Project Unity Functional Specification - Process Order Execution

P ROJECT U NITY

F UNCTIONAL S PECIFICATION - P ROCESS O RDER E XECUTION

VERSION: 01 REVISION: 0 0200 3

Document Approval and Release

ROLE NAME (AND TITLE) DATE AND SIGNATURE

AUTHOR

ACCENTURE CLAUDIA BIANCHI

REVIEW

CSV – VALIDATION CARLO CANDOTTI

CONSULTANT

BUSINESS – LOCAL TEAM LEAD DAVE MARKOVICH

YANICK GAUTHIER

BUSINESS – CORPORATE TEAM DAVIDE COHA

LEAD

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Project Unity Functional Specification - Process Order Execution

APPROVAL

IT – CORPORATE MARCO MAIOLI

BUSINESS – NORTH AMERICA LUC RAYMOND

TEAM LEAD

GQ – VALIDATION SANDRO TACCANI

COORDINATOR

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Project Unity Functional Specification - Process Order Execution

Document History

Version- Change date Responsible person Change summary

Revision

V00R00 25-NOV-2011 Claudia Bianchi Initial Version

V01R00 10-DEC-2011 Marco Introna Approved Version

V01R01 10-SEPT-2014 Elisabetta Sozio Document updated for GSM

Valeria Mulas

V01R02 10-FEB-2016 Valeria Mulas Document updated for PR 215249

V01R03 01-FEB-2017 Simone Palmisano Document updated for PR 255082

Last version revision information

Paragraph # Change

Par. 2 Paragraph updated for GSM

Par. 3 Paragraph updated for GSM

Par. 4 Paragraph updated for GSM

Par. 5 Paragraph updated for GSM

Par. 3 Paragraph 3.5 added for PR 215249

Par. 5 Line UNITY-FSP-MFG-03-0280 added for PR 215249

Par. 5.1 Line UNITY-FSP-MFG-03-0180 updated for PR 255082

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Table of Contents

1. Introduction.................................................................................................................... 5
1.1 Reference Documents............................................................................................. 5
1.2 Definitions & Acronyms...........................................................................................5
2. Document Purpose..................................................................................................... 6
3. Short Functional Description....................................................................................6
3.1 MFG02-03_Serial Number Status and Attributes...................................................6
3.2 MFG04-03_Components Good Issue / INV08-03_Components Consumption....7
3.3 MFG04-05_Production Execution with Serial Number Management.................10
3.4 MFG06-01_Continuous Flow Production.............................................................10
3.5 Goods Receipt in Acist US....................................................................................10
4. Business Process Flow Chart..................................................................................12
5. Solution.......................................................................................................................... 14
5.1 Goods Issue............................................................................................................ 14
5.2 Serial Number Management..................................................................................24
5.3 Continuous Flow Production................................................................................26
5.4 Goods Receipt in Acist US....................................................................................27
5.5 Functional Message Codes & Content.................................................................28
6. Overview Of SAP Transactions & Customizing Activities.........................................29
6.1 SAP Transactions................................................................................................... 29
6.2 Customizing Activities........................................................................................... 30
7. Overview of Additional Developments........................................................................32
7.1 Reports, Forms....................................................................................................... 32
7.2 Interfaces................................................................................................................ 32
7.3 Conversions........................................................................................................... 32
7.4 Enhancements........................................................................................................ 32
1. Introduction................................................................................................................ 5
1.1 Reference Documents............................................................................................. 5
1.2 Definitions & Acronyms...........................................................................................5
2. Document Purpose..................................................................................................... 6
3. Short Functional Description....................................................................................6
3.1 MFG02-03_Serial Number Status and Attributes...................................................6
3.2 MFG04-03_Components Good Issue / INV08-03_Components Consumption....7
3.3 MFG04-05_Production Execution with Serial Number Management.................10
3.4 MFG06-01_Continuous Flow Production.............................................................10
4. Business Process Flow Chart..................................................................................11
5. Solution.......................................................................................................................... 13
5.1 Goods Issue............................................................................................................ 13
5.2 Serial Number Management..................................................................................23
5.3 Continuous Flow Production................................................................................25
5.4 Functional Message Codes & Content.................................................................25
6. Overview Of SAP Transactions & Customizing Activities.........................................26
6.1 SAP Transactions................................................................................................... 26
6.2 Customizing Activities........................................................................................... 27
7. Overview of Additional Developments........................................................................29
7.1 Reports, Forms....................................................................................................... 29
7.2 Interfaces................................................................................................................ 29
7.3 Conversions........................................................................................................... 29
7.4 Enhancements.......................................................................................................... 29

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1. INTRODUCTION
1.1 REFERENCE DOCUMENTS
Reference Document

[1] UNITY-MFG-URS – Manufacturing User Requirements Specification

[2] UNITY-FSP-MFG-01 – Process Order Creation Functional Specification

[3] UNITY-FSP-MFG-04 – Process Order Confirmation Functional Specification

[4] UNITY-FSP-INV-03 – Inventory transfer & transfer posting Functional Specification

[5] UNITY-FSP-CS-01 – Service Master Data Functional Specification

[6] UNITY-FSP-INV-01 – Master Data Functional Specification

[7] UNITY-FSP-QUA-02 – Quality Process Management (Procurement / Production) Functional

Specification

[8] UNITY-FSP-MFG-02 – Process Order Release Functional Specification

[9] UNITY-FSP-INV-07 – Manage Manufacturing Process in WM Functional Specification

1.2 DEFINITIONS & ACRONYMS

Term/Acronyms Definition/Explanation

SAP Systems, Applications & Products in data processing

BoM Bill of Material; it is a complete, 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.

