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Table of Contents

SAP EAM Release 3 Processes


Planning Contracts Material Requirements Planning Inventory / WMS-ACG Manufacturing STO Overview (Shadow)
Delivery and Shipment Process WMS-LE interfaces Freight Payment Process Inbound Delivery
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P2P End to End Process Flow


Direct Procure to Pay End to End
Determine Required Materials Make PO / STO Supplier Fulfillment and Trans Opt . Transportation Optimization & Load Building
Yes

Receive Material Material Picked Up

Receive Invoice

Pay Invoice

ETM

Schedule Appointment

Run Tactical MRP Main tain Co nt rac ts


SAP

Execute Sourcing Rules /flag exceptions

ETM Optimized ? Convert /Create POs /STOs PO updated w / Confirmation

No

Create Inbound Delivery and Shipment

Update Inbound Delivery and Shipment

Post Goods Receipt against inbound delivery


No

Invoice Receipt Post Goods Receipt without PO


(Some Vendor are ERS)

Pay Vendor

Auto Create Planned Orders

Review MRP PRs /STRs

Create Inbound Delivery and Shipment from ASN or Manual

WMS site ?
Yes

Sup plier

52 week Planning File /Report

Receive PO

Ship Material

Create Invoice

W M S/ A DC

Create PO ( ADC )

Create Receipt Authorization (WMS )

Receive Goods Confirmation (WMS / ADC )

Ot h er Le g a cy

Generate Production Schedule

Receive 52 week Requirements

Record Goods Received (CCDS , Hold It , MARS - lot trace )

Goods Received ( Fruit )

Invoice Information Created (Fruit and Grainsmart )

Overview Planning Production Schedule


Quaker & Gatorade
Monday and Tuesday

52 week Prod Schedule from MIMI / AMAPS to SAP


Tuesday through Thursday

Delete past due orders In SAP

Plan FG in MIMI in weekly buckets

interface

FG planned orders created in SAP

Use SAP planning table to breakdown weekly schedule into daily or shift buckets Breakdown schedule for upcoming week from weekly to daily level Gatorade only

Planned orders in SAP are in weekly, daily or shift buckets

Tropicana

36245 interface

Download schedule from MIMI into excel sheet w/ macro Gatorade only

Delete past due orders In SAP

Plan FGs & some SFGs In AMAPS in daily and/or weekly buckets

interface

FG/SFG planned orders created in SAP

Introduction to Contract Administration

Contract Administration

P2P End to End Process Flow


Direct Procure to Pay End to End
Determine Required Materials Make PO / STO Supplier Fulfillment and Trans Opt . Transportation Optimization & Load Building
Yes

Receive Material Material Picked Up

Receive Invoice

Pay Invoice

ETM

Schedule Appointment

Run Tactical MRP M ain tain Co nt rac ts


SAP

Execute Sourcing Rules /flag exceptions

ETM Optimized ? Convert /Create POs /STOs PO updated w / Confirmation

No

Create Inbound Delivery and Shipment

Update Inbound Delivery and Shipment

Post Goods Receipt against inbound delivery


No

Invoice Receipt Post Goods Receipt without PO


(Some Vendor are ERS)

Pay Vendor

Auto Create Planned Orders

Review MRP PRs /STRs

Create Inbound Delivery and Shipment from ASN or Manual

WMS site ?
Yes

Sup plier

52 week Planning File /Report

Receive PO

Ship Material

Create Invoice

W M S/ A DC

Create PO ( ADC )

Create Receipt Authorization (WMS )

Receive Goods Confirmation (WMS / ADC )

Ot h er Le g a cy

Generate Production Schedule

Receive 52 week Requirements

Record Goods Received (CCDS , Hold It , MARS - lot trace )

Goods Received ( Fruit )

Invoice Information Created (Fruit and Grainsmart )

Transactional Contract Administration


Contract Administration is an important part of the P2R process. Transactional Contracts are often based on a legal Contract and are created and maintained in SAP. There are several activities that occur around Contract Administration: Create and maintain a Contract. Approve a Contract. Manage Source Lists.

Transactional Contract Administration Contract Creation


Create/modify Contract Approve Contract (if necessary) Create Source List Record (if necessary) PO Creation possible

The notification to create or change a Contract should come from Global Procurement.
The Buyer must first draft the Contract after negotiations with the vendor. The Contract Administrator then enters the information into SAP. The following prerequisites must be in place in order to complete this activity: Draft of contract from Global Procurement Material Master Record in the system Vendor master record in the system
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Transactional Contract Administration Contract Approval


Create/modify Contract Approve Contract (if necessary) Create Source List Record (if necessary) PO Creation possible

A Transactional Contract requires approval (or re-approval) when:


A new Contract has been created. The cumulative change to the target value of an existing contract exceeds +/-10% from the last time the contract was approved. The Contract is invalid until re-approval. The approval of contracts is handled through SAP and workflow (Universal Worklist). When a contract is saved, the approval process is triggered.
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Transactional Contract Administration Source List Overview


Create/modify Contract Approve Contract (if necessary) Create Source List Record (if necessary) PO Creation possible

A source list identifies the Transactional Contract lines that can be used to source Purchase Orders for a specific material at a specific plant within a predefined period. There is one Source List for each material at each plant. Source List can have multiple line items. Within the Source List a specific record can be defined as: Fixed Preferred sources over the validity period Blocked The source may not be used for a certain period of time Relevant to MRP (Indicated with a 1) MRP can use these records to assign a source to Purchase Requisitions.
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Transactional Contract Administration Source List Overview (cont.)


Below is a source list for Barley Flour at Bridgeview. It contains four source list records (Contract line items). This means that there are four possible sources that can be used when creating POs for barley flour at Bridgeview.

MRP Relevant

Different Source List Records (Contracts)

Fix or Block
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Transactional Contract Administration Key Point


Create/modify Contract Approve Contract (if necessary) Create Source List Record (if necessary) PO Creation possible

Key Point: Contracts contain the required data to enable Purchase Order creation (releases) by the production facilities. IMPORTANT: A Purchase Order (PO) can NOT be created with out a valid Contract and Source List for that material/vendor/plant combination. Contract must be approved in order to be valid. Contracts must be kept up to date and accurate at all times to ensure PO created are correct.
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Material Requirements Planning Overview

12

MRP Introduction Manufacturing End to End Process Flow


Create Planned Production Orders
ADC/YMS

Requirements

Source/Produce SFG Shift Batch Data (ADC/YMS) Source Materials

Record Production of FG

Report

Planned Production Orders Created

Material Planning Requirements

SAP

Make SFG

Confirm SFG Clear Production Backflush error log (End of Shift)

Stage Components in storage Location (Optional)

Make FG

MARS data confirmation (MTP Only)

Stage Components (Optional)

Production Receipt (Batch info as required)

Confirm FG (End of shift)

Interface to downstream systems

MARS data confirmation (MTP Only)

Clear Production Backflush error log (End of Shift) Production Receipt (LPN applied) Production Receipt (DCS) QA Reporting (Holdit) Volume Information (Consumer Complaints) Production FG, (SCR/ SCDB)

Change Inventory Location (Raw/Pack. Sites: Oakland, Blue Ridge, Pryor, Bridgeview, Albany) Generate Production Schedule Production Schedule (YODA, Cedar, Danville) Prod Schedule (SCR/ SCDB)

Change Inventory Location (Raw/Pack/SFG. Sites: Oakland, Blue Ridge, Pryor, Bridgeview, Albany)

Legacy (Site specific)

Legacy

WMS

Production Volume (Test Weights, Cedar Only)

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MRP Introduction
What is MRP ? Process used to plan direct materials necessary to support the master production schedule. The goal of MRP is to balance the supply of materials with the demand for materials over time which drives optimum efficiency in inventory levels and enables productivity. Right Material in the Right Place at the Right Time

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MRP Introduction Roles and Responsibilities


At PepsiCo, the specific roles that are involved in MRP are: Material Planner / Scheduler: Role responsible for scheduling materials to the QTG plant to meet planned production. Central Material Planner: Role responsible for central material management by insuring supply is available at the supplier and coordinating across multiple locations. DC Re-packer/Display Material Planner: Role responsible for MRP for repack / display materials. Co-pack Material Planner / Scheduler: Role responsible for material planning for Co-packers.

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Material Requirements Planning Overview Planning Process


Material Requirements Planning Process
Update Generate Determine Tactical Master Run Strategy Production Planning Schedule Parameters

GenerateRun Tactical Continuous Detailed Improvement MRP Schedule

Tactical Exception Management

Planner reviews planning parameters and makes an adjustment of requests adjustments through Data Maintenance Organization.

Production plan is imported from Manufacturing Planning tool (PP&S) to SAP ECC. Tactical MRP generates material requirements for MPS horizon. (MRP is initiated by batch process or planner).

MRP Planners review exception alerts and take appropriate action to resolve exceptions.

