____________________________________________________________________________________
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Vital Wires Consulting Pvt. Ltd.
301 Palm Court Building, MG Road,
Sector 16, Gurugram
PO Box: 122001, Haryana, India.
Tel: +91124-4958460
www.vitalwires.com
Vital Wires
Business Blue Print (Draft)
Molson Coors International, India SAP
Implementation – Project Sunrise
PP-BBP
Module: Production Planning
Master Data and Production Execution
April 19, 2019
STATEMENT OF CONFIDENTIALITY / DISCLAIMER
This document is the property of Vital Wires Consulting Pvt.
Ltd. and is produced in response to your request. No part of
this document shall be reproduced, stored in a retrieval
system, or transmitted by any means, electronic,
mechanical, photocopying, recording, or otherwise, to
parties outside of your organization without prior written
permission from Vital Wires
Confidential Page 1
Contents
Document History.....................................................................................................5
1. Introduction.......................................................................................................6
1.1 Implementation Team......................................................................................7
2. Materials Management– Organization Structure......................................................8
2.1 Business Case...............................................................................................8
2.2 As Is Process................................................................................................8
2.3 Core To-Be Process........................................................................................8
2.4 Plant........................................................................................................8
2.5 Storage Locations......................................................................................9
3 Production Planning– Master Data.....................................................................10
3.1 As Is Process..............................................................................................10
Material Master:...............................................................................................10
BOM................................................................................................................10
Resource..........................................................................................................10
Recipe.............................................................................................................10
Production Version............................................................................................10
3.2 Core To-Be Process.....................................................................................10
3.3 Material Master:..........................................................................................11
3.4 Bill of Materials:..........................................................................................15
3.5 Resource...................................................................................................18
3.6 Master Recipe...............................................................................................20
3.7 Production Version.........................................................................................22
3.8 Engineering change management:..................................................................23
3.9 Configuration consideration.........................................................................26
Defining Range of Coverage..............................................................................26
Defining Scheduling Parameters for Planned Orders............................................27
Defining MRP Controller....................................................................................27
Overall Maintenance of Plant Parameters...........................................................28
Define Material Types Allowed for BOM Header..................................................28

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 Define Control Key............................................................................................28
Determine Capacity Planner..............................................................................28
3.10 Open points for master data.....................................................................29
3.11 RICEFW/Gaps for master data..................................................................29
3.12 File conversion considerations master data................................................29
3.13 Reports required related to current business process.................................29
3.14 Document / Output would be printed for this business process................29
3.15 Integration aspects...............................................................................29
3.16 Authorization Consideration...................................................................30
3.17 As Is reference.....................................................................................30
4.Production Execution – Business Processes............................................................30
4.1 MRP: Material Requirement Planning...............................................................31
4.2 Planned Order:..............................................................................................33
4.3 Wort Production:.........................................................................................34
4.3 Fermentation..............................................................................................34
4.3.1 Yeast Management..............................................................................34
4.3.2 Maturation:..........................................................................................35
4.4 Filtration:...................................................................................................35
4.5 Bright Beer:................................................................................................35
4.6 Packaging:.................................................................................................35
4.7 Process order: COOISPI (Reporting Transaction)..............................................36
4.14 Rework:..................................................................................................40
4.14 Disposal Process:.....................................................................................40
4.15 Bottling preparation:................................................................................40
Production Execution Process Flow Chart- As - Is...............................................41
Changes to Existing System..................................................................................43
System Controls...................................................................................................43
Interface/Development Requirements...................................................................43
System Configuration Considerations....................................................................43
Defining Order Type-dependent Parameters.......................................................43
Defining Scheduling Parameters for Process order..............................................44
Defining Confirmation Parameters.....................................................................44
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 Defining Checking Control.................................................................................45
Defining Scheduling Margin Key........................................................................46
Configuring Planner Group................................................................................46
Determining Capacity Planner............................................................................47
Setting Up Production Scheduler Group..............................................................47
Production Scheduling profile............................................................................48
Define Assign Material type...............................................................................48
Define System Status Maintain..........................................................................48
Number Range.................................................................................................49
Open Points:....................................................................................................49
RICEFW/Gaps...................................................................................................49
File Conversion Considerations..........................................................................49
Reports required related to current business process..........................................49
Document / Output would be printed for this business process............................49
Integration aspects...........................................................................................49
Authorization Consideration...............................................................................50

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Document History
Version Release Date Author Reviewed By Change Description /
Comment

1.0 18.04.2019 Pushkar N Sujit Suman Initial Draft

Srivastava

2.2 22.04.2019 Pushkar N Sujit Suman

Srivastava

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 1. Introduction
This document contains the proposed blueprint for the SAP Implementation at
Molson Coors International, India; it outlines all the major processes associated
within the scope of the implementation project. The intent of the document is to
define the to-be model for some of the process that have been covered as part of
the as-is study conducted during the knowledge gathering phase.
If there are any functional elements or sub components which are
incidental and critical to the business scenarios of Molson Coors
International, India and which is not reflected in this blue print document,
it shall later be added as version changes to this document provided these
changes/functional elements are within the processes mentioned in the
original blueprint document. Those changes will be incorporated if
identified by the end of completion of unit testing phase.
If the changes are identified after the unit testing phase, these would be
taken up with the Steering Committee and evaluated there and will not get
included automatically. Please also note that if there are any additional
efforts required to incorporate any such changes that affects the project
timelines or which is outside the scope of the project, the same needs to
be mutually discussed and agreed upon as per the Change Order Terms
and Conditions.
This document also highlights the Organization structure that would be
mapped to the SAP system.
The entire document establishes the format for the final blueprint, which
would be subjected to audit by the business representatives for their
assessment and approval.
The document is a collaborative effort between the implementation team,
business team and the core team. The document also represents the
agreement of the core team to the proposed processes in individual
modules of the project and also of the deviations, where an agreement
needs to reach on the process change.
The process of arriving at the blueprint is as below:
Arrive at “AS-IS” process.
Propose “TO-BE” process, these would either be the Core Business Model
(CBM) itself or would be a deviation from CBM.

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1.1 Implementation Team
Name Role Module Organization
Sachin Selot Project Manager SAP MCI India
Ramendra Chaudhary IT Head SAP MCI India
Deepak Jammula Solution Architect SAP MCBC Global
Amit Saini Core Team Member FI (HO) MCI India
Manoj Jha Core Team Member CO MCI India
Gordon D’souza Core Team Member FI MCI India
Digvijay Yadav Core Team Member Supply Chain MCI India
Arvind Core Team Member Production MCI India
Pushkar Nath SAP Consultant PP
Sujit Suman Project Manager SAP Vital Wires
Arminder Singh SAP Consultant MM Vital Wires
Kanishk Kashyap SAP Consultant FICO Vital Wires
Kamlesh Arya SAP Consultant SD Vital Wires

Sign-off (Approval) for this document:

Name of Team Member Organization / Role Signatures
Sachin Selot
Manoj Jha
Digvijay Yadav
Arvind
Ramendra Chaudhary
Deepak Jammula
Manish Saxena

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2. Materials Management– Organization Structure

2.1 Business Case

Molson Coors International, India Procures Raw Material, Packing, Spares, Consumable, etc.
from Principal, Import and Local Vendor. These Materials can be used for internal consumption
or sales.