ECM Engineering change management; it is an Engineering change document which is used for
BOM and recipe creation and changes.

PO Process Order; it is the main control instrument used in production. It is used to describe,
update and monitor all production-relevant factors, both planned and actual.

QA Quality Assurance

PV Production Version; a production version determines which alternative BOM is used

together with which task list/master recipe to produce a material or create a master
production schedule.

S/N Serial Number

TECO Technical Completion

G/L General Ledger

WM Warehouse Management

GI Goods Issue

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2. DOCUMENT PURPOSE
The purpose of this document is to describe how the solution will respond to user
requirements concerning Manufacturing Process Order Execution process.

This document is relevant for the following manufacturing companies:

 EZEM Canada Inc.(Montreal)

 EZEM Inc. (Mississippi)
 ACIST US (Eden Prairie)
 ACIST EU (Maastricht)
 SMC / BINJ EU (Losanna)

Project Project Project Process Process Subprocess Subprocess

Stream Domai Domain Code Description Code Description
n Code
Operations MFG Manufacturing MFG02 Batch Management
& Serial Number
management
Serial Number Status
MFG02-03 and Attributes
MFG04 Production
Execution – Run
Operation
Components Good
MFG04-03 Issue
Production Execution
with Serial Number
MFG04-05 Management
MFG06 Production
Execution – Other
Processes
Continuous Flow
MFG06-01 Production
Operations INV Inventory and INV08 Manage
Warehouse Manufacturing
process in WM
Components
INV08-03 Consumption

For each of the above sub-processes, the following entities are in scope:

Subprocess Description ACIST US ACIST EU ACIST ASIA EZEM BDI SMC/

BINJ EU
Serial Number Status and Attributes X X X X
Components Good Issue X X X X
Production Execution with Serial X X X
Number Management
Continuous Flow Production X
Components Consumption X X X X

3. SHORT FUNCTIONAL DESCRIPTION

3.1 MFG02-03_SERIAL NUMBER STATUS AND ATTRIBUTES

The serial number is associated to an item of material in addition to the material number in
order to differentiate individual items from all other pieces of the material.

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For materials whose material pieces have to be managed using serial numbers 1, a Serial
Number profile (i.e., a four digit identification code) has to be configured and assigned in the
Work Scheduling view of the Material Master. The serial number profile is active at plant level
and it defines the business procedures during which serial numbers can be assigned. The
possible choices are:
 assign serial numbers for goods receipts, goods issues, stock transfers, stock
transport orders and physical inventory;
 assign serial numbers when production orders are released;
 assign serial numbers when entering the original value in an inspection lot;
 assign serial numbers for deliveries;
 assign serial numbers for returns deliveries.

There are two possibilities for assigning serial number:

 internally, triggering generation of a new serial number by the system;

 externally, manually inserting a new serial number.
Serial Number Profile customization is the instrument for setting this kind of information for a
serial number profile. In particular, it is possible to determine for a business transaction,
whether

 No serial numbers have to be assigned;

 Serial numbers can be assigned;

 Serial numbers must be assigned;

 Serial numbers are assigned automatically.

However, only the mandatory assignment of serial numbers is in scope and this is the only
option that will be implemented. In the serial number profile it is also possible to set whether
or not an equipment2 master record should be created for each number when assigning serial
numbers.

All the information related to the serial number management are stored in the Serial Number
Master Record.

Note: The combination of material and serial number is unique (getting at master data level).
In the material master record, it is also possible to display a report with the history of the
movement types associated to a specific serial number.

3.2 MFG04-03_COMPONENTS GOOD ISSUE / INV08-

03_COMPONENTS CONSUMPTION

A components goods issue is a goods movement that is used to post the internal use of
materials against a specific production process. A goods issue results in a decrease of stock in
the warehouse (components consumption).

When withdrawing components for a process order, the system distinguishes between the
following types of goods issues:

o Planned Goods Issue (for Process Order):

1
This topic is relevant only for ACIST, ACIST EU and SMC/BINJ EU since EZEM has no S/N managed
material in Process Order, as it is relevant for Inventory purposes.
2
For the details of equipment management, please refer to [5].

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With this type of withdrawal the system automatically creates a reservation for the
components planned in the process order. When the goods issue is entered, the
system determines all components to be withdrawn.
o Backflush:
This type of withdrawal means that the components are already available at the
production site. They are physically consumed during the production process and
logically consumed in the system at order confirmation decreasing stock based on the
standard quantity defined in the material list of the order. For these components, the
system performs automatic stock posting at inventory level.