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Material Requirements Planning Overview Key Integration Points


Key Outputs Material Requirement Planning
Purchase requisitions by material SKU/location ready to convert to purchase orders Visibility to MRP requirements for 52 week horizon STOs for materials utilizing special procurement type

Key Inputs
Planned Orders from MP BOM recipes, Material Master Data Raw material safety stock targets Inventory Balances Transactional data (open POs, ASN)

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MRP - BOM
Bill of Material

64oz Bottle Tropicana Pure Premium Orange Juice BR1004850000102

BR11133 Corrugate

BR81464 Chep Pallet

BR98323 Single Strength Orange Juice

BR16618 Fitment(Cap)

BR17967C Carton

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MRP Introduction Process Flow Overview


Manufacturing Planning Material Requirements Planning
2 4 4a Generate Purchase Requisition 5 Create Purchase Order

Direct Purchasing

1 FG,SFG Planned Orders From Production Schedule 2 2 2 Run MRP Generate Planned Orders

4b 4 Generate Stock Transfer Request

5 Create Stock Transport Order

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MRP Introduction Process Flow Overview


1 BOMs & MRP Parameters 2 5a Run MRP 3 Generate Planned Order /Purchase Requisitions

Review Exceptions/ Take Action if Necessary

1a FG Schedule 4 5b 5 5 Run MRP ?

6 Review Next 6 Material/Continue Planning Activities

Planner reviews planning parameters and makes an adjustment or requests adjustments through Data Maintenance Organization. Production plan is imported from MIMI.

MRP is initiated by batch process or planner. MRP generates material requirements for Master Production Schedule horizon. Planned Orders and Purchase Requisitions are generated based on finished goods demands.

MRP Planners review exception alerts and take appropriate action to resolve. Planner reruns MRP if necessary or continues planning activities.

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MRP Introduction Key Changes and Impacts


Key Changes
Enterprise Wide System
Data Management Exception Based Alerts Advanced MRP Capabilities

Impacts
Purchasing and production information flows directly into the tool. No more separate data entry for inventory or vendor updates.
Additional data will be required to coordinate the enterprise system. Some data will be locally controlled; some will be centrally managed. Critical task alerts trigger activity in the time frame set by the material planner. Enables the Planner to execute a Single-item Multi-level MRP run; restrict the planning run to a net change within the planning horizon; systematically prevent weekend scheduled deliveries if needed; and provides the ability to perform ad-hoc MRP runs. Numbering system and descriptions of materials have been changed. New nomenclature will have to be learned.

SAP Numbering System

Drill Down within the Tool


SAP Material Master Use Up Logic

The tool can help lead you through your analysis.


Enables a systematic approach to manage run out of on hand material inventories, reducing material obsolescence.
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Stock/Requirements List and MRP List

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Stock/Requirements List and MRP List 1 Viewing MRP Results


1 BOMs & MRP Parameters 2 5a Run MRP 3 Generate Planned Orders/Purchase Requisitions 4 Review Exceptions/ Take Action if Necessary

1a FG Schedule 4 5b 5 5 6 6 Review Next 6 Material/Continue Planning Activities

Run MRP ?

To perform the activities above a material planner needs the ability to view MRP results. In the new system MRP results are viewed in the Stock/Requirements list and the MRP List. Both lists provide the planner with a detailed view of the supply and demand situation for a material to identify any problems.
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Stock/Requirements List and MRP List Viewing MRP Results


Key Change Benefit MRP results are: Key changes to viewing

Data format Data organized vertically, not horizontally. Exception Messages Exception messages are created by changes in supply or demand without re-running MRP. Screens ease navigation Stock/Requirements List replaces screen types like SDDQ or 23.13. All key data within one screen.

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Stock/Requirements List and MRP List Viewing MRP Results


New View
Header Info Organized Differently

Data Vertical vs. Horizontal

Safety Stock is Subtracted from the Available Quantity.

Old View MMS 23.13

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Stock/Requirements List and MRP List Viewing MRP Results


1.Stock

2.Safety Stock

3. Purchase Requisition

4. Planned Order 5. Dependent Requirement

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Stock/Requirements List and MRP List Viewing MRP Results


The Stock/Requirements List and the MRP List provide two ways to view MRP results. These lists are detailed views of the supply and demand for a material to identify any problems. The Stock/Requirements List is a real-time list that is continually updated with demand requirements, inventory adjustments, and exception messages. It does not display MRP termination messages or new planned order exception messages. The MRP List is a static list that is updated at the time of the last MRP run and it does display exception messages for new or changed planned orders and MRP termination messages.
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MRP Planning, Exception Messages

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Exception Messages Exception Messages Definition


1 BOMs & MRP Parameters 2 5a Run MRP 3 Generate Planned Orders/Purchase Requisitions 4 Review Exceptions/ Take Action if Necessary

1a FG Schedule 4 5b 5 5 Run MRP ? 6 Review Next 6 Material/Continue Planning Activities

A key component of the stock/requirements list and the MRP List are exception messages. Exception messages are alerts that notify the material planner of issues with a material. Planners need to determine if exception messages require action and take corrective action if necessary.
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Exception Messages Exception Message List

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Exception Messages Stock/Requirements List

1. Double Click on the Exception Message Number

2. Exception Message Text will Display at Bottom of Screen

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Exception Messages MRP List


1. MRP List exceptions are similar to the Stock Requirements List but include new planned order exceptions and termination messages.``

2. Order proposal has been changed.

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Exception Messages Traffic Lights


Exception message groups are used to define traffic lights. Traffic lights are red, yellow, green symbols used to prioritize exceptions. Traffic lights appear on both Stock/Requirements List and the MRP List in the collective display.
3. Click on Define Traffic Lights to access Traffic Light Settings

2. Associated Traffic Light

1. Exception Message Group

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Exception Messages Define Traffic Lights


Traffic Light Settings

Exception Message Groups

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Generating the Material Requirements Plan

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Generating MRP - MRP Run


1 1 BOMs & MRP Parameters 2 5a Run MRP 3 Generate Planned Orders/Purchase Requisitions 4 Review Exceptions/ Take Action if Necessary

1a FG Schedule 4 5b 5 5 3cMRP ? Run 6 Review Next 6 Material/Continue Planning Activities

N 5a

6
4

The two options to execute MRP are: Batch Process scheduled MRP run (nightly). On-line Planning Run MRP on demand (ad hoc).
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Generating MRP - Batch Process


For all QTG locations the automatic batch process schedule is: Nightly (net change) Batch Process Weekly (regen) Batch Process The MRP batch process runs plant by plant until all plants are complete.
Run Net Change Regen No Run Definition Plan materials that have changed since the last planning run. Re-plans all materials. Frequency Daily Weekly Schedule M-F Sunday Saturday

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Generating MRP - On-line MRP Run


The reasons for executing an on-line MRP run are: An adjustment in inventory (inventory change, product on hold, receipt change, actual usage). Updated parameters from the DMO. Updated parameters by local planner. Updated/new production plan is loaded.

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Generating MRP - Generate MRP Planning Run You have three choices to generate an on-line MRP run. 1. MRP by MRP controller
Run MRP by controller number. Run MRP for the entire plant.

2. Single-Item, Multi-Level MRP


Run MRP through all levels of the BOM for a finished good, semifinished good.

3. Single-Item, Single-Level MRP


Run MRP for a single material. After selecting the MRP run there are three process key choices.

Net change for planning horizon (NETPL), planning horizon is 28 days. Net change for total horizon days (NETCH) Regenerative planning (NEUPL)
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MRP Material Master Overview

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MRP Material Master Planning Parameters


MRP parameters are settings that ensure the material master record accurately reflects the relevant business requirements. Material planners will be required to access, review, and update the material master to change the MRP parameters as necessary. Conditions which may necessitate a planner to review and/or update parameters include: Supply impacts supplier reliability increases leading to a decrease in safety stock. Ordering Parameters delivery days change. New products new material added and need to set parameters. Any necessary adjustments must take place prior to the MRP run to reflect the changes in MRP output.

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MRP Material Master MRP Material Master Views The MRP parameters are found on the MRP material master views (MRP 1,2,3,4 tabs ).

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Stock Transport Order Processing Overview

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STO Processing Overview P2R End to End Process Flow


Direct Procure to Pay End to End
Determine Required Materials Make PO/STO Supplier Fulfillment and Trans Opt. Transportation Optimization & Load Building
Yes

Receive Material Material Picked Up

Receive Invoice Pay Invoice

ETM

Schedule Appointment

Run Tactical MRP

Maintain Contracts

SAP

Execute Sourcing Rules/flag exceptions Review MRP PRs/STRs

ETM Optimized? Convert/Create POs/STOs PO updated w/ Confirmation

No

Create Inbound Delivery and Shipment

Update Inbound Delivery and Shipment

Auto Create Planned Orders

Post Goods Receipt against inbound delivery


No

Invoice Receipt Post Goods Receipt without PO


(Some Vendor are ERS)

Pay Vendor

Create Inbound Delivery and Shipment from ASN or Manual

WMS site?
Yes

Supplier

52 week Planning File/Report

Receive PO

Ship Material

Create Invoice

WMS/ADC

Create PO (ADC)

Create Receipt Authorization (WMS)

Receive Goods Confirmation (WMS/ADC) Goods Received (Fruit)

Other Legacy

Generate Production Schedule

Receive 52 week Requirements

Record Goods Received (CCDS, Hold It, MARS - lot trace)

Invoice Information Created (Fruit and Grainsmart)

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STO Processing Overview

All intra-company material transfers in SAP will be managed through the Stock Transport Order (STO) process. The inventory transfers process addresses the intra-company transfer of finished goods, semi-finished goods and raw materials inventory. Today, a STO at Quaker is referred to as a Mill Transit and at Tropicana as a Transfer Order.

