work of national European
committees such as NAMUR with ISA.
Recipes contain all the information required by the FDA (Food and Drug
Administration) in their GMP (Good Manufacturing Practice) guidelines for
the documentation of process specifications. For each recipe and recipe object (for example, operations/phases, material components, or process instructions) involved, changes are documented separately. If a change number is entered, it is possible to have changes with a validity period.

FDA/GMP Guidelines

The authorizations for changing recipes ensure that only authorized changes
are made, as required in the GMP guidelines. You can get more information
on this subject in the section entitled Approval for Recipes further on in
this chapter.

5-1

Master Recipes

Links to R/3-PP

The development of PP-PI places emphasis on maintaining full integration

with the data flows represented in the classical R/3 PP module. There are
many relationships between PP-PI and PP, since discrete and non-discrete
production flows contain common functionality such as scheduling and
product costing. In this way, manufacturers can use the functionality of discrete and process flow production simultaneously.

Master Recipe Functions

A master recipe describes the steps (operations and phases) involved in a
production process, allocates resources and materials to the process, and
contains process instructions and their characteristics for purposes of process
control.

Resource network
Recipe header

Material list
Operations
Secondary resources
Phases

Process instructions

PI characteristics

Material
components

Relationships

Inspection characteristics

Fig. 5-2: Structure of the master recipe

In the R/3 System, master recipes have the same basic structure as routings,
inspection plans, maintenance task lists, and library networks.

Recipe Header

The recipe header contains information on the charge quantity range, the
status or change rules for a recipe. The charge quantity range is user-defined. The status defines the usage and changeability of master recipes. All
recipes are subject to change management.
In the recipe you can store a long text for the recipe and maintain general
administrative and quality data.

5-2

Master Recipes

Seen from the perspective of process planning, it is important to consider the

time sequence in which production takes place. This information is stored in
the operations and phases of a recipe.

Operation/Phase

An operation is an independent part of a recipe carried out at a processing

unit (primary resource). An operation can be subdivided into phases. Operations as well as phases can have resources and materials allocated to them.

Allocation of Resources
to Operations/Phases

If operations are allocated to a particular processing unit, their execution

time corresponds to the duration that the substances remain at the processing unit. For each operation, additional resources (secondary resources) can
be defined, which can be allocated using a time offset. This could be labor
resources, energy, transport, etc.

Secondary
resource
Labor

Operation
Primary
resource
Processing
unit

Phase

Secondary
resource
Steam

Fig. 5-3: llocation of resources

In the master recipe, it is possible to first store only requirements for the
resource to be used, without specifying exactly which one. At the time a process order is released, the user can then select a particular resource. For this,
resources need to be classified via the R/3 classification system. From the
resources which correspond to the requirements of the operation, the user
can then select an appropriate one.

Resource Selection

Phases can have relationships with the phases of other operations. Relationships specify the type of time sequence for operations/ phases. A simple
example is the synchronization of phases belonging to different operations.
Another example involves the mixing and heating of substances in one
vessel, but where the duration of mixing is longer than that of heating. The
two phases mixing and heating have different durations, and their start
is linked by a relationship.

Relationships of Phases

5-3

Master Recipes

Fig. 5-4: Relationships of operations and phases

Scheduling

A master recipe is scheduled in order to specify basic dates for all operations. The scheduling function also determines the capacity requirements
needed to carry out a certain recipe.
In the master recipe, scheduling is carried out for phases, since the
operations themselves cannot be scheduled. The earliest start and latest
finish dates/times of the operations are then derived from the phase scheduling data.
A Gantt chart enables you to display the scheduling results in graphic form.

Process Instructions

Control Recipe
Destination

5-4

Information for the process control level is stored in process instructions in

the master recipe. A process instruction is a structure with which data or
instructions are transferred from process planning to process control. Process instructions are allocated to the phases of a recipe. After a process order
is released for production, the phases in it are combined to form control
recipes.
The process instructions to be combined in a control recipe are specified in
the master recipe using the so-called control recipe destination. This can be a
process control system or a line operator, to which the control recipe is transferred for further processing. Via the control recipe destination, you can
specify the technical address to which a control recipe is to be sent and how
the data transfer is to take place (for example, triggered by the R/3 System
or by process control).

Master Recipes

In normal operation, the effect process instructions and their characteristics

(created for the master recipe) have on the layout and the structure of the PI
sheet are only clear after the control recipe has been created. In order to
create a control recipe, you have to create a process order using a particular
recipe, and then generate a control recipe from this order. Since this is multistep process, a simulation function for the master recipe has been developed,
so that you can check the layout and the structure of the PI sheet in advance.

Simulation

You can get further information on process instructions and control recipes
in Chapter 9 Process Management.
An important part of the master recipe is formed by the material list linked
to it, which contains all input and output materials. It serves to represent all
the material flows involved in a process. The material list is designed for
process flows in which input materials are consumed and valuable
/remaining materials are produced. In contrast to the classical bill of material (BOM), which is created for a finished product, the material list is created for the process and can also contain, for example, catalysts.

Material List

Fig. 5-5: Material list for a master recipe

The material list is based on the BOM components of the BOM used, the
allocation of components to operations and phases and the material quantity
calculation.

5-5

Master Recipes

The material list contains planned values for the input materials, their mixing ratios as well as the yields and remaining substances (by-products,
wastes) to be produced. The user has to define the finished products, the
input materials and all other produced materials in the form of material
master records (MM).
The sequence of the material components in the material list describes the
flow of materials through a production line. For this reason, you have to
allocate material components to the operations and phases of the recipe.

Functions of the
Material List

A material can be included in the list more than once. It can appear as an
input material, as well as an output material (finished product or by-product).
The materials are grouped into a material list, either for an operation or for
the entire recipe. This has the following advantages:
It enables the adequate description of co-products, if more than one
product per process is to be manufactured. For this, you have to define
co-products as BOM items.
It makes it possible to represent circular material flows in a plant.
It enables you to plan the production of products as well as wastes.

Production Versions

The production version defines a unique combination of a material list/BOM

and a master recipe for the production of a material on a key date.

Recipe: Black varnish

Material

Process
Recipe 1 with:

Material list

z Operations/
z
z

phases
Relationships
etc.

z Components
z Co-products
z Material quantity
calculation

Production version
z

Period of validity

Charge quantity range

Fig. 5-6: Production version for a recipe

By means of the production version, you can

Use different BOMs for one recipe, in order to produce a different color
per production version, as in the example in Fig. 5-6 above.
Obtain period-specific cost accounting for each production version

5-6

Master Recipes

Production versions are used to represent various production techniques for

one product. They specify the following:
The material list/BOM used
The task list type (in this case, master recipes), the recipe group and the
specific recipe to be used
Existing lot-size restrictions and periods of validity
The material quantity calculation determines how much of each substance
used in production is necessary, taking into consideration the mixing ratios
of the input materials as well as the yield ratios of the products and by- or
co-products. The material quantity calculation includes:

Calculation of
Material Quantities

all quantities of materials in the material list

peration and phase quantities
the characteristics and their values
Ingredients
Active
ingredient

Catalyst

Solvent

Characs
Act.ingrf.:
80%

Characs
Viscosity:
1555 Pa-s

Yield
Product

Catalyst

Remaining
materials

Fig. 5-7: Calculation of quantities for input materials and yields

The prerequisite of a material quantity calculation is the creation of characteristics and characteristic values, in order to classify the materials and their
properties.
When a material is included in the material list of the master recipe, the characteristics of the classified materials are used. In the BOM, it is possible to
classify the individual material items again.

5-7

Master Recipes

Material quantity calculation uses these characteristics and their values. The
valuation of these characteristics provides planned values for material quantity calculation in the master recipe, as well as providing actual values for
the selection of batches in a process order. When finished batches from a
process order are posted to the warehouse, the charactgeristics of its materials are valuated.

Formulas

In material quantity calculation, you can use formulas to define how material and operation quantities are to be calculated. For this you can also use
quantitative values of material characteristics.
When you change the quantity of a material or the value of one of its characteristics, the system will recalculate all dependent quantities, in the recipe
as well as in the process order.
When planned or process orders are created, the actual operation quantities
are recalculated using the formulas stored in material quantity calculation.
When you change the quantity of a material or the value of one of its characteristics, the system recalculates all dependent quantities in the recipe as
well as in the process order.

Intra Materials

An intra material is a material which only appears temporarily between two

processing units. This can be, for example, a charge quantity which is flowing from one vessel into another. The charged substance needs, for example,
to be distilled before it comes out as a finished product. Intramaterials explode the levels of a BOM, provided the processes involved are connected.
It is necessary to define intra materials in orders, for example, to calculate
material quantities or carry out in-process inspections for them.
Operation on unit

Raw material

Waste

Intramaterial

Operation
on unit

Catalyst

Product A
Catalyst
Product B

Fig. 5-8 Material flow - example with intra material

5-8

Master Recipes

The user has the possibility of copying a master recipe. In this way, planners
can take a frequently used master recipe as the basis of planning, in order to
adjust it to various processes and/or plant lines.

Copying Function

The copying function can also be used for the transfer of already existing
standard routings. The header data, the main sequence and the operations
are taken over as is, sub-operations are transformed into secondary resources. This means that you can use routings existing in your firm for the
purposes of PP-PI.
The manufacturing of products with many variants (that is, using configurable materials) is supported as of Rel. 3.0D. For this, the customer order
(SD) has to have customer-specific attributes allocated to the product to be
manufactured. Using these attributes, the master recipe uses selection conditions to refer to the product. This is done using so-called object dependencies, which specify whether an operation or a phase is to be transferred from
the master recipe to the process order.

Configuration of
Master Recipes

You can carry out the following evaluations for your recipes:

Evaluations

Evaluations on recipe changes: all changes in recipe objects are displayed over the time axis
Where-used list of a master recipe in resources, process instruction categories, materials, documents and classes
Mass changes: replacement of process instruction categories and resources in the master recipe, and of materials in material lists/BOMs.
Besides the functionality for mass changes in the material list, you can use
the integrated change management functionality to obtain a full change history of materials, recipes, material list items, etc.

Change Management
Functions

In the pharmaceutical industry, recipes have to be approved before they can

be released and used for production. Changes made to approved recipes are
only possible with special authorization and need to be approved a second
time.

Approval of
Master Recipes

Change request

Master recipe
Change

approved/
permitted?

Status maintenance
Change rule
Workflow

Fig. 5-9: proval of changes for master recipe

5-9

Master Recipes

The change rule for a recipe specifies that a recipe necessitates official approval.
The way that a recipe is changed and approved is determined by the change
request involved. The change request is subject to status management, which
can be customized in various ways, for example, to initiate workflow.

Further Uses of the Master Recipe

Besides the recipes which serve to produce a batch, there are also non-manufacturing recipes in PP-PI:
Cleanout recipes can be inserted between two operations, if the product
sequence requires a cleanout operation.
Changeover recipes describe the requirements of particular resources,
the materials or substances required, as well as the changeover activities
to be carried out between two production campaigns.
Equipment-testing recipes contain process instructions that are used to
carry out and document periodic functional testing of a plant line.

The master recipe describes the steps of a process including the materials and
resources used.
Which information is contained in the master recipe?
The master recipe contains materials, the description of the process from the
planning as well as the control view, all resources as well as information for
quality control.

How are materials and their attributes represented during the calculation of
input and output quantities?
The material quantity calculation determines the required and generated
material quantities, taking into consideration the mixing ratios of the input
materials as well as the yield ratios of the products and by-products.

5-10

Chapter 6

Process Orders
The process order describes the actual production of one or several production lots or batches in a production process and contains dates and production quantities. Process orders belong to the transaction data of the R/3
System and are similar to PP production orders in their structure.

Introduction

The process order is usually generated on the basis of a master recipe. In the
period between dispatching of operations and the release of an order for the
production of a batch, the user needs to put information such as dates, floats,
specific resources, etc. into the process order.
Process planning uses the planning data provided by MRP or campaign
planning runs to generate process orders.Process planning also has to coordinate the production process with all available resources. For this, production runs must be controlled in such a way that despite malfunctions, a high
adherence to delivery dates and high quality of output must be combined
with low costs and inventory as well as with a high degree of capacity utilization.

Dates; Quality;
Costs; Inventory

The following graphic shows how the process order forms part of the R/3
data flows of production planning, capacity requirements planning and
costing.
Sales/ Distribution

Material forecast

Preliminary planning
Demand program

Sales requirements

MPR
Stock

Plan
Planned order
Conversion to process order

Costing

Capacity planning

Preliminary planning

Execution of process order

Inward stock movement
Accounting (settlement)

Goods issues

Fig. 6-1: The process order within the R/3 data flows

The process order is the main control instrument for carrying out production. It contains all planned and actual production-related data necesary to
effectively monitor your production runs.

6-1

Process Orders

The process order and its functions provide answers to the following questions:
What and how much is being manufactured?
What exact dates and times are scheduled?
What elements are involved in production (material, resources with
capacities, etc)?
What costs are involved and how are they settled?

Functions of the Process Order

Conversion from
Master Recipe

When a process order is created, the operations and phases of the master
recipe selected to carry it out are copied into the order. At the time that a
process order is released for production, you can generate control recipes
from these operations and phases, bundled for each control recipe destination.
If you do not select a master recipe or if you create a process order from a
planned order, the system automatically creates a process order with one
operation.

Order Creation using an

Approved Recipe

For each order type, you can define in Customizing that process orders can
only be generated from officially approved recipes.
Once this approval has been given, the process order obtains a special status
containing this information. In connection with this status, the system will
only permit you to change data in a restricted way. At this point you can
only change MRP data such as quantities and dates.
Archiving / Deleting

MR

let

Process data
documentation

er

m
co

Process order
creation

Operations
Phases

Costs

Materialkomponenten
Anordnungsbeziehungen

ex

de

en

or
In-process quality
inspections

Ressourcenzuordnungen

ec

ut

Order confirmation

ion

/ Process

na
ma

Material availability
check

Process
instructions

Capacity requiremts.
planning

planning

Process messages
for different destin.

Pro cess

Goods receipts

Scheduling

ss
oce

Ord

Proc. order

Pr

Process order
settlement

Production requirements

ion

ge

Release of
process order
Creating & downloading
control recipes

Material withdrawals

Fig. 6-2: Steps of a process order

6-2

Process Orders

Availaibility checks for material components ensure that only process orders
are released for which the raw or semi-finished materials are available.
When you release the order, reservations are made for the material components involved.

