Overview
ERP Batch Management Capabilities
Jrgen Wettengl, Solution Management, Manufacturing, SAP AG
September 2009
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 2
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 3
Definition What is a batch ?
In various industry sectors, you have to work
with homogeneous partial quantities of a material or product
throughout the entire quantity and value chain.
A batch is the quantity or partial quantity of a particular material or
product.
?
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 4
What is a batch ?
Example Process Industry
Batch Number
C1020
Physical
CAE_200
Quantity
Fllmenge:
Material
Batch Status
Released
500l
500 Liter
45 gram fat
Shelf Life
10.2011
Alcohol
55 %
100 Liter
100 Liter
90%
100 Liter
55 %
91 %
Batch
=
Quantity with
homogenous
characteristic
s
85 %
Shelf Life
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 5
12.2014
What is a batch ?
Example Discrete Industry
Production Order 700012
Output Batch
Input Batches
C2
C1
Production Line 1
Batch
=
Production
Order
Quantity
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 6
700012
Batch Number
700012
Material
P-100
Batch Status
Released
Production Date
02.01.2009
Production Order
700012
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 7
Batch Level
- Usage
You can manage batches in different plants for many materials.
For this reason, batches must be uniquely identifiable.
You use the batch level to specify whether the batch number for a
material is unique in one plant, or in all plants.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 8
Batch Level
- Example
Plant Level:
The batch number is unique in connection with the plant and material.
Material Level:
The batch number is unique in all plants in connection with the material.
Client Level:
The batch number is unique in the whole client.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 9
Batch Number Assignment
- Usage
You use this function to assign a unique key to a batch.
This batch number together with the material number and optionally
the plant identifies a batch in the SAP System.
The Batch Level you choose determines the area in which the batch
number is unique.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 10
Batch Number Assignment
- Example You can assign the batch number manually or automatically as
different times, for example:
During manual creation of a batch
When carrying out goods movements, for example, goods receipt or
transfer posting
During creation of a process or production order
When a usage decision is made in quality management
During quality analysis (due to aging, for example)
When creating a purchase order
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 11
Batch Number Assignment
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 12
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 13
Creating Batch Master
- Usage You use this function to enter batch data into a separate master
record.
You can only create batches and batch master records for a material if
the material is to be handled in batches.
To do this, you must set the Batch management indicator in the
material master record.
You can create the batch master manaually or automatically.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 14
Creating Batch Master
- Example The system creates a batch master record in the background
automatically in the following procedures:
The first time goods are received for a batch
During creation of a process or production order
When a usage decision is made in quality management
During a recurring inspection
For transfer postings (when you want to split a batch, for example)
When creating a purchase order
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 15
Batch Specifications
- Usage Batch specifications describe the technical, physical and/or chemical
properties of a batch.
You store batch specifications, such as batch status or active
ingredient potency, as characteristics in the Classification System.
You can use the classification system to assign the material
specifications to the material of a batch.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 16
Batch Specifications
- Example Batches of car paint are specified by color value, viscosity and expiration
date.
You store the characteristics color value, viscosity and expiration date for
these properties in the classification system
and
assign the respective values to each individual batch.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 17
Batch Master and Batch Specifications
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 18
Batch Master and Batch Specifications
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 19
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 20
Batch Status Management
- Usage
You use this component to indicate whether a batch is usable or not.
This allows you to prevent goods movements for batches that are not
usable, as well as their delivery to customers and their use in
Production.
You can use other characteristics that you have adapted to meet
your requirements to display in detail the differences between the two
statuses.
You
can thereby specify for what type of usage a batch is released or
for what type it has not been released.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 21
Batch Status Management
- Example The system uses an indicator in the batch master record to show batch
status.
Status unrestricted = the batch can be used
Status restricted = the batch cannot be used
The
status is entered as a batch characteristic in Classification, which
is then responsible for the selection of the batch during batch
determination
You can store comments e.g. why the batch is restricted as userdefined characteristics within the classification of the batch.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 22
Batch Master and Batch Specifications
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 23
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 24
Batch Determination
- Usage In the logistics process, that is from procurement to sales, you are
required to specify batches for individual business transactions.
This allows you to prevent goods movements for batches that are not
usable, as well as their delivery to customers and their use in
Production.
You can use batch characteristics that you have adapted to meet the
requirements to display in detail.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 25
Batch Determination
- Example In Inventory Management (IM), you can use batch determination in goods
movements when you are dealing with a goods issue posting (for instance, a
consumption posting to a cost center), with a stock transfer or with a transfer posting .