2.2 As Is Process
Molson Coors India head office is located in New Delhi, Procurement is done both centrally
from HO and as well as from Manufacturing Plants. There are two entities for MCI India, but
production and procurement generally happens in Molson Coors India Pvt. Ltd., other entity is
Molson Coors Cobra India Pvt. Ltd.

2.3 Core To-Be Process

The Organization Structure is the basic skeleton frame in SAP which structures the Company,
Organizational units, and all other departments essential in running the business. The following
are the organization levels in SAP

2.4 Plant
Plant is an organizational unit within Logistics, serving to subdivide an enterprise according to
production, procurement, maintenance, and materials planning.

A plant is a place where either material is produced, or goods and services are provided. The
plant is embedded in the organizational structure as follows:
 The plant is assigned to a single company code. A company code can have several plants.
 Several storage locations in which material stocks are managed can belong to a plant.
 A plant has its own material master data. You can maintain data at plant level for the
following views on a material master record in particular: MRP, Purchasing, Storage,
Production resources/tools, Forecasting, Quality management, Sales, Costing.

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For MCI India, all Manufacturing Units, Head Office, Depots/Marketing Office will be created
as Plants.
S. SAP Name Description Company Code
No.
1 7010 MCI Head Office 7000
2 7011 MCI Bhankarpur 7000
3 7012 MCI Saha 7000
4 7013 MCI Haryana Depot 7000
5 7014 MCI UP Factory (Upcoming) 7000
6 7015 MCI UP Depot 7000
7 7016 MCI Delhi Depot 7000
8 7017 MCI Chandigarh Depot 7000
9 7018 MCI Himachal Pradesh Depot 7000
10 7019 MCI J&K Depot 7000
11 7020 New Market 1 7000
12 7021 New Market 2 7000
13 7022 New Market 3 7000
14 7023 Micro Brewery 1 7000
15 7024 Micro Brewery 2 7000
16 7025 Tap Room 1 7000
17 7026 Tap Room 2 7000
2.5 18 7027 Contract Manufacturing 7000
19 7110 MCC Bihta Patna 7100 Storage
Locations
Storage Location is an organizational unit facilitating differentiation between the various stocks
of a material within a plant. These are the smallest unit in an organization hierarchy.

 There may be one or more storage locations within a plant

 Storage location is the place where stocks are physically kept within a plant.
 Stocks are managed only on a quantity basis and not on a value basis at storage location
level.
 Physical inventories are carried out at storage location level.

List of Storage Locations Plant wise has been attached.

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3 Production Planning– Master Data

3.1 As Is Process
Various masters are used by the MCIPL. These masters are available in various formats. All masters are
maintained either in system or as soft copy in MS Excel files.

 Material Master: In MCIPL, Material master gets created by IT Team in IBMS system. Brand and
State wise material created at MCIPL. Some of the Key Materials used in MCIPL are categorised as
Raw Material (Malt, Broken Rice, Sugar, Rice Flex, Hops, Enzymes, etc.); Packing Material (New
Bottle, Cans, Market Return Bottle, Wrinkle Caps, Cartons, etc.); Finished Goods (Miller Ace, Thunder
Bolt, Carling, etc.)
 BOM In MCIPL, Service master gets created by IT Team in IBMS system and is being used in service
order to procure services.
 Resource
 Recipe
 Production Version

3.2 Core To-Be Process

Successful functioning of SAP are dependent on the most important part i.e. Master Data which are
broadly classified under :

 Material Master
 BOM
 Resource
 Recipe
 Production Version

R/3
R/3
Organizational
Organizational PP
PP Basic
Basic Data
Data Use
Use of
of PP
PP Basic
Basic Data
Data
Units
Units

Work Center /
Company Resource Capacity Planning
Code
Routing / Recipe
10 Platz 1
20
Valuation
30
Area
Material Master Plan Material
Production &
Bill of Material / Procurement
Plant A
Material List
Material

Product Costing
Engineering Change Management (ECM)

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3.3 Material Master:
This section of document lists creation of the Material Master view related to PP module. The Materials
Management Module will include the detailed Process along with different parameters for all the
materials separately.

Process Flow Diagram

Co-ordinate with
Requirement different identified Create Material
of new department for input Master
material code in different fields

Based on Client Material codes are generated in different series as:

In proposed system material master will be company's central source for retrieving material-specific
data. SAP Organization Structure (company Code, Plant etc.) is a prerequisite to create/maintain any
material master.

Each Material Code will be unique and will have 40 Char description associated with it. Any additional /
detail description can be maintained in the long text field available in the material master.

Following is the some of the important key data structures/elements required to create a material
master. The detailed KDS (Key Data Structure) will be maintained in Production Planning and Materials
Management Module individual document.

The detail of the field value will be finalized during SIT & UAT, however following are some of the
important fields which need to be maintained related to PP module

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 Material type:

Material type controls following functions:

 Number ranges (internal/external)

 Field selection groups (making fields optional or mandatory)
 Qty/Value update in different plants
 Internal/external procurement
 Views available (Purchase/Sales/Quality/Costing/Accounting/MRP etc)

For detail, please refer KDS document for materials management. As a part of production
planning module special attention need to be given for:

 Finished Goods
 Semi-Finished Goods

Unit of Measurements:

Every material created will have Stock keeping units as Base unit of measure i.e. the unit in
which Stock reports are required, standard SAP provides a comprehensive list of UoM,
anything extra can be added subsequently and the same time alternate UoM will be
maintained as List with conversion factors. Base unit of measure is KG and issue unit is Nos.
this conversion factor can be maintained in materials master. Important Fields In Basic Views
- Old material Number, Material group

Classification:

Classification can be used to classify Materials and its different batches of the material
produced and capture the required attributes. The classification view captures lists different
attributes which are required for capturing relevant information.

For example - Material classification can be used to for bar code printing purpose & batch
logic determination.

Batch classification can be used to enter External Batch number (Vendor lot number), Expiry
Date, Production date etc. Details of Batch classification can be checked in MM Blueprint.

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 MRP and Work scheduling Views

Batch Management:

Batch is a subset of the total quantity of a material in stock, managed separately from
other subsets of the same material.

All in-house produced materials will be activated with batch management for
traceability of usage for a particular material lot. Batch management can be activated
with different Batch Attribute / Batch Characters (Complete List to be compiled by the
end of realization)

Once activated every transaction of Receipts/Storage/Issues/transfers of material

requires batch no. to be specified and selected by the user.

Batch entry –

Defines when batches have to be determined while using the PP/WM interface.

This indicator refers to the components of an order, not to the finished product to be
manufactured. You have the following options:

 The batches can be determined when the goods issue is posted.

 The batches must be entered in the order before it is released.

 The batches must be entered in the order before the goods issue is posted,
but not necessarily before the order is released.

If you use pick parts, the batches are determined in the transfer order and
then confirmed to the transfer order. If there is no direct link between the
transfer order and the production order (for example, with release order parts
or crate parts), you must enter the batches in the production order manually.

 The batches are determined automatically when the order is released.

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 Other relevant fields:

Prod. stor. location

Schedule Margin Key

Availability Check

Special Procurement Key (For planning of material in another plant during MRP Run)

MRP Type:

Standard MRP types ND (No planning), PD (MRP) , VB (Re-order Planning) will be

used for all of the materials. For APO relevant materials MRP type X0 will be used.
The selection of the relevant entry will depend on the MRP requirement.
Strategy group:

For MCI India planning strategy 40 (Planning with Final Assembly) will be
used.