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STO Processing Overview Roles and Responsibilities


At PepsiCo, the specific roles that is involved in the raw material, semi-finished and Finished good Stock Transport Order process is: Raw / Semi Material Stock Transport Order (STO) Processor: The Raw Material Stock Transport Order Processor
is responsible for creating Stock Transport Orders (STOs) that facilitate the transfer of direct materials from plant to plant. This profile deals only with raw and semi-finished goods transfers.

Finished Goods Stock Transport Order Processor The Finished Goods Stock Transport Order Processor profile is responsible for manually entering STOs for the movement of finished goods and possibly semi-finished goods between facilities.

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STO Overview (Shadows)

Deployment Scenarios Key terms The Basics

The Shadow Order Concept / Interfaces


Tropicana Shadow Interfaces Quaker/Gatorade Shadow Interfaces STO Document types and Description STO Deployed to Deployed FG

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Deployment Scenarios
Scenario 1: Deployed to Non-Deployed Scenario 2: Non-Deployed to Deployed Scenario 3: Non-Deployed to Non-Deployed Scenario 4: Deployed to Deployed

End to End STO Process Flows https://teamwork.pepsico.com/eRoom/anchor/ProjectOneUpQTG2CrossTeam/ 0_be33e STO Shadows only occur for Scenarios 1, 2, and 4. SAP does not receive shadow orders for Scenario 3, the process remains the same between 2 non-deployed sites, they continue to use legacy processes and the transactional information is entirely contained within legacy.

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STO Processing Overview Key Terms (1 of 2)


Outbound Monitor: Used to provide visibility to all outbound stock transport orders and sales orders. Details of the order, delivery and shipment documents are viewed in the outbound monitor. Source List: Master data element that links a specific material/plant to a contract line or supplying plant. Stock Overview Report: SAP report that provides the user with current information on the stock of a particular product at all organizational levels. It displays the quantities of the product at each storage location or site, and the inventory status of the stock.

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STO Processing Overview Key Terms (2 of 2)


Stock Transport Order (STO): A purchasing document used to accomplish the transfer of Raw Materials (RM), Semi-Finished Goods (SFG), and Finished Goods (FG) materials between PepsiCo locations. Stock Transport Requisition (STR): A type of purchase requisition that is used to represent the planned transfer of materials between plants (for semi-finished goods only). Storage Location: The physical or virtual location within a plant where the material is stored (Warehouse, etc.) within SAP. Plant: In SAP, the distribution centers, mixing centers, and all warehouses are considered plants.

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STO Processing Overview Key Terms (3 of 3)


Shipment Document: Expands the order document with transportation relevant information such as mode of transportation, carrier assignment, appointment times, shipment status and contains the transportation data that is downloaded to the WMS. Delivery Document: The Delivery Document includes the SKU (slash code), weight/volume, and contains the item details information that is downloaded to the WMS. The delivery is updated after shipping with actual shipped quantities and ship date. (Warehouse Instructions) The delivery document is created from information on the sales order and STO before the pick, pack, ship process. After product is picked, packed and shipped, it is updated to reflect exact items that were shipped to the customer.

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The Basics
SAP Term: Stock Transport Order = STO Legacy Q/G Term: Mill Transit Order = MTO Legacy Trop Term: Transfer Order = TO

Q-DCS or QDCS: Quaker/Gatorades version of DCS. Known to Q/G Legacy only as DCS. Inventory system for finished goods and semi-finished goods. Interfaces to WMS systems and financial systems, and M204.
T-DCS or TDCS: Tropicanas version of DCS. Known to Trop Legacy only as DCS. Contains finished good inventory, and feeds other types of orders (besides STOs) to Legacy Financial systems. Interfaces to WMS systems and financial systems, and M204. DCS is the planning system until R4 tools are live, and is financial book of record for inventory until P1 2009 STOs move materials between locations; Release 3 deployment moves more and more plant-to-plant movements as STOs as more locations become live.
To begin, intra-division movements will be STOs (QG to QG, Trop to Trop) Inside divisions, Finished Goods (FG) and Semi-Finished Goods (SFG) will be STOs Canada and Mexico produced FGs to US locations GGCS SFGs to US locations

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The Shadow STO Concept


STO Shadows often use the following lingo: Shadowing Shadow Order The Order is Shadowed to DCS We received a shadow order in SAP Writeback Sent a writeback/received a writeback The design of the STO Shadows is to keep the planning system and financial book of record in sync with SAP until SAP becomes the financial book of record. The design also allows STOs to be seamlessly shipped and received between locations that are nondeployed and deployed, without dual entry and without user intervention or knowledge in some cases. The generation and routing of the shadow STO is govern by these four main items: Deployment Scenario: determines the system that owns the order SAP Logic & STO Order Types: determines what IDOCs are sent to middleware Middleware (aka, TIBCO, which is the software provider name): receives IDOC, determines the type of message that gets sent; stores cross-reference between the 2 systems FMS Server: holds the files from middleware for DCS to pick up and process Outbound files from SAP to DCS are not processed by DCS immediately there is a batch schedule for SAP to send them to FMS, AND a batch schedule for DCS to pick up & process them. (aka, SAP to DCS Train Schedule is in the works) Incoming files from DCS to SAP are processed immediately however, there is a batch schedule for DCS to send them. Once received by SAP, they are processed immediately. 53

STO Document Types


Code Document Type Type of goods ETM Optimized ? How is it created? Shadows to Q-DCS / T-DCS CASS pays freight?

ZBT ZDIV ZLG ZMI ZMR ZMT ZPR ZPS ZRO ZUB ZRD ZSDW ZMQ ZMS ZMO

STO - Bulk Tanker STO - Diversion STO - Load and Go STO - Manual Intermodal STO - Manual Rail STO - Manual Truck STO - Planned Rail STO - Planned Standard STO - Raw Freight Optimized STO - Raw/Semi STO - Receipt Discrepancies STO - Shadow STO - Shuttle CASS STO - Shuttle Local STO - Manual Ocean**

FG FG FG FG FG FG, SFG FG FG RM, SFG RM, SFG RM, SFG, FG SFG, FG RM, FG, SFG FG SFG

No No No Yes* No Yes* No Yes* Yes* No No No No No No

User-created User-created User-created User-created User-created User-created User-created System-created User-created User-created System-created System-created User-created User-created User-created

Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 No No Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 Yes-ZNE5 No

Yes No Yes Yes Yes Yes Yes Yes Yes Yes No Yes Yes No Yes

FG Finished Goods; SFG Semi-Finsihed Goods; RM Ram Materials *Optimized if the shipping location uses ETM to plan shipments ** 30 day transport (Cork and Cidra to Saddle Creek

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STO Document Type Description


Code ZBT ZDIV Document Type Bulk Tanker Diversion Load and Go Manual Intermodal Description The STO Bulk Tanker is used for liquid shipments when an over-the-road bulk tanker trailer will be used to transport the goods. The materials will shadow to QDCS or TDCS The STO Diversion is used when an in-transit load has been diverted to another facility. See the Diversion Job Aid. The STO Load and Go is created in Quaker or Gatorade production facilities when the WMS Load and Go functionality will be used to load outbound shipments directly from the production line. The materials will shadow to QDCS to keep book of record and planning systems in sync with SAP. The STO Manual Intermodal is used for finished good shipments for Intermodal carriers and lanes. The load will be sent to ETM for optimization, and the materials on the order will shadow to TDCS or QDCS to keep book of record and planning systems in sync with SAP The STO Manual Rail is used for finished good and semi-finished good rail shipments. This order type is created manually by the user, and is not converted from a rail plan document. The materials on the order will shadow to QDCS or TDCS to keep book of record and planning systems in sync with SAP The STO Manual Truck is used for finished good and semi-finished good over-the-road truckload or LTL shipments. The load is sent to ETM for optimization, and the materials on the order will shadow to TDCS or QDCS to keep book of record and planning systems in sync with SAP. The STO Planned Rail is used for finished goods rail shipments. This order type is created exclusively for the Tropicana rail network in the Rail Load Builder Monitor, and is converted from a rail plan document. The materials on the order will shadow to TDCS to keep book of record and planning systems in sync with SAP. The STO Raw Freight Optimized is used for Raw or Semi-Finished Goods orders when the load will be sent to ETM for transportation planning and optimization. The materials will not shadow to QDCS or TDCS. The STO Raw/Semi is used for raw material and Tropicana semi-finished shipments. The load is not optimized by ETM and the materials do not shadow to any book of record or planning systems. This is the most common order type for raw material shipments, and for Tropicana semi-finished good shipments The STO Receipt Discrepancy document is created by the Receipt Confirmation interface when a discrepancy that includes an additional line item is recorded at the receiving facility.

