Advanced Batch usage in PP for Delivery in SD

[HaroldUK]

Dear SAP Gurus,
need your expertise / advice on the following scenario:
My company uses repetitive manufacturing for production which is a continuous process industry (oild & gas / petrochemicals). The main product is received into Tank A using a dummy batch number and then transfer to Tank B after quality inspection for final goods delivery. The actual batch number is entered at the time of GR after quality inspection only, but the delivery order is created way in advance immediately after the sales order is created to support the goods delivery shipment process without any batch number in the DO as the batch number is not mandatory at that time. The actual batch number will be known at a later stage and is enetered in the Delivery Order before PGI.

But we are doing some system enhancements in the SD module by making the batch number mandatory for delivery order creation, otherwise the logistics dept. is not able to proceed with the shipment planning process. If using a dummy batch number in the Delivery order and if proceed with the logistics shipment process. If need to use the actual batch number in the delivery later, they will have to delete the shipment number, then unpack the delivery with old batch number and do a repack of the delivery with the actual batch number in system once the actual batch number is ready, this causes lot of trouble to the logistics team.

The batch numbering used is external and the naming convention uses the actual day of GR and the Final Tank number from where the goods are delivered. This makes it impossible to pre-determine the actual batch number upfront and input it in the advanced delivery order for transport planning. Also there are other packed materials are produced using Process Orders (here not repetitive manufacturing, means the BOM consists of main product + drum) and the actual batch is entered on the day of GR in to storage location for final delivery. The actual issue is the advanced batch number creation due to the naming convention of the batch, otherwise we could have used the process orders as available stock in the ATP check for delivery creation.

Would appreciate if any of you can advice what kind of planning strategy is used in similar continuous process industries. Any particular PP planning scenario to be used for this kind of process (planning with final assembly, assembly order processing, etc). Also in repetitive manufacturing, can enter batch advanced in planned orders if it can be determined early?

Appreciate your great suggestions to tackle this issue and adopt the right process in SAP. Thank you

regards
Harold.

[Ramarao]

Harold

If I understood you, you actually have to complete the QM process before calling it a finished product. Normally in such an environment, the QM process is embedded as a the last step in the master recipe itself, but you seem to be putting it into stock first and then performing an inspection on GR. May I know if you've examined this alternative and provide any reasons for not adapting it?

Coming back to your question specifically - in your process you seem to have a situation of "processed" and "unprocessed" stock both at any time. Typically the batch determination should happen for what is deliverable - that is the "processed" stock. You may be able to perform an "availablity check" (not as specific as batch determination) one level below, if you go for an alternative approach of defining the unprocessed as a BOM component of the processed (this is called Capable-to-promise, and you need to go with specific settings of strategies etc in order to accomplish this). I am not suggesting you do this - it is quite a bit of master data for little benefit really, but just brainstorming about your requirement - which seems to be a little out of the normal.

[HaroldUK]

Hi Rama Rao,
thanks for your inputs; since the company is using planned orders (repetitive manufacturing), is there any way to input pre-defined batch numbers in Planned orders so that we can use the planned orders for ATP check in SD? Is there any provision for batch entry at planned order stage? Any user exits available for this in PP? Currently, the batch is entered at the time of GR (MFBF). Thanks

regards
Harold.

[Ramarao]

If one exists I don't know it - but I don't think it is even possible - the batch number field CHARG is not even on the planned order table PLAF.