E2E STO Knowledge Share 11-19-2007

1

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

Table of Contents

2

Direct Procure to Pay End to End

ET

MS

uppl

ier

Oth

er

Le

ga

cyS

AP

WM

S/A

DC

Determine Required Materials Make PO /STO Supplier Fulfillment and Trans Opt . Receive Material Receive Invoice Pay Invoice

Run Tactical

MRP

Review MRP

PRs/STRs

Convert /Create POs/STOs

Receive PO

Transportation Optimization & Load Building

ETMOptimized ?

Create Inbound

Delivery and Shipment

Create Inbound Delivery and

Shipment from ASN or Manual

Create Receipt Authorization

(WMS)

Create PO(ADC)

Receive Goods Confirmation(WMS/ADC )

Post Goods Receipt against inbound delivery

PO updated w /Confirmation

Material Picked Up

Invoice Receipt

(Some Vendor are ERS)

Pay Vendor

Create Invoice

Update Inbound


Schedule Appointment

Execute Sourcing Rules /flag exceptions

Generate Production Schedule

Auto Create

Planned Orders

Goods Received

(Fruit)

Post Goods Receipt

without PO

Invoice Information

Created(Fruit and

Grainsmart )

Record Goods Received

(CCDS , Hold It, MARS - lot trace )

52 week Planning

File/Report

Receive 52 week Requirements

Mai

ntai

n Co

ntra

cts

Ship Material

WMS site?

Yes

No

Yes

No

P2P End to End Process Flow

3

Plan FG inMIMI in weekly

buckets

FG planned orders

created in SAP

interface

Download schedulefrom MIMI into excel

sheet w/ macroGatorade only

Breakdown schedule forupcoming week fromweekly to daily level

Gatorade only

Use SAP planning table

to breakdown weeklyschedule into daily or

shift buckets

Planned orders in SAP are

in weekly, daily or shift

buckets

Delete past due ordersIn SAP

Monday and Tuesday Tuesday through Thursday

Plan FGs & some SFGs In AMAPS

in daily and/or weekly buckets

FG/SFG planned orderscreated in SAP

interfaceDelete past due ordersIn SAP

Quaker & Gatorade

Tropicana

interface

52 week Prod Schedule from MIMI / AMAPS to SAP

36245interface

Overview Planning – Production Schedule

4

Contract Administration

Introduction to Contract Administration

5


ET

MS

uppl

ier

Oth

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Le

ga

cyS

AP

WM

S/A

DC

Determine Required Materials Make PO /STO Supplier Fulfillment and Trans Opt . Receive Material Receive Invoice Pay Invoice

Run Tactical

MRP

Review MRP

PRs/STRs

Convert /Create POs/STOs

Receive PO


ETMOptimized ?

Create Inbound





(WMS)

Create PO(ADC)

Receive Goods Confirmation(WMS/ADC )


PO updated w /Confirmation

Material Picked Up

Invoice Receipt


Pay Vendor

Create Invoice

Update Inbound



Execute Sourcing Rules /flag exceptions


Auto Create

Planned Orders

Goods Received

(Fruit)

Post Goods Receipt

without PO

Invoice Information

Created(Fruit and

Grainsmart )


(CCDS , Hold It , MARS - lot trace )

52 week Planning

File/Report


Mai

ntai

n Co

ntra

cts

Ship Material

WMS site?

Yes

No

Yes

No

P2P End to End Process Flow

6

• 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

7

• 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

Approve Contract

(if necessary)

Approve Contract

(if necessary)

Create/modify Contract


PO Creation possible


Create Source List Record

(if necessary)


(if necessary)

Transactional Contract AdministrationContract Creation

8

• 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.

Approve Contract

(if necessary)

Approve Contract

(if necessary)






(if necessary)


(if necessary)

Transactional Contract AdministrationContract Approval

9

Approve Contract

(if necessary)

Approve Contract

(if necessary)






(if necessary)


(if necessary)

• 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.

Transactional Contract Administration Source List Overview

10

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.

Fix or Block

MRP Relevant

Different Source List Records (Contracts)

11

• 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.

Approve Contract

(if necessary)

Approve Contract

(if necessary)






(if necessary)


(if necessary)

Transactional Contract AdministrationKey Point

12

Material Requirements Planning Overview

13

AD

C/Y

MS

WM

SL

ega

cy (

Site

sp

eci

fic)

SA

PL

ega

cy

Planned Production

Orders Created

Record Production of FG

Clear Production Backflush error log

(End of Shift)

Requirements Source/Produce SFG

Shift Batch Data

(ADC/YMS)

MaterialPlanning

Requirements

Source Materials

Confirm SFG

MARS data confirmation (MTP Only)

Report


Volume Information(Consumer Complaints)

QA Reporting

(Holdit)

Production Volume

(Test Weights, Cedar Only)

Change Inventory Location(Raw/Pack/SFG. Sites: Oakland, Blue Ridge,

Pryor, Bridgeview, Albany)

Production Receipt

(LPN applied)

Make SFG

Make FG

Clear Production Backflush error log(End of Shift)

Production Receipt

(Batch info as required)

Production Receipt(DCS)

Production Schedule(YODA,Cedar,

Danville)

Production FG,

(SCR/SCDB)

Stage Components

in storage Location

(Optional)

MARS data confirmation (MTP Only)

Confirm FG(End of shift)

Stage Components

(Optional)

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

Blue Ridge, Pryor, Bridgeview, Albany)

Prod Schedule

(SCR/SCDB)

Create Planned Production Orders

Interface to downstream

systems

MRP IntroductionManufacturing End to End Process Flow

14

• 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”

MRP Introduction

15

• 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.