Availability Check
for Material

The material availability can be checked either statically or dynamically.

Although this availability is usually ensured by MRP runs, this additional
check ensures that work schedulers will be informed of material shortages
even in exceptional situations. A status function as well as a missing components list are available for schedulers to obtain a quick overview of material
availability.
Using the basic order dates from an MRP run, the scheduling function then
determines the actual start and finish dates for the order and its operations.

Scheduling

If capacity requirements and dates (scheduling) were already carried out in

the rough-cut planning phase, these results can be transferred automatically
into the process order.
The graphic presentation of the scheduling results in the planning table enables schedulers to obtain a current overview of the date/time situation of
orders at any time (see Chapter 8 Capacity Planning and Leveling).
When a process order is released, the following functions are activated:

Release

The material reservations generated for available and reserved stock are
updated in the corrresponding material master record. At this time the
availability of the material is checked by the system.
The specified resource classes can be replaced by individual resources
by means of a selection function.
You can print shop floor papers.
You can allocate an inspection lot record.
Depending on the Customizing options set, the above functions can also be
suppressed or carried out in another way.
After releasing an order, you can carry out material movements (to and from
the warehouse) and confirmations for it.

6-3

Process Orders

The following screen shows the two-line operation overview of a process

order.

Fig. 6-3: Two-line operation overview of the process order

Order Execution

Via the PI sheet, you can display information on the manual control of the
process. You can request process messages, for example, effecting material
withdrawals or confirmations in the R/3 system.

Printing Shop Floor

Papers

After scheduling and releasing a process order, you can also carry out the
printing of shop floor papers directly from the process order. This can
include detailed information on the operations of a process order, such as
found in the operation control ticket, job ticket, goods issue slip, picking list,
confirmation sheet and time ticket. You can also reprint all shop floor papers at any time.

Materials in
the Process Order

The material list used in a process order stems from the master recipe . Material lists can be changed in the process order in the same way as in the master recipe, for example, if you need to add new material components.
When a material list is changed, the system will carry out a re-calculation of
the material quantities involved in this process order. In this way new mixing ratios for the input substances can be calculated.
Further information on the material list can be found in Chapter 5 Master
Recipes.

6-4

Process Orders

In the material list, it is possible to allocate a batch to every material that is

managed in batches, that is, has a batch record. This batch is found using the
functionality of the classification system (valuation of characteristics),
provided you have classified the materials beforehand.

Batch Determination/
Batch Splitting

This ensures that the corresponding batch can be found from the existing
batches via the characteristics of a material (for example, the strength of an
active substance) defined in the material list.
It is also possible to split a batch. Depending on the availability situation, in
this case several batches can be allocated to a reserved material component,
in order to remove a shortage in the material list.
For each process order, you can obtain logs on scheduling, material availability and the costing run. These logs can be displayed at any time, and
updated in order to obtain detailed information on the results of the functions carried out.

Logging of Events

Material withdrawals (that is, goods issues) can be carried out for an entire
order or for individual reservations (materials reserved for operations).

Material Issues

These material issue postings do not have to be carried out manually, but
can be generated automatically from the corresponding process messages
contained in the process instruction sheet (PI sheet) or from the lower-level
process control system involved.
When the materials are issued, the actual costs are updated automatically in
the process order.
It is also possible to carry out backflushing (retrograde issue posting) of
components. In this case, the confirmation of an operation automatically
generates a withdrawal posting for the material components allocated to the
respective component.
Status maintenance ensures that you can get an overview of the current
situation of a process order at any time. User-defined status sequences support the company-specific processing of an order. Furthermore, the system
sets a so-called system status at important events in the business process. An
example: The status "created" designates a created process order. After release, the status "released" is set. When the control recipe is generated, a
further status is set, etc.

Status Maintenance

Completion confirmations are carried out for individual phases of process

orders, or for entire orders. You can also carry out confirmations via the PI
sheet.

Confirmations

6-5

Process Orders

During production, confirmations of actual quantities are carried out, involving finished products, co- and by-products, as well as wastes. Furthermore,
actual times (start/finish times and durations) and actual costs are also confirmed. These confirmations are carried out via the process management
component and partially also via the process order itself. The data to be
archived is then written to the electronic batch record.
Business
transactions

Confirmation
on phases

Manually
Jump
Process
Process
message
message

Events

Cap. load reduction

at resource

(Phase start/finish)
z

Activities

Cost updating

PI-sheet

Resources

Update of order data

(e.g. status, dates)

Backflushing

Autom. goods receipt

z
Process
Process
meldung z
meldung

Quantities
HR data

Proc. control
system

Fig. 6-4: Confirmations for a process order

Evaluations/Analyses

Planners and schedulers have a number of evaluations or analyses at their

disposal, thus enabling them to see at a glance what the order situation is
like:
You can display all process orders, for example, for a material, MRP
controller, shop floor controller, etc.
You can display a list of the missing material components.
You can display the pegged elements (planned orders, process orders,
etc).
You can display the orders in backlog for specific products to be manufactured.
You can branch directly to the Shop Floor Information System, in order
to carry out evaluations on resources, materials, operations/orders,
material consumption or product costs.

Warehouse Receipts

6-6

Warehouse receipts from finished process orders can be carried out for
batches, partial lots or the entire production lot. The receipt posting can be
carried out with reference to a specific customer order or to customer stock
defined as such.

Process Orders

As soon as a process order has been completely delivered to the warehouse,

the costs can be settled. For this, the balance between order debits (for example, issues, confirmations) and order credits via receipts to the warehouse is
calculated and the order account is debited or credited accordingly.

Order Settlement/
Valuation

The valuation of warehouse receipts is carried out according to the valuation

strategy defined in the material master (for example, according to production costs, planned price, standard price, etc.). The so-called settlement
receiver is usually the material to be produced (finished product).
The following section on cost object controlling explains how planned and
actual costs are calculated from the perspective of R/3-CO, the costing
module fully integrated with PP-PI.

Cost Object Controlling

Cost object controlling allocates the costs incurred in a firm to various cost
objects. Cost objects are objects used to allocate costs according to how they
were incurred. This could be an order, a material, a network, etc.

Introduction

For this, the costs for cost objects are derived directly from the single costs
involved (for example, goods issues, G/L accounts), or using costing procedures (such as internal activity allocation, overhead surcharges) from costcenter accounting. All costs per cost object or for an entire accounting period
can be displayed.
Order release
COPC

Process Order
Ist
Material withdrawal
posting

Material

800

Production

600

Ext. proc.
Changes to stock
Comp. confirmation

Comp. confirmation

Current stock

400
-1500

Material withdrawal
posting

300
Backflushing

Classical
material staging

MM
Warehouse

Fig. 6-5: Simultaneous costing for process orders

6-7

Process Orders

Costing of process orders is based on planned material consumptions and

the charge rates used for in-house production activities of these planned
rates (actual production costs). The basis of this is formed by the data on
resources, master recipes and material lists.

Functions of
Cost Object Controlling

For a process order, you can carry out the following functions:
Calculate planned costs
Calculate actual costs
Transfer actual costs to other objects, such as materials or customer
orders, in the R/3 System
Analyze planned and actual costs

CO Information System

Via the CO information system, you can select all process orders corresponding to specific criteria, for example, all process orders for a particular material. For these orders, you can display the cumulated costs, in order to
obtain an overview of your total costs.

Value of Work
in Process (WIP)

The extended functionality of process orders enables you to determine the

costs of process orders which have not been settled yet, and to periodically
transfer the value of work in process to financial accounting.
In process manufacturing, costs are settled to stock as soon as you have
posted a receipt to the warehouse (for example, for an operation). At the end
of the production run, all remaining costs for the order are also settled.

Scheduling of an Order

Scheduled dates are relevant to cost object controlling, since the planned
costs have to be distributed over the scheduled periods. The planned costs of
a phase are updated in the period in which it is carried out. The distribution
of costs is carried out according to calendar days.
The following screen shows the results of a costs analysis. The costs expected
for a process order are displayed according to cost elements. There are the
following types of cost elements:
Primary cost elements
The primary cost elements correspond to G/L accounts in financial
accounting (for example, for raw materials or semi-finished goods).
Secondary cost elements
These cost elements contain costs from the CO area (for example, for
internal activity allocation, overhead costs).

6-8

Process Orders

Fig. 6-6: Results of a costs analysis

It is furthermore possible to use the following types of cost calculation:

Cost itemization
Cost itemization structures the costs according to cost elements and
origin groups, or according to costing items. The costing items are the
individual materials and activities whose costs were calculated in a
costing run.
Cost component split
Here, planned costs are displayed according to individual cost elements.
These are defined in Customizing and determine the costs which are
relevant for material valuation and profitability analysis.
When you are manufacturing co-products, the extended functionality of the
CO module for process manfacturing enables you to:

Costs for Co-Products

distribute the costs incurred for a process over the co-products

(see following section) and
settle the costs allocated to the co-products to stock.

6-9

Process Orders

Co-Products
The manufacturing of co-products enables firms to produce several different
materials using one process order. Within an order containing co-products,
these can be allocated to the operation or phase in which they are to be produced.
Leading material
Co-product
(SEMI, FIN, ...)

Carbide

Co-product
(SEMI, FIN, ...)

Cement

Without leading material

Process material
(PROC)

Co-product
(Semi, FIN, ...)

Chlorine-alkali
Chlorine-alkali
elektrolys is
elektrolysis
C
-

Cl2

.
.
.

C
NaOH
Coal

Lime
Waste

Sludge

Ingredient
(RAW, SEMI, ...)

NaCl

HCl

ngredient
(RAW, SEMI, ...)

Legend:
C

+
-

= Co-product
= Input material
= Output material

Fig. 6-7: Representation of co-products

Material Type
Process Material

If several co-products are to be manufactured in one run, of which none is a

leading material, you can create a dummy material for the process, called
a process material. The creation of the process order can take place using
such a process material or using one of the co-products (see Fig. 6-7).
Furthermore, you can maintain several order items with different materials.
The co-products are taken from the material list of the master recipe and
written into the order item fields.

Co-Products in the
Material List

Co-products as well as wastes or by-products can be represented in the

material list via a negative component quantity. Co-products are also
marked via an indicator. In the MRP run as well as in the costing run, these
negative quantities are taken into consideration.
The costs of an order with co-productgs are collected for the entire order and
can then be distributed over the co-products using equivalence numbers.

6-10

Process Orders

Further Functionality the Process Order

Planned inspection characteristics for operations and phases are maintained
in the master recipe. This data is then taken over into the process order.
For a process order involving a material to be inspected, an inspection lot is
generated automatically. A material is marked as to be inspected if you
have maintained the quality management screen of the material master and
activated it.

Integration between
Process Order and
Inspection Lot

Material master
QM data

Master recipe
header

Process order header

Material

Operation
.
.
.

Operation

Inspection
characteristics

.
.
.

Phase

.
.
.

.
.
.

.
.
.

Inspection
characteristics

Inspection
lot header

Inspection
characteristics

Phase

Inspection
characteristics
.
.
.

.
.
.

Unplanned
inspection
characteristics
.
.
.

.
.
.

Fig. 6-8: Integration of QM functionality in PP-PI

The inspection lot is generated automatically as soon as the first operation or

phase of the process order has been released. It is also possible to generate
an inspection lot manually previously to this. When an inspection lot is generated, the inspection characteristics maintained in the master recipe are
transferred to the inspection lot.
Unplanned (process-order specific) inspection characteristics can be entered
from the operation/phase screen of the order. For this, the system branches
to the QM inspection results entry screen.
You can get further information on the link between PP-PI and R/3-QM and
external LIMS systems in Chapter 10.
External relationships are relationships linking phases of different orders.
This function can be used, for example, to create a link between a process
order and one or several filling or packing orders for this process order.

External Relationships

Using the functionality of variant configuration, you can select a configurable BOM and a configurable master recipe for a customer order. This will
facilitate the manufacturing of the corresponding process order.

Variant Configuration

6-11

Process Orders

This is done by allocating a configured material to the corresponding master

recipe (later to be used for a process order).

Configurable
master recipe

Customer order
PC varnish

Configurable
BOM/material list

Color
Black

Process order
z

Configured
master recipe

Configured
BOM/material list

Fig. 6-9: Variant configuration for process orders

Assembly Orders

When you create a customer order, you can have the system automatically
generate an assembly order. This is a special type of process order generated
for purposes of covering the independent requirements of the customer
order. An example in process industries would be the providing of animal
foodstuffs, which are mixed in the last step, according to each customer order.
Provided this has been indicated in the material master record, the following
data is exchanged between customer order and process order:
The staging date of the material and the customer order quantity are
written to the process order
The costs of the goods to be manufactured, the available quantity
(provided an availability check was carried out), and the confirmed
delivery date are transferred from the process/assembly order to the
customer order.

Collective Orders

A collective order refers to the linking of planned or porcess orders on

various production levels. Via order networks, you can group all the steps
in a manufacturing process in one display and thus obtain an integrated
view of your manufacturing runs.
Warehouse movements are only carried out for the order on the uppermost
production level. Changes to an order are automatically passesd on to
dependent orders or pegged requirements. Furthermore, you can display
planned and actual costs of any order within a collective order.
The flagging of a finished product as forming part of a collective order is
carried out in the material master record for this product.

6-12

Process Orders

From the R/2 System, as well as from other external applications, it is possible to transfer single and multi-level orders in the form of so-called production requirements. All production requirements can be displayed and
changed via the PP-PI menu.

Integration with
Higher-Level Systems

You can get further information on this topic in Chapter 11 Integration with
Higher-Level Systems.

The maintenance of process orders in PP-PI enables you to control dates,

costs, inventory and quality of your production runs. The process order is
completely integrated in other R/3 production data flows, such as MRP or CRP.
How can a process order be created?
A process order can be created with or without a planned order (from
MRP runs), i.e. with or without previous planning. You can also use
requirements defined by an external system for process orders.

How are resources selected for a process order?

In the resource network, you can display the path of a product.
Via the classification system, you can select a suitable resource.