Withdrawals for production are entered in the system as goods issues with reference to the
process orders for which the components are required.
It is important to enter the goods issue with reference to the Process Order for the following
reasons:

o The production department can check whether what was requested is actually issued
and, if necessary, change the default quantity for the items;

o During entry of goods issue, the system can suggest data from the process order (for
example, requested material, quantity, account assignment, etc.). This simplifies both
data entry and checking (overdeliveries and underdeliveries) when entering a goods
issue;

o After a withdrawal, the quantity withdrawn is updated in the process order and the
reserved quantity is reduced accordingly. Thus, Inventory Management can monitor
the withdrawal process and Materials Planning can update the stock/requirements
list;

o When completion of the order is confirmed, it is possible to decide that all quantities
reserved for the order but not needed are to be flagged as Final issue and the
reservation on the item is removed.

At components good issue it is possible to:

o declare a different quantity 3 with respect of the theoretical one assigned in the
process order;
o reverse component Goods Issue posting, if any error occurred during the original
declaration.

A Goods issue is possible, until final Process Order closure (Technical Completion). When the
order is TECO status it is not possible to post any other goods movement.

Components consumption (GI posting) has the following results in the system:

• Material Document creation:

The material document is created as proof of the goods movement.
• Accounting Document creation:
The accounting document contains the posting lines (for the corresponding
accounts) that are necessary for the movement.
• Update of G/L Accounts:
The system automatically creates posting lines on the accounts of the accounting
system.
• Stock Update:

3
It is possible to consume an actual quantity also greater than planned one.

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Reserved stock is reduced by the issued quantity. From the point of view of
Materials Planning, available stock remains unchanged when posting a planned
goods issue because the quantity withdrawn was reserved and therefore no
longer available anyway
• Reservation Update:
The quantity withdrawn is updated in the reservation item. The reservation item
is completed when the total reservation quantity has been withdrawn or when
the final issue indicator is set manually at goods issue.
• Process order update:
The quantities withdrawn for the components are updated in the process order.

If the storage location for components consumption is WM-managed, then the Inventory
Management posting reduces not only the storage location stock, but also the warehouse
number stock. The consumed quantity is therefore booked out directly from production
storage bins where materials have been staged. No other user input is required.

ACIST, ACIST EU and SMC/BINJ EU:

Components goods issue is performed manually at the end of assembly production taking into
account that:

 Material-managed components require a quantity confirmation;

 Batch/Lot-managed components require quantity and batch/lot number confirmation;
 S/N-managed components require quantity and S/N declaration.

In case master data setting for backflushing is set, system allows the booking of consumption
of specific materials using automatic back flushing. This type of withdrawal means that the
components are already available at the production site and they are physically consumed
during the production process. For these components, the system performs automatic stock
posting at inventory level.

It is possible to change the consumption quantity and batch/lot if they are different from
theoretical quantity and batch/lot specified in the Process Order.

Note: In case of error, user is able to correct the backflushing consumption.

EZEM:

Components goods issue has to be performed during production process (both for
manufacturing and packaging) whenever material is physically consumed: consumption is
performed at operation level and completion of each phase is then declared by the end of
each shift. Consumption of components for packaging order is evaluated according to what
was picked and sent to the production and what was returned to the warehouse.

For manufacturing process, user has to declare actual consumption for components/batches
used in the Process Order according to:
 weighed quantity during dispensing activities (for raw materials weighed in
dispensing);
 weighed quantity during manufacturing activities (for raw materials weighed in
production);
 quantity used during production activities (for packaging components and semi-
finished goods, materials and intermediate materials).

Current integration with DSI is guaranteed in order to let operator declare

material/batch/quantity received on the line and trigger automatic consumption in SAP
according to goods issue posting results described above.

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3.3 MFG04-05_PRODUCTION EXECUTION WITH SERIAL NUMBER

MANAGEMENT

For materials serial number managed, during the manual Goods Issue, the system requires to
the operator to specify the serial number to consume and then it checks the stock availability
at serial number level. If no stock is available in the production area then the system rejects
the issue transaction.

In case of external Serial Number range management, the system allows either numeric or
alphanumeric values.

Definition of materials managed with serial numbers can be done at material level and at
plant level. If it is done at material level it is possible to define the length of the serial number
code (max 18 digits). For more details please refer to [7].

3.4 MFG06-01_CONTINUOUS FLOW PRODUCTION

For specific finished products, bulk materials are used prior final disposition (batch status
“Pre-approved”) from QA department in order to speed up production activities.

Continuous Flow Production is in scope only for packaging 4 activities and it is managed as a
Normal Production process (please refer to the previous sections for a detailed discussion
about it).
Specific users (belonging to the Quality Control authorization group) are assigned to perform
preliminary testing and conditional releasing in Pre-approved status on bulk materials to be
used in continuous flow production.

