Skip to Content

Frozen to Chilled Material Movement

                                   Foozen to Chilled Material Movement

Business Situation :

Batch Management has been activated at the material level. This means that when material is transferred from one plant to another, the batch, and its particulars like Shelf Life Expiration Date remains the same. The requirement arises as a result of semi finished material being stored in frozen condition after production at one plant and then being shipped to another where it is thawed before being put into further processing (producing finished goods). The material has a much longer shelf-life in frozen condition than it has in the thawed condition. The batch of the semi finished material produced shows the expiration date calculated based on the longer shelf-life. When it is thawed, the material has a much shorter shelf life, and yet the batch master shows the longer shelf life. This leads to a risk that some of the materials being thawed might actually have expired even when the system shows the longer expiration date. Therefore it is necessary to update the information about the batch shelf life in the system. This however, is a complicated procedure.

For one, if the users change the batch shelf life expiration date manually using MSC2N, it will change the shelf life for the batch at all the plant locations, even for the batches which are still in frozen condition, where the shelf-life is still longer than the thawed material shelf-life. The alternative is to create a new batch manually and transfer stock from old batch to new one as the STO is received at the thawing plant. However, this requires manual calculation of reduced shelf lives, manual monitoring, and a lot of transactional work.

Proposal 1 :

If a material had to have a different life – then we would define a new material number and maintain corresponding shelf life on a new material number. This allowed us to have a different shelf life for the same ingredient (or product), but it complicated matters on master data maintenance and other planning and execution process including the internal plant transfers with stock transport orders.

User Acceptance – Not acceptable.

Proposal 2 :

When a material batch was received, a user exit in MIGO updated the ‘date’ fields in ‘Basic Data 2’ Tab of Batch Master Record. This did provide some information on the newly calculated Shelf Life Expiration Dates. However, this didn’t help with everyday functions such as labeling, batch determination during stock movement, and reports. It also did not provide any guarantee against the consistency of this date field value if multiple receipts of a batch were to take place.

User Acceptance – Not acceptable.

Proposal 3 :

Next a manual solution was put in place. When a frozen material was received, the receiving clerk manually deleted the batch information in MIGO, let the system generate a new batch and then update the ‘date’ fields in that new batch. Later, the user would go to MSC2N and then copy the values from the ‘date’ fields into the ‘Date of Manufacture,’ ‘SLED,’ and ‘NID’ fields. However, this was cumbersome as well.

User Acceptance – Not acceptable.

Proposal 4 :

Automatic shelf-life change during GR of STO from frozen to chilled plant in MIGO

The movement of Semi Finished material from frozen to chilled may happen either from plant to plant or within different storage conditions within the same plant.

When a material to be thawed for production is received as Stock Transfer Order (STO), it can be either shipped from frozen to chilled, or frozen to frozen, or chilled to chilled. Only in the first case, is there a need to change the shelf-life expiration date (SLED). Since an SLED change in a given batch would change it across the plants, a new batch must be created to avoid this. So an SLED change is necessarily linked with a new batch creation. Also, irrespective of whether the SLED needs to be changed or not, incoming material needs to be inspected.

The basic idea is for a 311 movement to be executed for only these Semi Finished materials at the time of saving a GR in MIGO and using condition tables (custom control table) to influence whether a new batch is required (frozen to chilled) or not (all other conditions).

If an 08 inspection type were to be active for these materials, they would be received into Q stock and a 311 movement would not be allowed. Hence this inspection type should be deactivated. However, for an inspection lot to be created, we can use Custom Inspection Type (that is triggered through 311) to achieve the same functionality.

When material from a plant (frozen storage) is received as an STO to another plant (chilled condition) in MIGO, a custom table is looked up. If conditions are satisfied at material level, then at the time of saving, a 311 Movement is done. Within 311, if further conditions are satisfied at the level of “from” and “to” storage conditions, then accordingly either a new batch # is requested from the system and quantity of old batch transferred to the new one, or else the batch # remains the same. If a new batch is created, while the 311 movement is saved, the SLED and Next Inspection Date (NID) are changed in this new batch record as per the Lcl Sh. Life of the control table.

If the batch # is changed as a result of 311, the system prompts for the need for printing labels. If the batch # is unchanged, it does not.

The following is condition table that would be looked up:

Send. Plant

Rcv. Plant

Mat #

Condition From

Condition To

New Batch

Lcl Sh. Life

1000

1100

12345

Chilled

Chilled

No

128

1000

1000

34567

Frozen

Chilled

Yes

29

1000

1100

12345

Frozen

Chilled

Yes

42

 

 

 

 

 

 

 

Process Step Overview:

  • Check custom table for valid entries. If no entries in the Custom Table, process system should run the standard MIGO process.
  • Check current expiration date against current date to determine whether a new batch needs to be created.
  • Create new batch if needed.
    • Bapi: Name-1 could be used to create new batch.
    • Bapi: Name-2 could be used for Transfer posting
  • Create Transfer Order for Posting Change Notice.
    • Function Module: L_TO_CREATE_POSTING_CHANGE could be used to create Transfer Order.

Process Details:

  • If a valid entry is found a check of the current batch to decide if is in a frozen state or in a thawing. This can accomplished be the following :

           a.    Subtract the current date from the Batch’s Shelf Life Expiration date.

           b.    If the result is greater than xxx days, this would indicate that the batch is still considered frozen. If the result is less than xxx days then no further processing should occur for the new Batch Check.

  • If a new batch number is deemed necessary then the new batch number should have all the same information as the source that it is being copied from. The new expiration should be calculated with the following :

            a.    The current date plus “Expiration in Days” from the custom table. This value should be populated in the new Batches Shelf Life Expiry date field. The source Batch number should also be copied to Vendor Batch number field.

  • Using a dialog box, User should be displayed the new information for Batch and should be prompted to input numbers of labels to print. Transaction should not post unless user prints new labels. Current label formats can be used.
  • Convert Posting Change Notice to a Transfer Order and confirm it to the same bin.

 Table entry for Batch Creation (Frozen to Cooler) Process

Send. Plant

Rcv. Plant

Mat #

Condition From

Condition To

New Batch

Lcl Sh. Life

1000

1100

12345

Chilled

Chilled

No

128

1000

1000

34567

Frozen

Chilled

Yes

29

1000

1100

12345

Frozen

Chilled

Yes

42

 

 

 

 

 

 

 

 User Acceptance : Acceptable.

2 Comments
You must be Logged on to comment or reply to a post.
  • This blog details the thought process behind the solution.   Nice.

    I’d like to see Name-1 and Name-2 be replaced with the actual BAPIs.  (BAPI_BATCH_SAVE_REPLICA?)  But that’s OK. We need to do some work.

    Michelle

    • Hi Michelle

      Thanks for reading the Blog
      The name of the BAPIs :
      Bapi: BAPI_BATCH_CREATE could used to create new batch.
      Bapi: BAPI_GOODSMVT_CREATE could used for Transfer posting

      Regards

      Aman