MRP IntroductionRoles and Responsibilities

16

Generate Detailed

Schedule

Generate Master

Production Schedule

Continuous Improvement

Determine Run Strategy

• Material Requirements Planning Process

Update Tactical Planning

Parameters

Run Tactical MRP

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.

Material Requirements Planning OverviewPlanning Process

17

• Planned Orders from MP

• BOM recipes, Material Master Data

• Raw material safety stock targets

• Inventory Balances

• Transactional data (open PO’s, ASN)

Key Inputs

Material Requirement

Planning

• Purchase requisitions by material SKU/location ready to convert to purchase orders

• Visibility to MRP requirements for 52 week horizon

• STO’s for materials utilizing special procurement type

Key Outputs

Material Requirements Planning OverviewKey Integration Points

18

MRP - BOM

BR81464Chep Pallet

BR98323Single StrengthOrange Juice

BR17967CCarton

BR11133Corrugate

BR16618Fitment(Cap)

64oz Bottle Tropicana Pure Premium Orange JuiceBR1004850000102

Bill of MaterialBill of Material

19

FG,SFG PlannedOrders

From ProductionSchedule

FG,SFG PlannedOrders

From ProductionSchedule

Generate Planned Orders

Generate Planned Orders

2 3

Create Stock Transport

Order

Create Stock Transport

Order

Create Purchase

Order

Create Purchase

Order

Manufacturing Planning

Material Requirements Planning

Direct Purchasing

1

2

4a

4b

Generate Purchase

Requisition

Generate Purchase

Requisition

Generate StockTransferRequest

Generate StockTransferRequest

Run MRPRun MRP

2

2

4 5

4 5

MRP Introduction Process Flow Overview

20

•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.

Run MRP ? Run MRP ?

BOMs &MRP

Parameters

BOMs &MRP

Parameters

Generate Planned Order /Purchase

Requisitions

Generate Planned Order /Purchase

Requisitions

3 ReviewExceptions/

Take Action if Necessary

ReviewExceptions/


5a

Run MRPRun MRP

21 4

4 5bFG ScheduleFG Schedule

1a

5

Y N6

6Review Next Material/Continue

Planning Activities

Review Next Material/Continue

Planning Activities

6 5

MRP IntroductionProcess Flow Overview

21

Enterprise WideSystem

Purchasing and production information flows directly into the tool. No more separate data entry for inventory or vendor updates.

Data Management Additional data will be required to coordinate the enterprise system. Some data will be locally controlled; some will be centrally managed.

Exception Based Alerts

Critical task alerts trigger activity in the time frame set by the material planner.

Advanced MRPCapabilities

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.

SAP Numbering System

Numbering system and descriptions of materials have been changed.New nomenclature will have to be learned.

Drill Down within theTool

The tool can help lead you through your analysis.

SAP Material MasterUse Up Logic

Enables a systematic approach to manage run out of on hand material inventories, reducing material obsolescence.

Key Changes Impacts

MRP IntroductionKey Changes and Impacts

22

Stock/Requirements List and MRP List

23

Run MRP ? Run MRP ?

BOMs &MRP

Parameters

BOMs &MRP

Parameters

Generate PlannedOrders/Purchase

Requisitions


Requisitions

1

3 ReviewExceptions/


ReviewExceptions/


5a

Run MRPRun MRP

21 4


1a

• 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.

5

Y N6

6Review Next

Material/Continue Planning Activities


Planning Activities

6 5

Stock/Requirements List and MRP ListViewing MRP Results

24

Key Change Benefit• Key changes to viewing MRP results are:

– 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.

Stock/Requirements List and MRP List Viewing MRP Results

25

Data Vertical

vs.Horizontal

Header Info

Organized Differently

Old ViewMMS 23.13

New View

Safety Stock is

Subtracted from the Available Quantity.


26

1.Stock

3. Purchase Requisition

4. Planned Order5. Dependent

Requirement

2.Safety Stock

Stock/Requirements List and MRP List Viewing MRP Results

27

• 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.


28

MRP Planning, Exception

Messages

29

• 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.

Run MRP ? Run MRP ?