6-13

Chapter 7

Batch Management
Many companies are faced with more stringent environmental and consumer protection laws as well as with increasing requirements in the area of
product liability. R/3 batch management contains cross-application functionality enabling you to fulfill the complex requirements of the pharmaceutical and chemical industries, among others.

Introduction

By systematically managing batches, or production lots (as they are frequently called), you can greatly improve customer satisfaction, as you can then
precisely plan and control product quality. A usability check enables you to
locate the optimum batches meeting customer specifications. You can use
this function to find batches you want to use in a production process.

Batch
management

Procurement

Production
Warehouse
Management

Warehouse
Management

A
A A

A
A

Purchase
order

Sales and
Distribution

Warehouse

Process/
Production
order

Warehouse

Salesorder

Fig. 7-1: Integration of batch management with the supply chain

Using the batch management functionality, you can improve the quality of
your warehousing since you can locate the optimum batch to be used or
sold. Using the batch where-used list, you can track batches over the complete supply chain; that is from receipt of a batch of raw material, through
production, right up to final delivery to your customer. Should it be necessary to recall a product, you can initiate the required measures immediately.

7-1

Batch Management

Batch management contains cross-application functionality available as of

Release 3.0 and is integrated with all logistics-related applications:
Purchasing
Inventory Management
Production
Sales & Distribution
Warehouse Management
Quality Management

Definition of the
Term Batch

SAPs usage of the term batch (lot) concurs with the following definition
published by the Food and Drug Administration (FDA) in their Good Manufacturing Practices (GMP):
Batch: a batch is a quantity of any drug produced during a given cycle of
manufacture. The essence of a batch is its homogeneity.
For SAP a batch is thus a quantity of any given material, produced during
one production process. It is characterized by clearly defined specifications.
Using Batch Management, you can manage partial quantities of a material
seperately in stock.
The figure below shows how batches are created during a production process. Depending on the requirements of your industry, you can also combine
batches of materials that have identical specifications during quality inspections.
Process order 1

Process order 2

Quantity 1

Quantity 2

Material Epoxy resin

Batch 2

Batch 1
Viscosity
pH value

1930 cst
7.5

Viscosity
pH value

Fig. 7-2: Batch creation during a production process

7-2

1950 cst
8.5

Batch Management

Batch Management is a general-purpose function but is used mainly by the

following industries:
Chemicals
Pharmaceuticals
Cosmetics
Food
Health and Hygiene

Batch Specifications and Levels

Every batch features certain specific physical, technical or chemical properties that enable you to describe it (for example, pH value, viscosity, color
purity). These values are determined, for example, in a quality inspection
carried out by R/3 Quality Management, which is directly linked to batch
management.

Management of
Batch Specifications

These batch specifications are the cornerstone of batch management. They

are stored as characteristics in the R/3 Classification System. You can
maintain characteristics either when you maintain batch master records
during goods receipt or during usage decisions in Quality Management. The
specifications you use depend solely on your requirements. Apart from the
above types of properties, you can also use characteristics such as the shelf
life expiration date or usability.
A batch is always posted to a certain material. The system checks the batch
specifications (actual values) against the material specifications (target
values). This process is illustrated below.
Product
Epoxy resin

Characteristics





Viscosity at 25
Color
Epoxy count
Volatile portion

Material
Epoxy resin X

Viscosity
Color
Epoxy count
Volatile portion

5000-12000
0-5
23-25
0.00-0.50

Batch 1
Epoxy resin





Viscosity
Color
Epoxy count
Volatile portion

7250
1-3
23-25
0.30

Fig. 7-3: Material and batch specifications

7-3

Batch Management

Batch Levels

You can define at which level you want batches, or more precisely batch
numbers, to be unique.
at plant level
at material level
at client level for a material
Plant Level
Choose this option if you want a batch number to be known only in the plant
in which it was created, and not in plants that might also stock the same
material. In this case, the batch number is unique in combination with a
plant and a material. In another plant, the same batch number identifies a
different batch of the same material.
Material Level
Choose this option if you want the batch number to be unique in combination with a material. When you create a batch, it is automatically known in
all plants that use this material. If you use this option, a batch number cannot refer to different batches in two plants. If you transfer the batch from
one plant to another, the batch specifications will also be known in the new
location, even if the batch is stored there for the first time.
Client Level
Choose this option if you want your batch numbers to be unique at client
level. In this case, the batch number is a unique reference to the material for
which you created the batch. The specifications of the batch are identical in
all plants in which you use the batch. You cannot assign the same batch
number to different materials.
Should you decide to change the batch level after you have already created
batches, you can use a conversion tool to change the batch level.

Batch Management Functions

Batch Management provides the following functions:
Batch number assignment
Batch status management
Batch tracking
Batch determination

Batch Number
Assignment

7-4

In order to be able to identify batches, you need to assign a batch number to

each batch. In the R/3 System, you can choose between automatic and
manual batch number assignment. You can assign batch numbers whenever
you create a batch (for example, during master data maintenance, goods
receipts, in process orders, during usage decisions, recurring inspections,
and transfer postings).

Batch Management

You can also influence the structure or layout of batch numbers. This, for
instance, enables you to link other information with the batch number: information on the plant in which the batch was manufactured, or on the
material type as well as on other application data for a particular business
transaction.
A batch can be either usable or not usable. In the R/3 System, you can portray batch usability using status types unrestricted and restricted. The
appropriate stock type is directly connected to the batch status. If the batch
status changes, a stock transfer posting is automatically triggered from restricted to unrestricted stock or vice versa.

Batch Status
Management

All other stock types (for example, stock in quality inspection, blocked stock,
open purchase order quantities, GR blocked stock) are not affected by this
type of transfer posting. You can post new stocks to them, independent of
their respective status.
Like all other batch specifications, the batch status is stored as a characteristic in the Classification System. You can either set the status manually or
automatically during the usage decision in Quality Management. You can
store all authorized usages of unrestricted stocks and the reasons for
restricted usage using additional characteristics.
You activate batch status management in Customizing. If batches are unique
at client or material level, batch status management is active for all batches in
the client. If the batches are unique at plant level, you can activate batch
status management separately for each plant.
You can use the batch where-used list and the batch record to track batches.

Batch Tracking

Batch Where-used List

The batch-where-used list records the complete life cycle of a batch from
procurement to delivery. This record contains all material documents as
well as all production and process orders in which you used a specific batch.

Fig. 7-4: Top-down analysis of a batch where-used list

7-5

Batch Management

In this way, it is possible to display all materials and respective batches used
during the manufacture of a product that has been supplied to one of your
customers (top-down analysis, see figure 7-4). You can also display all steps
in production during which a specific batch of a material was used (bottomup analysis).
You can use this function not only for raw materials, intermediate and
finished products, but also for trading goods.
Batch Record
The batch record contains all data on the manufacturing process of a batch
that is required to ensure compliance. In PP-PI, the requirements of an
electronic batch record are met using process data documentation. Process
data documentation is a tool that enables you to collect target and actual
data and to store this data in an optical archive. For detailed information,
refer to chapter Process Data Documentation and Evaluation.

Batch Determination

Batch determination is a usability check. You can use this function for all
outward movements to find batches that meet certain specifications. The
functionality is identical in all applications.
You can run batch determination in the following areas:
Inventory Management
Production
Distribution
Warehouse Management
Search strategies are the cornerstones of batch determination. Search strategies are master data and contain information on the selection criteria you
want to use to find batches and on the further handling of the batches found
(for example, wether batch splits are authorized). Search strategies are
defined for individual business transactions.
In process manufacturing, you can use batch determination to find batches
of material components to be handled in batches. There are several methods
you can use to store the selection criteria required for batch determination.
The system automatically checks batch availability during batch determination.
The figure 7-5 shows the screen generated after you trigger batch determination in a process order.

7-6

Batch Management

Fig. 7-5: Batch determination in process orders

Batch determination in process orders makes it possible to reserve batches

for specific orders at an early point in time. In this way, these batches are not
available for other orders. If you do not need to reserve specific batches in
the process order, that is, if a reservation at material level suffices, you can
trigger batch determination, for instance, in Inventory Management during
consumption posting for the order.

Batch Management is an integral logistics component that enables you to

describe partial quantities of materials using specifications and to manage
them separately in stock.
What is Batch Management based on?
on the management of batch specifications
on the batch level at which batch numbers are valid
What are the core functions of Batch Management?

Batch number assignment

Batch status management
Batch tracking using the batch where-used list and batch record
Batch determination

7-7

Chapter 8

Capacity Planning and Leveling

Capacity planning and leveling involves the functions of campaign planning (rough-cut or long-term planning) and process planning (detailed/
short-term planning). These functions serve as tools for MRP controllers,
plant managers, shop floor controllers, shift foremen and plant operators to
plan the use of plant resources, control production runs and ensure that
waste facilities are working properly.
Train/Line

Campaign Planning

Process Planning
Vessel 1

Vessel 2

Fig. 8-1: Campaign and process planning

In the case of a production plant, planning is initiated via planned requirements, either using a production plan or a campaign.

Forms of Planning

In the case of a recycling or waste disposal facility, we are dealing with the
quantity of remaining materials which has accumulated from other production plants, and which must be processed. In this case, planning is not carried out starting with the product, but rather starting with the ingredients
delivered for production.
In both cases, you can specify the available and required capacity and carry
out capacity leveling.

8-1

Capacity Planning and Leveling

Campaign Planning
Planning of Production
Campaigns

A production campaign is an uninterrupted sequence of process orders of

the same type, based on one master recipe. Whereas the planning of batches
takes place shortly before production, campaign planning serves to carry out
planning from a long-range perspective, at a time when only aggregated
information on material requirements, product yields, remaining material
quantities and resource requirements is needed or available.
This functionality will be implemented after Release 3.0. Until R/3 campaign planning is available, you can use rough-cut planning for planned
orders (MRP) to plan your campaigns.

Process Planning
Process planning refers to the scheduling of operations in a process order,
the checking of material and capacity availability and the release of orders
for production.
Master recipe
Process order

Scheduling

Availability

Release

OK

Control recipes

Process control system

Fig. 8-2: Functions of process planning

Process Orders and

Scheduling

8-2

The core of process planning is formed by the process orders and their operations. The standard values of the operations are used to calculate the lead
times in the formulas you have defined. The lead time is calculated using
forward or backward scheduling, depending on whether you enter a start or
a finish date. In this way the system calculates all operation dates and thus
also the lead time and dates for the entire order.

Capacity Planning and Leveling

The duration of operations from process orders are determined via phases
and the relationships defined for them. You can get further information on
this subject in the section on planning strategies below, as well as in Chapter
6 Process Orders.
Capacity requirements are calculated using the operations in planned and
process orders. For all capacities of resources to be scheduled, the system
calculates the corresponding requirements.

Capacity Requirements

The available capacity is calculated using the capacity allocated to the resources involved in a production process. There are two ways of calculating
the capacity: exactly for a point in time or aggregated over defined periods.
When the available capacity is calculated, two questions need to be
answered:

Available Capacity

When is the capacity available? This is represented via the shift schedule defined for the resource.
How much capacity is available? This is represented using individual
capacities and capacity utilization.

Resource

over time

2
1

MO

TU

WE

TH

FR

SA

SU

MO

TU

12-13 o' clock

8 o' clock

Resource

Time

by period

x hours
16
8

MO

TU

WE

TH

FR

SA

SU

MO

TU

Time

Fig. 8-3: Capacity available, regarded over time and by period

Resources are characterized by one or several capacities. Time-oriented

capacities are defined by the shift schedule allocated to this resource, which
contains pre-defined shift sequences valid for a certain period and for all
resources.

Defining Available Capacity

for Resources

The capacities defined for this can also be subdivided into individual
capacities and displayed as such.
You can get further information on available capacity in Chapter 4 Resources.

8-3

Capacity Planning and Leveling

Capacity Scheduling

When process orders are scheduled (dispatched) to the resources, the system
carries out capacity scheduling. In this form of scheduling, also called finite
scheduling, the limited available capacity of the resource is taken into consideration when the dates are determined. The comparison of capacity available for individual resources and the adjustment of underloads or overloads
for them is called capacity leveling. It forms part of the functionality of the
R/3 PP module and is used accordingly for the scheduling of resources in
PP-PI.

Capacity Leveling
The functionality of capacity leveling has been available since Release 2.2. It
enables various user-defined views of different scheduling data, as well as
providing a number of functions for the planning of process orders (process
planning).
Capacity leveling is controlled via a so-called overall profile, which is set in
Customizing and which contains several sub-profiles. These sub-profiles
contain settings for selection screens and general settings for evaluations and
the screen layout of lists.

Grouping of Capacity
Requirements

Within the framework of capacity leveling, you can group capacity requirements according to the needs of your plant. This means that you can group
them according to various criteria, such as:
Capacity requirements per capacity category
Capacity requirements listed according to planned and process orders
Capacity requirements per process order and/or operation
Every requirements group is displayed in a separate line of the planning
table.

Filtering of Requirements

Capacity leveling supports the definition of user-defined filters for the planning table, for example the display of only one type of capacity (time available to processing units in a plant, or volume per vessel) and the requirements determined for this capacity.

Sorting of Requirements
Groups

Via a user-defined sort key, you can specify the display sequence of all
requirements groups. This sorting can be changed dynamically, that is,. you
can choose between various user-defined sort keys.

Evaluation and
Planning Period

For the evaluation and planning period, there are user-defined time profiles.
They enable you to define time periods in absolute form, for example the
months 6/96 to 9/96. It is also possible to use the current date for this display, for example all working days -10 to +30.

8-4

Capacity Planning and Leveling

Process planning can be carried out period by period. For this, the system
dispatches operations to the individual planning periods (month, week, day,
etc.). For operations taking longer than a defined period, there is an automatic distribution of operations over the periods in question.

Period-oriented Process
Planning

For every period, the available and the required capacity are displayed and
the quotient displayed in the form of a percentage load. For each resource,
you can set an overload factor specifying the permissible overload.
For period-oriented process planning, the R/3 System provides the Planning
Table in tabular form, which contains the above planning data.

Planning Table
(Tabular Form)

Process planning can also be carried out continuously over time. For this, the
operations are scheduled at an exact start or finish time. The start date/time
enables scheduling to calculate the finish date/time and vice versa. The
prerequisite for successful dispatching of operations is the available capacity
for the scheduled duration of the operation.