ZLG

ZMI

ZMR

Manual Rail

ZMT

Manual Truck

ZPR

Planned Rail
Raw Freight Optimized

ZRO

ZUB

Raw/Semi
Receipt Discrepanci es

ZRD

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STO Document Type Description


Code
ZSDW

Document Type
Shadow

Description
The STO Shadow is created by the QDCS or TDCS Shadow order interfaces when a nondeployed shipping location creates an STO order in QDCS or TDCS for a deployed receiving location. The STO Shuttle CASS is used for two different scenarios: Finished Goods The STO Shuttle CASS is used for local shuttle shipments. The materials on the order will shadow to TDCS or QDCS to keep book of record and planning systems in sync with SAP. Quaker / Gatorade Semi-Finished Goods The STO Shuttle CASS is used for non-ETMoptimized truck shipments of semi-finished goods. The materials on the order will shadow to TDCS or QDCS to keep book of record and planning systems in sync with SAP. In both cases, the freight bill for the shipment is paid via CASS The STO Shuttle Local is used for local shuttles of finished goods. The materials on the order will shadow to TDCS or QDCS to keep book of record and planning systems in sync with SAP. The freight bill is paid locally by the facility. The STO Manual Ocean is used only by Semi-Finished Goods Planners who are converting STRs to STOs for GGCS Shipments from PCTI Suppliers inbound to Saddlecreek. This document uses the lead time in the GGCS material master record to be used as the route, which allows for sufficient planning and transportation time to get the product to the receiving facility.

ZMQ

Shuttle CASS

ZMS

Shuttle Local

ZMO

Manual Ocean**

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Inventory Management

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Agenda
Inventory Management (IM) and Integration with other SAP Modules SAP IM interfaces (WMS/ADC) Inventory Reconciliation between SAP-WMSDCS systems

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Inventory Management : Overview

Inventory Management comprises of 3 main tasks:


1. Goods Movement: Concept of Movement Type
When you enter a goods movement in the system, you must enter a movement type to differentiate between the various goods movements. A movement type is a three-digit identification key for a goods movement. Transactions resulting in a change in stock: Goods receipt - A goods receipt (GR) is a goods movement with which the receipt of goods from a vendor or from production is posted. A goods receipt leads to an increase in warehouse stock. Goods issue -A goods issue (GI) is a goods movement with which a material withdrawal or material issue, a material consumption, or a shipment of goods to a customer is posted. A goods issue leads to a reduction in warehouse stock. Stock transfer - A stock transfer is the removal of material from one storage location and its transfer to another storage location. Stock transfers can occur either within the same plant or between two plants. Transfer posting - A transfer posting is a general term for stock transfers and changes in stock type or stock category of a material. Examples of transfer postings are: Transfer postings from material to material; Release from quality inspection stock When posting a goods movement in the SAP System, the following documents are created: Material document In the Inventory Management system, when a goods movement is posted, a material document is generated that serves as proof of the movement and as a source of information for any applications that follow. A material document consists of a header and at least one item. The header contains general data about the movement (for example, its date). Each item describes one movement. Accounting document If the movement is relevant for Financial Accounting (that is, if it leads to an update of the G/L accounts), an accounting document is created parallel to the material document.

59

Inventory Management : Overview (Contd)

2. Management of material stocks on a quantity and value basis Managing Stocks by Quantity Gives an overview of the current stock situation of any given material at any time. Managing Stocks By Value The system automatically updates the following data each time there is a goods movement: Quantity and value for Inventory Management Account assignment for cost accounting G/L accounts for financial accounting via automatic account assignment 3. Carrying out the Physical Inventory This component allows you to carry out a physical inventory of your companys warehouse stocks for balance sheet purposes

60

IM integration with other SAP Modules

Inventory Management is part of the Materials Management module and is fully integrated in the entire logistics system

61

Key Data elements of IM

1. PLANT o A physical location within a company, where materials are stored, manufactured, purchased or sold
Settings in IM for plant include whether to turn on shelf life expiration check at the time of goods receipt if the Goods movement has it set. Stock type for which physical inventory should be carried out.

2. MATERIAL TYPE When creating a material master record, you must assign the material to a material type. The material type is a key that assigns the material to a logical group such as semi-finished goods or finished goods.

62

Key Data elements of IM

3.

STORAGE LOCATION
The business entity / function within a Plant that houses either the raw material, semi or finished products. It could be a physical or a logical location
0001

Storage Location

Description

Raw Materials

0002

Staging

4.

BATCH
Materials that require such precise identification, for example pharmaceutical products, are identified and managed in stock not only according to material number, but also according to batch number.

0003

Manufacturing

0004

Warehouse

0005

Whse Inv Hold

0006

Whse Expired

0007

Whse Damaged

0008

Whse QA Hold

63

Key Data elements of IM

5.

UNIT OF MEASURE (UoM)


Finished goods category Base UoM EA Each Alt UoMs Proportion al UoMs Examples

Finished Goods (ZFIN)

CS Case PAL Pallet

Single bottle of Gatorade Case of Gatorade 6 packs One layer on a pallet Capn Crunch Pallet RollStock

Packaging Good (ZPKG)

EA CYL LB (or IN) RL TPS TGL* GAL

Semi-Finished Goods (ZSFG)

Tropicana Juice

* Concept of Brix Value 64

Key Data elements of IM

6.

Inventory Status

Stock Status
Unrestricted use

notes
available for general use blocked from being used in SOs, but available for STOs.

Qual. inspection

Returns

available for use in returns only

Blocked

not available for general use

65

Stock Overview - Key Data Elements

SAP Unrestricted Status and Warehouse Storage Location = DLx SHIP Status

SAP Quality Inspection Status and Warehouse Storage Location = DLx INCB Status

SAP Blocked Status and Whse Expired Storage Location = DLx EXPR Status

SAP Blocked Status and Whse Damaged Storage Location = DLx DMGD Status

SAP Blocked Status and Whse QA Hold Storage Location = DLx QAHD Status

66

Batch Number Data Element

SAP Batch Number (10 Char)

WMS Fields
ITEM_NUM LOT_NUM (12 Char) WH_ID

Quaker/Gatorade Lot Number = MMDDYYPP, where MMDDYY = Mfg Date and PP = Plant Designator Code

Tropicana Lot Number = MMDDYYPPLSHH, where MMDDYY = Exp Date, PP = Plant Designator Code, L = Line, S = Shift, and HH = Hour

Quaker/Tropicana/Gatorade SAP Batch Number = MMDDYYPP, where MMDDYY = Mfg Date or Exp Date and PP = Plant Designator Code

67

SAP / WMS Inventory Management Interfaces

Inventory Management Interfaces

68

Manufacturing Integration Production Receipts

Production Receipts (Cal ID # 33501)


For sites with a WMS, finished goods inventory will be transferred from manufacturing to the warehouse via production receipt interfaces Finished goods inventory in SAP will be managed at the plant, item, lot, and inventory status level. The production receiving process will create the lot (SAP batch) and post the inventory to the SAP batch and inventory status. Each pallet of finished goods that is received in WMS will be transferred to the SAP warehouse inventory. At the end of the shift, the manufacturing production confirmation process will transfer the legal entity/product cost to the warehouse. Reconciliation will be done at the end of each shift instead of each day. An SAP shift reconciliation report will compare the production confirmation quantities to the WMS received quantities. Inventory differences will be reconciled by both departments. The production receipt reversal interface will transfer inventory back to manufacturing for rework if needed. For sites without a WMS, finished goods inventory will be manually transferred from manufacturing to the warehouse within SAP The transfer will be done prior to the production confirmation (once per shift or once per day). No reconciliation report will be required since all inventory activity will be executed in SAP.
69

Manufacturing Integration Lot number

Lot number
Since SAP will manage inventory at the lot level, the WMS lot number will be used to create the SAP batch number For Quaker/Gatorade sites, the lot number format in WMS will be the same as the batch number format in SAP. For Tropicana sites, the lot number format is larger than the SAP batch number field, so only the first 8 characters of the lot number will be used to create the SAP batch number. The manufacturing date and expiration date values will also be stored on the SAP batch number.

70

Incubation Management

The incubation management process will leverage SAP functionality to provide better inventory visibility and streamline incubation releases
Incubation settings for an item will be stored on the SAP material master. When these items are received from manufacturing, an SAP inspection lot will be created and the inventory will be stored in quality inspection status. The inspection lot will provide visibility to the expected incubation release date to the planning systems. For Quaker/Gatorade WMS sites, a new interface will send an inventory status change to WMS to release the lot from incubation or block the inventory if incubation checks fail. This will replace the manual incubation status change in WMS. For Tropicana WMS sites, existing DLx quality management applications manage the incubation release and will send the inventory status change to SAP.