BOMs &MRP

Parameters

BOMs &MRP

Parameters


Requisitions


Requisitions

3 ReviewExceptions/


ReviewExceptions/


5a

Run MRPRun MRP

21 4


1a

5

Y N6


Planning Activities


Planning Activities

6 5

Exception Messages Exception Messages Definition

30

Exception Messages Exception Message List

31

2. Exception Message Text will

Display at Bottom of

Screen

1. Double Click on

the Exception Message Number

Exception Messages Stock/Requirements List

32

1. MRP List exceptions are similar

to the Stock Requirement

s List but include new

planned order

exceptions and

termination messages.``

2. Order proposal has been changed.

Exception Messages MRP List

33

• 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.

1. Exception Message Group

2. Associated Traffic Light

3. Click on Define Traffic Lights to

access Traffic Light Settings

Exception Messages Traffic Lights

34

Exception Message Groups

Traffic Light Settings

Exception Messages Define Traffic Lights

35

Generating the Material Requirements Plan

36

• The two options to execute MRP are:

– Batch Process – scheduled MRP run (nightly).

– On-line Planning Run – MRP on demand (ad hoc).

1

5a3c4 Run MRP ? Run MRP ?

BOMs &MRP

Parameters

BOMs &MRP

Parameters


Requisitions


Requisitions

3 ReviewExceptions/


ReviewExceptions/


5a

Run MRPRun MRP

21 4


1a

5

Y N6


Planning Activities


Planning Activities

6 5

Generating MRP - MRP Run

37

• 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 Definition Frequency Schedule

Net Change Plan materials that have changed since the last planning run.

Daily M-F

Regen Re-plans all materials. Weekly Sunday

No Run Saturday

Generating MRP - Batch Process

38

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.

39

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, semi-finished 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)

40

MRP Material Master Overview

41

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.

42

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

MRP Material Master MRP Material Master Views

43

Stock Transport Order Processing Overview

44


ET

MS

uppl

ier

Oth

er L

egac

yS

AP

WM

S/A

DC

Determine Required Materials Make PO/STO Supplier Fulfillment and Trans Opt. Receive Material Receive Invoice Pay Invoice

Run Tactical

MRP

Review MRP

PRs/STRs

Convert/Create POs/STOs

Receive PO


ETMOptimized?

Create Inbound





(WMS)

Create PO(ADC)

Receive Goods Confirmation(WMS/ADC)


PO updated w/Confirmation

Material Picked Up

Invoice Receipt


Pay Vendor

Create Invoice

Update Inbound



Execute Sourcing Rules/flag exceptions


Auto Create

Planned Orders

Goods Received

(Fruit)

Post Goods Receipt

without PO

Invoice Information

Created(Fruit and

Grainsmart)


(CCDS, Hold It, MARS - lot trace)

52 week Planning

File/Report


Mai

ntai

n Co

ntra

cts

Ship Material

WMS site?

Yes

No

Yes

No

STO Processing Overview P2R End to End Process Flow

45

• 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.

STO Processing Overview

46

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 STO’s for the movement of finished goods and possibly semi-finished goods between facilities.

47

• 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

STO Overview (Shadows)

48

• 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.

Deployment Scenarios

49

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.

50

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.

51

• 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.

STO Processing OverviewKey Terms (3 of 3)

52

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/Gatorade’s 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: Tropicana’s 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 FG’s to US locations• GGCS SFG’s to US locations

53

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 non-deployed 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.

54

STO Document Types

Code Document TypeType of

goodsETM Optimized? How is it created?

Shadows to Q-DCS / T-DCS

CASS pays freight?

ZBT STO - Bulk Tanker FG No User-created Yes-ZNE5 Yes

ZDIV STO - Diversion FG No User-created Yes-ZNE5 No

ZLG STO - Load and Go FG No User-created Yes-ZNE5 Yes

ZMI STO - Manual Intermodal FG Yes* User-created Yes-ZNE5 Yes

ZMR STO - Manual Rail FG No User-created Yes-ZNE5 Yes

ZMT STO - Manual Truck FG, SFG Yes* User-created Yes-ZNE5 Yes

ZPR STO - Planned Rail FG No User-created Yes-ZNE5 Yes

ZPS STO - Planned Standard FG Yes* System-created Yes-ZNE5 Yes

ZRO STO - Raw Freight Optimized RM, SFG Yes* User-created No Yes

ZUB STO - Raw/Semi RM, SFG No User-created No Yes

ZRD STO - Receipt DiscrepanciesRM, SFG,

FGNo System-created Yes-ZNE5 No

ZSDW STO - Shadow SFG, FG No System-created Yes-ZNE5 Yes

ZMQ STO - Shuttle CASSRM, FG,

SFGNo User-created Yes-ZNE5 Yes

ZMS STO - Shuttle Local FG No User-created Yes-ZNE5 No

ZMO STO - Manual Ocean** SFG No User-created 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

55

STO Document Type Description

CodeDocument

TypeDescription

ZBT Bulk Tanker 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

ZDIV Diversion The STO Diversion is used when an in-transit load has been diverted to another facility. See the Diversion Job Aid.

ZLGLoad and

Go

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.