In Production (PP/PP-PI) you can use batch determination in production and process
orders and run schedule headers to find suitable material components for the product to
be produced, and to pick these from stock.
In Sales and Distribution (SD), it is possible to determine batches that match
customer specifications. Batch determination can be triggered at two points in the
process, either when the sales order is entered, or when the delivery is created.
In the Warehouse Management System (WM), batch determination is used to
optimize warehousing, for example, in view of stock removal strategies and
replenishment from stores.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 26
Batch Determainination
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 27
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 28
Batch Where Used List
- Usage This component determines how a batch is created and used in
Production Planning PP through various stages of production and
displays the result in a list.
You can use this to find out:
In which other batches a batch was used.
From which other batches a batch was created.
This is important in the case of complaints and questions about
product safety if the composition of semi-finished and finished products
has to be documented across all production levels.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 29
Batch Where Used List
- Usage
Top-Down Analysis:
This function determines all batches that were used in one or
more stages of production for the specified batch.
Bottom Up Analysis:
This function determines all batches for which the specified
batch was used in one or more stages of production.
Pick Up Lists:
This function generates a list of sales documents which contain a
specific batch of a material. If you know the sales document, you
can enter it directly.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 30
Batch Where Used List (Top Down)
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 31
Batch Where Used List (Bottom Up)
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 32
Agenda
Definition What is a batch ?
Batch Level / Batch Number Assignment
Creating Batch Master and
Batch Specifications
Batch Status Management
Batch Determination
Batch Where Used List
Batch Work List
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 33
Batch Work List
- Usage -
In a batch worklist, you can group batches together and display and
change their data.
To obtain a better overview of your worklist, you can structure it using
worklist folders.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 34
Batch Work List
- Example
You can assign folders to as many users as you wish.
Public
Batch Worklist Folder:
The contents of a folder marked as public can be displayed and processed by all
users assigned to it.
Private Batch Worklist Folder:
A private folder can only be processed by the user assigned to it.
If several users are assigned to a private folder, each of these users has their
own separate worklist folder with the same name. Each folder can only be viewed
and processed by the respective user.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 35
Batch Work List
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 36
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 37
Batch Specific Unit of Measure
- Usage In some industry sectors (for example, the pharmaceutical, chemical,
steel, or paper industry sectors), the composition or attributes of
products vary to some degree.
Therefore, you cannot use a conversion factor to convert quantities
of these products into various units of measure.
Instead, each batch has to be given an individual conversion factor.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 38
Batch Specific Unit of Measure
- Example Pharmaceuticals/Chemicals/Foods (Active Ingredient Management)
These material consist of one or more active ingredients, concentrates,
carrier materials, or impurities, and so on.
The potency of the active ingredients varies from batch to batch.
Steel/Paper/Wood/Textiles
These materials are handled in batches. Among other things, these batches
convey the products grade.
There is a fixed relationship between the number of pieces and the weight of
each batch; the weight per piece.
e.g. The quantity in the purchase order is listed in pieces, but billed in kilograms.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 39
Batch Specific Unit of Measure
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 40
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 41
Shelf Life Expiration Date
- Usage -
Batches of materials that may no longer be used or sold after a
certain time period are normally assigned a shelf life expiration date
(SLED).
This function calculates the SLED from the total shelf life and the
production date during the following procedures:
At goods receipt
Upon automatic goods movements
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 42
Shelf Life Expiration Date
- Example Gourmet, a quiche manufacturer, produces quiches on 01.07. The
total shelf life of 50 days means the SLED would be 20.08.
In batch determination, you can use object dependencies to
dynamically determine a date (SLED) to be used as criteria for batch
determination.
A customer specifies that the sherry trifle he obtains from a supplier must feature
a remaining shelf life of 14 days on the date of delivery. In this case, the supplier
uses the dynamic determination of the SLED during batch determination so that he
does not have to enter the selection criteria manually for each delivery.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 43
Shelf Life Expiration Date
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 44
Shelf Life Expiration Date
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 45
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 46
Batch Information Cockpit
- Usage -
The Batch Information Cockpit (BIC) represents a central switching
point with wide-ranging options for analysis and control of batches.
You can use the BIC to
Select batches
Display information relevant to batches
Call up detail functions
Trigger follow-up actions
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 47
Batch Information Cockpit
- Example
e.g. the BIC enables you to answer the following questions:
Which batches should be consumed if their shelf-life expires soon?