MRP controller:

MRP Controller is the person who is responsible for planning of materials in a

particular plant.
MRP controllers are assigned to an individual material under MRP view.
Selection by production version – 03. This will determine BOM and recipe selection will
happed based on production version only. This is explained in detail in master data
section.
Production Scheduler:
Production Scheduler is the person responsible for scheduling a material in shop floor
control. We are using production scheduler for reporting the responsible department
for delivering the material.
Prod. Sched. Profile:
Specify that certain business transactions are carried out in parallel in a process order
(you can, for example, create and release an order at the same time, or release an
order and print the shop papers), at MCI India, production scheduling profile will be
used in such a way that Production number will be generated on creation of
production order. Release will be done after checks the usage of correct batch used in
production order BOM as per specification of SOP.

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3.4 Bill of Materials:
Bills of Material (BOM) contain essential master data for integrated Production Control and Materials
Management e.g. In the Project / Production department; a new Finished Good is designed using the
inputs from client & internal departments.
Bill of Material is a formally structured list of the components that make up a product or assembly. The
list contains the material number of each component, together with the quantity and unit of measure.
BOMs are used in their different forms in various situations where a finished product is assembled from
several component parts or materials. BOM will be maintained for SFG & FG.

At present Batch Record are created by Planning/ QA which contain the list of material with required
quantity to produce. In SAP a part of (BATCH Document) will be reflected by the Bill of Material. The
finished semi-finished and components need to have Material Number (Item Number) to be created in
SAP system as a prerequisite.

Multi-Level BOMs 

Wort Fermenting Conditioning Bright Beer

Finished
Batch Batch Batch Batch Product
Brew # Tank Tank Tank

One can break down large and complex product structures into a number of related units. Each unit can
be represented by a BOM, referred to in this documentation as a single-level BOM.

A single-level BOM describes one or more assemblies by means of component quantities. A single-level
BOM can be either a Finished Good e.g. Patient Pack or an individual WIP Item.

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You can use single-level BOMs to define one-time solutions for recurring tasks. Once you have defined
your solution in the form of a single- level BOM, you can use it whenever you need it and combine it with
other BOMs as required.

There is no system restriction on how the BOM is prepared (sequence) i.e. built up from Brew to Cold
wort, fermented beer , bright beer and packed beer which will be finished product and then finished or
broken down from finished to semi finished then to components.

The data contained in a BOM is managed at different levels:

Header data is data which is relevant for the whole BOM

Item data is data with is relevant for a specific item within the BOM.

Component scrap

During BOM explosion, component quantities are increased according to the calculated scrap quantity to
cover component faults. The component scrap figure input in the BOM will override the component scrap
figure on the material master MRP4 screen.

Assembly scrap

Assembly scrap is input in the MRP1 screen of the material master in the form of a percentage (%). A
figure is entered here only if the material is an assembly. The scrap quantity calculation for a component
in MRP causes the material requirements for all components in the assembly to increase.

Operation scrap

Operation Scrap occurs during the actual production process. This figure allows material requirements to
be planned precisely. It can be used in place of assembly scrap for high-value materials. The net
indicator is needed.

The provision of parts may be planned in production order processing with the help of BOM data.

BOM usage: Allows each functional area within a plant to have its own BOM. For example, engineering,
production and cost accounting could have their own BOM data. The production BOM is set up from
the manufacturing points of view. For the assembly, for example, data relevant to the assembly
procedure is required.

BOM Alternates : BOM alternate 1 will be create for mass production process. To capture rework BOM
alternate 2 will be create with same component quantity for semi-finished goods as of alternate 1. Other
components will be added with zero quantity. Which can be increased when created rework.

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In MCI India BOM will have following levels:

Brewing : Entire brew house processes will be mapped under Brewing and First level of BOM will be brewing
which will give output of cold worth.

Fermenting and Conditioning : Cold worth is then passed to fermenting tank after taking yeast fermented beer is
passed for conditioning. Since both of these tanks are same the output of BOM will conditioned beer.

Filtration : Conditioned beer will be filtered and bright beer will be ready to for filling.

Packing : Filling will be done in bottles, can or kegs (for institutional sales). Depending upon which state this beer
will be supplied crown (on bottles) and label will be applied. Bottles are packed in cartons of predefined size.

Apart from product BOM, MCI India will also have BOM for RGB. Which will be used in bottle cleaning. (Detail
process of bottle cleaning is explained in production execution).

Rework BOM : An alternate bom to capture rework will be created at Conditioned beer and Bright Beer. Once
process order is created user can re read master data and choose rework production version.

BOM Header Data to be maintained for India Business:

SAP Material Number xxxxx for HALB, xxxxxx for ZFER,

SAP Plant ID 7011 = Bankapur, 7012 = Saha

BOM Usage -1 (Production BOM)

BOM Alternate System assigned - If alternate BOMs are required the system will assign
alternate numbers sequentially.

BOM Text - Will use Process Stage , Brand, Line ID. In case of FG it will be FG material group.

BOM Alt Text - Will use BRAND, Material Group Description, Line ID
example: Miller Fermenting 01

Base quantity- Set to 1000 except WORT - WORT BOMs are based on brew size (to be
decided during master data preparation) for packaging BOM base quantity will be based on
pack size.
Base unit of measure - All WIP BOMs are HL. FG BOM will be in EA.

BOM status - 1 - BOM active

Indicator showing that the BOM header or the BOM item has been deleted with reference
to the change number.

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BOM Item Data to be maintained for India Business:

Line item sequence - format is 0010, 0020.

BOM Item Category -L - Stock Item

SAP Material Number xxxxx for HALB, xxxxxx for ZALB, xxxxxx for ZFER, xxxxx for ZDIR
material types.

Material Description -Defaults from material master

Material usage based on base qty of 1000, or XXX HLs of WORT for WORT BOMs.
For FG Material usage based on base qty of 1000 EA.

UOM -Defaults from material master.

BOM Valid from Date : Defaults to Initial date that the BOM is created - and then is
overridden by any change number effectivity date
BOM Valid to Date : Defaults to 31.12.9999 when the BOM is created - and then may be
overridden by any change number effectivity date

Costing Relevancy : Defaults to set X for all BOM material items

Change number : Unique reference that controls the changeover date of any material qty or
number changes on the BOM line. Comes automatically if an ECN is applicable and BOM is
changed an ECN number.
Set for line items where usage qty is less than 1

Overrides any value on the Material Master - used to distinguish between stocks of the
same material held in different locations.

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3.5 Resource
Resources are production facilities and persons involved in a production process that have capacities.
They are subdivided into categories to specify their suitability for certain purposes or their use in certain
processes.

Resources will be, for following:

• Persons involved in production that are also recorded as employees in personnel administration
• Parts of the plant that are used for production (processing units)
• Parts of the plant that are used for intermediate storage (storage resources)
• Parts of the plant that are used for both intermediate storage and production (storage resources /
processing units)

Resources will be assigned to operations and phases in the master recipe and in process orders to specify
with whom or at which parts of the plant a process step is carried out. Depending on the resource
category, you can assign resources as follows:

• Resources used for production are assigned as the

– Primary resource for the operation (if the resource is occupied for the entire duration of the
operation)

• Resources that are only used for storage are assigned a storage location at which the stocks are
managed.You can assign a storage location for:

– Header material that is stored

– Material components that are withdrawn from storage (in the case of ingredients)

The data in the resource are used, for :

Scheduling : Operating times and formulas for calculating the operation duration are maintained in the
resource.
Capacity Requirements Planning :

Formulas for calculating capacity requirements for an operation are maintained in resources.

