Figure 61: Definition of Terms
The term Batch in the SAP system: The same production- and inspection specifications are valid for a production lot. A batch is a unique subset of a material. The batches of one material are managed separately in stock. With regard to the production process, a batch is a quantity of a specific material during a given production run. This quantity, therefore, represents a unit with unique specifications.
The definition of the term 'batch' influences the definition of the material. All criteria (characteristics) that would allow a batch to be reproduced, should be assigned to a material (object); the batch (object) however should only contain characteristics that are unique to this batch. The characteristic values in this specification denote that the batch cannot be reproduced.
Figure 62: Functions in the Classification System
When structuring a classification system, you first define characteristics and the allowed characteristic values (characteristic maintenance).
Then you define classes, to which you assign characteristics (class maintenance).
You assign objects to the classes (such as, materials, batches) and describe these by giving the characteristics in the class object-related attributes. This batch valuation can also take place using the inspection results that have been recorded in QM.
You can then use the Classification System to search for classed objects (for example, in batch determination).
Figure 63: Process Flow with Partial Lot Creation and Batch Assignment
In the process manufacturing, the process order is created based on a master recipe.
The data from the master recipe that also contains QM data, is copied into the order.
Depending on the Customizing settings, an inspection lot is created when the order is released. The inspection lot can also be created manually.
In the production process, quality inspections are carried out that are based on inspection points defined in the recipe. You can form partial lots based on varying quality results. A batch number can be assigned to each partial lot.
Partial quantities of the produced material are confirmed and posted to the warehouse.
Figure 64: Inspection Points, Partial Lots and Batches in the Master Recipe
Partial lot assignment in the master recipe header
You make settings for the different levels at which you want to control and document the production process:
• Inspection Points
• Inspection points - partial lots
• Inspection points - partial lots - batches
Indicators for the last partial lot assignment at operation/phase level
• This indicator defines the operation that plans the last inspection during production and if necessary the last assignments to the partial lots from a QM standpoint. The quantities in the inspection points/partial lots for this operation are proposed when the goods receipt for the order is posted. A goods receipt can only be posted automatically for operations that have this indicator set.
Indicator for partial lot quantity at operation/phase level
• If time-based inspection points are created in production, this indicator controls whether a quantity is to be assigned to each inspection point, or whether the quantity is only to be determined once for each partial lot.
Figure 65: Creation of Partial Lots
The inspection characteristics for an in-process inspection are included in the operations and phases of the master recipe. You can create new inspection characteristics in the master recipe or can reference existing master inspection characteristics.
This graphic shows the interaction between the inspection points and the partial lots.
If you have planned inspection points in the master recipe, you record results with reference to these for each inspection during production. Unlike an inspection without inspection points, inspection results can therefore be recorded for inspection characteristics in the same inspection operation several times directly after one another.
For each production or process order, an inspection lot can be created for which partial lots can be created if necessary.
If you do not confirm any partial quantities during production or do not work with inspection points, the inspection results are recorded for each operation for the entire inspection lot.
If you produce goods in partial quantities, the system gives you the option of creating a new partial lot or copying the previous one for each inspection point.
The decision should depend on whether varying inspection results for the partial quantities produced require these quantities to be assigned to separate partial lots.
Several partial lots enable the stock to be separated for inventory management purposes, as a batch can be created from each partial lot.
Figure 66: Inspection Points, Partial Lots and Batches
This graphic shows the interaction between the inspection points, partial lots, and batches.
If an inspection point identification is defined in the master recipe in the recipe header detail screen 'QM data', all inspection results recorded during production are related to the inspection point. Unlike an inspection without inspection points, inspection results can therefore be recorded for inspection characteristics in the same inspection operation several times directly after one another. The interval between such inspection points can be time-based (at specific times),
You record results for the inspection characteristics in the inspection lot. Only one inspection lot for an inspection during production can be created for a process order. If partial quantities with different properties are produced in a process order, you can inspect with inspection points and record the inspection results in each inspection point for a corresponding partial lot. Several partial lots can be formed.
A partial lot identifies a specific production quantity during production. This quantity undergoes various operations or phases, in which different inspection characteristics are inspected based on inspection points and the results can be assigned to the partial lots. A new partial lot is created when the first inspection lot for this partial lot is processed.
If the finished product is handled in batches, you can assign the partial lots to individual batches.
Figure 67: Relationship Between Partial Lots and Batches
If several partial lots are created during production, you can assign an individual batch number to each partial lot. This batch number is then used for the goods receipt from production.
In addition, you can combine partial lots to form a batch, when recording inspection results for inspection points.
The inspection results for the individual partial lots are the deciding factor in this case. If there is a difference between the values of the partial lots that have been produced, you can manage the stock subsequently in separate batches.
You can form partial lots and split batches based on the confirmation of results.
Figure 68: Assignment of Batch Numbers
You can enter the batch number for the subsequent goods receipt in the following ways:
• For individual partial lots that have been created for an inspection lot and confirmed as partial lots. You can assign a batch number to each partial lot, or can combine several partial lots under the same batch number.
• At header level in the process order that has been created, if the whole order is confirmed as one quantity.
• The batch number is only assigned at the goods receipt.
Scenarios:
• A) No batch is entered in the process order. An inspection during production takes place using inspection points. Partial lots are formed for this inspection and batches (C1, C2) are created. These batches C1 and C2 are then proposed at goods receipt. In this scenario, the batch could also be entered in the process order and would then be proposed as the default batch in the 1st partial lot.
• B) When you create a process order, the batch number C1 is specified and no inspection during production takes place with inspection points at batch level. This batch C1 is then given in the goods receipt transaction.