71

Physical Inventory Counting

For sites with a WMS (DLx/EDI), the inventory counting process will continue to be executed in WMS
ABC count indicators will be updated in SAP once per quarter and downloaded to DLx via the item master interface. Values can be overridden in SAP or DLx as needed. Once inventory counting has been conducted and reconciled, results will be sent to SAP and inventory adjusted as required.

For sites without a WMS, the inventory counting process will be executed in SAP
The SAP inventory counting process will be similar to the WMS process. Cycle counts will be scheduled based on the ABC count indicators. Count sheets will be generated by SAP. Count result entry screens and inventory difference evaluations will be available in SAP. Inventory counting will be managed at the plant, item, lot, and inventory status level.

72

Cycle Count based on ABC Indicators

Process
Physical Inventory Documents for materials with ABC Indicators will be created for Tropicana by an automatic weekly batch process based on the count frequency determined. Any desired changes to the cycle processes will need to be managed through the Data Maintenance Organization (DMO).
Users will not need to create Physical Inventory Documents as the document will be created by the weekly automated batch process. Users will simply need to identify which Physical Inventory Documents were created via the batch process and print the Physical Inventory Documents.

73

Physical inventory Process Flow Overview


Create Physical Inventory Document Print Physical Inventory Document Count & Record Inventor y

Enter Inventory Count

Post Inventory Differences

Show results of post transaction

Initiate Recount, if Needed

Inventory Planner creates and prints count sheets from SAP Inventory is physically counted and recorded

Material counts are entered in SAP


Material variances are verified and posted in SAP
LEGEND - SAP transaction - Non SAP System - Manual Process

74

SAP / WMS Inventory Management

SAP / WMS Inventory Management


SAP Item Type

SAP Unrestricted

SAP Quality Inspection

SAP Blocked

SAP Return

ZING ZPKG
SHIP ALTC RFID

ZSFG ZFIN

1SHP

1SHP

SHIP

RHLD

WEXP

SHIP

SHIP

1INS
WMS Inventory Status

1INS

INCB

1DMG 1EXP 1HLD ZQAH

1DMG 1EXP 1HLD

BLOK CASH DEST FDHD FDBK INSP

EXPR SECM

DMGD SECD

QAHD

CRTN

WMS Host Location

BULK
Bulk Material Storage

BSTG
Bulk Material Staging

PROD
Production

WHSE
Warehouse

WHSE
Warehouse

WHSE
Warehouse

WHSE
Warehouse

WHSE
Warehouse

DWIP
Display WIP

DASM
Display Disassemble

SAP Storage Location

0001
Raw Materials

0002
Staging

0003
Manufacturing

0004
Warehouse

0005
Whse Inv Hold

0006
Whse Expired

0007
Whse Damaged

0008
Whse QA Hold

0009
Whse DWIP

0009
Whse DWIP

Location Type

Warehouse Storage

Production Line

Warehouse Storage

Display Line

75

Future Balancing Process

Changes in DLX/DCS Balancing & SAP addition Snapshot ICS ensures all Inventory Variances documented on both Snapshot(s) daily are resolved in the course of balancing each day. Batch level on SAP Snapshot vs. UPC Level DCS Inventory Status Changes/Storage Locations overview Reports used include: WMS/DCS Snapshot Discrepancy Report WMS/SAP Snapshot Exception Report Measles Exception Reports 247 Inventory Transfer Register (201/300/301) (DCS) Shipment Notification Report (DCS) 243 Inventory Adjustment Register (101/400/401/502/503) 235 Inventory Receipts Control Register (100) Exception Reasons handling Any exceptions found in balancing shipments/mills/receiving/production/inventory transactions as outline in previous slides and new SAP nuances as discussed. 99/98 location clearing daily Research and resolution through variety of means not captured in previous steps

76

Manufacturing Process
Production Master Data
Material Master BOM Work Center Routing Production Version

Production Execution
Production Process Production Confirmation - GR, GI and time Batch Management Incubation Interfaces

Post Production
Period End closing - Variances, WIP, OH and settlement Reconciliation - mfg and WMS Reporting

Demand Planning - Planned orders

77

Material Master Data


The Material Master contains information on materials that a company manufactures, procures, stores and sells. The information is stored in a database that is a central source of data on materials. ECC is the repository for all the master data including customers, vendors, purchasing, etc. There are 29 views available in the material master and 5 of these are custom views, specific to PepsiCo. Manufacturing is affected by the most views in the material master, some of them being - Basic 1&2, MRP 1-4, PepsiCo 1&2, Work Scheduling, Plant Stock, Plant data 1&2, Accounting 1&2, Costing 1&2.

78

Bill Of Materials(BOM)
A bill of material is a complete list of components that make up a product or assembly. The list contains material #, description, quantity and unit of measure for each component. BOMs can exist at the Plant or client level

64oz Bottle Tropicana Pure Premium Orange Juice (BR1004850000102)

BR11133 Corrugate

BR81464 Chep Pallet

BR98323 Single Strength Orange Juice

BR16618 Fitment(Cap)

BR17967C Carton

79

Bill Of Materials(BOM)

80

WORK CENTER
Location (Production Line) at which a particular operation is executed
Work Centers
Work center 1 WC 4 WC 2 WC 3 Work center 6 WC 5

Bridgeview Near East Plant Floor WC = Work center

Work centers are business objects that can represent the following, for example: Machines, machine groups Assembly work centers Employees, groups of employees The work center is also where we capture labor, efficiency and machine time.

81

Rate Routing
A set of operations that must be performed in sequence to manufacture a product a production cycle.
Material Routing group Operation 20 Operation 10 Work center Texts Activities

The planned time for each operation is stored in the routing as standard values. A rate routing is used in repetitive manufacturing to describe the following: 1. Where a product is produced (Work Center(s)) 2. The time required to produce it (production rate)

82

Production Version

A Production Version tells you on what shift and what work center you can produce each BOM version of a material. It defines, shift, line, and where to assign costs. A material can be assigned multiple production versions
Production Versions
Shift 1 Shift 2 Shift 3 Line 1 Line 1 Line 3

A Production Version in SAP links the: Material Bill of Material (BOM) and BOM Version Rate Routing Production Line for Repetitive Manufacturing

83

Production Version
The production version allows you to look at production for a particular material by shift. Production Versions are numbered in the following manner:

2114

2 1 14
Shift #

BOM Version

Work Center
(Production Line)

Note: Since each material exists on a routing group, and each routing group is associated with a work center, if you know the material and the work center, SAP will know what routing group it is a part of

84

Manufacturing Process
Production Master Data
Material Master BOM Work Center Routing Production Version

Production Execution
Production Process Production Confirmation - GR, GI and time Batch Management Incubation Interfaces

Post Production
Period End closing - Variances, WIP, OH and settlement Reconciliation - mfg and WMS Reporting

Demand Planning - Planned orders

85

Process Flow
Create Planned Production Orders Process Step Legacy Interface New Interface Interface Controls Shift Batch Data (ADC) Shift Batch Data (YMS) Determine Requirements Source (Raw/Pack/SFG)/Produce SFG Record Production of FG Report

ADC/YMS

Source Raw/Pack Materials


(Direct P2R, DIR STO)

MARS confirmation data 33520 Optional Stage Components in proper Storage Location

31853 Source SF Materials


Manual QTG (optional)

Planned Production Orders Created

(STO SFG)

Make FG

SAP

Run Tactical MRP Make SFG

Confirm FG SLOC 003 (End of shift) (Mvmt 131, 261)

Confirm SFG

SAP Inventory Balances

Clear Production Backflush error log (End of Shift)

Production Receipt (Batch info as required) SLOC 003 is Negative SLOC 004 is Positive

Interface to downstream systems

36245 90330
Excel (creates HF daily schedule)

Optional Stage Components

Clear Production Backflush error log (End of Shift)

MARS confirmation data

Production Receipt (Batch info as required) SLOC 003 is Negative SLOC 004 is Positive

23800 33501 37741 34610 Change Inventory Location


(Raw/Pack/SFG. Sites: Oakland, Bridgeview)

39927

23800 36245

WMS

90323 (Trop) 38169 ????? (Trop)

Change Inventory Location (Raw/Pack. Sites: Oakland, Bridgeview)

33501
Production Receipt SFG (Bridgeview, Danville, Cedar)

Production Receipt
(LPN applied)

36178

110048 Generate Production Schedule


(MIMI, AMAPS)

Legacy

Generate Production Schedule


(Quaker Prenote)

Manual QG

SFG Production and Material Usage Recorded (DCS)

Manual SFG Usage QG

Production Receipt (DCS)

QA Reporting
(Holdit)

Volume Information
(Consumer Complaints)

Production FG,
(SCR/SCDB)

Legacy (Site specific)

Production Schedule
(YODA, Cedar, Danville)

Prod Schedule
(SCR/SCDB)

Production Volume
(Test Weights, Cedar Only)

86

Production Confirmation is the transaction in MARS or SAP that consumes raw materials and/or semi-finished goods and associated activities to generate SFGs or FGs. - GR of SFGs and FGs to Stock (Movt Type 131) - GI of Raw materials ( Movt Type 261) - Time ( Labor/ Machine) Across the plant all SFG confirmations must be performed prior to all FG confirmations since packaging will consume the semi-finished liquid produced in the processing confirmation. Not following this sequence might lead to backflush errors.