The data to be processed is functionally subdivided in the following way:

• Basic data

The standard value key is part of the basic data. Standard values are used as parameters in formulas for
determining the execution time, capacity requirements, and costs.

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• Default values (for example, for the control key, the wage type, or the wage group)

• Capacity data (for example, the capacity type and the available capacity)

• Scheduling data (for calculating the execution time)

• Cost center assignment

Tank/container Resources are created with capacity category 012 (Processing + Storage) and these will
have time and storage capacity. Filling and Packaging machines/lines will be created with capacity
category 008 and these will have only Time capacity.
Container Resource will also be created as a storage location in ECC and same will be linked with ECC
Resource Master in Basic data view.
Resource will be created in ECC and same will be transferred to APO using Integration Models as Multi-
Mixed Resources.
Resource class will be created in ECC with class type 019. We use, Resource classification in ECC to
reduce efforts to maintain huge no. of Master Recipe in ECC.
In MCI India for fermentation we will be clubbing resource based on tank capacity and will be assigned to
its class and characteristics for validation for example its capacity, brand etc.
 The container characteristics are defined using the fill level description.
 The maximum stock level represents the maximum quantity of the product that can be stored in
the container.
 The minimum production quantity defines the minimum quantity of the product that must be
stored in a container.
 A custom development will be done for MCI India for tank based storage location validation.
 This development will validate capacity of a tank and check storage location on which goods is
issued.
 Multiple batches can be mixed in what capacity will be validated in this development.
Control key to be used for production related resources will be relevant for scheduling, detail capacity
requirement and auto goods recipe.
Backflush function is not applicable for MCI India (for beer preparation process) as user wants to do
manual GI (based on order).
Control Key: Z02G will be used for the resources with auto goods receiving and Z002 will be used for non
auto GR phases. These control key will be relevant to scheduling and capacity only.
Resource usage will be for “ALL” task list type.
Standard value key will be SAP4 where duration will be captured in “H” hours.

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Production resources will not be costing relevant hence costing view will not be maintained on such
resources and no activity type assignment will be done.
In MCI India costing related resource will be created to capture costing activity (details can be checked in
Costing blueprint number ……..
Resource to be maintained in following way for MCI India.

Resource Name : The ID of the individual resource Max 8 CHARS - must be unique and follow format B01 for
Bankapur and S01 for Saha (Details in B01_XXXX)

SAP Plant: ID 7011 = Bankapur, 7012 = Saha.

Resource Category :Defines the resource type and the data expected to be provided - Values are: 0008 Processing
Unit - e.g A Filler A Filter A Packer, 0015 Proc. unit/Stor.res. e.g. An FV A CT A BBT, Z20 AS (Advanced
Scheduler)Process Resource Group , Z025 AS Tank Resource Group, Z030 AS Enabling Resource Group, Z035 AS
Enabling Resource, ZAPO APO resource group
Resource Description : A description of the Resource/Resource Group.
Task list usage : Key to control how/where a resource can be used - ALL

Person Responsible : Value that indicates which part of the production process this resource belongs to - Values
are ; Z00 AS - None Applicable , Z01 AS - Brewing , Z02 conditioning , Z05 AS - Bright Beer , Z06 AS – Filling.

Standard Value: Key defining and giving a dimension (for example, time or volume) Values are ; SAP4 Process
manufacturing , ZBRW Brewing Tank Resources , ZPAC Packing Resources.
Storage location storage resource: Links the storage location to category (VERWE) 0015 Resources - i.e. All vessels
FV's , CT's , BBT's…

Capacity Category: All Category Resources - Have a capacity category of 002 Labour AND either 012 on Vessels and
Backflush Resources OR 008 on all other resources.

Controls how the capacity is calculated & applied in planning/scheduling/process orders - Either Time Duration Only,
where value = SAPC00 OR Quantity per Time Duration, where value = SAPC02

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3.6 Master Recipe
In a master recipe, you plan:

• The individual steps to be carried out in a process, that is, the operations and its subdivisions, the
phases

• The activities that are to be carried out in a phase and are used as the basis for determining dates,
capacity requirements, and costs

• The process sequence by defining relationships between phases

• The use and production of materials in the course of the process

• The use of resources

• The quality inspections to be carried out during production

In addition, you use process instructions to provide information that is collected during production and is
required by process control to carry out the process.
Process Flow:

1. You enter recipe editing and create the basic structure of your master recipe. You enter the general
header data and create the operations and phases of the recipe.

2. If you want to use your own classification characteristics for recipe selection, you classify the recipe
header.

3. If you want to schedule the recipe, you create relationships that determine how phases relate to each
other in terms of time. In addition, you edit the following detail data about the phases:

− For internally processed phases, you enter standard values and, if required, user-defined fields with
extra data that is not included in the standard system.

− For externally processed phases, you enter the details of the vendor (see general phase data).

4. You carry out the following steps in whichever order you like:

− You plan the materials to be used during production.

− You plan the resources to be used for internally processed operations and phases.

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5. If you intend to inspect the quality during production, you enter the inspection specifications and, if
necessary, the production resources/tools you need as test equipment.

6. You enter the data that is relevant to process control.

7. You check whether the recipe data is consistent.

8. You schedule the recipe.

9. If necessary, you transfer the scheduling results to the material master record of the material you
want to produce. You can then use this data to determine the basic order dates in material requirements
planning.

10. After you have completed recipe editing, you release the master recipe for use in process orders
and/or costing. You do so by setting the appropriate recipe status in the general header data.

Master Recipe is a type of task list and will have all information’s about individual operations/phase.

The phase of the Master Recipe will be classified (If the phase uses classified Resource). This is only
required if, same is performed on similar resources.

Master recipe will be created for following in SAP for MCI India :

Packaging Recipe: Will have packing as phases , finance related resources will also be added after
finance phase which will start from 7000. However production related phases will start from 0010. Final
packing will be done in this phase based on SKU demand from each state.

Filling Recipe: Will have filling as phases , finance related resources will also be added after finance
phase which will start from 7000. However production related phases will start from 0010. All bottles and
cans will be issued here and filling will be completed. Crown will be placed on bottles based on demand
of state (Punjab or out of Punjab).

Bright Beer Recipe: Flirtation and cleaning will be captured as phase to get output of BBT.

Conditioned (mat) Beer Recipe: For MCI India Fermentation and conditioning is done in one step and
hence Filling , fermentation , centrifuge , conditioning and cleaning will be part of phase.

Brew House Recipe: Entire brew house will be captured in brew house phase as operation.
Where we will have only one phase then control key Z02G (with Auto GR) will be used. In case of
multiple phases last operation control key will be Z02G and preceding phases will have Z002 control key
(without auto GR).

Bottle Cleaning: Bottle cleaning will have only one phase.

Rework Recipe: Rework recipe will be created with one default operation however user will enter
operation and phases manually depending upon what action to be performed.