3.5 GOODS RECEIPT IN ACIST US

At the Goods Receipt posting in Acist US (plant AC01), if the material is relevant, a csv
document is automatically created and saved in the directory ZDIR_BARTENDER - \\bep-2k8-
label01.am.bracco.priv\labels.
The file is then processed by the external Bartender Label server.
The csv file is generated when the goods receipt is posted with movement type 101 in MIGO
transaction for material internally produced, if the following conditions are verified:
- The header material in the Process Order is present in the custom table ZINVTT0019;
- The GTIN (EAN/UPC field in the material master) is filled for the UoM of the Process
Order and with EAN Category equal to ‘GT’;
- The Marked Code is filled for the header material;
- The Process Order Type is equal to ZNOR or ZREW
The layout of the .csv document will be the following:
- Header
o Label File Format linked to the header material in the custom table. In case
this field is not filled in the custom table for the material, the .csv file will be
sent anyway and this field will be blank;
o Printer ID, linked to the header material in the custom table. In case this field
is not filled in the custom table for the material, the .csv file will be sent
anyway and this field will be blank.
The header file format is as follows:

4
Since packaging process is not relevant for ACIST, continuous flow production is discussed only for
EZEM plant.

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Project Unity Functional Specification - Process Order Execution

%BTW% /AF="[Label File Format]" /D="%TRIGGER FILE NAME%" /P /PRN="[Printer ID]

" /R=3%END%

- Item
o User who performed the GR;
o Material Document created at the GR posting in MIGO;
o Order Type for the PO
o Material Number, the header material in the PO for which the GR has been
performed;
o Material Description, description of the header material in the material
master;
o Label Quantity, for materials batch managed equal to the ‘Qty in Unit of
Entry’ registered in MIGO transaction; for materials S/N managed equal to 1
for each serial number produced
o GTIN number, for the header material in the material master and related to
the UoM of the PO, with EAN category equal to GT;
o Marked Code, for the header material in the material master (Sales org. 2
view);
o Serial Number, assigned to the material during the GR (if relevant);
o Lot Number, assigned to the material in the PO (if relevant);
o Expiration Date (if relevant);
o Manufacturing Date (if relevant);

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4. BUSINESS PROCESS FLOW CHART

ACIST, ACIST EU, SMC/BINJ EU:

EZEM:

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5. SOLUTION
5.1 GOODS ISSUE

ACIST:

Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference

SMC/BINJ EU
Acist Asia
Acist US

Acist EU

Ezem
BDI
UNITY-FSP- Step 1-2-3: Posting goods issue (initial screen) MIGO 001 MFG04-03_0050
MFG-03-0010
MFG04-03_0060
A goods issue is performed at the end of assembly production activities to declare
the internal use of material for production purposes.
This information is posted in the system directly as an inventory transaction X X X
accessing the MIGO screen using the movement type 261 (Goods issue for Order)
and selecting the process order. The consumption has to be posted by the
authorized user in reference to the process order.
Note: it is possible to post good issue only for orders whose status is not TECO.

UNITY-FSP- Step 4-5b: Automatic backflushing MM01 MFG04-03_0110 X X X

MFG-03-0020
MM02
Backflushing can be set at material level or at phase level in master recipe:
C201
 Backflushing at material level is defined in the MRP2 view of the
C202
material master. This means that the backflushing is always active for
the material. COR2

Note: Backflushing at material level can be set, by exception, accessing the COR2
transaction with the PO number and selecting the backflushing item for the
relevant material in the material list.

 Backflushing at phase level is defined into the master recipe. It

means that all the materials related to the phase for which backflushing
is set are automatically backflushed managed (no manual goods
movements are allowed) by the system even if they do not have the
backflushing item setting active in the material master.

Note: Backflushing at phase level can be set, by exception, accessing the COR2
transaction with the PO number and selecting the backflushing item for the

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Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference

SMC/BINJ EU
Acist Asia
Acist US

Acist EU

Ezem
BDI
relevant phases in the Operations Overview.

In case the master data setting for backflushing is set, the goods issue posting for
backflushed components is performed automatically at the time of order
completion confirmation based on standard quantities defined in the material list
of the order. For more details please refer to [3].

For these components, there is no need to manually enter a goods movement in

the Inventory Management system.

Note: It is not possible to set backflushing for materials S/N managed.

UNITY-FSP- Correct back-flushing CORS MFG04-03_0110

MFG-03-0030
MFG04-03_0120
Errors may occur when the system is saving the data in the backflushing
transaction. It is possible that the logical stock level is insufficient at the time of
the withdrawal posting, or errors occurred in the master data (e.g., the system X X X
could not determine a storage location) or the material data is locked by another
user. It is possible for the authorized user to correct the back flushing
consumption in case of error, posting the reversal of the confirmation of the
relevant phase. Please refer to [3] for more details.