Production Confirmation

87

Back flush
Back flush example for SFG:

88

Production Data Collection Systems


Production confirmation data will be captured and entered using different methods. Some confirmation data will be captured using legacy systems (both automatically and manually) and interfaced to SAP. Other data will require manual input into SAP. This will vary by site and by operation within a site. We have various ways to complete production confirmation: 1. MARS interfaces to SAP (Q & G) 2. ADC interfaces to SAP (Tropicana only) 3. YMS interfaces to SAP (Cedar Rapids only) 5. SAP user directly enters into SAP (Tropicana)
Accurate data entry into all systems is key!

89

Production Confirmation

90

Material Document

91

Production Execution External Integrations


MARS Material Master 62454 Production Data 62455

SAP ECC 6.0

Material Master Production Data 36178 Test Weights

Production Data 33520 YMS

Material Master Production Data 34610

Consumer Affairs

Juice Shipments 33173

ADC

Production Data 31853


Tank Balances 33243

Inventory Inventory Management Management Production Production Master Master Data Data Shop Shop Floor Floor Activities Activities

Fiinished Good Production 37741

HoldIT

Planned Orders MMMI/AMAPS

Production Schedule 38169 YODA

Display Planning Pre- Note

Planned Orders 90330

Co- Packer PO / STO / Receipt 62453 Co- Packer Production 62450 SAP Portal

Canada ASN 90328 Electronic Comerce Gateway


Connectors Legacy Interface End-State QTG2 Interface Retouch (Original Deployment) Temporary QTG1 Interface Temporary QTG2 Interface SAP Retouch (New Deployment) Reporting Manual Systems Legacy External ISCP

92

Manufacturing Process
Production Master Data
Material Master BOM Work Center Routing Production Version

Production Execution
Production Process Production Confirmation - GR, GI and time Batch Management Incubation Interfaces

Post Production
Period End closing - Variances, WIP, OH and settlement Reconciliation - mfg and WMS Reporting

Demand Planning - Planned orders

93

Period End Close

94

Warehouse and Manufacturing Handshake


Warehouse tabulates FG output
Both Individuals Compare results and agree on output

Manufacturing tabulates FG outputs

If error in Warehouse receipts, adjust WMS

Both Individuals sign the PepsiCo Audit Form

Manufacturing confirms FG batch in SAP or MARS

Production outputs are reconciled with warehouse and the total number is agreed upon MFG team inputs production, raw material usage actuals, and labor hours.

95

Stock Overview

96

Material Documents

97

Target/Actual/Variances - KKRC / KKBC_HOE

98

MFG Reports ECC & BW


Caliber ID
33315 62315 65355 77737 30541 30545 37021 30542 42733 37118 65353

Description
Compare Inventory Balances - Red Prairie and SAP Material Stock Report Inventory by Batch Characteristic Report PTD Cost Center Performance Shift Performance Summary Material Variance Report Material Efficiency Report Production Attainment and Adherence Report Labor Variance Report Labor Efficiency Report Tolling Variance Report

Source
ECC ECC ECC ECC ECC BW BW BW BW BW BW

37105 37330
39932 37025

Overtime Hours Report Production Performance Report


Enterprise Performance Report Composite Ranking Report

BW BW*
BW* BW*

99

STO Deployed to Deployed FG


Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG
Create STO Process Step Legacy Interface Trans Opt. Interface Frequency RT = real time FB = frequent batch NB = nightly batch PB = periodic batch M = manual Create Delivery and Ship Docs
TCode On TCode Off TBL On TBL Off EPRO On EPRO Off Acct On Acct Off IF On IF Off POCs On POCs Off

EDI ADMIN Ship Product

EAM P2P Create Inbound Shipments

Draft

1UP Reviewed

BIL Reviewed

Final

Receive Product

CASS

New Interface

Rate Shipment

62352 ZSHPT_ASN Transportation Optimization & Load Building

62353 Z210CASS

NB

ETM

23840 ZETM_SHIPMENT

Receive Shipment Confirmation 25619 SHPMNT

Dr. INV FG (1020000) Cr. INV FG (1020000) Cr. Price Diff (COPA)(6700074)

RT

VL01N/ VT01N

ME21N
Manual QTG *Including IRP FG STO Processor

RT

RT

37629 ZORDTIB

ZV02

Shipment Processor / Delivery Processor Delivery Processor / Shipment Processor

VL02N
Delivery Processor Freight Payment Analyst Delivery Processor / Shipment Processor

VL32N /MIGO
FG Inventory Execution Processor

Delivery Processor / Shipment Processor

RT

Manual Trop Rail

(Outbound Monitor)

ZR 238 EC 36 PT (94 C 4) O N F

Create STR using Rail Load Builder

STO CREATED (Rail STO created from Rail Load Builder)

SAP

ETM Optimized?

No

Create Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Post Goods Issue (641) (BSEG)

Create Freight Accrual/Payments (BSEG)

Auto Create Inbound Delivery and Shipment (VTTS/LIPS)

Update Inbound Delivery (VTTS/LIPS)

Post Goods Receipt (BSEG)

FB

FB

FB

Xref

FB

QDCS/TDCS

23 ZD 438( LV 85 _A 6) SN

RT

56149 56727 Trop (QG) 56147 53533 PORDCR (QG) (Trop) ORDERS ORDERS

23288 0) ZPICKSTAT_TIB_QTG2 94 9( DEL 23539 3 5 V ZSHPDEL 23 DL Z 53551 ECG ZAPPCAR_TIB_QTG2 3rd Party Warehouse 25912 ZVESLCHK_TIB_QTG2

FB

Order Shipped in DCS/TDCS

ECG
3
rd

56765 (QG)
Shipped from non WMS site ZDLV_ASN

RT

3rd Party Warehouse

Party Warehouse

Order Recieved in DCS/TDCS 23836 Trop ZRECPTCONF

RT

RT

STO CREATED
Order & Master Shipment created in WMS (SHP)

RT

Vessel Check in (SHP)

48560 ZDMPLUS_DLX_SHIPMENT_CONF

WMS

RT

Appointment Time Update (SHP)

Order in Picking status - Pick List generated (SHP)

Shipment Confirmation (SHP) QG QG FACS Shipment Receipt

Vessel Checkout (SHP)

Create Receipt Authorization (RECV) Trop

Vessel Check-in

QG

Receive Goods Confirmation (RECV)

-2 Legacy

FB

Genesis Inventory Accounting

Phoenix

Genesis Inventory Accounting

100

FB NB

Trop

25912 ZVESLCHK_TIB_QTG2

ECG
CHEP 3rd Party Warehouse

25912 ZVESLCHK_TIB_QTG2

RT

90999 (QG) ZSHPT_ASN

ZE DI 485 94 60 5_ (9 CO SHIP 45) N F ME NT _

Dr. Freight (COPA)(6701100) Cr. GR/IR Freight (2010001)

ECG

91001 (QG) ZRECPTCONF

RT

Outbound Monitor

101

STO Deployed to Deployed FG


Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG
Create STO Process Step Legacy Interface Trans Opt. Interface Frequency RT = real time FB = frequent batch NB = nightly batch PB = periodic batch M = manual Create Delivery and Ship Docs
TCode On TCode Off TBL On TBL Off EPRO On EPRO Off Acct On Acct Off IF On IF Off POCs On POCs Off

EDI ADMIN Ship Product

EAM P2P Create Inbound Shipments

Draft

1UP Reviewed

BIL Reviewed

Final

Receive Product

CASS

New Interface

Rate Shipment

62352 ZSHPT_ASN Transportation Optimization & Load Building

62353 Z210CASS

NB

ETM

23840 ZETM_SHIPMENT

Receive Shipment Confirmation 25619 SHPMNT

Dr. INV FG (1020000) Cr. INV FG (1020000) Cr. Price Diff (COPA)(6700074)

RT

VL01N/ VT01N

ME21N
Manual QTG *Including IRP FG STO Processor

RT

RT

37629 ZORDTIB

ZV02

Shipment Processor / Delivery Processor Delivery Processor / Shipment Processor

VL02N
Delivery Processor Freight Payment Analyst Delivery Processor / Shipment Processor

VL32N /MIGO
FG Inventory Execution Processor

Delivery Processor / Shipment Processor

RT

Manual Trop Rail

(Outbound Monitor)

ZR 238 EC 36 PT (94 C 4) O N F

Create STR using Rail Load Builder

STO CREATED (Rail STO created from Rail Load Builder)

SAP

ETM Optimized?