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Parameters to maintain recipe for MCI India:

SAP Material Number: xxxxx for HALB, xxxxxx for ZALB, xxxxxx for ZFER material types

SAP Plant ID: 7011 = Bankapur, 7012 = Saha

Recipe Description : Has Format Like; 01 - CBL Wort Where 01 refers to the Process Stage the recipe applies
to e.g. 01 = Brew, 02 = Ferm & Cond, 04 Bright, 05 Filling FG

Recipe Status : 4- Released (General)

Recipe Usage : 1 – Production.

Unit of Measure: Relating to the Recipe - HL for 01 - 05 Stage Recipes , EA for 05 Stage Recipes

Base Quantity : Always set to 1

Base UoM - Same as Charge Qty UoM - HL for 01 - 05 Stage Recipes , EA for 05 Stage Recipes

Operation or Phase Number e.g. 0010, 0011 Identifies an individual step / sub step within the Recipes
against which process activities are recorded

Phase Indicator : Indicates that this is a sub step of a higher process operation

Superior Operation : Connects the phase to it's higher process operation

Relationship type : Indicates whether the phase or operation can be progressed in parallel to others or
has to wait for completion to start
Control Recipe Destination : Indicates which System module is using this specific phase of the recipe ;
ZI = Bankapur and Saha, YA = APO, ZZ = Finance Costing Element Only
Resource: which a specific phase of the recipe is using - Can be a Vessel/Tank , Filter Centrifuge, Filler, Packer etc…
an APO only aggregate, or a Finance cost carrier.
Control Key : Indicates / controls how the previous Resource/Hierarchy operates within planning/scheduling
solution and communication of messages between the various systems ECC, APO Z0002 for recipe where we
have multiple operation the Z0002 will be used for all operations but last where auto Gr will trigger.
In case of last operation / where auto GR will trigger use Z02G.

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 Standard text key : Used to label the individual phases and communicate the stage in the whole process

Operation Text : Text description of previous field (standard text key to be created and assigned to WorkCentre
as part of master data creation. This text will name what operation to be performed)

Operation Base Quantity : Quantity or Duration of this Operation/Phase

Operation UoM : Unit of Measure Relating to the Volume/Quantity of this Operation/Phase - HL, EA

Standard Value : Time corresponding to the Volume/Quantity in Operational Base qty

Standrad Value UoM : Unit of Measure Relating to the Duration of this Operation/Phase - DAYS, HR, MINS

Production Version : The Current unique combination of Recipe & BOM required to create the Material(s) on this Recipe

BOM Material Number : Material Number

Operation Number : Operation on the recipe where each Material is consumed - will be Issued

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3.7 Production Version
A production version comprises the following data:

• Details on the material you want to produce, for example, the material number and storage location
where the material is to be stored

• General data about the production version

− Key, lot-size range, and validity period of the production version

− Information on whether the production version is locked

− The date of the latest consistency check

• The assignment of task lists/master recipes to the production version

The system distinguishes the following planning levels:

− Detailed planning

This assignment determines which master recipe is used for material requirements planning (MRP),
product costing, and process order creation.

− Rough-cut planning

A check status is assigned for each planning level. It contains the result of the latest consistency check of
the production version.

• The assignment of the alternative BOM to the production version

A check status is assigned for the assignment. It contains the result of the latest consistency check of the
production version.

• The change number that was last used to change the production version as well as further
administrative data.

Brew and Fermentation Chart using production version DIR:

DIR (document info record) will be created and assigned to production version of brew and fermentation.
To capture in process parameters to get brew and fermentation chart ZBREW_Chart and ZFERM_Chart
class 019 will be used in DIR to capture brew and fermentation characteristics. DIR will be used as only
characteristic carrier and it will not hold any document in system. This is being done to make system

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future proof so that plugin of QM module is easy in phase-2 and unnecessary data migration can be
avoided.

For rework one production version will be created (along with combination or alternate BOM and one
operation).

3.8 Engineering change management:

This section covers explanation of certain key SAP terminology and elements which would come into
usage for ECM (Engineering Change Management) processes.
Engineering Change Management (ECM) is a central logistics function that can be used to change various
aspects of production basic data (e.g. BOM’s, task lists, materials and documents) with history (i.e. date
effectively) or depending on specific conditions (with parameter effectively).
A change with history has the following distinctive characteristics:
 It takes effect under precisely defined conditions (precise date or specific effectively
parameter value).
 The changed object is saved twice: in its state before and after the changes.
 A change master record or ECN controls and documents the changes.

For ‘change with history’ there are following two approaches available in SAP
 Using Engineering Change Master (ECM) - this involves creation of simple
change master document, which in turn is referenced at the time of making changes
to the relevant object. It does not involve any workflow, digital signatures and
typically used for simple changes quickly without involving significant administrative
effort.

Key Terminologies Used in ECM

Following are some of the key SAP terms used in engineering change management and find
frequent mention in subsequent explanation of process

 Change Master Record - The change master record is a master record that
contains information necessary for the management and control of changes. The
change master record contains data of a descriptive character (such as the reason for

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 the change) and control data (such as effectively data, object type indicators). In the
SAP system, change master records are identified by a change number.
 User-Status - Company-specific user statuses to control the process flow for
changes of a change master record and of object management records can be done.
When a change master record is processed, the system determines which user
statuses are supported in the current situation. The user status can be represented in
the form of a status profile.
 Object Types – Object types essentially mean the different SAP objects for which a
change master record would be created. For example – BOM, master reciepe,
production version etc are some of the object types relevant to business.
 Object Management Record - An object management record is used to control
changes to one particular object and document these changes. The number of objects
that you can process with reference to a change number is unlimited. The object
management record supports the following functions for the change object:
 Special documentation
 Object-specific valid-from date (alternative date)
 Object-specific status network (user status)
 Revision level (for materials and documents)
Explanation of Functions and Events
Engineering change management (ECM) processes are triggered when there is a need to change the
bill of material, recipe, production version or documents. With respect to (ECM approach) in SAP,
following are the set of sub-processes:

1. Initiate change request – change request can be initiated for changes to PP master data or
documents. Analysis of impact of the change shall be done prior to initiating the change. The
impact analysis could be from the perspective of current in-process batches in production,
existing inventory in warehouse, disposal actions of existing stock (if any), re-release of standard
cost estimate (if required) etc.
a. In case there is a pre-approval for changes to be done, then a change control notification
shall be created in SAP.
b. An engineering change master (ECM) record shall be created. It could be created directly
or with reference to the approved change control notification. All details of changes to be
entered in the change request. The key fields that need to be chosen at the stage of

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 creating ECM record is – ‘profile’. The ‘profile’ selection would help in identifying the
objects (e.g. BOM, Recipe, Documents etc) which can be changed with the ECN.

c. Typical information that would be entered are - the description of change, a valid from
date, a reason for change text, change number status (active, inactive or lock),
additional explanation texts, the object(s) to be changed. Upon saving this ECM record,
the SAP system would assign an internal number to it (number range shall be set for
internal numbering scheme). This ECM record would then have unique identification in
system and in all subsequent processes this ECM number will have to be keyed in.

