SAP DMC Apps for Life Sciences manufacturing – Process Order Lifecycle
The SAP Digital Manufacturing Cloud (DMC) 2208 release offers key details of processes covered in Life Sciences. While I was studying SAP DMC Level3 understanding provided SAP PartnerEdge, I found that the key question of how Life Sciences manufacturing process should be designed combining SAP S/4HANA and SAP DMC is answered thoroughly. You can find the document from SAP PartnerEdge. The link is provided at the end of the blog.
What is SAP DMC
SAP Digital Manufacturing Cloud is an offering from SAP Cloud solutions to cover Manufacturing Execution System (MES), Internet of Things (iOT) functionality for Industry 4.0 and analytics. It has close integrations with SAP S/4HANA. The key strength of SAP DMC is that it is capable of handling end-to-end life cycle of process orders for Life Sciences manufacturing.
How SAP DMC helps Life Sciences manufacturing process
The conventional concept of MES and SAP S/4HANA coverage in manufacturing system is that the transactional flow will happen in SAP S/4HANA while MES will handle the electronic batch records (EBR), work instructions, alerts & non-conformance for quality process. This makes the user experience low due to multiple navigation between SAP S/4HANA and MES. However, SAP DMC is capable of handling end-to-end SAP manufacturing process along with the overall MES functionality. It lowers the integration point between SAP DMC & SAP S/4HANA and increases user’s experience with respect to time spent on system.
The following diagram shows the SAP S/4HANA process flow for Life Sciences.
With SAP DMC 2208 release, the transactions done by production in-charge and production operator is SAP S/4HANA mapped to SAP DMC Apps. However, the master recipe, work instructions and standard operating procedures (SOPs) will come from SAP S/4HANA. After completion of full cycle in SAP DMC, the process order confirmation details, goods movement along with end-to-end batch record will be shared with SAP S/4HANA. So, the day-to-day system interaction of production team is only featured by SAP DMC.
The applicable SAP DMC Apps are following:
- Manage Material
- Integrate Class- and Characteristics Data for Batch classes (Class Type 023)
- Integrate Class- and Characteristics including values for Material Class (Class Type 001)
- Show characteristic details in “Manage Material App” in DMC
- Retrieve Material Class characteristics values via API
- Manage BOM
- Define formulas for BOM components to enable calculations during goods issue
- Use Formula Builder to define parameters and link to BOM component fields (context-specific
- Manage Recipe
- Maintain execution relevant data such as Work Instructions or Data Collection parameters in DMC
- Graphical interface for recipe display
- Integrate Production Versions with S/4HANA Cloud
- Production Operator Dashboard (POD): POD is one stop user dashboard to control end-to-end shop floor process. The feature of this app is as follows:
- Integrate process orders with S/4HANA
- Provision of the new Order POD to support order- based execution of process orders with single batches
- Support Operators with a highly flexible and intuitive user interface (POD)
- Configure and design the POD based on user requirements
- Start and Complete Phases
- Guide operators using Work Instructions in the POD
- Support of Data Collections to collect execution related data
- Display Long text for Process Order Phases
- Record inspection results for process order operation/phase (inspection lot type 03) and integrate with S/4HANA
- Log Defects for an Order which can be viewed in the Product History Report
It provides the following in-apps functions.
- Process Order split through POD
- Supporting flexible split scenarios in order to produce multiple batches with one or multiple SFC/Charges.
- Splitting orders into multiple SFCs/Charges with different quantities and batches via API
- Split orders into multiple SFCs/Charges via SFC-Split API
- Split order manually from the POD
- Select and Assign other Resources prior to starting a phase
- Execute orders with multiple SFC/Charges.
- Display both order and SFC data in Order POD
- Assign Default Batch on SFC Level via API or in the POD to support Multi-Batch Production
- Batch Integration with POD
- Display and Search for Batch characteristic values in the POD during material consumption to give guidance to operators
- Manage Next Number
- Create batches for Goods Receipt either directly calling S/4HANA or through local number ranges in DMC – based on configurations in ‘Manage Next Number’ app
- Batch Search with POD
- Filter & Search batches based on Storage location and Characteristic values.
- Find batches across materials
- Search and consume unplanned materials based on storage location and batch characteristic values in the POD
- Batch Management in POD
- Valuate batches (record Batch characteristics) during Goods receipt from the POD
- Batch number creation and Batch valuation for Co-products and By-products
- Shop Floor Integration with POD
- Integrate Equipment via Equipment Connectivity
- Define Setpoints for dedicated equipment indicators (tags)
- Start Process Order Phases in the Production Operator Dashboard
- Send Setpoints to Machine Tags via Plant Connectivity (PCo)
- Goods Movement with POD
- Confirm quantities and activities on phase level
- Record consumption of components and batches to trigger goods movements in S/4HANA
- Create batches for Main and Co-/By-Products in S/4HANA triggered from DMC
- Post Goods Receipts and integrate with S/4HANA
- Consumption through POD
- Apply formula-based calculations during material consumption in Order POD
5. Product History App: The features of product history app are following.
- Existing PHR report has been enhanced to enable using by Process Industry Customers.
- Input parameters and report terminology will be set automatically either to Process or Discrete based on industry type for Plant specified in User profile.
- User can search by Batch, Material or Order after pressing a value help button
SAP DMC caters into 2 types of manufacturing scenarios. These are “Design-to-Operate” and “Design-to-Consume”. The first scenario is relevant for discrete production processes like Textile and garments whereas the second one is relevant for Life Sciences, chemicals and processing industry. SAP DMC is on innovation path. The upcoming releases will also bring lots of solution to industry specific problems.
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