Figure 69: Co-products
Figure 70: Typical Material Flow in Co-Product Manufacturing
This graphic illustrates a typical material flow in process manufacturing, using the example of two operations in the primary resources 'charging vessel' and 'reactor vessel'.
The following cases are shown:
• Introduction of ingredients
• The temporary creation of an intermediate product between two process units, which is subject to further treatment within the process; Such materials are represented by the material type INTR intramaterial.
• The production of waste
• The use of a catalyst that enters the process at a certain stage and subsequently leaves the process.
• The manufacture of one or several products; the production of several materials in a production run is known as the manufacture of co-products.
Figure 71: Bill of Material in Manufacture of Co-Products
Co-products can be included in the bill of material in the following way:
• A co-product can be assigned to the bill of material header as a leading material. Additional co-products appear as bill of material items.
Planned orders can be created for a leading material in material requirements planning. A process order must be created (manually if necessary) to create requirements for co-products that are listed as items in a bill of material.
Prerequisites for the production of co-products are:
• The 'Co-product' indicator must be set in the material master for co-products.
• The co-product indicator must also be set for the BOM items, to which co-products are assigned. However, it does not need to be set for a leading product in the BOM header.
• The creation of a process order can either take place for a co-product or for a process material.
Figure 72: Representation of Co-Products in QM
An example for the formation of partial lots is the simultaneous manufacture of co-products for several materials in a process order. Here, each co-product/product can be identified with a partial lot.
Figure 73: Material Specification - Planning
The class characteristic that is assigned to the master inspection characteristic must be defined either with the format (NUM) or the format (CHAR) with selected sets.
The inspection specifications can come from the following sources:
• From the master inspection characteristic (the master inspection characteristic is referenced in the material specification and is not linked to a class characteristic).
• The master inspection characteristic is referenced in the material specification and is not linked to a class characteristic.
• From the class characteristic (the master inspection characteristic is
referenced in the material specification and is linked to a class characteristic).
• From the batch classification of the relevant material (the linked master inspection characteristic is referenced in the material specification).
Figure 74: Using a Material Specification
The inspection type in the (QM view) of the material master controls whether goods are to be inspected using the material specification.
If you only inspect with the material specification, the default values must be maintained in Customizing for the inspection type.
If you inspect with a task list and specification, the specification takes precedence.
Figure 75: Batch Valuation With Material Specification
The material specification provides a simple template for inspecting a material across all clients.
It consists of the assignment of the material and inspection characteristics.
In addition to the “normal” specification, the function can be extended so that the inspection results lead to a batch valuation.
For this to take place, the material in the material specification must be
classified (class type 022/023) and handled in batches, and the master inspection characteristics that are used must be linked to the relevant class characteristics.
Figure 76: Batch Valuation Without Material Specification
You must set the indicator “Batch valuation without material specification” in the plant-dependent settings in Customizing.
When using this function, you can no longer control which characteristics from the batch are to be supplied with the QM inspection results based on material.
The transfer of inspection results always occurs if there is a link between the master inspection characteristic and the class characteristic [batch characteristic]
(independent of material).
During inspection lot creation, there must be a link between the master inspection characteristics and the class characteristics in the batch class, so that a batch valuation occurs when making usage decisions or inspection point valuations.
Figure 77: Time of Batch Evaluation
The system only copies results from master inspection characteristics that are linked to a class characteristic in the batch class.
You do not need to inspect with a material specification.
In the class characteristic
• The mean value for quantitative master inspection characteristics
• The attribute code for qualitative, summarized master inspection characteristics with characteristic attributes
are described for the corresponding inspection characteristic.
• The long text for the usage decision logs which class characteristics in the batch class have inspection results.
• Batch derivation is possible as of Release 4.7. You can use this to transfer data, for example, when you make the usage decision. This may be necessary when several batches of heterogeneous materials are based on one bulk batch.
Figure 78: Specification for Produced Batches
In an in-process inspection, the inspection requirements are defined using inspection characteristics for the operations and phases that are contained in the master recipe. The process order or inspection lot is based on this master recipe. You can either create new inspection characteristics in the master recipe, or reference master inspection characteristics for this inspection.
Master inspection characteristics are master data created in QM. They simplify the standard inspection process and enable a link to the class characteristics of batches.
This link allows the automatic transfer of inspection results from the inspection characteristics to the corresponding class characteristics of the batches produced.
When you inspect with inspection points, the inspection results are recorded for a specific partial lot in each inspection point. You can assign several partial lots to an inspection lot. A partial lot identifies a discrete production quantity that can be assigned to a batch. The inspection results for an inspection point are transferred to the class characteristics in the batch that are linked to master inspection characteristics, once the inspection point has been valuated.
Figure 79: The Batch Where-Used List over Several Production Stages The where-used list tracks the batch, using the Inventory Management
functions. From initial posting to deletion from inventory, each batch has its own document journal. In addition, links between batches across all manufacturing levels through to the sales order and batch splits are logged.
The lifecycle of a batch is only logged, if an inventory posting has taken place.
The numbers of the reference documents, the process order and sales order are stored, as well as the material document.
The 'Top down' and 'Bottom up' display variants describe the direction, in which you view the 'family tree' of the batch.
You can also display the batch where-used list as a graphic.
The Batch Information Cockpit that was developed in 4.6C was enhanced in Release 4.7. Using a customer-specific BAdI, it is now possible to make a customer-specific selection on a selection tab page. This selection tab page is delivered with an example implementation that you can use to select inspection lots.