Which unrestricted batch stocks are there for a certain product group?
How are the stocks divided across alternative units of measure?
The BIC offers you the following control options:
Selected batches can be stored in the Batch Worklist in a structured way (for
example, according to the required work steps), and can then be "held" for further
processing.
You can directly call up e.g. the batch master.
You can integrate and trigger follow-up actions for mass changes using Business
Add-Ins (BAdIs).
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 48
Batch Information Cockpit
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 49
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 50
Batch Derivation
- Usage -
This component enables you to derive batch master data and
classification data of the component batches for produced batches:
Transfer
Display for selection
Display
To be able to derive batch data, you must have set up the batch
where-used list.
only those component batches are included that were used in the produced
batch.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 51
Batch Derivation
- Example -
Filling / Packaging:
A batch
of a material is produced and is placed into various
containers, before the results of the quality check are available. If
the bulk batch is specified, these results should be transferred to
the container batches.
The shelf life expiration date (SLED) of the unpacked material
(e.g. bulk material) should be transferred to the packed material.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 52
Derivation of Batch data
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 53
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 54
Documentary Batches
- Usage You use documentary batches to ensure that partial stocks of a
material are traceable, without it being necessary to manage the
stock of the material in batches.
This reduces the amount of effort involved in tracing where batches
have been used.
In comparison to "real" batches, documentary batches have the
following advantages:
A lower level of complexity
Less effort involved in entering batches
Lower costs for inventory management, physical inventory and confirmation
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 55
Documentary Batches
- Example The consumed batches can only be dedicated to the produced
batches in recognizing certain variations.
For example:
Consumption of pipeline material.
Consumption of material from a tank in which more than
one batch is stored.
Automated
production processes. e.g. the machines will not
be stopped in case of changing a component batch.
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 56
Documentary Batches
- Example Automated Production Processes:
Production Line 1 :
Output Batches
Input Batches
C2
C0_A
C1_A
C1
Goods Receipt
Automatic Batch
Determination
Identify Batches via
Barcode
Writing Buffer Table:
Actual Batch(es) in
use e.g.
C1
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 57
Documentary Batches
- Example -
Documentary
Batch
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 58
Documentary Batches
- Example -
Stock for Material WE_SEMI_20
(Documentary Batches)
only on plant/storage location level
(not on batch level)
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 59
Real Batches: Stock for Material
WE_Finish_10
on batch level
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 60
Batch History
- Usage
To get the complete history data for a batch with all details.
Functionality:
A transaction
as a flexible environment to select relevant batch-related object
types for batch history search from SAP and non-SAP systems
Flexible Display of the Results
Options to initiate follow-up activities
Index table approach to store information relevant to all batch-related object types
from SAP as well as non-SAP systems
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 61
Batch History
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 62
Agenda
Batch Specific Unit of Measure
Shelf Life Expiration Date
Batch Information Cockpit
Batch Derivation
Traceability with Documentary Batches
Batch History
Work in Process Batches
85%
alcohol
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 63
Work in Process Batches
- Usage
Definition:
The work in process batch (WIP Batch) is a partial quantity of the production- or
process order header material confirmed per operation or phase.
Usage:
Work in process tracking on operation / phase level of a production or process
order
work in process stock analysis
valuation of work in process
Documentation of the actual characteristics / status of a product which is in
production
Subcontracting to send work in process batches to subcontractors
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 64
Example: Work in Process Batches (WIP
batches)
Stock Batch R1111
Goods issue
Length:
6 meter
Length:
6 meter
Length:
2 meter
Inventory
Create with
reference
Production Order
WIP_A
Split
Cutting
WIP_S_B1
Split
WIP_S_B2
WIP_S_B3
WIP Batches
Merge
Forging
WIP_M_C1
Oven 1
Heat Treatment
Goods Receipt
WIP_O_D1
WIP_U_C2
Oven 2
WIP_O_D2
Length:
2 meter
Length:
2 meter
Quality:
Quality:
Length:
2 meter
Length:
2 meter
Quality:
Quality:
Oven:
Oven:
Inventory Batch GR_FIN_1
Inventory Batch GR_FIN_2
Length:
2 meter
Length:
Quality:
Quality:
Oven:
Oven:
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 65
2 meter
Inventory
Work in Process Batches
- Example -
SAP 2009 / ERP Batch Management Overview 2009 Juergen Wettengl Page 66