2. Review & approval of change (offline; outside SAP) – Manual offline paper based approval
process as per business defined SOPs shall be followed for approval of the ECM record. The
desired change to the object would be done only after approval, however this check is a manual
control and not a system control.
a. There would not be any workflow which will get triggered from the SAP system. Offline
co-ordination between relevant business departments & users would require to be done
to ensure the review and approval process

3. Making changes to the relevant objects – the changes to the respective object (BOM,
recipe, production version etc) shall be done with reference to ECM record number.
a. Version Control – the requirement for version control of BOM & Recipe change, is
mapped with the help of revision level concept in SAP ECM. A revision level (could be an
internal number or external number) is first assigned to the material (whose BOM or
recipe is to be changed) & corresponding ECM record number. And subsequently when
making change to that BOM or Recipe, the ECM record number & revision level is
specified as input.

4. Check of changes done (in SAP) – Once the changes are done to the objects, business shall
check and verify that the changed are indeed as per desired. This again is a manual control.
a. For each of the object which is under change, a status ‘locked’ or ‘inactive’ can be
assigned at the time of change is being carried out & saved. Status setting in the said
manner would not allow usage of this object for any new process order. Existing process
order (i.e. already created prior to change) can continue without any block.

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 b. Once the changes as done are verified, the status ‘inactive’ in that object can be changed
to ‘active’ and changed object would be available for everyone to use. This way a
mitigating control is established in SAP system.
In MCI India ECM will be used for BOM , recipe and material master. Recipe and material
master will be used in great extend in phase 2 of QM implementation.

3.9 Configuration consideration

Defining Range of Coverage

Use

Range of coverage profile for calculating the dynamic safety stock.

With the dynamic,safety stock you can determine a safety stock based on requirements and range of coverage.
The dynamic safety stock adapts automatically to the changed requirements and is fully available for planning
purposes.

You can limit the quantities used in the calculation of the dynamic safety stock by defining maximum and minimum
ranges of coverage. You can also limit the period of time by defining different time periods in which the range of
coverage is valid.

Defining Scheduling Parameters for Planned Orders

Use
In this step you define the parameters for scheduling planned orders for each plant, order type
and production scheduler.
Order Prod
Plant type super
7011 * *
7012 * *

Defining MRP Controller

Use
In this step, you define a number that is assigned to the MRP controller. The MRP controller is a
person or a group of persons responsible for monitoring material availability. You can use the
number entered here, for example, to select the planning results per MRP conroller.

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Overall Maintenance of Plant Parameters

Use
In this step, you can specify all plant parameters for the material requirements planning.
In addition, you receive an overview of the maintenance statuses of the individual MRP
parameters on plant level.

Define Material Types Allowed for BOM Header

Use
In this step, you specify which material types in conjunction with BOM usages are allowed for
the BOM header material.

Define Control Key

Use
In this step, you define the control key of an operation. The control key specifies the
business functions you want to carry out with an operation and how the SAP System
processes an operation.
Determine Capacity Planner

Use
In this menu option, you determine the person/group of persons who is responsible for
planning capacities. Following capacity planners will be created.

BRW
CON
FIL
PAK

3.10 Open points for master data

None

3.11 RICEFW/Gaps for master data

None

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3.12 File conversion considerations master data

BOM Governance Resource Recipe Governance

Doc.xlsx Governance Doc.xlsx Doc.xlsx

3.13 Reports required related to current business process

MM60: List of material code based on material type, plant, Material Group, Created By

CS11: Display of BOM Level by Level

CS12: Display of BOM Multilevel Explode of BOM

CS13: Display of BOM Summarized BOM

CR05: List of resource, CA81: Resource Where Used List

3.14 Document / Output would be printed for this business

process
None
3.15 Integration aspects
Data transfer via CIF (process to be covered in APO blueprint)

3.16 Authorization Consideration

Will be decided during realization.
3.17 As Is reference

MCBC_India_PP_AS-I
S_Process_Overview.docx

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4.Production Execution – Business Processes.

A SAP Process Order will be used for each key stage. Raw materials are issued to each stage’s
order and consumed from stock. Work In Progress (WIP) / semi-finished product or finished
goods produced into stock when receipted from it. All Process Orders will be of the existing
standard template order type ZI01. The WIP / semi-finished product of one stage is used as an
input material of the next stage. As semi-finished or finished goods are receipted from the
process order they will be placed in stock at the location recorded in that order – determined by
planned at time of scheduling or revised by the operator at the time of starting execution.
Brewing, Conditioning, Filtration and Packaging output will be batch managed. Details of batch
management can be checked in MM Blueprint.

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4.1 MRP: Material Requirement Planning
Demand for Stocked raw materials will be determined by scheduled runs of Materials
Requirements Planning (MRP) executed in SAP ECC by background jobs. Where there is
insufficient stock to meet the planned demand, MRP will create purchase requisitions for any
shortfall with required quantities, delivery dates and selected vendor (derived from sourcing list
and vendor master). Materials are assigned MRP types of PD where MRP planning is to be
executed. Materials planned in APO have the MRP type X0.
The business requirements also ask that options be available for MRP to plan materials
dynamically calculating the level of safety stock by a number of days of demand. This will be
addressed by configuring ‘Range of Coverage Profiles’ for use with MRP type PD.
This will require assignment of specific range of coverage profiles in the MRP2 view of the
material master. The configuration of the Range of Coverage Profiles is plant specific hence
these will not become available for use in other plants by default.
Standard use of safety stocks and Reorder Point planning will be available for planning
procurement of consumables.

Following MRP controller will be used for semi finished levels :

IP1 Brewing – Producing Wort for use in the Fermenting process orders
IP3 Conditioning – Producing tanks of conditioned beer
IP4 Filtration – producing tanks of Bright beer
FL1 Bottle filling
FL2 Can filling
FG1 Bottle packing
FG2 Can packing

Following MRP controller are proposed for other materials:

GEN General Packing (Pallet Labels, Pallet Film)
PKE Finish goods packing Materials (Label, Printer ribbon, Bottle, Can, Caps.
RAW Raw Materials (Eg Malt, Fructose, Gypsum, Hops, Yeast, Antifoam)
CON Consumable Materials (Non BOM items)

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4.2 Planned Order:

The planned order shows a planned receipt for a particular material in a plant. Basically, it
specifies when the receipt is to take place and the quantity of goods that is to be received
A planned order has the following characteristics:
• It is a procurement proposal in MRP for requirements coverage, that is, an internal
planning element. It is not binding and does not therefore trigger procurement directly,
but serves for planning purposes.
• It can be changed or deleted at any time (exceptions: planned orders for direct production
and for direct procurement).
• Whether a material will later be produced in-house or procured externally is left open.
• For materials produced in-house, it represents the pegged requirement for dependent
requirements and can be used in the capacity calculation.
• For materials produced in-house, it specifies the basic dates for production.

For MCI India, planned order will be created automatically in APO planning.

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4.3 Wort Production:
o Wort production - Consume your raw and Malt.
o All wort production materials are not quality managed and no inspection lots.
o Output which is cold worth will be batch managed.
o At the time of process order release batch will be created.