ZMIManual Intermodal

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

ZMR Manual RailThe 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

ZMTManual Truck

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.

ZPR Planned RailThe 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.

ZRORaw Freight Optimized

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.

ZUB Raw/SemiThe 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

ZRDReceipt Discrepancies

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.

56

STO Document Type Description

CodeDocument

TypeDescription

ZSDW ShadowThe STO Shadow is created by the QDCS or TDCS Shadow order interfaces when a non-deployed shipping location creates an STO order in QDCS or TDCS for a deployed receiving location.

ZMQ Shuttle CASS

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-ETM-optimized 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

ZMS Shuttle Local

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.

ZMO Manual Ocean**

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.

57

Inventory Management

58

• Inventory Management (IM) and Integration with other SAP Modules

• SAP IM interfaces (WMS/ADC)

• Inventory Reconciliation between SAP-WMS-DCS systems

Agenda

59

Inventory Management : Overview

1. Goods Movement: Concept of Movement TypeWhen 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.

Inventory Management comprises of 3 main tasks:

60

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 company’s warehouse stocks for balance sheet purposes

61

IM integration with other SAP Modules

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

62

Key Data elements of IM

1. PLANTo 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.

63


3. STORAGE LOCATIONThe 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

4. BATCHMaterials 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.

Storage Location Description

0001 Raw Materials

0002 Staging

0003 Manufacturing

0004 Warehouse

0005 Whse Inv Hold

0006 Whse Expired

0007 Whse Damaged

0008 Whse QA Hold

64


Finished goods category

Base UoM

Alt UoMs Proportional UoMs

Examples

Finished Goods (ZFIN) EA – Each CS – Case

PAL – Pallet

Single bottle of GatoradeCase of Gatorade 6 packs

One layer on a palletCap’n Crunch Pallet

Packaging Good (ZPKG)

EA

CYLLB (or IN)RL

RollStock

Semi-Finished Goods (ZSFG)

TPS TGL*GAL

Tropicana Juice

5. UNIT OF MEASURE (UoM)

* Concept of Brix Value

65


6. Inventory Status

Stock Status notes

Unrestricted use available for general use

Qual. inspectionblocked from being used in SOs, but available for STOs.

Returns available for use in returns only

Blocked not available for general use

66

Stock Overview - Key Data Elements

SAP Unrestricted Status andWarehouse Storage Location

= DLx SHIP Status

SAP Unrestricted Status andWarehouse Storage Location

= DLx SHIP Status

SAP Quality Inspection Status andWarehouse Storage Location

= DLx INCB Status

SAP Quality Inspection Status andWarehouse Storage Location

= DLx INCB Status

SAP Blocked Status andWhse Expired Storage Location

= DLx EXPR Status

SAP Blocked Status andWhse Expired Storage Location

= DLx EXPR Status

SAP Blocked Status andWhse Damaged Storage Location

= DLx DMGD Status

SAP Blocked Status andWhse Damaged Storage Location

= DLx DMGD Status

SAP Blocked Status andWhse QA Hold Storage Location

= DLx QAHD Status

SAP Blocked Status andWhse QA Hold Storage Location

= DLx QAHD Status

67

Batch Number – Data Element

WMS FieldsWMS Fields

ITEM_NUM

LOT_NUM (12 Char)

WH_ID

SAP Batch Number (10 Char)SAP Batch Number (10 Char)

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

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

Quaker/GatoradeLot Number = MMDDYYPP, where MMDDYY = Mfg Date andPP = Plant Designator Code

Quaker/GatoradeLot Number = MMDDYYPP, where MMDDYY = Mfg Date andPP = Plant Designator Code

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

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

68

SAP / WMS Inventory Management Interfaces

InventoryManagement

Interfaces

InventoryManagement

Interfaces

69

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.

70

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.

71

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.

72

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.

73

Cycle Count based on ABC Indicators

ProcessPhysical 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.

74

Physical inventory – Process Flow Overview

• 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

Enter Inventory

Count

Post Inventory

Differences

Create Physical Inventory Document

Print Physical Inventory Document

Count & Record Inventor

y

Initiate Recount

, if Needed

Show results of

post transaction

- SAP transaction

- Non SAP System

- Manual Process

LEGEND

75

SAP / WMS Inventory Management

SAP ItemType

WMSInventory

Status

WMSHost

Location

SAPStorageLocation

LocationType

1SHP

0001Raw

Materials

BULKBulk Material

Storage

0002Staging

0003Manufacturing

0004Warehouse

0005Whse Inv

Hold

0006Whse

Expired

0007Whse

Damaged

0008Whse QA

Hold

0009WhseDWIP

BSTGBulk Material

Staging

PRODProduction

DWIPDisplay

WIP

WHSEWarehouse

WHSEWarehouse

WHSEWarehouse

WHSEWarehouse

WHSEWarehouse

1DMG1EXP1HLDZQAH

1INS

SHIPSHIPALTCRFID

INCB

SHIP

BLOKCASHDESTFDHDFDBKINSP

RHLD

EXPRSECM

WEXP

DMGDSECD

1SHP

1DMG1EXP1HLD

1INS

CRTN

0009WhseDWIP

DASMDisplay

Disassemble

QAHD

SHIP

ZINGZPKG

ZSFGZFIN

Production Line Display LineWarehouse StorageWarehouse

Storage

SAP / WMS Inventory Management SAPUnrestricted

SAP QualityInspection

SAPBlocked

SAPReturn

76

Future Balancing Process

Changes in DLX/DCS Balancing & SAP addition

SnapshotICS 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 DCSInventory Status Changes/Storage Locations overview Reports used include:

WMS/DCS Snapshot Discrepancy Report WMS/SAP Snapshot Exception ReportMeasles Exception Reports247 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 – handlingAny 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

77

Manufacturing Process

Production Master Data

Material Master BOM Work Center Routing Production Version

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

Production Execution Post Production

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

Demand Planning - Planned orders

78

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.

79

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

BR81464Chep Pallet

BR98323Single StrengthOrange Juice

BR17967CCarton

BR11133Corrugate

BR16618Fitment(Cap)

64oz Bottle Tropicana Pure Premium Orange Juice (BR1004850000102)

80

Bill Of Materials(BOM)

81

WORK CENTER

• Location (Production Line) at which a particular operation is executed

Work center 1

WC 2 WC 3

WC 4

WC 5

Work center 6

Bridgeview Near East Plant FloorWC = Work center

Work CentersWork Centers

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

82

Rate Routing

• A set of operations that must be performed in sequence to manufacture a product – a production cycle.

Operation 20Operation 20

Work centerWork centerTextsTextsActivitiesActivities

Operation 10Operation 10

MaterialMaterial

RoutingRoutinggroupgroup

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)

83

• 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 Version

Production VersionsProduction Versions

Shift 1Shift 2Shift 3

Line 1Line 1Line 3

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

84

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:

2 1 14

2114

Shift #BOM

VersionWork 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

85








86

Process FlowA

DC

/YM

SW

MS

Le

ga

cy (

Site

sp

eci

fic)

SA

PL

eg

acy

Planned Production

Orders Created

ManualQTG

(optional)

Create Planned Production Orders Record Production of FG

Process StepLegacy Interface

New Interface

Interface Controls

Source Raw/Pack Materials

(Direct P2R, DIR STO)

Interface to downstream

systems

Clear Production Backflush error log

(End of Shift)

Shift Batch Data

(YMS)

Determine Requirements Source (Raw/Pack/SFG)/Produce SFG

Shift Batch Data

(ADC)

Run Tactical MRP

Source SF Materials(STO SFG)

Confirm SFG

MARS confirmation

data

Report

90330

36245


(Quaker Prenote)


(MIMI, AMAPS)

Volume Information

(Consumer Complaints)

QA Reporting(Holdit)

Production Volume

(Test Weights, Cedar Only)

3992737741

34610

36178Change Inventory Location

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

Production Receipt

(LPN applied)

Make SFG

Make FG

Clear Production Backflush error

log(End of Shift)

3350123800

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

Production Receipt(DCS)

Production Schedule

(YODA,Cedar, Danville)

Production FG, (SCR/SCDB)

Optional Stage

Components in proper Storage

Location

MARS confirmation

data

Confirm FGSLOC 003

(End of shift) (Mvmt 131, 261)

31853

33520

Optional Stage

Components

Change Inventory Location

(Raw/Pack. Sites: Oakland,

Bridgeview)

23800

110048

Prod Schedule(SCR/SCDB)

38169

ManualQG

SFG Production and Material Usage

Recorded(DCS)

Manual SFG

UsageQG

Excel(creates HF

daily schedule)

36245

90323(Trop)

SA

P I

nve

nto

ry

Ba

lan

ces

?????(Trop)

Production Receipt SFG (Bridgeview,

Danville, Cedar)

Production Receipt(Batch info as

required)SLOC 003 is

NegativeSLOC 004 is

Positive

33501

87

Production Confirmation– 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 SFG’s and FG’s 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.

88

Back flush

Back flush example for SFG:

89

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!

90

Production Confirmation

91

Material Document

92

Production Execution – External Integrations

End-State QTG2 Interface

Temporary QTG1 InterfaceLegacy Interface

Temporary QTG2 Interface

Retouch (Original Deployment)

Connectors

Retouch (New Deployment)Reporting

Legacy

SAP

External ISCP

Manual

Systems

• Inventory Management• Production Master Data• Shop Floor Activities

SAP ECC 6.0Production Data

62455MARS

YMS

ProductionData33520

ADC

Production Data31853

Material MasterProduction Data

34610 ConsumerAffairs

Material MasterProduction Data

36178Test Weights

Fiinished GoodProduction

37741 HoldIT

YODA

Production Schedule38169

Material Master62454

Tank Balances33243

Juice Shipments33173

MMMI/AMAPS

Planned Orders

SAP PortalCo- PackerProduction

62450

Co- PackerPO / STO / Receipt

62453Display

Planning Pre- Note

Planned Orders90330

ElectronicComerceGateway

Canada ASN90328

• Inventory Management• Production Master Data• Shop Floor Activities

93








94

Period End Close

95

Warehouse and Manufacturing Handshake

• Production outputs are reconciled with warehouse and the total number is agreed upon

• MFG team inputs production, raw material usage actuals, and labor hours.