Process Planning over Time

For time-oriented process planning, the R/3 System provides the graphic
planning table (see figure below). It is interactive and enables the dispatching, deallocation and rescheduling of operations at resources (usually the
processing units).

Graphic Planning Table

Fig. 8-4: Graphic planning table

8-5

Capacity Planning and Leveling

The graphic planning table is made up of several parts, each consisting of a

table area and a graphic area.

Table Area

The table area contains information on the identification and description of

the individual requirements groups (for example, resources, orders, operations) to be displayed. The tables can be scrolled through individually.

Graphic Area

The graphic area contains the capacity requirements and their dates on a
time axis, displayed by bars, lines and other symbols, similarly to a Gantt
chart.
The graphic area can be seen as a window on the time axis. This window
shows the same time period for all tables involved, but it can be changed via
a zoom function changing the scale.
In the graphic area, the capacity requirements and their dates are displayed
on the time axis via bars, lines and symbols, similarly to a Gantt chart.

Preliminary Planning Period

Follow-up Period

The planning table contains all capacity requirements for a specific evaluation period. However, you can also define a so-called planning period.
For this, the periods before and after the period in the window can be scaled
in relation to the planning period itself. In this way, you can aggregate the
data before and after the planning period for overview purposes (see Fig. 85).

Planning table
Monday

Preliminary period

Planning
period

00:00

06:00

Tuesday
12:00

18:00

00:00

12:00

18:00

00:00

Monday
00:00

06:00

06:00

00:00

Follow-up
period

Tuesday
06:00

00:00

Overall period under consideration

Graphic area

Fig. 8-5: Planning table as a window on the time axis

Customizing of
Colors/Patterns

You can customize many different parts of the graphic planning table with
respect to colors and patterns desired. In particular, you can highlight requirements groups and individual capacity requirements with a bright color,
for example, so that important information is visible immediately.
In the table area, you can change the font size and color of individual objects
from the requirements groups. In the graphic area, you can set the type of
dates to be used for the graphic display (for example, earliest dates, latest
dates or both).

8-6

Capacity Planning and Leveling

In addition, you can specify colors and patterns for the lines and bars representing capacity requirements. You can also add other symbols (such as triangles, diamonds, arrows, etc.) in order to code specific information.
All the data on a particular object of capacity requirements can be selected
for display and adjusted accordingly.
For many objects linked to individual or grouped capacity requirements, you
can display the corresponding data:

Capacity Requirements and

Pegged Requirements

Resource, capacity, person

Process order, operation, material component, inspection characteristic,
inspection lot
For important objects, it is possible to branch directly to the detail screen, for
example, on operation dates, standard values for an operation, etc.
Objects with a direct planning relevance can be changed directly in the planning table.

Changing Objects

The capacity can be changed, in order to maintain alternative shifts, for

example, in the case of restricted or extended capacities.
Orders can be changed, in order to adjust to existing delivery dates.
Operations can be changed, for example, in order to correct standard
values for them.
All changes made to objects are first carried out temporarily. Together with
the planning results, you can then save or reject the changes made.
Planned and process orders can be dispatched directly in both forms of the
planning table. You can also deallocate operations or reschedule them.

Dispatching/Deallocation/
Rescheduling of Operations

In the Planning Table Screen, you can do this by linking process orders
and periods.
In the Graphic Planning Table, you can dispatch operations via the bar
representing capacity requirements using Drag & Drop (see Fig. 8-6).
The requirements can be shifted on the time axis for a resource, so that
the desired start or finish date is displayed. The system will check the
availability of the capacity over the entire period of the requirements.
When an order is scheduled, the operation dates/times are derived from the
phase dates/times. During capacity leveling, the operation whose duration
has been determined by the phases is now dispatched. This ensures that all
phases of an operation can be dispatched without interruption by other
operations.

Scheduling of Phases

8-7

Capacity Planning and Leveling

Scheduling of
Secondary Resources

The requirements of secondary resources of an operation or phase can be

taken into consideration during capacity scheduling. The dates for these
required resources are derived from the dates of the operation or phase involved.
Resources
Monday

Resources

00:00

06:00

Tuesday
12:00

18:00

00:00

06:00

14100
Vessel 1
14200
Vessel 2

Pool of orders/operations
Order Opert. Qty.
2010

0010
0020
0010

Tuesday
12:00

18:00

00:00

06:00

2030

06:00

10

2020

Monday
00:00

10

Message area

Table area

Graphic area

Fig. 8-6: Dispatching, deallocation and rescheduling of planned/process orders

Automatic Dispatching

For the automatic dispatching of one or several capacity requirements, there

are several planning strategies available (see next section).

Planning Strategies
Introduction

Capacity leveling is carried out along the company-wide process chains, in

order to schedule required resources in accordance with a limited available
capacity. This needs to be done although some of the goals involved (short
lead times, low inventory, adherence to delivery dates, optimum order mix,
etc) are contradictory.
A planning strategy is a combination of control parameters in order to reach
one or more of the above goals.

Planning Parameters

You can make use of the following planning parameters for the control of
dispatching:
Planning direction: The system can carry out the scheduling of operations in forward or backward direction.
Dispatching at earliest dates: This indicator is activated if an operation
is to be scheduled as early as possible within the planning period.

8-8

Capacity Planning and Leveling

Insertion of operations: An operation or a number of operations can be

inserted at a particular point in time. Other resource commitments are
shifted, depending on the planning direction, and rescheduled.
Closing of planning gaps: This indicator specifies that you can trigger
further actions after you have deallocated an operation. The gaps ensuing from the deallocation can be closed by the system shifting commitments normally displayed at the end of the deallocated operation in the
ensuing gap.
Error-based planning termination: This indicator enables you to specify
that the planning of the current order is to be terminated if an error occurs when another function (for example, basic order dates cannot be
adhered to) is activated.
"ATP logic" when regarding periods: Overloads in individual periods
must be taken into consideration in future periods. For example, a 200%
load of one period will mean that the next period cannot have any work
dispatched to it.
Dispatching sequence: The sequence according to which the selected
operations are to be sorted and dispatched can be specified via a userdefined sort key. Alternatively, you can also program a "user-exit"
which will carry out the sorting in the way you need.
Planning log: In every planning run, the functions activated will generate log messages for the operations. These messages can be grouped (all
information, warning or error messages) and analyzed for future reference. This may mean that the planning strategy needs to be changed.
Operation data can be "influenced" via the planning strategy. This strategy
can be set up in such a way that an operation can only be scheduled within
the floats calculated during order scheduling (floats before/after production). If, for example, an operation is dispatched in such a way that it consumes part of the float before production, this means that the other operations of this order only have the rest of the float before production available
for scheduling.

Influencing of Operations

In connection with capacity scheduling, additional functions are provided

which can be deactivated if necessary. These are:

Activating of Functions

Sorting of operations to be dispatched

Checking of operation dates: Here, the system checks the dispatch dates
against the basic order dates (from the planned order) or against the
dates of previous or following operations in the order.
Immediate midpoint scheduling of the order.
Capacity requirements can be split and in this way distributed over several
individual resources, for example, in order to reduce lead times.

Splitting and Allocating

Capacity Requirements

8-9

Capacity Planning and Leveling

It is also possible to further detail the planning run by allocating individual

resources such as persons. You can get more information on the allocation of
resources in Chapter 4 Resources.

Resource Selection

In order to dispatch operations and phases, you have to determine which

resources are to be committed for production.
In the master recipe, you can define technological and other selection criteria
for the subsequent selection of a resource to be committed. These selection
criteria are valuated in the form of characteristics in the R/3 classification
system.
When the operation of a process order is dispatched, it is necessary to select
a resource from the defined class. In process order management, you can
make a manual resource selection. The corresponding characteristics of the
operation are valuated for this.
In the case of automatic dispatching of several operations, the selection of the
resource is carried out using the correspondences of the characteristics of
operation and resource. During rescheduling as well, the suitability of a new
resource can be checked using the defined characteristics.
In the case of automatic dispatching with a planning strategy, this rule limits
the selection of potential resources.

Resource Network

The planning functions take the resource network into consideration. This
means that the system will only permit dispatching of an operation if there is
a network link from the preceding resource.
You can get more information on resources in Chapter 4 Resources.

Capacity leveling in PP-PI, together with the graphic functionality of the

planning table, enables an exact and detailed planning and display of all
scheduled production data flows.
For which objects in PP-PI can capacity planning be carried out?
On the rough-cut planning level, you can plan the capacities of
planned orders and (after Rel. 3.0) campaigns.
On the detailed planning level you can carry out detailed (finite)
capacity scheduling for process orders, including capacity leveling.
What is the purpose of the graphic planning table?
The graphic planning table serves to help you plan your production runs in
a user-friendly interactive manner. Using the graphic planning table, you
can dispatch, deallocate and reschedule process orders/individual
operations, as well as display and change the use of resources.

8-10

Chapter 9

Process Management
The task of process management is to coordinate between the R/3 System
and all the systems involved in process control when a process order is
carried out. The following activities are involved here (see Fig. 9-1):

Tasks of Process
Management

Information relevant to control, which is stored in the process order in

the form of process instructions, is found in the control recipes. Control
recipes are sent to the respective process control systems involved.
In turn, process management receives process messages from process
control, with which actual process data is reported. Process messages
are passed on to predefined destinations.
The information to be exchanged via process management as well as the
destinations involved can be set in Customizing. Via this flexibility, process
management can fulfill the requirements of all types of control scenarios,
ranging from manually operated to partially or fully automated plants.
Process
planning

Process
management

Process
order

Control
recipe

Process
messages
and other
message
destination

Process
control

Execution

Process
control
system
PI sheet

R/3 or
external system

Fig. 9-1: The role of process management within PP-PI

Process instructions are defined in the process order, where they are
assigned to the phases. They contain precisely the information needed by
process control to execute a phase. Their contents are specified via the
assignment of characteristics (for example, material number or quantity) and
characteristic values.

Process Instructions

9-1

Process Management

Process instructions are user-defined. This means that they can be adapted to
the specific requirements of a process as well as to the control systems
involved. It is possible to have process instructions in which control
parameters are transferred to automatic control systems, as well as process
instructions to be displayed in natural language for process operators (line
operators).
Depending on the type of information to be transferred, you can use various
types of process instructions:
A process parameter is used to transfer information to the process control system. In the case of manually operated lines, the process parameter contains a text for the line operator.
A process data request specifies that the process control system or the
plant operator is to send a process message with actual process data to
PP-PI.
A process message subscription reports the unplanned events, such as
alarms, exceeding of limits, etc. to the process control system.
A process data calculation formula specifies that a value must be calculated in the PI sheet. This value is then to be sent to specific destinations
using a process message.
An inspection results request specifies that inspection results are to be
recorded for one or more operations during the production process.
A dynamic function call enables the line operator to call an R/3
function module from within the PI sheet. Depending on the function
module called, this option can be used to confirm orders, calculate
material quantities, access R/3 document management system or access
a user-defined function.
Using sequence definitions, the relationships between phases
maintained in an order can be transferred to the PI sheet. In this way,
the process instructions of a phase in the PI sheet remain inactivated
until the preceding phase has been concluded.
Process instruction types maintained in Customizing facilitate the maintenance of process instructions in a process order. They are copied when you
create new process instructions, and then completed with line and processspecific information.
The work of maintaining orders can be further reduced by generating
process instructions automatically for a specific control recipe destination
(see below), as well as having the system valuate specific process instruction
characteristics automatically. The setting necessary for this can be carried out
individually in Customizing.

9-2

Process Management

The control system or operator to receive the process instructions, and the
type of data transfer involved (for example, transfer initiated by R/3 or by
process control) is information stored for in the process order using the
control recipe destination.

Control Recipe Destination

Control recipe destinations are user-defined in Customizing. Their assignment to a process order takes place on the phase level. This assignment is
independent of the bundling of phases in operations carried out from the
planning view, that is, when the master recipe is defined. This means that
the control recipe destination can be assigned according to the technical
aspects controlling the process.
Process management
Manually controlled
11
Charging

Automated

13
12
Processing Discharging

21
Charging

23
22
Processing Discharging

PI sheet
Process
order

Operation 1

Process
control system
Control recipe destination :
Process control system

Operation 2

PI sheet
Phase
11

Phase
12

Phase
13

Phase
21

Phase
22

Phase
23

Fig. 9-2: Allocation of control recipe destinations to phases

In the example above, a substance is pumped from Operation 1 to Operation

2 without intermediate storage. The phases "Discharging" (Operation 1) and
"Charging" (Operation 2) are therefore closely linked. This means that they
have to be assigned to the same control recipe destination. Their process
instructions are sent to the same control system for execution.
Control recipes are generated from the process instructions of the process
order. The prerequisite for this is that either the entire process order or at
least its phases, whose process instructions are used to generate the control
recipe, have been released for production.

Control Recipes

Process management generates and sends one control recipe for each control
recipe destination specified in the process order.
If the destination is an external system (for example, a process control system or an external process instruction sheet), the transfer of the control
recipe takes place via RFC (Remote Function Call) in the form of Program-toProgram Communication. Depending on the control system involved, it can
be initiated by PP-PI or by process control.

9-3

Process Management

For partially automated or manual process control systems, process management offers the possibility of editing control recipes for the line operator
in the form of a process instruction sheet. This means that the control recipe
data is transferred internally to the process instruction sheet.

Process Instruction Sheet

(PI Sheet)

The process instruction sheet represents an interactive electronic form in

which the process instructions of a control recipe are edited for display and
maintenance at the screen.

Fig. 9-3: PI sheet

Depending on the process instructions involved, the PI sheet can contain the
following functions:
Display of control instructions in natural language.
By providing input fields, the system enables the line operator to enter
requested actual process data. The entries of the line operator are checked
immediately for validity and if a value has been exceeded, the system
will display a message to this effect. The entries are reported using
process messages, which are sent to predefined destinations.
Using predefined formulas from the control recipe, quantity calculations
are carried out. The results are sent to predefined recipients via process
messages.