4.3 Fermentation
In this process we add yeast to cold wort material and begin fermentation. Yeast consume sugar cold
wort and produce ethanol (Alcohol) - These orders are open for approximately 7 days to ferment.
o Fermentation materials are not quality managed.
o At the time of process order release batch will be created.
o Process orders in process characteristics will get recorded in Z transction based wrt to
batch.
o Output will be batch managed
o Batch will be captured in ECC
o Auto GR will be done at first operation to occupy tank

4.3.1 Yeast Management

 Yeast is propagated in the MCI India. The process orders to produce yeast in its first generation
are manually created. This produces generation 1 yeast to be consumed into Fermentation for the
first time. Yeast will be taken as by product.
 Batch Managed and a characteristic will be recorded to capture its “generation”.

Happy Yeast means Great Beer:

Yeast will be stock transferred from from Saha to Bankapur for this a special procurement key will be
added in material master.

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4.3.2 Maturation:
Aging of beer. The fermented beer sits in maturation tank. This will be just another operation/phase in
recipe.
o For some brands, a secondary ferment occurs. Where ABV(Alcohol by volume) will still climb
o Upwards of 20 days
o For other brands maturation time is much less, something 7 days.
o Batch managed
o Batch Characteristic - Characteristics will be captured in ECC
o Actual ABV (Alcohol by volume) = Relevant for price
o System will do a check and ensure if tank can be loaded as per its capacity by mixing other
batches or not. In such case new batch number will be generated. If capacity of one tank is
full next batch can not be issued to the same tank. To ensure this a custom development will
be done and detail of validation will be captured in functional spec.

4.4 Filtration:
o Cotton filters shaped like disks. The beer is passed through it and once complete is in its
final state, ready to be packaged.
o Batch managed
o Batch Characteristics – NONE

4.5 Bright Beer:

o Finishing is essentially blending of multiple batches of mature produce with water (Diluent).
o Material descriptions Batch managed
o Batch Characteristics – alcohol % to be achieved. SAP indicate the alcohol to be achieved.

4.6 Filling:
Note: Filling orders always require a valid BBT batch to the filler.
There are two types of containers.
o Bottles
o Cans

 Bottles and Cans

o Bottles, cans, lids, ends, crowns, cardboard carriers are all of material type ZPCK.
o Bottle crowns are different for Punjab and Non-Punjab (which is call export)

 Phase Confirmations
o There is only one phase that gets confirmations in packaging. 0040 - Packaging Phase
o Confirmations trigger the backflush (for crowns) based on yield in confirmation.

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4.6 Packaging:
Note: Packaging orders always require filled bottle batch to the filler.
There are two types of containers.
o Bottles
o Cans

 Bottles and Cans

o Bottles labels and cardboard carriers are all of material type ZPCK.
o Coding will be done on can.

 Phase Confirmations
o There is only one phase that gets confirmations in packaging. 0040 - Packaging Phase
o Confirmations trigger the backflush (for packaging materials) based on yield in confirmation.

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4.7 Process order: COOISPI (Reporting Transaction)

The Brew House To Be Cycle

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The Green Beer - Fermentation and Conditioning Process to Be Cycle

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The Clean Beer- Filtration To be cycle.

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Filling Process :

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Ready for Market : Packed Beer

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Definition of key components in production process:
A process order defines which material is to be processed, at which location, at what time and
how much work is required. It also defines which resources are to be used and how the order
costs are to be settled.
 
The planned orders are converted to process order. When a process order is created the following
actions are carried out (Done in APO)
• A production version is selected; which automatically select the master recipe and BOM
attached to it. Master recipe’s operations and sequences are transferred to the order.
• The BOM is exploded and the items in the bill of material are transferred to the order.
• Reservations are generated for bill of material items held in stock.
• The planned costs for the order are calculated.
• The capacity requirements are generated for the Resources.
• Production data includes the operations required, any confirmed quantities & dates from
actual production.
• Scheduling data includes the order start and finish dates as well as operation dates and
times will be generated.
• Accounting data includes production cost information such as material and labor cost.

Release of process order:

Process order can be released in create or change mode. When the Process order is released, the
planned costs of the order are calculated. During the release of the process order the batches of
the components can be determined automatically by the system.
After releasing the Process order following activities can be executed:
• User can carry out goods movements for the order, that is, user can withdraw any
material components
• User can carry out completion confirmations for the order

Order type is a like a document type against which you will be producing the order. An order
type decides:
• The number range of the order,
• The method in which the Recipes and BOM is pulled in the order.
• Documentation of order information.
• Goods movements.
• Batch determination search procedures.
• Reservation creation possibilities.
• The order costing controls.
• Recommended Order type: ZI01 for all production steps , ZBP1 for Bottle preparation
and ZI06 for Rework.
• Number range will be decided by configuration team
• User status – Brewing process order will have a user status EXC (informed to excise)

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4.8 Production Scheduling:
Backward scheduling will be done in MCI India- order end date will be entered. Process
order will be scheduled from APO and send to ECC. Any manual adjustment can be done
in ECC. Capacity leveling will be done in APO.

4.9 Production Scheduler:

For production reporting purpose following production schedulers will be created:
BRW1 Brew House Scheduler
CNB1 Conditioned Beer
FLT1 Filtered Beer
BOF1 Bottle Filling
BOP1 Bottle Packaging Line
CAF1 Can Filling
CAP1 Can Packaging Line

4.10 Production Scheduling profile:

In a production scheduling profile, We can:
 Specify that certain business transactions or processes are to be carried out in parallel in
a production or process order
• Order release at the time the order is opened
• Generation of document link from the material master when the order is opened
• Printing at the time of order release
• Scheduling upon order release
 Specify whether only partial quantities are to be confirmed at the time of an availability
check
 Specify that an automatic goods receipt is to take place
 Specify an overall profile for capacity leveling
 Specify how the capacity requirements of the operations are to be taken into account in
the basic load
 Specify when capacity scheduling is to be carried out in the capacity availability check
 Specify that in the case of the confirmation:
• No short quantities are to be updated
• No excess quantities are to be updated
• Neither short nor excess quantities are to be updated
• An adjustment of the operation and component quantities to the actual values is to
take place
For MCI India, Following Production scheduling profile :
“ZIN01” (For beer production) and “ZIN02 (For bottle preparation)”. These scheduling
profiles will have link to process order types ZI01 and ZBP1.

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4.11 Goods Issue (MIGO)
• Planned Goods Issue: When business user creates a Process order, the system
automatically generates a reservation for the required material components. Each material
component of the order receives a separate item number within the reservation. User can
only withdraw the reserved materials from the warehouse if the operation to which the
materials are assigned in the order has already been released. 
• Unplanned goods issue: Due to some problem at manufacturing area sometimes
production may ask extra Raw materials apart from the planned goods issue will be
identified as unplanned goods issue. The cost of unplanned goods issue will be rolled up
to the same Process order for which it is made
• The process orders which are released to the shop floor are available for goods
issue.
• Automatic goods issue will be done (back flushing) will be done only for
packaging materials.
• To do any unplanned goods issue an offline approval will be required (out side of
SAP). Person who is authorized to change process order will add component in
approved quantity manually. Then user will be able to get it issued on process
orders again.

