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CEMENTINDUSTRY SAP

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MANUFACTURING OF CEMENT

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SAP SOLUTIONS FOR CEMENT INDUSTRIES

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SAP SOLUTIONS FOR CEMENT INDUSTRIES

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INTEGRATED PROCESS FLOW FOR A CEMENT

PLANT

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HOW SAP INTEGRATE THE PROCESS FLOW

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PRODUCTION PLANNING & CONTROLING

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PRODUCTION PLANNING :

Sales & Operational Planning (SOP)

Demand Planning (DP)

Demand Management (DM)

Material Requirement Planning

(MRP)

Capacity Requirement Planning

(MRP)

Planned Independent

Requirement (PIR)Customer Requirement (CR)

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PRODUCTION PLANNING MASTER DATA:

Material Master

Bill of Materials (BoM)

Resource

Master Recipes

Production Version

Process Order

Goods Received

Goods Issue

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PRODUCTION PLANNING MASTER DATA:

Terms

Definition

Example

Material Master

Contains descriptions of thematerials a company procures,

produces, and stores. The material

master is the central repository of

material information (such as stock

levels) for the company.

Limestone, Cement stone, Gypsum

etc.

Bill of Materials

A bill of materials (BoM) is a list of

the parts or components that are

required to build a product. The

BoM provides the manufacturer's

part number (MPN) and the quantity

needed for each component.

Which material and how muchquantity is required to produce OPC

cement

Resource

An organizational unit that defines

where and when an operation must

be performed. The resource has an

available capacity. The activitiesperformed at or by the resources

are valuated by charge rates, that

are determined by cost centers and

activity types.

Machine , labor etc. can be treated asresource.

Master Recipe

is the description of an enterprise-

specific process in process

industries, that does not relate to aspecific order.

Crusing, Burning, Grinding, Packaging

etc.

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PRODUCTION PLANNING MASTER DATA:

Terms

Definition

Example

Production Version

A production version determineswhich alternative BOM is used

together with which task list/master

recipe to produce a material or

create a master production

schedule.

For one material, you can have

several production versions for

various validity periods and lot-size

ranges

Process order

Process orders are the main

element used for the detailed

planning and execution of process

manufacturing.

A process order describes the

production of batches (materials) ina production run or the rendering of

services. It is generated from the

master recipe and contains all the

information specified during

process planning.

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PRODUCTION PLANNING MASTER DATA:

Terms

Definition

Example

Goods receipt

When a material has been producedin a process, a goods receipt for the

order must be posted. Whether and

how you can trigger the goods

receipt posting using a process

message depends on the type of

material produced:

Goods issue

Goods Issue is basically movement

of material within the plant for

consumption/manufacturing or

outside the plant as delivery to

Customer.

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QUALITY CONTROL:

Quality Control enables recording, tracking and analysis ofproduct and process characteristics to ensure quality

compliance.

Key Benefits

Supports automatic or manual triggered inspection lots. Integrated tightly with the complete supply chain (e.g. inventory,

batch, purchasing).

Enables statistical process control (SPC) to monitor critical

product and process characteristics in the manufacturingprocess and allows instantaneous intervention.

Documents product quality to achieve regulatory compliance.

Includes integrated problem management .

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QUALITY CONTROL:

Key Functionalities

Quality Inspections

Laboratory Integration

Test equipment Interfacing

Usage Decision / Release Certificate of Analysis

Statistical Process Control

Problem Management

Test Equipment Calibration Quality Information System

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QUALITY INSPECTIONS

Comprehensive inspection processing

Goods receipt inspection .

In-process control

Post-process control Inspections at goods issue

Recurring inspections

Test equipment interfacing

Statistical process control (SPC) with integrated problemmanagement

Results recording - mobile or Web-based

Functions integrated in logistics (e.g. inventory management)

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QUALITY INSPECTION DASHBOARD