9-4

Process Management

The line operator can branch directly from the PI sheet into the R/3 QM
module, in order to enter the results of in-process control/inspection runs.
The line operator can call up the following functions directly from the PI
sheet:


Entering of confirmations for the phases of an order

Display of material quantity calculations carried out for the order

Display of documents (for example, standard operating

procedures) generated in the document management system

other user-defined functions

The process instructions of a phase can be locked until the processing of

the preceding phase has been concluded.
The transfer of information from process control to PP-PI is carried out via
process messages, which are normally requested via a process instruction.
They are then generated by an automated control system or by manual data
entry in the PI sheet. In the case of unplanned events, such as malfunctions,
it is also possible to manually generate and send process messages, without
their having been requested.

Process Messages

The contents of a process message are determined by the assignment of characteristics and characteristic values (for example, measured values and units
of measure).Message categories defined in Customizing facilitate the
maintenance of messages in the system. The SAP standard has pre-set
message categories to transfer data to other R/3 components. The user can
however also define company-specific message categories in Customizing
(for example, for external functions or for user-defined ABAP/4 tables).
Some R/3 functions are predefined by SAP as message destinations. In
addition, the usesr can also define other destinations. The following destinations are supported:

Process Message
Destinations

R/3 function module

External function
Users of SAPoffice mail system
ABAP/4 tables in which the contents of a message can be stored

9-5

Process Management

Process messages to R/3 function modules are processed immediately upon

receipt by the function module in question. The following are some examples of this:
The process control system sends information on the amount of ingredients which have been charged and the quantity produced. The change
in stock is posted to the inventory control module of materials
management (MM
As with process instructions from control recipes, the transfer of
message data takes place either internally within R/3 or via RFC. The
transfer is triggered by the sender (that is, by process control) or passed
on by process management.phase.
The process control system reports a change to the control recipe status.
In the order, the status of the corresponding phase is updated.
A process message contains data on product quality which is transferred to the batch record for long-term archiving.
In the case of process messages to external functions, the process management component has a primarily coordinating function, sending information
between the persons and systems involved in the control of the process,
who/which would otherwise be acting independently of one another.
For the sake of example, let us assume that in a partially automated plant
line, a line operator reports via the PI sheet that a vessel has been charged
manually. The message is transferred to the process control system and there
initiates the execution of a control recipe for further processing.
Process messages to mail destinations are sent via the SAPoffice mail
system. It enables those within and outside of the plant to obtain information
on the current status of production at any time, depending on the process
events or operator actions involved.
Process messages can also be stored in user-defined data tables, which are
then available for further evaluations.

Data Transfer to
Message Destinations

Process messages can be sent to any number of destinations. The predefined

destinations are assigned to the message categories in Customizing. If individual messages of a message category are also to be sent to a further destination, it is possible to assign the destination to precisely these messages.
The sending of process messages, that is, their transfer by process management, is carried out in the following two steps:
1.
2.

9-6

The messages are transferred from the process control system or from
the PI sheet to process management.
Process management checks the incoming messages and passes them on
to the predefined destinations.

Process Management

EBR

Process
planning

Production
info. mgmt.
Link to
LIM S

Process
order

Mail
Process
management

Resource
management

Process
messages

Process
messages

PI sheet

Process control

Process control
system

Fig. 9-4: Transfer of data from process control

In the case of the destination types R/3 function module and ABAP/4 table, you
can transfer message characteristics to specific data fields of the destination.
This assignment is also user-defined in Customizing for the respective
message category.
Control recipes and process messages are controlled via so-called monitors.
These contain an overview as well as logs with detailed information on the
history and processing of each message or control recipe.

Monitoring: Control Recipes

and Process Messages

The control recipe monitor displays the current status of the control recipe
from its generation up until its completion (see Fig. 9-5).
The process message monitor in turn displays the status of process messages
from their receipt by process management until they are sent to their destinations. If a destination does not exist or is temporarily not accessible, the
process message is stored temporarily. After the malfunction has been
removed, the message can be sent directly from the monitor. Incomplete
process messages can be completed in the message monitor and then sent.
The following screen shows a control recipe monitor with various statuses
displayed. All changes and malfunctions are documented in the corresponding log.

9-7

Process Management

Fig. 9-5: Control recipe monitor

Process management is fully integrated in the data flows of process planning.

Via process instructions and messages, process management supports the
exchange of information between PP-PI and fully automated, partially automated and manual process control systems.
What are the tasks of process management?
Process management serves as an interface between PP-PI and the systems
involved in process control. Via process management, control recipes are
sent to process control systems and actual process data is sent back in the
form of process messages.
What are the main functions of process management?
The receipt of control recipes with process instructions from released
process orders
The sending of control recipes to the corresponding line operators and
process control systems
The display of process instructions in naturla language, so that they can
be displayed and processed at the screen by the line operator
The receipt, checking and transfer of process messages with actual data
on a process
The manual creation of process messages

9-8

Chapter 10

Integration with R/3 Quality

Management and LIMS
Between the production plant and the laboratory analyzing production data,
information on quality and analysis values needs to be exchanged. This is
carried out via the integration of PP-PI to the R/3 Quality Management
System, with or without a link to external laboratory information management systems (LIMS).

Introduction

The functionality of the R/3 Quality Management (QM) system comprises

the maintenance of master data (integrated in production planning) as well
as the control of inspection processing. The product quality can be preplanned, monitored and authenticated throughout all steps involved, from
product development to preliminary planning, the production process itself,
and warehousing and delivery. This means that R/3 QM supports the basic
elements of quality assurance as required by ISO 9000.

Analysis specifications (LIMS)/

inspection characteristics (R/3-QM)
for active ingredient TOLUOL

z
z

pH value
strength

Analysis results (LIMS)/

inspection results (R/3-QM)
for active ingredient TOLUOL
z 7.3 pH
z 70%

Fig. 10-1: Integration with LIMS or R/3 Quality Management

R/3 differentiates between analyses accompanying the process (in-process

control or inspection) and analyses which follow after the process has been
carried out (post-process control/inspection).
In the case of an in-process inspection, process events are recorded
directly during the production process, either by a process control
system or manually by a plant operator. The results of the inspection
then determine the further processing in this production run.
In the case of a post-process inspection, inspection results are recorded
after the production run and then passed on to the lab in order, for
example, to make a decision on the further usage of a batch. This
inspection can be carried out at the screen or via a linked laboratory
information system (LIMS).

10-1

10

Integration with R/3 Quality Management and LIMS

The results of both methods are then written to the batch record.

In-Process Control/
Inspection

At present, there is a distinct trend towards the linking of process-related

analytical data and the process control functions generating them. This inprocess control function integrates the equipment used for analysis, such as
gas or liquid chromatography equipment, within the process control technology. In this way, account is taken of the fact that measured values from a
process, such as the current pH value of a substance, are also relevant for the
evaluation of the product quality, as well as for the continuation of the
process.
In many cases, the inspection of finished products as well as in-process
inspections are carried out in a production laboratory. The data exchange
between production plant and quality control (lab) is carried out via the
functions of process management (inspection results recording).
When a process order is released for production, an inspection lot for the lab
can be generated on the basis of the master recipe used. This inspection lot
contains the analysis specifications, but you can also enter quality data
directly in the PI sheet and then save this data in the form of an inspection
lot.
Furthermore, you can enter a manual inspection results request, in which a
line operator is requested to enter inspection results for an operation when
maintaining the PI sheet. These must then be confirmed by means of an
electronic signature.

Fig. 10-2: Entry of inspection results data in QM

Planning of Laboratory
Capacities

10-2

The capacity of a laboratory can be included in process planning, that is, in

the capacity planning and scheduling of such resources. Provided the lab is
specified as a resource in the recipe, the period in which this capacity is
available or used can also be scheduled. This is an important aspect to be

10

Integration with R/3 Quality Management and LIMS

considered if production takes place around the clock, but the lab is only
available for a certain number of hours during the day.
In order to link laboratory information management systems (LIMS)with the
automatic creation of inspection lots, as well as to enter inspection results
manually, there is an interface which transfers inspection lot specifications
from QM to LIMS, and then transfers the results of the inspections back to
QM.

Linking up with LIMS

You can get more information on this interface in the document QM-IDI
Interface. A White Paper is available on R/3 Quality Management and
Complementary Laboratory Information Management Systems (LIMS).

PI
Process planning/
Process order

Process
management

QM

Entry of
inspection results

Insp. lot
Insp. characs/
Insp. results
request

PI
sheet
Process
control
system

Lab. information
mgmt. system
(LIMS)

Fig. 10-3: Inspection with entry of external inspection results

In the QM system, inspection lots carry out different functions, from their
generation up to their archiving. When they are generated, inspection lots
document an inspection request, meaning that the production situation
requires an inspection to be carried out.

Generation of
Inspection Lots

The inspection results entered during the inspection run are stored under the
inspection lot number in the database. The access to the individual inspection results is always carried out via the inspection lot. It is possible to
allocate several partial lots to an inspection lot.
Partial lots are generated if the several inspection points are specified for an
operation and inspection results are entered for each one during production.
The total quantity of a process order can be split up into partial lots, if partial
quantities with different characteristics exist for different inspection points.
A partial lot is used to represent a specific production quantity during the
production run. This quantity goes through several operations/phases. For
each operation or phase, you can check different inspection characteristics
and allocate the results to the partial lot.

10-3

10

Integration with R/3 Quality Management and LIMS

The following figure illustrates the above:

Partial lot 1

Viscosity
ph-value
Strenght

Charge 1

1930 cst
7,5
31,7%

Partial lot 2

Viscosity
ph-value
Strenght

Partial lot 3

1950 cst
7,5
40%

Viscosity
ph-value
Strenght

1950 cst
7,5
40%

Charge 2

Fig. 10-4: Generation of partial lots and allocation to batches

Inspecting Batches

The materials management module MM can manage stock of a material in

the form of individual batches. Here the attributes (classified characteristics)
of a batch are specified using the R/3 classification system. The batches of
the material are distinguished according to characteristics defined for a batch
class. Every batch is unique, since it has individually defined characteristics
and values assigned to it.

Allocation of Batches

If a finished product is managed by batches, it is possible to allocate the

partial lots to individual batches after the process order has been carried out.
The inspection characteristic values determined during the inspection run
are transferred to the corresponding batch characteristics. Partial lots with
the same or similar inspection results can be combined in one batch (see Fig.
10-4).
You can get further information on R/3 Quality Management in the
Functions in Detail Brochure Quality Management.

Production and inspection operations are integrated within R/3 QM. Defining
time or quantity-related inspection points enables you to monitor the quality of
your processes on a continuous basis, as well as making it possible to define
partial lots and batch information.

10-4

Integration with R/3 Quality Management and LIMS

10

What links exist from PP-PI to check the quality of products?

R/3 QM is fully integrated with PP-PI manufacturing.
You can link external LIMS systems to PP-PI.

What are the advantages provided by the integration of the QM system in

the R/3 System?
The integrated system supports the elements of quality management according to ISO 9000. It links the functions of quality management with all
enterprise-wide processes and thus enables these functions to be carried out
during the entire life cycle of a product.

10-5

Chapter 11

Integration with Higher-level Systems

In many firms of the process industry, the individual plants work largely
independently of one another and use requirements stemming from quite
different MRP systems. They could be coming from SAP systems (R/2 or
R/3) or from external systems provided by other software vendors. Seen
from the perspective of the R/3 PP-PI component, this data can be interpreted as requirements to be processed by a local R/3 PP-PI System and then
confirmed to the higher-level MRP system.
Basically, the above systems can work as horizontally or vertically linked
systems, or else they can be integrated within one system.
In the case of integrated systems, the rough-cut MRP level and the lowerlevel detailed planning system (PP-PI) are both in the R/3 System.
Integrated in R/3

Linked to R/2 or external host

("process control station")
R/2 or external system

R/3
SOP

PPS
MRP link

MRP

R/3
SFC
SOP

Sales and operation

planning
MRP Material requirements planning
SFC Shop floor control

SFC
PPC

Production planning and control

Fig. 11-1: Possibilities of implementing PP-PI in integrated and linked systems

Linked Systems
In the case of linked systems, there are two different types:
In the vertically linked system, the MRP system is the higher-level system
and the detailed planning system (PP-PI) is the lower-level system.
Here we are always dealing with a hierarchical linking of the systems, in
which the lower-level system is dependent on the specifications made
by the higher-level system.
In the horizontally linked system, the rough-cut planning and detailed
execution systems are networked. This means that the MRP level and
the PP-PI levels are of equal importance, and the PP-PI level is not
subordinate to the MRP level.

11-1

11

Integration with Higher-level Systems

When systems are linked, requirements are placed on the integration functionality above and beyond the limitations of differing hardware types and
software vendors. If one classifies the existing integration possibilities, there
are three basic types of integration:
R/3-R/3 linked systems
Here we are dealing with a link of independent R/3 systems running on
their own databases. These systems can be linked horizontally as well
as vertically. This type of integration is not supported for Release 3.0.
R/2-R/3 linked systems
This is a link between an R/2 system and several different R/3 systems.
Integration only exists vertically and is supported for Release 3.0.
Technically, this integration is carried out via CPI-C/LU 6.2.
External systems linked with the R/3 System
This refers to a link between an external host system and the R/3
System. The integration can also be only carried out vertically and is
supported for Release 3.0.
Technically, this integration is carried out via file transfer.
The following graphic illustrates the above:

R/2
or
external system

Production requiremts.
.
.
.

R/2
External
requirements:
z Materials
z Quantities CPI-C
z Dates
TCP/IP

Production
orders
CPI-C
LU 6.2

PP-PI
Transfer of
production
requirements

R/3

Communication
modules

Check
new
existing
released

Posting
of production
requirements

R/3
Production
requirements

Fig. 11-2: Linked system, containing external or R/2 System and R/3 System

Vertically Linked Systems

11-2

For vertically linked systems, Release 3.0 will provide the possibility of integrating the MRP level of any higher-level system with the detailed planning
system of PP-PI.

11

Integration with Higher-level Systems

Depending on the type of data needed, the requirements can be classified as

follows:
Transfer of material master data:
The transfer of material master data is carried out within the migration
project (file transfer).
Transfer of material requirements
If the higher-level system is an R/2 System, the requirements from the
production order, with quantities and dates, are transferred to the R/3
System.
If the higher-level system is an external host, the requirements have to
be converted to a UNIX file. From here, they are read into the PP-PI
component.
In both cases, the requirements are read into the list of external requirements of the PP-PI component.
Transfer of inventory records:
The transfer of inventory records is carried out via the batch input interface for goods receipts.
Allocation of requirements to process orders:
The requirements coming from an MRP system can be allocated to different process orders in an n:m fashion. These can then be processed in
the usual way.
Confirmation of material consumption for the process order:
If the consumption of materials is to be confirmed,you can read this data
into a UNIX file after the order has been processed, in order to make the
data available to other systems.
Confirmation of processed production commitments (goods receipt):
From the list of processed production commitments, production
confirmations are transferred to the R/2 System in the form of order
confirmations.
You can also place these confirmations in a UNIX file, in order to make
them available to external systems.
For the horizontal linking of systems, at present no cross-system linking
logic is available.