UNITY-FSP- Step 5a: Confirm/change theoretical quantity MIGO 001 MFG04-03_0080

MFG-03-0040
INV08-03_0040
In case of S/N managed, batch/lot managed or material managed materials at the
Goods Issue (mov. type 261) the authorized user has to select the material/s for INV08-03_0060
which he wants to post the Goods issue and to change/confirm the quantity used.
This information has to be inserted in the “Quantity” tab of the Material Item
Record in the field “Qty in Unit of Entry”. The quantity may be lower, equal, or
X X X
greater than the planned one. In case the quantity is greater or equal to the
planned one, the delivery is automatically set as “final” by the system and the
reservation is closed. If the quantity is lower than the planned one, the good issue
is considered partial and the reservation is not automatically closed by the system
until the total quantity has been posted; however, the authorized user can force
the closure of reservations selecting manually the “final issue” field in the
Reservation tab.

UNITY-FSP- Step 6a: Type of components MIGO 001 MFG04-03_0020 X X X

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Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference

SMC/BINJ EU
Acist Asia
Acist US

Acist EU

Ezem
BDI
MFG-03-0050 It is possible to post components consumption for the following materials and MFG04-03_0030
kinds of management:

- raw materials material-managed;

- raw materials lot-managed;

- raw materials serial number-managed;

- sub-assemblies lot-managed;

- sub-assemblies serial number-managed;

- assemblies serial number-managed.

UNITY-FSP- Step 7a: Confirm/change batch/lot MIGO 001 MFG04-03_0070

MFG-03-0060
COR2 MFG03-02_0140
In case of batch/lot managed materials at the Goods Issue (mov. type 261) the
authorized user has to insert in the material list the batch/lot of the material that
has been used (in case of lot/batch allocation on the order, the system inherits the
information not allowing any change during goods issue posting). The user can
directly write a batch number, or choose one of those proposed by the system
inquired by material and batch search strategies.
X X X
If the lot is already allocated for the material (for example, in case of change of
priorities during production execution), the appropriate way to change it is to
access the COR2 and repeating batch/lot allocation. For more details please refer
to [8].

Note: For material managed materials the batch allocation is not performed and
the batch allocation field line is not editable.

UNITY-FSP- Step 7b: Serial Number declaration MIGO 001 MFG04-05_0010 X X X

MFG-03-0070
INV08-03_0100
For materials S/N managed, at the Goods Issue (mov. type 261) the authorized
user has to insert in the Serial Number tab the S/N to consume. When the system
performs the material availability check, it verifies also the stock availability at
serial number level, and if no stock is available in the production area, the issue

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Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference

SMC/BINJ EU
Acist Asia
Acist US

Acist EU

Ezem
BDI
posting is rejected by the system.

UNITY-FSP- Step 8: Goods Issue Posting MIGO 001 MFG04-05_0020

MFG-03-0080
MFG04-05_0030
The authorized user clicks on “post” to post the Goods Issue.
INV08-03_0080
For lot and material-managed components the goods issue posting effect is to
INV08-03_0110
decrease the stock in the production storage area of the WM-managed storage
location as specified in the control cycle.

For materials serial number managed, the goods issue posting effect is to X X X
decrease the stock in the related storage location defined at material master level.

In all the scenarios, the system checks the stock availability for the
material/lot/serial number and if no stock is available in production area the issue
posting is rejected by the system.

Note: no manual good issue posting is possible for materials for which
backflushing setting is active.

UNITY-FSP- Step 9: Material reservation update/Accounting document MIGO 001 MFG04-03_0110 X X X

MFG-03-0090 posting/Material document creation INV08-03_0060
Final Goods Issue posting has the following results in the system:

• Material Document creation:

The material document is created as proof of the goods movement.
• Accounting Document creation:
The accounting document contains the posting lines (for the
corresponding accounts) that are necessary for the movement.
• Update of G/L Accounts:
The system automatically creates posting lines on the accounts of
the accounting system.
• Stock Update:
Reserved stock is reduced by the issued quantity. From the point of
view of Materials Planning, available stock remains unchanged
when posting a planned goods issue because the quantity
withdrawn was reserved and therefore no longer available anyway.
• Reservation Update:

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Line No. Description of solution with Business process step number T.Code Cust. No Dev. No URS Reference

SMC/BINJ EU
Acist Asia
Acist US

Acist EU

Ezem
BDI
The quantity withdrawn is updated in the reservation item. The
reservation item is completed when the total reservation quantity
has been withdrawn or when the final issue indicator is set
manually at goods issue.
• Process order update:
The quantities withdrawn for the components are updated in the
process order.
However, it is also possible to post partial good issue, and in this case the only
difference is that the material reservation is only updated and other goods issue
for the material are still possible.

UNITY-FSP- Damaged components MIGO 001 INV08-03_0120

MFG-03-0100
INV08-03_0140
In case a component is damaged before the assembly, it is segregated into the
NCMR location manually generating a stock transfer to the destination area and it
is possible to post the Goods issue for the additional material request against the
X X
same Process Order. In this latter case, the authorized user has to access the
MIGO screen with the same PO number and posting another goods issue for the
damaged material number. Please refer to line no. from FSP-MFG-03-0040 to FSP-
MFG-03-0070 for the details of the goods issue posting. For more details please
refer to [9].