Both Individuals sign the PepsiCo

Audit Form

Warehouse tabulates FG output

Manufacturingtabulates

FG outputs

If error in Warehouse

receipts, adjust WMS

Both IndividualsCompare results

and agree onoutput

Manufacturing confirms FG batch in SAP

or MARS

96

Stock Overview

97

Material Documents

98

Target/Actual/Variances - KKRC / KKBC_HOE

99

MFG Reports – ECC & BW

Caliber ID Description Source

33315 Compare Inventory Balances - Red Prairie and SAP ECC

62315 Material Stock Report ECC

65355 Inventory by Batch Characteristic Report ECC

77737 PTD Cost Center Performance ECC

30541 Shift Performance Summary ECC

30545 Material Variance Report BW

37021 Material Efficiency Report BW

30542 Production Attainment and Adherence Report BW

42733 Labor Variance Report BW

37118 Labor Efficiency Report BW

65353 Tolling Variance Report BW

37105 Overtime Hours Report BW

37330 Production Performance Report BW*

39932 Enterprise Performance Report BW*

37025 Composite Ranking Report BW*

100

Stock Transport Orders (STO) DEPLOYED TO DEPLOYED FG

-2 L

egac

yW

MS

QD

CS

/TD

CS

SA

PE

TM

CA

SS

23840ZETM_SHIPMENT

23539ZSHPDEL

37629ZORDTIB

No

56765(QG)

Shipped from non WMS site

ZDLV_ASN

90999(QG)

ZSHPT_ASN

23836ZRECPTCONF

Trop

91001(QG)

ZRECPTCONF

Trop

62353Z210CASS

Trop

QG

53533(Trop)

ORDERS

56149(QG)

PORDCR 56147(QG)

ORDERS

QG

25912ZVESLCHK_TIB_QTG2

QG

ECG3rd Party Warehouse ECG

3rd Party Warehouse

ECG3rd Party Warehouse

ECGCHEP

3rd Party Warehouse

56727Trop

Order & Master Shipment created

in WMS(SHP)

ManualQTG

*Including IRP

TCode On

FACSShipment Receipt

FB

Update Deliveryand Shipment

RT

ManualTrop Rail

RT

Genesis Inventory

Accounting

Order “Recieved” in DCS/TDCS

(VTTS/LIPS)

POCs On

Shipment Processor / Delivery Processor

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

Vessel Check in(SHP)

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

Create STO

STO CREATED

Create Freight Accrual/Payments

Receive Shipment Confirmation

Final

(BSEG)

TCode Off

Trans Opt.

ETMOptimized?

(VTTS/LIPS)

Process Step

FB

TBL Off

FG Inventory Execution Processor

M

Update Delivery and Shipment

Shipment Confirmation

(SHP)

Delivery Processor / Shipment Processor

Post Goods Receipt

RT


RTDelivery Processor /

Shipment Processor

VL02N

TBL On

IF On

FB

Create STR using

Rail Load Builder

STO CREATED(Rail STO created

from Rail Load Builder)

Create Inbound Shipments

RT

1UP Reviewed

RTF

B

Vessel Check-in

RT

POCs Off

VL32N/MIGO

(VTTS/LIPS)


Draft

FB

FB

ZV02

Create Delivery and Ship Docs Ship Product

Post Goods Issue(641)

RT

Phoenix

FB

FG STO Processor

NB

Rate Shipment

Order in Picking status - Pick List

generated(SHP)

Acct On

EPROOn

Delivery Processor

Vessel Checkout(SHP)

NB

RT

Receive Product

IF Off

(BSEG)

Update Inbound Delivery

New Interface

Order “Shipped” in DCS/TDCS

Acct Off

BIL Reviewed

Freight Payment Analyst

RT

(VTTS/LIPS)


(RECV)

EPRO Off

RT

Receive Goods Confirmation

(RECV)Appointment Time Update

(SHP)

Xref

VL01N/VT01N

Auto Create Inbound Delivery

and Shipment

RT

(BSEG)

GenesisInventory

Accounting

Create Delivery and Shipment(Outbound Monitor)

ME21N

Legacy Interface

(VTTS/LIPS)

Interface FrequencyRT = real time

FB = frequent batchNB = nightly batch

PB = periodic batchM = manual

53551ZAPPCAR_TIB_QTG2

23288ZPICKSTAT_TIB_QTG2

48560ZDMPLUS_DLX_SHIPMENT_CONF


25619SHPMNT

62352ZSHPT_ASN


EDI ADMIN EAM P2P

STO Deployed to Deployed FG

101

Outbound Monitor

102


-2 L

egac

yW

MS

QD

CS

/TD

CS

SA

PE

TM

CA

SS

23840ZETM_SHIPMENT

23539ZSHPDEL

37629ZORDTIB

No

56765(QG)