Horizontally Linked
Systems

For the planning of your production runs, you can use various systems in
different combinations. You can link up to external systems, such as an R/2
System. You can also import data from higher-level systems, such as MRP or
production data, for example.
What kind of planning scenarios are supported by PP-PI?
You can carry out the planning of your production runs using data from
higher-level or external systems (vertical) or using horizontally linked systems (for example, many plants on one level, but within one R/3 System).

11-3

Chapter 12

Documentation and Evaluation of

Process Data
The logging and evaluation of process data contained in recipes and process
orders (planned values), inspection lots (quality data), PI sheets and process
messages (actual values) is becoming increasingly important for modern
manufacturers.
Increasingly, public authorities and international standards are requiring
that an electronic batch record (EBR) be generated and archived. The EBR
documents the entire process run and is necessary for firms to secure longterm archiving of such data, so that proof can be given of compliance with
legal requirements at a later date.

Tasks of Process Data

Documentation

Evaluations and reports are required in order to obtain reliable information

and key figures on your production runs, such as obtained production yields
or the utilization of resources. The evaluations can be used to detect and
solve plant problems such as bottlenecks, malfunctions, environmental noncompliance, etc., so that there is a uniform and solid basis for decisionmaking on all levels of a firm.

Tasks of Process Data

Evaluation

Blue

Planning data from

the process order

Actual data from

Process data documentation

using optical archive

z PI sheet

Evaluation of actual data using:

z process control system

z shop floor information system

z laboratory

z SAP XXL
z SAP Business Graphics
z external tools

Fig. 12-1: Documentation and evaluation of planned and actual data for process
manufacturing

12-1

12

Documentation and Evaluation of Process Data

Fulfilling Requirements
with R/3

The R/3 System covers the above-mentioned requirements quite extensively.

You can generate electronic batch records and carry out evaluations on all
levels of your firm. The following tools are available for this:
Using process data documentation, you can generate lists of batch or
order-specific process data and transfer this data to an optical archiving
system.
You can carry out evaluations using the Shop Floor Information System
(for resurces, materials, process orders, product costs), the process
message evaluation functionality, as well as using external evaluation
tools.

Process Data Documentation

Legal Requirements

Not only in the pharmaceutical industry do legal specifications increasingly

require an individual logging of all steps involved in the production of a
batch. This is required by the Good Manufacturing Practices of the American
Food and Drug Administration, for example. These guidelines have now
become an international standard for the pharmaceutical and foods
industries.
According to GMP, the electronic batch record must document the entire
process run, from the planning and execution of production up to results of
quality-related inspections.
The following graphic shows the individual data involved and where in the
R/3 System this data is to be found.
GMP:

R/3:

Log for each batch produced containing a complete

documentation of all planned and actual data required

Documentation and archiving of process order and order-related data

Process order and material list

Inspection lot

(Master formulas, planned data)

(In-process quality inspection)

z Insp. specification, Insp. results

z
z
z
z
z

usage decision
Plant, order number
Material, material list
Operations, phases, resources
Process instructions
Inspection lot for the order

z Batch number, product

Process messages and PI sheet
(Actual data with time stamp & signature)

z
z
z
z

Dates
Materials consumed/produced
Problems/deviations
Changes to process instructions

Fig. 12-2: Information included in the electronic batch record

12-2

12

Documentation and Evaluation of Process Data

Using the process data documentation function of PP-PI, you have a tool
which puts together this data automatically, but which also allows you to
make company-specific additions to your batch record.

Archived List Types

All the relevant data to be archived for a batch is selected via the process
order and compiled in the form of five lists generated from the following
data:
Process order data
Material list for process order
Inspection lot for process order
PI sheets for process order
Process messages for process order
The scope of these lists has been pre-set by SAP according to the
specifications of GMP (see Fig. 12-2). The user determines the actual data to
be archived by requesting the corresponding process messages from process
control and storing them in the process message record.
If the pre-set lists do not correspond to your requirements, you can also add
your own user-defined lists.
The process data to be contained in your batch record is transferred to the
archiving system via the ArchiveLink Interface of the R/3 System. This
interface enables you to link up to optical archiving systems in which the
archiving lists from process data documentation can be stored on a longterm basis, without the possibility of manipulation.

Transfer to Archiving
Systems

You can call up the archiving lists from the archive at any time and display
them online. The corresponding objects can now no longer be changed in the
R/3 System.
Whether process orders are to be archived using the functionality of process
data documentation can be set in Customizing for each order type.

Prerequisites for Archiving

Triggering the archiving function is only possible if an order has the status of
technically complete. In this way, you can ensure that the order has been
carried out and all lists are complete before they are exported to the archive.

12-3

12

Documentation and Evaluation of Process Data

Process Data Evaluation

Advantages

Evaluations provide you with answers to questions regarding the planning,

execution and improvement of your production runs. This is valid for the
long-term observation of critical data as well as for ad-hoc evaluations. The
data evaluated varies according to the company level on which the
evaluation is performed (see Fig. 12-3):
On the planning level (managers, MRP controllers), costing or performance data needs to be looked at, often in aggregated form. This could be
yield data, data on resource output, etc.
On the production level, typical evaluations are related to batches or
their production runs, for example: how high was the actual yield of a
certain product within a certain period?
On the level of the process control system (line operator), for example,
value ranges over a time scale are regarded, such as temperature curves
of a vessel during the course of executing a process order.
Business managers
Accountants
Planners

Company management level

z General company

planning data
z Cost data
z SOP data
z High-level reports

Production managers
Technical support staff
Supervisors
Maintenance
managers

z
z
z
z
z
z

Production
Resource usage
Materials
Schedule delays
Breakdowns
Quality inspection results

Process operators
Maintenance
personnel

z
z
z
z
z

Instrument readings
Resource status
Events/alarms
SPC
Data logs/archiving

Production management level

Process control level

Fig. 12-3: Process data evaluated on different enterprise levels

Evaluation/Analysis Tools

With the R/3 System, you can evaluate process data and process events on
all enterprise levels described. You can request, display and compare data,
as soon as this data is available in the system. Using the following tools, it is
possible to carry out ad-hoc or routine evaluations as needed:
The Shop Floor Information System (LIS) enables you to carry out evaluations on the usage of resources and materials, on planned and actual
production times as well as on planned and actual product costs, as far
as these are logged in the order or in the CO product costing component. From here, you can branch directly to SAP Business Graphics.

12-4

12

Documentation and Evaluation of Process Data

The actual data reported by process control can be evaluated by process

message evaluation functions.
If you prefer to use your own evaluation tools, you can request the
necessary data directly from the database.
The shop floor information system, which forms a part of the Logistics Information System, is a flexible tool to collect, aggregate and analyze data
from process or shop floor control.

LIS Shop Floor

Information System

The goal of the production information system is to enable the user to define
his views on information relevant to the application (for example, resource
usage). The degree of information depth is user-defined.
After the list display of the data, you can have data on all list levels displayed in graphic form. You can obtain the following types of evaluations or
analyses:
Evaluations on resources, for example, planned and actual values
Evaluations on operations/phases or process orders, for example,
execution times, lead times, schedule deviations, etc.
Evaluations on materials used and their consumption - for example,
what was consumed, which material components were involved, comparison of planned/actual values, etc.
Evaluations on product costs, for example, overall costs, fixed costs,
variable costs, planned costs
The following screen shows an evaluation of planned and actual material
consumption.

Fig. 12-4: Evaluation of material consumption (planned and actual values)

12-5

12

Documentation and Evaluation of Process Data

Evaluation of Process
Messages

Process message evaluations serve to analyze actual data reported to PP-PI

by process control. As with process data documentation, this function accesses the messages collected in the process message record.
For the editing and display of your evaluations, you have the following
possibilities:
You can display the results using the SAP Business Graphics
component.
You can transfer the data to Microsoft EXCEL using the SAP-XXL
function and process it further in this application.
Previous to your evaluation, you can obtain a quick list display to check
whether the evaluation criteria you have specified will actually give you the
desired data.

SAP Business Graphics

The link to SAP Business Graphics provides you with an overall graphic
display of trends such as material consumption values. In the following example, the obtained yields are displayed per process order, in list form
(process message evaluation) as well as in graphic form.

Fig. 12-5: Process message evaluation with SAP Business Graphics

12-6

Documentation and Evaluation of Process Data

Process message data can be transferred to Microsoft EXCEL using SAPXXL. The criteria for message selection as well as the layout of the EXCEL
spreadsheet are defined in PP-PI. However, once the data has been
transferred, it can be further processed using EXCEL functionality.

12

XXL Listviewer

The following figure illustrates the temperature curve of a vessel for different process orders over the time axis. You see the definition of the evaluation
criteria in PP-PI as well as the spreadsheet and a graphic created in EXCEL.

Fig. 12-6: Process message evaluations using the XXL Listviewer

If you would like to use your own evaluation tools, you can call the necessary process data directly from the database. The tool you use must support
the database interface software ODBC (Open Database Connectivity). If you
are using a client/server architecture, you must also be able to support the
network interface software SQL*NET.

Evaluation Using
External Tools

Due to these interfaces, you now have more freedom in selecting your
evaluation tools and designing your evaluation or reporting displays. You
are no longer limited to the R/3 System, but can include all information
stored in the database, even if it stems from other systems.

12-7

12

Documentation and Evaluation of Process Data

Process data documentation and evaluation in PP-PI serve to create an

electronic batch record, report on resource utilization or malfunctions, as well
as provide data for the purpose of analyzing and improving your production
runs.
What are the tasks of process data documentation?
Process data documentation refers to the creation of an electronic batch
record which provides long-term documentation of the production
process and excludes manipulation.
It serves to authenticate your correct production runs.

What is the task of process data evaluation?

Process data evaluation serves to obtain production-related key figures,
as they are required on all levels of an enterprise in order to improve
the planning and production runs.

What tools and functions are available to evaluate and visualize processrelated data?
Process data evaluation comprises planned and actual data, permitting
standard analyses as well as ad-hoc reporting.
The results can be displayed in graphic form as well as in the form of a
spreadsheet.
Besides the SAP tools Shop Floor Information System and Process
Message Evaluation, the R/3 System also has an interface for external
evaluation tools.

12-8

Chapter 13

Environment, Health & Safety

The SAP Development Project EH&S
Environmental protection, health, and safety in the industrial arena have
become a focal point of public interest in recent years. Legislators have
passed a multitude of laws and regulations in order to minimize hazards
encountered during the manufacture and handling of substances.
The large number of substances used or manufactured within a company
and their manifold properties relevant to safety and environmental protection play a crucial role. Industries directly affected are the chemical industry
as well as all other types of corporations that process, use, store or transport
chemical products.

Substances

Environmental protection and safety closely interface with a number of

business applications:

Integration

Materials management
Distribution
Production planning and control
Maintenance
Quality management
Human resources
This high degree of integration led SAP users from the chemical industry to
call for an SAP solution. SAPs contact with the process industry had been
intensified during the development of the PP-PI module. Preliminary requirements on an EH&S solution were defined in workshops conducted by
the German Association of Chemical Industries. However, requests for an
EH&S solution also came from SAP customers in the automotive industry,
mechanical engineering, utilities as well as transportation companies. For
this reason, the EH&S system is designed for use across all sectors of industry.

Importance of EH&S

Before the development project got underway, SAP actively pursued close
cooperation with its partners in industry. In the planning and detailed design phases, SAP was able to work with a number of major corporations
from the chemical industry.

Partners in Industry

13-1

13

Environment, Health & Safety

Overview of Functionality
Release Policy

The following functionality will become available as part of Release 3.0E:

Substance database
Phrase management
Flexible substance reporting including MS-Winword integration
featuring:


Material safety data sheets

Labels

User-defined substance reports

Substance information system

Shipment of material safety data sheets from SD
Management of inbound material safety data sheets

Substance Database

The substance database is used by the EH&S system to store various types of
information. It is not only used to store substance identifiers but also compositions, physical, chemical, and toxicological properties, substance classifications, an array of instructions (first aid, handling, storage, etc.) plus information on the inclusion of substances in statutory lists.
 Substance master

Aceton
(technical)

Characteristic Type

Substance: Methanol
Property
Boiling point
Vapor pressure
Flash point

 Substance property

Value
56,5 oC
128 hPa
12,0 oC

Condition
1 bar
20 oC

Substance to be monitored: Super glue

 Substance listing

Acetone
Methyl alcohol

Acetone (techn.)

 Composition

 Phrase library

Analysis
_______
_______
_______
___

Acetone
Methyl alcohol
Water
Residual

98,0 %
1,3 %
0,6 %
0,1 %

Risik-records
R12 Highly inflammable
R23 Poisons by inhalation

Fig. 13-1: Elements of the substance database

Flexibility of the
Substance Database

13-2

It also became clear that, in some applications, substance-related information,

as described above, can be so varied as to make the implementation of predefined data structures impossible. Use of R/3s cross-application classification
system enables a flexible approach to the definition of substance properties.

13

Environment, Health & Safety

You can define any given properties (classes) using any number of fields
(characteristics). The EH&S module can be shipped with a number of standard
substance properties. These standard substance properties can be added to as
required; with upward compatibility, every customer system can be enhanced to include customer-specific properties.
Many substance properties base on textual information. During the development of the substance database, it has proven very useful to manage these
texts as so-called phrases. In this context a phrase is a standard text module.

Phrase Management

You can use substance reporting to create substance-related documents such

as material safety data sheets, TREMcards, labels and others. Microsoft
Word Version 6.0 (Winword) is integrated with the EH&S system for this
purpose.

Substance Reporting

SD shipment of material safety data sheets comprises MSDS shipment, a

complete shipment log as well as automatic distribution of revised material
safety data sheets in accordance with legal requirements.