UNITY-FSP- Step 11a: Goods Issue Reversal MBST 001 MFG04-03_0090

MFG-03-0110
INV08-03_0020
In case of error when entering a goods movement the user has to cancel the
material document, since the data in the material document can no longer be
changed. The user enters as reference for the reversal the original material
document in the MBST transaction and post the reversal of the movement. This
action generates immediately the reversal of the material document, the reversal
of the reservation and the reversal of the accounting documents related to the X X X
material document in input.

Note: in case of reversal of goods issue for process order no partial reversal is
allowed, otherwise system does not reflect reversed quantity at reservation level.

A new material document is created and recorded into the system to track the
reversal of the movement.

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UNITY-FSP- Step 11b-12b-12c: Decreasing of stock MIGO 001 INV08-03_0040
MFG-03-0120
The Goods issue Posting automatically triggers a reduction in the storage location MFG04-01_0040
stock. If the storage location for components consumption is WM managed, the
Goods Issue posting reduces not only the storage location stock, but also the
warehouse number stock. The consumed quantity is therefore booked out directly
X X X
from production storage bins where materials have been staged. No other user
input is required.

For S/N managed BoM components the system does not require replenishment
activities since direct consumption is allowed on the storage location where stock
is located.
UNITY-FSP- Step 13b-14b: Remaining quantity LT01 INV08-03_0050
MFG-03-0130
LT10 INV08-03_0090
In case of remaining quantity in the production area for lot and material-managed
components, a stock transfer for the remaining materials is posted to the main
warehouse. The stock transfer is posted with the production area as source type
and the warehouse area as destination. X X X

Please refer to [4] for the details of material transfer process.

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EZEM:

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UNITY-FSP- Step 1-2b: Posting goods issue using DSI N/A MFG04-03_0100
MFG-03-0140
The process of Goods issue can be executed entirely in SAP or through a direct
interface with DSI. In case the choice is to use DSI, all the activities related to the X
posting are performed using palm devices and at goods issue posting in DSI, data
are transferred to SAP for GI posting recording (as per line FSP-MFG-03-0180)

UNITY-FSP- Step 1-2a-3: Posting goods issue in SAP (initial screen) MIGO 001 INV08-03_0030
MFG-03-0150
MFG04-03_0040
A goods issue is performed at operation level as soon as materials are used in
production area during manufacturing/packaging activities to declare the internal MFG04-03_0060
use of them. This information is posted in the system directly as an inventory X
transaction accessing the MIGO screen using the movement type 261 (goods issue
for order) and inserting the process order number.

Note: it is possible to post good issue only for orders whose status is not yet
TECO.
UNITY-FSP- Step 4: Confirm/change theoretical quantity MIGO 001 MFG04-03_0010 X
MFG-03-0160
MFG04-03_0080
At the Goods Issue (mov. type 261) the authorized user has to select the
material/s for which he wants to post the Goods issue and to change/confirm the INV08-03_0010
quantity used. This information has to be inserted in the “Quantity” tab of the
Material Item Record in the field “Qty in Unit of Entry”. The quantity may be lower, INV08-03_0030
equal, or greater than the planned one. In case the quantity is greater or equal to INV08-03_0040
the planned one, the delivery is automatically set as “final” by the system and the
reservation is closed. If the quantity is lower than the planned one, the good issue INV08-03_0060
is considered partial and the reservation is not automatically closed by the system
until the total quantity has been posted; however, the authorized user can force
the closure of reservations selecting manually the “final issue” field in the
Reservation tab. During component consumption performed by production, the
inventory stock level is decreased in the production areas according to the
declared quantity.

It is possible to post components consumption for the following materials and

different kinds of management for components/batches used in the Process Order
according to:

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- weighed quantity during dispensing activities (for raw materials weighed
in dispensing);

- weighed quantity during manufacturing activities (for raw materials

weighed in production);

- quantity used during production activities (for packaging components

and semi-finished goods materials).

UNITY-FSP- Step 5-6: Confirm/change batch/lot MIGO 001 MFG04-03_0070

MFG-03-0170
COR2 MFG03-02_0140
In case of batch/lot managed materials at the Goods Issue (mov. type 261) the
authorized user has to insert in the material list the batch/lot of the material that
has been used (in case of lot/batch allocation on the order, the system inherits the
information not allowing any change during goods issue posting). He can directly
write a batch number, or the user can choose one of those proposed by the
system inquired by material and batch search strategies.
X
If the lot is already allocated for the material (for example, in case of change of
priorities during production execution), the appropriate way to change it is to
access the COR2 and repeating batch/lot allocation. For more details please refer
to [8].

Note: For material managed components the batch/lot allocation is not performed
and the batch allocation field line is not editable.

UNITY-FSP- Step 7: Goods Issue Posting/Material Reservation updated/Accounting MIGO 001 MFG04-04_0010 X
MFG-03-0180 documents posting/Material Document creation INV08-03_0060
The authorized user after performing the previous steps, clicks on “post” to post
the Goods Issue.