4.12 Confirmation (COR6)

A confirmation documents the processing status of orders, operations. It is an instrument for
controlling orders. Confirmation specifies,
• The quantity in an operation that was produced as yield, scrap and the quantity to be
reworked.
• How much work was actually done.
• Which Resource was used for the operation.
• Who carried out the operation.
Business user can enter confirmations for
• A phase
Following goods movements can be created with a confirmation:
• Automatic Goods Receipt
• Only yield to be posted in confirmation.
• For finished goods scrap to be posted while confirmation.
• Following reason codes will be used for posting any scrap:
• 0001 Machine malfunction
• 0002 Operating error
• 0003 Defective material
• 0004 Waste
Manual transaction of goods issue and receipt will be performed by business users.
SFG & FG batch generation will happen at the time of process order creation.
RM & PM batch determination will happen at the time of goods issue.

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4.13 Process Order settlement & Closing.
• When a Process order is settled, the actual costs incurred for the order are settled to one
or more receiver cost-objects (for example, to the account for the material produced or to
a sales order). Offsetting entries are generated automatically to credit the Process order:
• If the costs for the process order are settled to a material account, the order is credited
each time material is delivered to stock. The material stock account is debited
accordingly.
• If the costs for the Process order are settled to another receiver (for example to a sales
order), the order is credited automatically at the time of settlement. The cost-objects are
debited accordingly.
• Settlement rule is automatically created by system and cost is settled on final material
only.
• The debit posting remains in the order and can be displayed even after the costs have
been settled. The settled costs are updated in the corresponding receiver cost-object and
can be displayed in reporting
For MCI India:
• Settlement rule and variant will be discussed during product costing discussion

Holistic View of End to End Department Integration in MTS Scenario:

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PP Miscellaneous Scenario’s

4.14 Rework:
Rework should be happening ONLY on beer that was placed into BLOCKED stock (rejected to
use) from the quality inspection / usage decision of a producing Process Order.
Where material is to be issued to process order MIGO will be used to manually enter a 343
movement of Blocked stock to available stock.
Manual Process orders will be raised for rework, using rework Recipe / Production Version
R001 which will be pre-created for each production stage at which rework will be possible. The
WIP product being reworked will be issued to the process order and the resulting WIP product be
Goods receipted from it. Any additional materials (including Conditioned / bright beer) used in
the process will be issued in the COR6N confirmation in the usual way.

4.14 Disposal Process:

Disposal process batch will be booked as loss at specific cost center. During production if it is
decided that another suspected batch could have been impacted then post production that batch
will be moved to blocked stock. QA team will move blocked stock to unrestricted stock and
record comments/ observations during goods movement. Tadcaster reason codes to be shared
with business.

4.15 Bottling preparation:

Manual process order with order type ZBP1 will be created for bottle cleaning. Cleaning solution
will be part of BOM along with old bottle material code.
When order is confirmed auto GR and GI will happen. Auto GI will consume old bottle and
generate stock of cleaned bottles.
Batch characteristic will be captured to identify if it’s a new or old bottle (for reporting purpose).
This will be an offline data entry and hence user will be able to identify how many new bottle vs
old bottles were used and same data will be entered during production entry.

4.15 Blending:
Sometimes at time of filtration (before or during), product requirement changes, i.e. if one brand
is not required then its blended to make another brand. Parameters of other brands needs to be
maintained. There is also a possibility that a specific ABV is not achieved, target value will be
maintained in process order long text.
In above mentioned scenario’s a manual process order will be created and components quantity
will be calculated out of SAP and it will be entered as a component along with batch number.
Post that process order will be released to shop floor for production process. Achieved ABV will
be captured in new batch as a characteristic.

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 5. Production Execution Process Flow Chart- As - Is

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Vital Wires Confidential Page 50
 6. Changes to Existing System
Now system will create process order numbers for each stage.
Batch management will be active now.
User will be able to see WIP.
User will be able to record rework.
Planned vs Actual material consumption and activity confirmation will be available.

7. System Controls
To create process order system will need relevant master data for example : BOM, Recipe ,
resource and production version.
If process order is not released no business functions can be carried out.

8. Interface/Development Requirements
Batch number generation
Capture in process characteristics
Tank capacity (storage location) validation

9. System Configuration Considerations

Defining Order Type-dependent Parameters

Use

In this step, you define the parameters that are valid for each order type and plant

Order
Plant type
7011 ZI01
7011 ZI06
7011 ZBP1
7012 ZI01
7012 ZI06
7012 ZBP1

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Defining Scheduling Parameters for Process order

Use
In this step you define for each plant, order type and production scheduler the parameters for
scheduling Process orders.
Order
Plant type Supervisor
7011 ZI01 *
7011 ZI06 *
7011 ZBP1 *
7012 ZI01 *
7012 ZI06 *
7012 ZBP1 *

Defining Confirmation Parameters

Use
The purpose of this step is to define confirmation parameters.
Procedure
Access the activity using one of the following navigation options:
Order
Plant type
7011 ZI01
7011 ZI06
7011 ZBP1
7012 ZI01
7012 ZI06
7012 ZBP1

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Defining Checking Control

Use

In this activity, you define the check control. The checking rule together with the checking group specify the scope
of the check.

Procedure
Access the activity using one of the following navigation options:

1. On the screen that appears, choose New Entries.

2. Make the following entries:

Order Business
Plant type Application
7011 ZI01 1
7011 ZI01 2
7011 ZI06 1
7011 ZI06 2
7011 ZBP1 1
7011 ZBP1 2
7012 ZI01 1
7012 ZI01 2
7012 ZI06 1
7012 ZI06 2
7012 ZBP1 1
7012 ZBP1 2

Defining Scheduling Margin Key

Use

In this menu option, you specify time floats for order scheduling as well as the release period for order release.

Procedure

Business will decide during realization period. Have given example of Tadcaster system.

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Configuring Planner Group

Use
In this step, you define planner groups per plant. A planner group is a group of people
responsible for the maintenance of Master Recipes. You can use the planner group as a
selection criterion for task list selection.

Setting Up Production Scheduler Group

Use
The purpose of this step is to define a production schedular group.

Production Scheduling profile

Use

In this step you can create production scheduling profiles for specific plants.

Define Assign Material type

Use
You define process manufacturing cockpits for your plant.

Define System Status Maintain.

Use
System should allow to set order status to EXE (informed to excise)

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 10. Number Range
Order number range will be decided during realization.

11. Open Points:

None.

12. RICEFW/Gaps
https://molsoncoors.sharepoint.com/:x:/r/teams/ProjectSunrise-IndiaSAP/_layouts/15/Doc.aspx?
sourcedoc=%7B96a9820c-02ee-4ddd-8e4c-17b96fbcc07d%7D&action=default&uid=
%7B96A9820C-02EE-4DDD-8E4C-17B96FBCC07D%7D&ListItemId=709&ListId=
%7B00599D23-F178-4D40-8B71-C29FC6844159%7D&odsp=1&env=prod&cid=8627cca6-
d060-428b-85f6-662a7bc9f12d

13. File Conversion Considerations

None

14. Reports required related to current business process

MD04: Stock Requirement List & option of checking capacity situation for different time period (Day,
Week, Month)
COOISPI: Process Order information System: TO view various reporting for process order: View Order
header details information, Documented Goods Movement against process order, Operation details, and
components details of process order.

15. Document / Output would be printed for this business process

None.

16. Integration aspects

Data transfer via CIF (process to be covered in APO blueprint)
17. Authorization Consideration
Only authorized person should be able to change process order.

MCBC_India_PP_AS-I

18. As Is reference S_Process_Overview.docx

Process Maps for SKUs India.xlsx

19. Process documents SAP PP.pptx

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