ZDLV_ASN

90999(QG)

ZSHPT_ASN

23836ZRECPTCONF

Trop

91001(QG)

ZRECPTCONF

Trop

62353Z210CASS

Trop

QG

53533(Trop)

ORDERS

56149(QG)

PORDCR 56147(QG)

ORDERS

QG


QG


3rd Party Warehouse


ECGCHEP

3rd Party Warehouse

56727Trop


in WMS(SHP)

ManualQTG

*Including IRP

TCode On


FB


RT

ManualTrop Rail

RT

Genesis Inventory

Accounting


(VTTS/LIPS)

POCs On





Create STO

STO CREATED



Final

(BSEG)

TCode Off

Trans Opt.

ETMOptimized?

(VTTS/LIPS)

Process Step

FB

TBL Off


M



(SHP)


Post Goods Receipt

RT



Shipment Processor

VL02N

TBL On

IF On

FB

Create STR using

Rail Load Builder




RT

1UP Reviewed

RTF

B

Vessel Check-in

RT

POCs Off

VL32N/MIGO

(VTTS/LIPS)


Draft

FB

FB

ZV02



RT

Phoenix

FB

FG STO Processor

NB

Rate Shipment


generated(SHP)

Acct On

EPROOn

Delivery Processor


NB

RT

Receive Product

IF Off

(BSEG)


New Interface


Acct Off

BIL Reviewed


RT

(VTTS/LIPS)


(RECV)

EPRO Off

RT



(SHP)

Xref

VL01N/VT01N


and Shipment

RT

(BSEG)

GenesisInventory

Accounting


ME21N

Legacy Interface

(VTTS/LIPS)








25619SHPMNT

62352ZSHPT_ASN


EDI ADMIN EAM P2P


103

23288 - Updated Delivery Block Status

Delivery

104


-2 L

egac

yW

MS

QD

CS

/TD

CS

SA

PE

TM

CA

SS

23840ZETM_SHIPMENT

23539ZSHPDEL

37629ZORDTIB

No

56765(QG)


ZDLV_ASN

90999(QG)

ZSHPT_ASN

23836ZRECPTCONF

Trop

91001(QG)

ZRECPTCONF

Trop

62353Z210CASS

Trop

QG

53533(Trop)

ORDERS

56149(QG)

PORDCR 56147(QG)

ORDERS

QG


QG


3rd Party Warehouse


ECGCHEP

3rd Party Warehouse

56727Trop


in WMS(SHP)

ManualQTG

*Including IRP

TCode On


FB


RT

ManualTrop Rail

RT

Genesis Inventory

Accounting


(VTTS/LIPS)

POCs On





Create STO

STO CREATED



Final

(BSEG)

TCode Off

Trans Opt.

ETMOptimized?

(VTTS/LIPS)

Process Step

FB

TBL Off


M



(SHP)


Post Goods Receipt

RT



Shipment Processor

VL02N

TBL On

IF On

FB

Create STR using

Rail Load Builder




RT

1UP Reviewed

RTF

B

Vessel Check-in

RT

POCs Off

VL32N/MIGO

(VTTS/LIPS)


Draft

FB

FB

ZV02



RT

Phoenix

FB

FG STO Processor

NB

Rate Shipment


generated(SHP)

Acct On

EPROOn

Delivery Processor


NB

RT

Receive Product

IF Off

(BSEG)


New Interface


Acct Off

BIL Reviewed


RT

(VTTS/LIPS)


(RECV)

EPRO Off

RT



(SHP)

Xref

VL01N/VT01N


and Shipment

RT

(BSEG)

GenesisInventory

Accounting


ME21N

Legacy Interface

(VTTS/LIPS)








25619SHPMNT

62352ZSHPT_ASN


EDI ADMIN EAM P2P


105

WMS Vessel Check In at ShipperPicking Status from Shipper


WMS Vessel Check Out at Shipper

Shipment

106


-2 L

egac

yW

MS

QD

CS

/TD

CS

SA

PE

TM

CA

SS

23840ZETM_SHIPMENT

23539ZSHPDEL

37629ZORDTIB

No

56765(QG)


ZDLV_ASN

90999(QG)

ZSHPT_ASN

23836ZRECPTCONF

Trop

91001(QG)

ZRECPTCONF

Trop

62353Z210CASS

Trop

QG

53533(Trop)

ORDERS

56149(QG)

PORDCR 56147(QG)

ORDERS

QG


QG


3rd Party Warehouse


ECGCHEP

3rd Party Warehouse

56727Trop


in WMS(SHP)

ManualQTG

*Including IRP

TCode On


FB


RT

ManualTrop Rail

RT

Genesis Inventory

Accounting


(VTTS/LIPS)

POCs On





Create STO

STO CREATED



Final

(BSEG)

TCode Off

Trans Opt.