The goods issue posting effect is to decrease the stock in the production storage
area of the WM-managed storage location as specified in the control cycle.

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The system checks the stock availability for the material/lot and if no stock is
available in the production area the issue posting is rejected by the system . In
details, goods consumption for production from Warehouse is blocked if stocks are
not moved from WIP/WIF storage bins. .
Final Goods Issue posting has the following results in the system:

• Material Document creation:

The material document is created as proof of the goods movement.
• Accounting Document creation:
The accounting document contains the posting lines (for the
corresponding accounts) that are necessary for the movement.
• Update of G/L Accounts:
The system automatically creates posting lines on the accounts of
the accounting system.
• Stock Update:
Reserved stock is reduced by the issued quantity. From the point of
view of Materials Planning, available stock remains unchanged
when posting a planned goods issue because the quantity
withdrawn was reserved and therefore no longer available anyway.
• Reservation Update:
The quantity withdrawn is updated in the reservation item. The
reservation item is completed when the total reservation quantity
has been withdrawn or when the final issue indicator is set
manually at goods issue.
• Process order update:
The quantities withdrawn for the components are updated in the
process order.
However, it is also possible to post partial good issue, and in this case the only
difference is that the material reservation is only updated and other goods issue
for the material are still possible.

Even if the goods issue is the result of a posting from DSI the results in the system
are the same of a goods issue posted in SAP.

UNITY-FSP- Steps 8b-9: Goods Issue Reversal from DSI N/A MFG04-03_0100 X

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MFG-03-0190 Goods issue reversal can be triggered through DSI and in this case at the
confirmation of reversal in DSI data are transferred to SAP for posting GI reversal
(as per lines FSP-MFG-03-0200, FSP-MFG-03-0210.

UNITY-FSP- Steps 9a-10: Goods Issue Reversal in SAP MBST 001 MFG04-03_0090
MFG-03-0200
INV08-03_0020
In case of error when entering a goods movement the user has to cancel the
material document, since the data in the material document can be no longer
changed. The user enters as reference for the reversal the original material
document in the MBST transaction and post the reversal of the movement. This
action generates immediately the reversal of the material document, the reversal
of the reservation and the reversal of the accounting documents related to the X
material document in input.

Note: in case of reversal of goods issue for process order no partial reversal is
allowed, otherwise system does not reflect reversed quantity at reservation level.

A new material document is created and recorded into the system to track the
reversal of the movement.

UNITY-FSP- Step 9b-10a-10b: Decreasing of stock MIGO 001 INV08-03_0040

MFG-03-0210
The Goods issue Posting automatically triggers a reduction in the storage location
stocks. If the storage location for components consumption is WM managed, the
Goods Issue posting reduces not only the storage location stocks, but also the X
warehouse number stocks. The consumed quantity is therefore booked out directly
from production storage bins where materials have been staged.

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UNITY-FSP- Remaining quantity LT01 INV08-01_0120
MFG-03-0220
In case of remaining quantity in the production area after actual components LT10 INV08-03_0070
quantities declaration, this quantity remains available for following process Orders.

In particular, remaining pre-printed materials after printing execution in X

production, are transferred from the production area to the Labelling room area.

Please refer to [4] for the details of material transfer process.

5.2 SERIAL NUMBER MANAGEMENT

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UNITY-FSP- Serial number profile MM02 MFG02-03_0010
MFG-03-0230
MFG04-05_0080
The serial number is given to an item of material in addition to the material
number, in order to differentiate individual items from all other pieces of this
material. X X X X
Serial Number profile is represented by a four digit identification code that has to
be inserted in the Work Scheduling view of the Material Master.

Serial number profile is active at plant level.

UNITY-FSP- Serial number assignment OIS2 001 MFG02-03_0020 X X X X

MFG-03-02540
MIGO
The business procedures, defined at serial profile level, during which serial MFG02-03_0030
numbers can be assigned are: MM03 MFG02-03_0040
 assign serial numbers for goods receipts, goods issues, stock
transfers, stock transport orders and physical inventory; MFG02-03_0050

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 assign serial numbers when production orders are released; MFG04-05_0040
 assign serial numbers when entering the original value in an
inspection lot; MFG04-05_0050
 assign serial numbers for deliveries;
 assign serial numbers for returns deliveries.
MFG04-05_0060
There are two possibilities for assigning serial number, internally or externally:
MFG04-05_0070
 in case of internally assignment, the user has to click on “Create Serial
Nos automatically”;
 in case of externally assignment, the user has to manually insert the
Serial Number5.

All the information related to the serial number management is stored in the Serial
Number Master Record in the material master. In both the cases (internal and
external assignment) the correspondent Master record for S/N is created in real
time at the act of assignment.
Note: The combination of material and serial number is unique (at master data
level).
UNITY-FSP- Configuration of S/N profile OIS2 MFG02-03_0020 X X X X
MFG-03-0250 Configuration is managed, at procedure level, during the serial number definition. MFG02-03_0050
Serial number profile configuration is performed accessing the OIS2 transaction,
selecting “New Entries” and creating a new serial number profile. Then it is MFG04-05_0030
possible to set a new serialization procedure (referred to a specific business
procedure) for the new profile created in which setting the serialization usage of
the S/N profile. The possible entries are:

SerUsage Description
No serial numbers are
01
assigned
Serial numbers can be
02
assigned
03 Serial numbers must be

5
The user can insert any kind of numeric or alphanumeric combination of values for Serial Number, however, the maximum length allowed is 18 digits.