No

Create Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Post Goods Issue (641) (BSEG)

Create Freight Accrual/Payments (BSEG)

Auto Create Inbound Delivery and Shipment (VTTS/LIPS)

Update Inbound Delivery (VTTS/LIPS)

Post Goods Receipt (BSEG)

FB

FB

FB

Xref

FB

QDCS/TDCS

23 ZD 438( LV 85 _A 6) SN

RT

56149 56727 Trop (QG) 56147 53533 PORDCR (QG) (Trop) ORDERS ORDERS

23288 0) ZPICKSTAT_TIB_QTG2 94 9( DEL 23539 3 5 V ZSHPDEL 23 DL Z 53551 ECG ZAPPCAR_TIB_QTG2 3rd Party Warehouse 25912 ZVESLCHK_TIB_QTG2

FB

Order Shipped in DCS/TDCS

ECG
3
rd

56765 (QG)
Shipped from non WMS site ZDLV_ASN

RT

3rd Party Warehouse

Party Warehouse

Order Recieved in DCS/TDCS 23836 Trop ZRECPTCONF

RT

RT

STO CREATED
Order & Master Shipment created in WMS (SHP)

RT

Vessel Check in (SHP)

48560 ZDMPLUS_DLX_SHIPMENT_CONF

WMS

RT

Appointment Time Update (SHP)

Order in Picking status - Pick List generated (SHP)

Shipment Confirmation (SHP) QG QG FACS Shipment Receipt

Vessel Checkout (SHP)

Create Receipt Authorization (RECV) Trop

Vessel Check-in

QG

Receive Goods Confirmation (RECV)

-2 Legacy

FB

Genesis Inventory Accounting

Phoenix

Genesis Inventory Accounting

102

FB NB

Trop

25912 ZVESLCHK_TIB_QTG2

ECG
CHEP 3rd Party Warehouse

25912 ZVESLCHK_TIB_QTG2

RT

90999 (QG) ZSHPT_ASN

ZE DI 485 94 60 5_ (9 CO SHIP 45) N F ME NT _

Dr. Freight (COPA)(6701100) Cr. GR/IR Freight (2010001)

ECG

91001 (QG) ZRECPTCONF

RT

Delivery

23288 - Updated Delivery Block Status

103

STO Deployed to Deployed FG


Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG
Create STO Process Step Legacy Interface Trans Opt. Interface Frequency RT = real time FB = frequent batch NB = nightly batch PB = periodic batch M = manual Create Delivery and Ship Docs
TCode On TCode Off TBL On TBL Off EPRO On EPRO Off Acct On Acct Off IF On IF Off POCs On POCs Off

EDI ADMIN Ship Product

EAM P2P Create Inbound Shipments

Draft

1UP Reviewed

BIL Reviewed

Final

Receive Product

CASS

New Interface

Rate Shipment

62352 ZSHPT_ASN Transportation Optimization & Load Building

62353 Z210CASS

NB

ETM

23840 ZETM_SHIPMENT

Receive Shipment Confirmation 25619 SHPMNT

Dr. INV FG (1020000) Cr. INV FG (1020000) Cr. Price Diff (COPA)(6700074)

RT

VL01N/ VT01N

ME21N
Manual QTG *Including IRP FG STO Processor

RT

RT

37629 ZORDTIB

ZV02

Shipment Processor / Delivery Processor Delivery Processor / Shipment Processor

VL02N
Delivery Processor Freight Payment Analyst Delivery Processor / Shipment Processor

VL32N /MIGO
FG Inventory Execution Processor

Delivery Processor / Shipment Processor

RT

Manual Trop Rail

(Outbound Monitor)

ZR 238 EC 36 PT (94 C 4) O N F

Create STR using Rail Load Builder

STO CREATED (Rail STO created from Rail Load Builder)

SAP

ETM Optimized?

No

Create Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Post Goods Issue (641) (BSEG)

Create Freight Accrual/Payments (BSEG)

Auto Create Inbound Delivery and Shipment (VTTS/LIPS)

Update Inbound Delivery (VTTS/LIPS)

Post Goods Receipt (BSEG)

FB

FB

FB

Xref

FB

QDCS/TDCS

23 ZD 438( LV 85 _A 6) SN

RT

56149 56727 Trop (QG) 56147 53533 PORDCR (QG) (Trop) ORDERS ORDERS

23288 0) ZPICKSTAT_TIB_QTG2 94 9( DEL 23539 3 5 V ZSHPDEL 23 DL Z 53551 ECG ZAPPCAR_TIB_QTG2 3rd Party Warehouse 25912 ZVESLCHK_TIB_QTG2

FB

Order Shipped in DCS/TDCS

ECG
3
rd

56765 (QG)
Shipped from non WMS site ZDLV_ASN

RT

3rd Party Warehouse

Party Warehouse

Order Recieved in DCS/TDCS 23836 Trop ZRECPTCONF

RT

RT

STO CREATED
Order & Master Shipment created in WMS (SHP)

RT

Vessel Check in (SHP)

48560 ZDMPLUS_DLX_SHIPMENT_CONF

WMS

RT

Appointment Time Update (SHP)

Order in Picking status - Pick List generated (SHP)

Shipment Confirmation (SHP) QG QG FACS Shipment Receipt

Vessel Checkout (SHP)

Create Receipt Authorization (RECV) Trop

Vessel Check-in

QG

Receive Goods Confirmation (RECV)

-2 Legacy

FB

Genesis Inventory Accounting

Phoenix

Genesis Inventory Accounting

104

FB NB

Trop

25912 ZVESLCHK_TIB_QTG2

ECG
CHEP 3rd Party Warehouse

25912 ZVESLCHK_TIB_QTG2

RT

90999 (QG) ZSHPT_ASN

ZE DI 485 94 60 5_ (9 CO SHIP 45) N F ME NT _

Dr. Freight (COPA)(6701100) Cr. GR/IR Freight (2010001)

ECG

91001 (QG) ZRECPTCONF

RT

Shipment

WMS Vessel Check In at Shipper Picking Status from Shipper Shipment Confirmation WMS Vessel Check Out at Shipper

105

STO Deployed to Deployed FG


Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG
Create STO Process Step Legacy Interface Trans Opt. Interface Frequency RT = real time FB = frequent batch NB = nightly batch PB = periodic batch M = manual Create Delivery and Ship Docs
TCode On TCode Off TBL On TBL Off EPRO On EPRO Off Acct On Acct Off IF On IF Off POCs On POCs Off

EDI ADMIN Ship Product

EAM P2P Create Inbound Shipments

Draft

1UP Reviewed

BIL Reviewed

Final

Receive Product

CASS

New Interface

Rate Shipment

62352 ZSHPT_ASN Transportation Optimization & Load Building

62353 Z210CASS

NB

ETM

23840 ZETM_SHIPMENT

Receive Shipment Confirmation 25619 SHPMNT

Dr. INV FG (1020000) Cr. INV FG (1020000) Cr. Price Diff (COPA)(6700074)

RT

VL01N/ VT01N

ME21N
Manual QTG *Including IRP FG STO Processor

RT

RT

37629 ZORDTIB

ZV02

Shipment Processor / Delivery Processor Delivery Processor / Shipment Processor

VL02N
Delivery Processor Freight Payment Analyst Delivery Processor / Shipment Processor

VL32N /MIGO
FG Inventory Execution Processor

Delivery Processor / Shipment Processor

RT

Manual Trop Rail

(Outbound Monitor)

ZR 238 EC 36 PT (94 C 4) O N F

Create STR using Rail Load Builder

STO CREATED (Rail STO created from Rail Load Builder)

SAP

ETM Optimized?

No

Create Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Post Goods Issue (641) (BSEG)

Create Freight Accrual/Payments (BSEG)

Auto Create Inbound Delivery and Shipment (VTTS/LIPS)

Update Inbound Delivery (VTTS/LIPS)

Post Goods Receipt (BSEG)

FB

FB

FB

Xref

FB

QDCS/TDCS

23 ZD 438( LV 85 _A 6) SN

RT

56149 56727 Trop (QG) 56147 53533 PORDCR (QG) (Trop) ORDERS ORDERS

23288 0) ZPICKSTAT_TIB_QTG2 94 9( DEL 23539 3 5 V ZSHPDEL 23 DL Z 53551 ECG ZAPPCAR_TIB_QTG2 3rd Party Warehouse 25912 ZVESLCHK_TIB_QTG2

FB

Order Shipped in DCS/TDCS

ECG
3
rd

56765 (QG)
Shipped from non WMS site ZDLV_ASN

RT

3rd Party Warehouse

Party Warehouse

Order Recieved in DCS/TDCS 23836 Trop ZRECPTCONF

RT

RT

STO CREATED
Order & Master Shipment created in WMS (SHP)

RT

Vessel Check in (SHP)

48560 ZDMPLUS_DLX_SHIPMENT_CONF

WMS

RT

Appointment Time Update (SHP)

Order in Picking status - Pick List generated (SHP)

Shipment Confirmation (SHP) QG QG FACS Shipment Receipt

Vessel Checkout (SHP)

Create Receipt Authorization (RECV) Trop

Vessel Check-in

QG

Receive Goods Confirmation (RECV)