Shipment of Material Safety

Data Sheets from SD

Management of inbound material safety data sheets enables storage of

scanned MSDS as well as the recording of identifiers and selected properties
in the substance database.

Inbound Material Safety

Data Sheets

The next development phase will include hazardous goods processing from
SD. SAP plans to continuously enhance EH&S functionality provided by
R/3. Preliminary studies for the next design phases have already been initiated.

Planned Functionality

Substance Database - Overview

In EH&S, the term substance refers to a chemical or group of chemicals,
that is, a chemical element, a chemical compound or a mixture of the two.

Definition

A substance may be a natural substance, come into existence during manufacture or be an ideal substance (a substance not found in reality). It may
consist of several substances (preparation, compound or solution) or be a
pure substance. A substance may be used to categorize common properties
(substance group).
A substance is normally assigned to several materials. The material carries
information relevant to logistics and the substance carries data on substance
properties. A substance distributed in various packaging sizes or trading
units does not vary as far as its properties are concerned. However, data
such as price, weight, dimensions, will differ. The figure 13-2 illustrates
possible material/substance relationships.

Material /Substance
Relationship

13-3

13

Environment, Health & Safety

Material

Relationship

Substance

1:1

Acetone p.a.

Acetone p.a.

1:n

Super
glue

SAE
15-W40

Oil
1 liter

Synthetic
resin
Hardener

SAE
15-W40

n:1

Oil
5 liter

0:1

SAE
15-W40

Oil
SAE 15-W40

Salts of chromium

Fig. 13-2: Substance / material relationships

Substance Identification
A substance identification is an identifying description of a substance. As a
rule, an identification consists of several identifiers. One identifier is not
sufficient to ensure unique identification. Only a combination of several
identifiers guarantees unique identification.

Substance Identifiers

A substance identifier is characterized by its identification type and identification category. The identification type specifies the data type, whereas the
identification category defines the precise meaning of the identifier. The
following three identification types exist:
Names
Numbers
Chemical formulas

Names
Numbers

Numbers are derived from various official substance registration systems.

Each new substance is, for instance, included in the Chemical Abstract
Service (CAS number).

Chemical Formulas

13-4

Standard name categories such as IUPAC names, trivial names, and synonyms are supported by EH&S.

The third identification type are chemical formulas. EH&S is configured for
empirical and structured formulas. SAP plans to connect EH&S to the R/3
document management system, enabling you to store graphics of, for instance, two or three-dimensional structural formulas for a substance.

Environment, Health & Safety

13

The figure below illustrates the structure used for substance identification.
Identification
Identification type

Identification category

Names

Name category

ID-Keys

ID key category

Trade name
IUPAC
Synonym
CAS-number
Index- number
Internal number
H

Formulas

Category of formulas

CL

O
N=
O

X Grafik

Molecular formular

Fig. 13-3: Substance identification - structure

Substance Properties
A substance property provides information on a substance either as a numerical value, with the appropriate unit of measure, or as a text.
This information can be linked to further details, such as the source of the
information, method of determination, etc.
Substance properties can be grouped, for example, according to:
physical properties
Chemical properties
Toxicological properties
Ecological properties
First aid measures
Safety instructions
Hazard ratings, etc.
As a rule, a substance property consists of more than one item of information. A physical property may consist of several characteristics, for instance,
a numeric value range (maximum and minimum value), an accuracy requirement in form of a +/- deviation, one or more parameters, a method, etc.
EH&S uses the R/3 classification system to define substance properties. In
the language of the classification system, a substance property is represented
by a class. You can assign any desired number of characteristics to a class.

Classification System

13-5

13

Environment, Health & Safety

Substance Characteristics

The values you record for a substance property are stored as substance characteristics. You can maintain any number of substance characteristics for a
substance or substance property. The sources, methods or one or more of the
parameters (for example, the pressure at which the boiling point was determined) may differ for the various substance characteristics.
The figure below illustrates the method used to represent substance properties.
Substance

Properties

Valuation

No.: 1
No.: 2

-3 oC 1013 mbar
2 oC 1200 mbar

DIN 1243
DIN 1243

No.: 1

87oC

ISO 1812

Safety
instructions
.
.
Super glue

Melting point

Flash point

Benzene

No.: 1

S2 Keep away from children...

S13 Keep away from food ...

Flash point

No.: 1
No.: 2

124 oC
130 oC

ISO 9876
DIN 1234

Fig. 13-4: Substance property - structure

Enhancement

The main requirements on the substance database are its flexibility and
scope for enhancement. The use of the R/3 classification system enables the
user to enhance the substance database by any desired number of properties
featuring any desired structure.

Substance Compositions
The substance composition is a listing of all substance components and their
respective concentrations in substances consisting of several components.
Substance components are those substances that remain components of a
substance after the manufacturing process has been completed.

Substance Composition
Category

The level of detail required for a substance composition listing varies depending on the intended usage and recipient. The details contained vary as
far as the listed components and the required accuracy of the quantitative
values are concerned.
Composition categories, might, for instance, be:
Precise chemical composition
Composition compliant with TSCA (Toxic Substance Control Act)

13-6

Environment, Health & Safety

In order to describe a real substance, it is often necessary to describe the

substances used to obtain the real substance or those that it contains or may
release.

13

Substance Listing

For this purpose, substance listings, that is, the specification of substances for
a substance are used. This is a listing of substances without any quantitative
details. Example of substance listing categories are:
Substances to be monitored at a work center
Decomposition products released by heating
A substance may have many properties in common with other substances.
The substance database enables you to create references between substances.

Substance Reference

Properties Tree
The properties tree makes controlled navigation between the many substance properties possible. The properties are structured using the properties
tree. You can define any number of grouping levels (nodes) between the
individual properties (end nodes) and a substance (root).

Fig. 13-5: Properties tree

13-7

13

Environment, Health & Safety

If requested, EH&S is supplied with a standard properties tree. Using Customizing, you can define properties trees that display any desired structure.
You can, for instance, use this functionality to create trees for specific tasks
(departmental trees) or individual (user-specific) properties trees.

Phrase Management
Phrase Libraries

EH&S enables you to maintain any number of phrase libraries.

Import/Export of Phrases

EH&S provides you with an import/export interface that you can use to
import commercially available phrase libraries. Using this interface, you can
also transfer modifications made to phrase libraries. The original phrase key
is maintained in the EH&S source library for this purpose. You can exchange
phrase libraries using the combined export/import function.

Translation

All textual information on a substance must be translated into the national

languages of the countries with which your company does business. EH&S
phrase management enables the language-dependent storage of all texts
assigned to a phrase and controls their translation. The figure below shows a
phrase and its translations.

Fig. 13-6: Maintenance of phrase texts and translation

13-8

13

Environment, Health & Safety

Substance Reporting
Documents created using the substance database and especially those
addressing external recipients, require the functionality provided by modern
word processors. EH&S provides features such as the insertion of graphics
files such as logos, hazard symbols, pictograms as well as color printing,
tables, etc.

Requirements for
EH&S Documents

Due to the multitude of documents required, users must be able to individually define document layouts and contents.
EH&S substance reporting uses Microsoft Word Version 6.0 (Winword),
with which the user can layout documents then assigning data proposed by
the substance database to certain areas of the document.

Winword Integration

The following examples are intended to provide you with an impression of

the features provided by EH&S substance reporting:

Examples

Hazardous substance label (multi-lingual)

Material safety data sheet pursuant to EU guideline

Fig. 13-7: Hazardous substance label (multi-lingual)

13-9

13

Environment, Health & Safety

EC Safety Data Sheet

Date of issue: 12.05.96 13:45

Page: 1/1

1. Identification of substance / preparation and of the company / undertaking

Information about product:
Tradename:
Super Solvent A

Information about manufacturer / supplier:

Company
TechniDATA
D-88677 Markdorf
Phone number: 07544/5095-0
Emergency phone :07544/5095-0

2. Composition / information on ingredients

Hazard symbols
T F
C

Super Solvent A
Benzyl amine

R-phrases
R 11-23/24/25
R 34

Index number
608-001-00-3
612-001-00-3

Concentration
20 - 30 %
< 15 %

3. Hazards identification
Highly flammable, toxic by inhalation, in contact with skin and if swallowed.

4. First aid Measures

General advice
Skin contact
Eye contact

: Take off all contaminated clothing immediatly.

Move to fresh air.
: Wash off with plenty of water.
Remove contaminated clothing.
: Rinse with plenty of water. Keep eye wide open while rinsing.

5. Regulatory information
Classification
according to EEC
directives

Has to be labeled

Hazard symbols

: F
T

Highly flammable
Toxic

R-phrases

: 11
23/24/25
: 16
27
44

Highly flammable
Toxic by inhalation, in contact with skin and if swallowed.
Keep away from sources of ignition - No smoking
Take off immediately all contaminated clothing.
If you feel unwell, seek medical advice (show the label
where possible).

S-phrases

Fig. 13-8: Material safety data sheet compliant with EU guideline

13-10

Environment, Health & Safety

13

Material Safety Data Sheet Processing

Material safety data sheet processing comprises the creation, management
(version storage) as well as the automatic shipment of material safety data
sheets. The system reacts to relevant MSDS revisions and automatically triggers their distribution.
Apart from the shipment of material safety data sheets, you can also use
material safety data sheet processing for the management of inbound MSDS.
The shipment of material safety data sheets is triggered automatically from
SD sales or SD shipment. Shipment is controlled by the requirements that
apply to the appropriate jurisdiction (such as OSHA, Occupational Safety
and Health Administration).

Integration with Logistics

You can distribute MSDS by mail, fax EDI, or CD. The system automatically
selects the valid MSDS version for the country/language variant. You can
choose color or shading options. If you want to send several MSDS to one
recipient, the system automatically bundles them into one shipment. MSDS
processing also features subscription management that enables you to send
MSDS to interested parties (public authorities, institutes, etc.) with which
you have no business relationship.

Performance Features

The SAP EH&S development project provides software support for business
processes in those areas of environmental protection and occupational health
and safety that interface with SAP R/3 business transactions.
Which main features does the first EH&S release provide?
EH&S Release 3.0 provides you with a substance database, phrase
management, as well as substance reporting functionality integrated with
Microsoft Word.

How is EH&S integrated with other R/3 modules?

EH&S Release 3.0 is linked with the R/3 material master records. You can
trigger automatic MSDS shipment in SD. EH&S can be used to manage and
record inbound MSDS.

13-11

SAP AG
IDS Prof. Scheer GmbH

Neurottstrae 16

69190 Walldorf

Altenkesseler Strae 17

Geb. C2

Germany

66115 Saarbrcken

Germany

Copyright 1996 SAP AG. All rights reserved.

No part of this description of functions may be reproduced or transmitted in any
form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice.
Some software products marketed by SAP AG and its distributors contain
proprietary software components of other software vendors.
Microsoft, WINDOWS, NT, EXCEL and SQL-Server are registered
trademarks of Microsoft Corporation.
IBM, OS/2, DB2/6000, AIX, OS/400 and AS/400 are a registered trademark
of IBM Corporation.
OSF/Motif is a registered trademark of Open Software Foundation.
ORACLE is a registered trademark of ORACLE Corporation, California, USA.
INFORMIX-OnLine for SAP is a registered trademark of Informix Software
Incorporated.
UNIX and X/Open are registered trademarks of SCO Santa Cruz Operation.
ADABAS is a registered trademark of Software AG.
SAP, R/2, R/3, RIVA, ABAP/4, SAPoffice, SAPmail, SAPaccess, SAPEDI, SAP ArchiveLink, SAP EarlyWatch, SAP Business Workflow are
registered trademarks of SAP AG.

All rights reserved.

Production Planning - Process Industry

August 1996

Contents
Production Planning for Process Industries
Preface...................................................................................................................................................v
Introduction........................................................................................................................................1-1
CAPISCE Project Overview.................................................................................................................1-3
Product Positioning ..........................................................................................................................2-1
Overview of Functions......................................................................................................................3-1
Resources ..........................................................................................................................................4-1
Resources and Capacities...................................................................................................................4-6
Maintaining Resource Data .................................................................................................................4-8
Further Resource Functionality ...........................................................................................................4-9
Master Recipes ..................................................................................................................................5-1
Master Recipe Functions.....................................................................................................................5-2
Further Uses of the Master Recipe....................................................................................................5-10
Process Orders..................................................................................................................................6-1
Functions of the Process Order...........................................................................................................6-2
Cost Object Controlling........................................................................................................................6-7
Co-Products.......................................................................................................................................6-10
Links of the Process Order................................................................................................................6-11
Batch Management............................................................................................................................7-1
Batch Specification and Levels............................................................................................................7-3
Batch Management Functions.............................................................................................................7-4
Capacity Planning and Leveling ......................................................................................................8-1
Campaign Planning .............................................................................................................................8-2
Process Planning.................................................................................................................................8-2
Capacity Leveling ................................................................................................................................8-4
Planning Strategies .............................................................................................................................8-8

iii

Process Management........................................................................................................................9-1
Integration with R/3 Quality Management and LIMS....................................................................10-1
Integration with Higher-level Systems ..........................................................................................11-1
Linked Systems .................................................................................................................................11-1
Documentation and Evaluation of Process Data..........................................................................12-1
Process Data Documentation............................................................................................................12-2
Process Data Evaluation ...................................................................................................................12-4
Environment, Health & Safety ........................................................................................................13-1
Overview of Functionality ..................................................................................................................13-2
Phrase Management .........................................................................................................................13-8
Substance Reporting.........................................................................................................................13-9
Material Safety Data Sheet Processing...........................................................................................13-11
Glossary ............................................................................................................................... Glossary-1

Preface
With its module PP-PI, SAP is for the first time providing a set of R/3 functions to
cover the requirements placed on production planning and control by process
industries.
This brochure describes the conceptual design, integration and functionality of the
module PP-PI on the basis of Release 3.0. It is intended for decision-makers as well
as for those in charge of selecting and implementing the functions.
The development of this module is based on the guidelines published by various
standardization organizations, as well as on the pilot installations carried out
during the past few years. The design as well as the implementation phases were
influenced strongly by the experiences and suggestions made by pilot customers.
The first two chapters deal with the history of the pilot project CAPISCE and the
positioning of PP-PI in the market. The following chapters describe in overview
form the functionality of resources, master recipes, process orders, process and
capacity planning, process management (link to process control systems), as well as
the links to higher-level systems or laboratory/inspection systems. The final
chapter deals with the documentation and evaluation of process data as it is
required in a modern production firm by management or government authorities.