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assigned
Serial numbers are assigned
04
automatically

Note: Serial number usage “01”, “02” and “04” are mentioned since they are
possible entries from standard SAP, however, they are not planned to be used.
Hence, the unique S/N usage used is “03”.

At this level it is also possible to define whether or not an equipment master

record should be created for each S/N number when assigning serial numbers. For
the details of the equipments please refer to [5].

For more details on S/N profile defined for the project please refer to [6].

In the serial number profile view it is possible to set also the Stock Check for Serial
Numbers. This indicator states whether the system should perform a stock check
during serial number assignment. If it should, it also establishes with what type of
notification (warning or error) the system reacts in the event of stock
inconsistencies with Inventory Management.

For the details of the Stock Check please refer to [6].

UNITY-FSP- Serial number history IQ03 MFG02-03_0060

MFG-03-0260
In the material master record, it is also possible to display a report with the history X X X X
of the movement types associated to a specific serial number, clicking on the
SerData tab.

5.3 CONTINUOUS FLOW PRODUCTION

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5.4 GOODS RECEIPT IN ACIST US

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UNITY-FSP- Goods Receipt in Acist US MIGO MFG04-05_0120 X
MFG-03-0280
At the Goods Receipt posting in Acist US (plant AC01), if the material is relevant, a
csv document is automatically created and saved in the directory
ZDIR_BARTENDER - \\bep-2k8-label01.am.bracco.priv\labels.
The file is then processed by the external Bartender Label server.
The csv file is generated when the goods receipt is posted with movement type
101 in MIGO transaction for material internally produced, if the following
conditions are verified:
- The header material in the Process Order is present in the custom table
ZINVTT0019;
- The GTIN (EAN/UPC field in the material master) is filled for the UoM of
the Process Order and with EAN Category equal to ‘GT’;
- The Marked Code is filled for the header material;
- The Process Order Type is equal to ZNOR or ZREW
The layout of the .csv document will be the following:
- Header
o Label File Format linked to the header material in the custom
table. In case this field is not filled in the custom table for the
material, the .csv file will be sent anyway and this field will be
blank;
o Printer ID, linked to the header material in the custom table.
In case this field is not filled in the custom table for the
material, the .csv file will be sent anyway and this field will be
blank.
The header file format is as follows:
%BTW% /AF="[Label File Format]" /D="%TRIGGER FILE NAME%" /P
/PRN="[Printer ID] " /R=3%END%

- Item
o User who performed the GR;
o Material Document created at the GR posting in MIGO;
o Order Type for the PO

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o Material Number, the header material in the PO for which the
GR has been performed;
o Material Description, description of the header material in the
material master;
o Label Quantity, for materials batch managed equal to the ‘Qty
in Unit of Entry’ registered in MIGO transaction; for materials
S/N managed equal to 1 for each serial number produced
o GTIN number, for the header material in the material master
and related to the UoM of the PO, with EAN category equal to
GT;
o Marked Code, for the header material in the material master
(Sales org. 2 view);
o Serial Number, assigned to the material during the GR (if
relevant);
o Lot Number, assigned to the material in the PO (if relevant);
o Expiration Date (if relevant);
o Manufacturing Date (if relevant);

5.5 FUNCTIONAL MESSAGE CODES & CONTENT

Message Code Message Content

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6. OVERVIEW OF SAP TRANSACTIONS & CUSTOMIZING ACTIVITIES

6.1 SAP TRANSACTIONS
Transaction Code Transaction Title

MM01 Create Material

MM02 Change Material

MM03 Display Material

C201 Create Master recipe

C202 Change Master recipe

COR2 Change Process Order

CORS Cancel Process Order Confirmation

MIGO Goods Movement

MBST Cancel Material Document

LT01 Create Transfer Order

LT10 Create Transfer Order from List

IQ03 Display Material Serial Number

OIS2 Maintain Serial Number Profile

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6.2 CUSTOMIZING ACTIVITIES

Cust. No Customizing Description with Values T. Code or Path

001 Determine Movement Types SPRO/Production/Shop Floor

Control/Integration/Determine
Movement Types

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Cust. No Customizing Description with Values T. Code or Path

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7. OVERVIEW OF ADDITIONAL DEVELOPMENTS

7.1 REPORTS, FORMS
Dev. No FS-R Document Name Description FS Line No.

7.2 INTERFACES
Dev. No FS-I Document Name Description FS Line No.

7.3 CONVERSIONS
Dev. No FS-C Document Name Description FS Line No.

7.4 ENHANCEMENTS
Dev. No FS-R Document Name Description FS Line No.

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