-2 Legacy

FB

Genesis Inventory Accounting

Phoenix

Genesis Inventory Accounting

106

FB NB

Trop

25912 ZVESLCHK_TIB_QTG2

ECG
CHEP 3rd Party Warehouse

25912 ZVESLCHK_TIB_QTG2

RT

90999 (QG) ZSHPT_ASN

ZE DI 485 94 60 5_ (9 CO SHIP 45) N F ME NT _

Dr. Freight (COPA)(6701100) Cr. GR/IR Freight (2010001)

ECG

91001 (QG) ZRECPTCONF

RT

Effects of Vessel Checkout


Vessel Check Out sets Shipment Start status
ASN Generated:
Send EDI 856 to Customer Ship Confirmation to ETM EDI204 to Cass for Rating Shipped status to QDCS Inventory Posting Cost Of Goods Sold Billing Index Populated Create Inbound Shipment and Delivery

PGI of Delivery:

107

Freight Payment & Freight Accounting


1 Optimized Loads Manual Build Supplier ASNs

CARRIER
Shipment
Inbound or Outbound

Outbound Ship Confirm Inbound Receipt

S
RATE

Allocate to Products
Acct 1
$100

Acct 2
$100

Post to G/L

Shipment Cost Doc

Accrue Freight Costs


Linehaul Fuel & Stop Offs Unload Labor Detention

Feed CO-PA
Profitability Analysis CosttoServe

Reverse Accrual & Book Actuals

MATCH

INVOICE Or EDI 210

Fund Cass from the appropriate Legal Entities

ACH FUNDS

PAY

CARRIERS

APPLY CASH 108

Shipment Cost Document

109

Shipment Cost Document

110

Shipment Cost Document

111

Shipment Cost Document

112

STO Deployed to Deployed FG


Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG
Create STO Process Step Legacy Interface Trans Opt. Interface Frequency RT = real time FB = frequent batch NB = nightly batch PB = periodic batch M = manual Create Delivery and Ship Docs
TCode On TCode Off TBL On TBL Off EPRO On EPRO Off Acct On Acct Off IF On IF Off POCs On POCs Off

EDI ADMIN Ship Product

EAM P2P Create Inbound Shipments

Draft

1UP Reviewed

BIL Reviewed

Final

Receive Product

CASS

New Interface

Rate Shipment

62352 ZSHPT_ASN Transportation Optimization & Load Building

62353 Z210CASS

NB

ETM

23840 ZETM_SHIPMENT

Receive Shipment Confirmation 25619 SHPMNT

Dr. INV FG (1020000) Cr. INV FG (1020000) Cr. Price Diff (COPA)(6700074)

RT

VL01N/ VT01N

ME21N
Manual QTG *Including IRP FG STO Processor

RT

RT

37629 ZORDTIB

ZV02

Shipment Processor / Delivery Processor Delivery Processor / Shipment Processor

VL02N
Delivery Processor Freight Payment Analyst Delivery Processor / Shipment Processor

VL32N /MIGO
FG Inventory Execution Processor

Delivery Processor / Shipment Processor

RT

Manual Trop Rail

(Outbound Monitor)

ZR 238 EC 36 PT (94 C 4) O N F

Create STR using Rail Load Builder

STO CREATED (Rail STO created from Rail Load Builder)

SAP

ETM Optimized?

No

Create Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Post Goods Issue (641) (BSEG)

Create Freight Accrual/Payments (BSEG)

Auto Create Inbound Delivery and Shipment (VTTS/LIPS)

Update Inbound Delivery (VTTS/LIPS)

Post Goods Receipt (BSEG)

FB

FB

FB

Xref

FB

QDCS/TDCS

23 ZD 438( LV 85 _A 6) SN

RT

56149 56727 Trop (QG) 56147 53533 PORDCR (QG) (Trop) ORDERS ORDERS

23288 0) ZPICKSTAT_TIB_QTG2 94 9( DEL 23539 3 5 V ZSHPDEL 23 DL Z 53551 ECG ZAPPCAR_TIB_QTG2 3rd Party Warehouse 25912 ZVESLCHK_TIB_QTG2

FB

Order Shipped in DCS/TDCS

ECG
3
rd

56765 (QG)
Shipped from non WMS site ZDLV_ASN

RT

3rd Party Warehouse

Party Warehouse

Order Recieved in DCS/TDCS 23836 Trop ZRECPTCONF

RT

RT

STO CREATED
Order & Master Shipment created in WMS (SHP)

RT

Vessel Check in (SHP)

48560 ZDMPLUS_DLX_SHIPMENT_CONF

WMS

RT

Appointment Time Update (SHP)

Order in Picking status - Pick List generated (SHP)

Shipment Confirmation (SHP) QG QG FACS Shipment Receipt

Vessel Checkout (SHP)

Create Receipt Authorization (RECV) Trop

Vessel Check-in

QG

Receive Goods Confirmation (RECV)

-2 Legacy

FB

Genesis Inventory Accounting

Phoenix

Genesis Inventory Accounting

113

FB NB

Trop

25912 ZVESLCHK_TIB_QTG2

ECG
CHEP 3rd Party Warehouse

25912 ZVESLCHK_TIB_QTG2

RT

90999 (QG) ZSHPT_ASN

ZE DI 485 94 60 5_ (9 CO SHIP 45) N F ME NT _

Dr. Freight (COPA)(6701100) Cr. GR/IR Freight (2010001)

ECG

91001 (QG) ZRECPTCONF

RT

Inbound Monitor

114

Inbound Delivery

115

Inbound Shipment

116

STO Deployed to Deployed FG


Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG
Create STO Process Step Legacy Interface Trans Opt. Interface Frequency RT = real time FB = frequent batch NB = nightly batch PB = periodic batch M = manual Create Delivery and Ship Docs
TCode On TCode Off TBL On TBL Off EPRO On EPRO Off Acct On Acct Off IF On IF Off POCs On POCs Off

EDI ADMIN Ship Product

EAM P2P Create Inbound Shipments

Draft

1UP Reviewed

BIL Reviewed

Final

Receive Product

CASS

New Interface

Rate Shipment

62352 ZSHPT_ASN Transportation Optimization & Load Building

62353 Z210CASS

NB

ETM

23840 ZETM_SHIPMENT

Receive Shipment Confirmation 25619 SHPMNT

Dr. INV FG (1020000) Cr. INV FG (1020000) Cr. Price Diff (COPA)(6700074)

RT

VL01N/ VT01N

ME21N
Manual QTG *Including IRP FG STO Processor

RT

RT

37629 ZORDTIB

ZV02

Shipment Processor / Delivery Processor Delivery Processor / Shipment Processor

VL02N
Delivery Processor Freight Payment Analyst Delivery Processor / Shipment Processor

VL32N /MIGO
FG Inventory Execution Processor

Delivery Processor / Shipment Processor

RT

Manual Trop Rail

(Outbound Monitor)

ZR 238 EC 36 PT (94 CO 4) NF

Create STR using Rail Load Builder

STO CREATED (Rail STO created from Rail Load Builder)

SAP

ETM Optimized?

No

Create Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Update Delivery and Shipment (VTTS/LIPS)

Post Goods Issue (641) (BSEG)

Create Freight Accrual/Payments (BSEG)

Auto Create Inbound Delivery and Shipment (VTTS/LIPS)

Update Inbound Delivery (VTTS/LIPS)

Post Goods Receipt (BSEG)

FB

FB

FB

Xref

FB

QDCS/TDCS

23 ZD 438( LV 85 _A 6) SN

RT

56149 56727 Trop (QG) 56147 53533 PORDCR (QG) (Trop) ORDERS ORDERS

23288 0) ZPICKSTAT_TIB_QTG2 94 9( DEL 23539 3 5 V ZSHPDEL 23 DL Z 53551 ECG ZAPPCAR_TIB_QTG2 3rd Party Warehouse 25912 ZVESLCHK_TIB_QTG2

FB

Order Shipped in DCS/TDCS

_
ECG

56765 (QG)
Shipped from non WMS site ZDLV_ASN

RT

3rd Party Warehouse

3 Party Warehouse

rd

Order Recieved in DCS/TDCS 23836 Trop ZRECPTCONF

RT

RT

STO CREATED
Order & Master Shipment created in WMS (SHP)

RT

Vessel Check in (SHP)

48560 ZDMPLUS_DLX_SHIPMENT_CONF

WMS

RT

Appointment Time Update (SHP)

Order in Picking status - Pick List generated (SHP)

Shipment Confirmation (SHP) QG QG FACS Shipment Receipt

Vessel Checkout (SHP)

Create Receipt Authorization (RECV) Trop

Vessel Check-in

QG

Receive Goods Confirmation (RECV)

-2 Legacy

FB

Genesis Inventory Accounting

Phoenix

Genesis Inventory Accounting

FB NB

Trop

25912 ZVESLCHK_TIB_QTG2

ECG
CHEP 3rd Party Warehouse

25912 ZVESLCHK_TIB_QTG2

RT

90999 (QG) ZSHPT_ASN

ZE DI 485 94 60 5_ ( 9 S CO HIP 45) N F ME NT

Dr. Freight (COPA)(6701100) Cr. GR/IR Freight (2010001)

ECG

91001 (QG) ZRECPTCONF

RT

117

Q&A

118