Glossary

Constituent

Glossary
Batch
A quantity of a material produced during a
given production run. The main characteristic of
a batch is its homogeneity.

Batch record

A substance that is a known component of

another substance.
The ingredients of a substance are those substances that are still contained as constituents of
that substance after the manufacturing process
has been completed.

Co-product

A logging of all the batch-related planned and

actual data. The batch record can be defined by
the user according to guidelines or legal specifications (such as the GMP guidelines).

Valuable materials generated during a production run together with other valuable materials.
Example: When gas is produced, other products
obtained are gas, tar, benzol and other carbon
derivatives.

Campaign

Control recipe

The uninterrupted execution of process orders of

the same kind based on the same master recipe.

scheduling of a campaign

A recipe containing all process instructions for

the execution of a process order by a process
control system or a line operator. Control recipes are generated from the process instructions
in a process order and sent to the corresponding
process control system. One control recipe is
generated for each control recipe destination
defined in the process order.

allocation of a campaign to a specific resource such as a line or a processing unit

Control recipe destination

Campaign planning
The planning of a campaign, comprising the
following tasks:

availability check of the resources to which

the allocation is made

Process control system or operating group to

which a control recipe is transferred for processing. The control recipe destination specifies

Changeover recipe

A changeover recipe defines the activities necessary to transfer aprocessing unit from an initial
state to a subsequent state.

the technical address to which a control

recipe is transferred

how the transfer takes place (for example,

initiated by R/3 or by process control)

Circulating material
A material used in a process, which is also
(partially) recovered/recycled, such as a catalyst. A circulating material appears twice in the
operation material list, first as an ingredient and
secondly as a yield.

Cleanout recipe
Recipe which describes the time, resource and
material requirements, as well as the activities
that are necessary to clean out a vessel after the
productive run of a campaign.

Coordination of material requirements

Planning coordination for different production,
recycling and waste disposal facilities.

Dangerous good
Substance or mixture that poses an immediate
danger to any person coming into contact with
it.

Glossary-1

Glossary

Dynamic function call

Line operator

Process instruction which enables the line operator to call a user-defined function module from
within the PI sheet. Depending on the function
module, this option can be used to start a dialog
or retrieve data from internal or external applications. The process instruction specifies

Operator of a line in a process.

the function module to be called

the import and export parmeters to be transferred

Hazard note
A document that notes the dangers in the handling, transportation, and storage of a material. A
hazard note can be allocated to a material, a
resource, or a recipe.

Ingredient
A material used in a process. Ingredients are
contained in the recipe material list. They can
also be allocated to an operation or a phase.

Listed substance
A substance whose characteristics are described
in the relevant literature or any type of legislative text. This substance is neither manufactured, traded, or procured. It serves only as a
model for defining the attributes of real substances.

Master recipe
A recipe describing the production of materials
in one production run. The master recipe contains detailed information on the use of a process at a specific plant. It is the basis of the process order.

Material
Substance or object dealt with on a commercial
basis or used, consumed, or generated during
production. A material can be a chemical element or a compound.

Inspection results request

A type of process instruction which specifies
that inspection results are to be recorded for one
or more operations during the production process. The inspection results request specifies the
operation(s) for which inspection results must be
recorded. For these operations, the function for
recording inspection results can be accessed
directly from within the PI sheet.

Intra material
A material which only exists temporarily between two processing steps. An intra material is
listed in the material list.

Line
A production facility at which materials are
changed by means of processes. A line consists
of processing units used in sequential or parallel
order for the execution of process orders. The
following types of lines exist:

production line

recycling line

waste disposal line

Glossary-2

Material list
A list containing all materials required during a
production run and their quantity specifications.
There are recipe material lists and operation
material lists.

Material quantity calculation

The material quantity calculation comprises the
charge and yield calculations. The charge calculation determines how much of each material or
ingredient is to be used in a process. The yield
calculation determines the quantities of product
yield (main product, by and co-products) to be
obtained. The mixing and yield ratios between
the materials or ingredients used in a process, as
well as the material characteristics must be taken
into consideration when carrying out the material quantity calculation.

Operation
Independent part of a recipe which is executed
on a processing unit. An operation is subdivided into phases.

Glossary

Phase

Process data documentation

A subdivision of an operation. Phases can be

arranged in sequential or parallel order. A
phase can have materials from the material list
allocated to it. Phases have the same primary
resource classes/resource as the operation. It is
possible to allocate further secondary resources
to them.

A component of PP-PI used to generate orderrelated data and store it in an optical archive.

Phrase

Process data request

A type of R/3 standard text. Phrases can be used

as substance characteristics or in reports. Phrases are grouped into phrase libraries. A phrase
may group text in several languages.

A type of process instruction which specifies

that process control is to send a process message
with actual data on a process. A process data
request contains the following information:

PI sheet

the process messages category to be used

See process instruction sheet.

information to be provided by process control

The lists to be archived are generated based on

international standards defined in GMP (Good
Manufacturing Practices). Customer-specific
extensions are possible.

Primary product
The product for whose production the process is
carried out. A primary product is distinguished
from other products in that its material number
is stored in the recipe header.

Primary resource
The primary resource is the processing unit or
reaction vessel at which an operation is carried
out. It is occupied for the duration of the operation, which means that all the phases of this
operation are automatically carried out at this
primary resource.

Process instruction
A structure used to transfer data or instructions
from PP-PI to process control. Process instructions are allocated to the phases of the master
and the process order. They are combined in a
control recipes and transferred to process control for execution. Depending on the type of
information sent, there are the following types of
process instructions:

process parameters

process data requests

All the activities of measuring, controlling, and

regulating processes, regardless of whether or
not they are carried out manually or automatically.

process journal subscriptions

process data calculation formulas

inspection data requests

Process data calculation formula

dynamic function calls

sequence definition

Process control

A type of process instruction which specifies

that a value must be calculated in the PI sheet.
This value is then sent to a particular destination
using a process message. The process data calculation formula specifies:

the value to be calculated

A categorization of process instructions according to structure and usage.

the formula to be used for calculation

Process instruction category

the message category of the requested process message

Glossary-3

Glossary

The process instruction category specifies:

Process instruction type

the type of process instruction (for example,

process parameter or process data request)

A classification of process instructions according

to their function. See Process instruction.

the characteristics of this process instruction, that is, the information to be sent via
this instruction

Process instruction characteristic

A characteristic of a characteristics group released for use in process instructions. Process
instruction characteristics are allocated to process instructions either directly or via the instruction category. Together with the corresponding characteristic values, they determine

the information transferred or requested in

a process instruction (for example, the
status of a control recipe)

the requested data is to be processed (for

example, the message category to be used
to report it)

Process instruction sheet

Editing of process instructions of a control recipe
for display and processing at the screen. The PI
sheet enables a dialog between PP-PI and the
line operator in a line which is operated manually (either totally or partially). Depending on
the process instructions, the PI sheet supports
the following functions:

display of control information in natural

language

recording of actual process data

calculation of values

reporting the entered or calculated data

using process messages

recording inspection results by jumping

directly to the QM module

calling user-defined function modules in

order to start a dialog or retrieve data from
internal or external applications

Glossary-4

Process management
A component of PP-PI which is the interface to
process control. Process management comprises
the following functions:

receiving released process orders from the

process planning component

creating control recipes from process order

data

passing on the control recipes to the line

operator or process control system involved

receiving, checking, and distributing process messages

manual creation of process messages

Process manufacturing
Process manufacturing refers to the processing
of gases, grains or liquids. The processes involved can be continuous or discontinuous, i.e.
manufactured in batches.

Process message
A structure used to send actual data on a process
from process control to one or several destinations of the following types:

other R/3 components

user-defined ABAP/4 tables

users of the SAPoffice Mail system

external function modules

Process messages are used to update existing

data records, as well as to generate batch and
production records. The content of process messages is determined by the process message
characteristics as well as by the characteristic
values assigned to them.

Glossary

Process message category

Process message record

A subdivision of process messages according to

their structure and usage. The process message
category specifies:

A logging of process messages which is stored

for a certain period of time.

the characteristics to be allocated to a process message, that is, the information to be

sent

which message destinations a process message is to be sent to

The messages to be included in the process message records are defined for a plant via the message categories allocated to the corresponding
destination. The messages contained in the
process message record can be evaluated using
the process message evaluation component and
archived using the process data documentation
component.

Process message characteristic

A characteristic in a characteristic group which
has been released for use in process messages.
Process message characteristics are allocated to
process message categories. Together with the
corresponding characteristic values, they determine the content of a process message.

Process message subscription

the unplanned events which must be reported by process control to process management

Process message destination

the message category to be used in order to

report an event

A user or component to which process messages

are sent for processing. The R/3 System supports the following types of message destinations:

R/3 function modules

user-defined ABAP/4 tables

users of the SAPoffice Mail system

external function modules

Process message evaluation

A component of PP-PI used to evaluate process
messages collected in the process message record. The process message evaluation enables:

the selection of process messages acording

to characteristic values

the display of message data using the SAP

Business Graphics component

the display and further processing of message data in EXCEL using the XXL list
viewer

A type of process instruction which specifies

Process order
An order describing the production of batches in
a production run or the output of a service such
as a cleanout. The process order is generated
from the master recipe and contains all the information specified during process planning.

Process parameter
Process parameters are process instructions used
to transfer information to the process control
module. In the case of manually operated lines,
the process parameter contains a text for the
lineoperator.

Process planning
The planning of process orders. This involves:

the scheduling of operations

the checking of material availability

the release of process orders for production

Production line
See Line.

Glossary-5

Glossary

Production record
User-defined compilation of the actual data of a
production run, in which all the events occurring during the production run are logged with
a time stamp.

Qualification
The capability or authorization to perform a
specific task. You can allocate qualifications to
your personnel resources.

Real substance
A substance which exists physically in an enterprise. As a rule, one or more materials are allocated to a real substance.

Recipe
The general instructions for the use of a production process. There are manufacturing recipes
describing a production process as well as nonmanufacturing recipes, which check to see that
all functions of a resource are working correctly
or which carry out the clearing or changeover of
a line. Manufacturing recipes are:

master recipes

Recipe object
A type of data object that can be maintained for
a recipe. The following recipe objects exist:

operations

resources

material list components

phases

process instructions

process instruction characteristics

Relationship
The linking of start and finish points of operations or phases in a master or process order.
There are the same types of relationships as in
the Project System. Relationships form a model
of the time flow of operations or phases.

SS relationship (Start - Start)

FF relationship (Finish - Finish)

SF relationship (Start - Finish)

FS relationship (Finish - Start)

control recipes

Remaining material
Non-manufacturing recipes are:

changeover recipes

setup recipes

cleanout recipes

An output of a process which must be recycled

or disposed of.

Repeated process data request

Grouping of recipes that describe alternative

production processes. Together with the recipe
group counter, a recipe group uniquely identifies a recipe.

Type of process data request for the R/3 PI

sheet. Repeated process data requests can be
used to request several messages of different
categories. In the PI sheet, several messages can
be created from every message category requested. The message data to be specified is
maintained in a table.

Recipe material list

Resource

A list containing all materials required to execute a process order as well as their quantity
specifications.

Objects and persons involved in a production

process which have capacities allocated to them.
Resources are subdivided into resource categories, such as plant line or labor. Resources of the
same category can be networked in a resource
structure and grouped into resource classes
using hierarchies.

Recipe group

Glossary-6

Glossary

Resource category

Simple process data request

A grouping of resources of the same kind. The

resource category is user-defined via Customizing. You could, for example, define the following resource categories:

Type of process data request for the PI sheet. A

simple process data request can be used to
request one message of a specific message category. In the PI sheet, individual entry fields are
provided for the message data to be specified.

line

processing unit

Substance

team

labor

Term used for a chemical substance or a group

of chemical substances, i.e. an element, a chemical compound, or a mixture of the two. .

transport

storage

services

A substance may be characterized by its

chemical properties and/or physical properties.

A substance may be defined as a natural

substance, as a substance created during
manufacture, or as an idealized substance
that does not physically exist.

A substance may consist of several substances (preparation, mixture, or solution), or it

may be a pure substance.

Resource network
A resource network describes the physical links
between resources, such as processing units
(reactors, vessels, etc.) in a plant. It serves to
describe the flow of materials through a plant.

Secondary resource
Besides the primary resource, an operation or a
phase can also have further resources, called
secondary resources, allocated to it. This allocation can be carried out with a start/finish time
which is relative to the start/finish time of the
operation or phase (time offset).

Sequence definition
Process instruction which specifies that the
superior phase can only be processed in the PI
sheet after you have finished processing another
phase. By generating sequence definitions, you
can copy the phase relationships maintained in
the process order to the PI sheet.
In the PI sheet, the process instructions of the
phase containing the sequence definition remain
inactive until all required messages have been
created for the process instructions of the predecessor.

Substance composition
A listing of all components including their concentration found in a substance consisting of
several components. See Constituent.

Substance identification
A unique description of a substance. As a rule,
the description consists of several identifiers.

Substance identification category

Describes the substance identification type. The
following substance identification categories are
provided for the substance identification type
name:

IUPAC name

Synonym

Trivial name

Trade name

Setup recipe
A recipe which describes the time, resource and
material requirements that exist at the beginning
of a campaign as well as the activities that need
to be carried out to set up a production run.

Substance identification type

General description used for substance identification. Substance identification types are the
name, number and formula of a substance.

Glossary-7

Glossary

Substance property
Information stored on a substance, either in the
form of figures or texts. Substance properties
can be linked to information on its origin, on the
source literature, etc. Substance properties can
be grouped according to the following criteria:

physical properties

chemical properties

toxicological properties

ecological properties

first-aid information

safety note

allocation to a hazard classification

Workflow
The term workflow refers to a sequence of tasks
to be processed by persons or automatic processing units.
The workflow manager determines the logical
and time sequence of the tasks. Flexible eventdriven response mechanisms take over the
workflow control.

Yield ratio
The quantity relationship between the yields
(materials) created during the execution of a
process order.

Glossary-8

Functions in Detail - PP-PI

R/3 System
Production
Planning
for
Process Industries