ETMOptimized?

(VTTS/LIPS)

Process Step

FB

TBL Off


M



(SHP)


Post Goods Receipt

RT



Shipment Processor

VL02N

TBL On

IF On

FB

Create STR using

Rail Load Builder




RT

1UP Reviewed

RTF

B

Vessel Check-in

RT

POCs Off

VL32N/MIGO

(VTTS/LIPS)


Draft

FB

FB

ZV02



RT

Phoenix

FB

FG STO Processor

NB

Rate Shipment


generated(SHP)

Acct On

EPROOn

Delivery Processor


NB

RT

Receive Product

IF Off

(BSEG)


New Interface


Acct Off

BIL Reviewed


RT

(VTTS/LIPS)


(RECV)

EPRO Off

RT



(SHP)

Xref

VL01N/VT01N


and Shipment

RT

(BSEG)

GenesisInventory

Accounting


ME21N

Legacy Interface

(VTTS/LIPS)








25619SHPMNT

62352ZSHPT_ASN


EDI ADMIN EAM P2P


107

• 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

– PGI of Delivery:• Inventory Posting

• Cost Of Goods Sold

• Billing Index Populated

• Create Inbound Shipment and Delivery

Effects of Vessel Checkout

108

Freight Payment & Freight Accounting

RATE

MATCH

PAY

CARRIER

S

Shipment Cost

Doc

ACH FUNDS

Shipment

Inbound or Outbound

Optimized Loads

Manual Build

Supplier ASN’s

1

2

Outbound Ship Confirm

Inbound Receipt

Allocate to Products

$100

Acct 1 Acct 2$100

Post to G/L

3

Accrue Freight Costs

• Linehaul• Fuel & Stop Offs• Unload Labor• Detention

Reverse Accrual & Book Actuals

5

Feed CO-PA

Profitability AnalysisCost–to–Serve 6

Fund Cass from the appropriate Legal Entities

CARRIER

S

APPLY CASH

INVOICE

Or

EDI 210

4

7

109

Shipment Cost Document

110


111


112


113


-2 L

egac

yW

MS

QD

CS

/TD

CS

SA

PE

TM

CA

SS

23840ZETM_SHIPMENT

23539ZSHPDEL

37629ZORDTIB

No

56765(QG)


ZDLV_ASN

90999(QG)

ZSHPT_ASN

23836ZRECPTCONF

Trop

91001(QG)

ZRECPTCONF

Trop

62353Z210CASS

Trop

QG

53533(Trop)

ORDERS

56149(QG)

PORDCR 56147(QG)

ORDERS

QG


QG


3rd Party Warehouse


ECGCHEP

3rd Party Warehouse

56727Trop


in WMS(SHP)

ManualQTG

*Including IRP

TCode On


FB


RT

ManualTrop Rail

RT

Genesis Inventory

Accounting


(VTTS/LIPS)

POCs On





Create STO

STO CREATED



Final

(BSEG)

TCode Off

Trans Opt.

ETMOptimized?

(VTTS/LIPS)

Process Step

FB

TBL Off


M



(SHP)


Post Goods Receipt

RT



Shipment Processor

VL02N

TBL On

IF On

FB

Create STR using

Rail Load Builder




RT

1UP Reviewed

RTF

B

Vessel Check-in

RT

POCs Off

VL32N/MIGO

(VTTS/LIPS)


Draft

FB

FB

ZV02



RT

Phoenix

FB

FG STO Processor

NB

Rate Shipment


generated(SHP)

Acct On

EPROOn

Delivery Processor


NB

RT

Receive Product

IF Off

(BSEG)


New Interface


Acct Off

BIL Reviewed


RT

(VTTS/LIPS)


(RECV)

EPRO Off

RT



(SHP)

Xref

VL01N/VT01N


and Shipment

RT

(BSEG)

GenesisInventory

Accounting


ME21N

Legacy Interface

(VTTS/LIPS)








25619SHPMNT

62352ZSHPT_ASN


EDI ADMIN EAM P2P


114

Inbound Monitor

115

Inbound Delivery

116

Inbound Shipment

117


-2 L

ega

cyW

MS

QD

CS

/TD

CS

SA

PE

TM

CA

SS

23840ZETM_SHIPMENT

23539ZSHPDEL

37629ZORDTIB

No

56765(QG)


ZDLV_ASN

90999(QG)

ZSHPT_ASN

23836ZRECPTCONF

Trop

91001(QG)

ZRECPTCONF

Trop

62353Z210CASS

Trop

QG

53533(Trop)

ORDERS

56149(QG)

PORDCR 56147(QG)

ORDERS

QG


QG

2353

9(94

0)

ZDLVDEL


48560(945)

ZEDI945_SHIPMENT_

CONF


2383

6(94

4)

ZRECPTCONF


2343

8(85

6)

ZDLV

_AS

N

ECGCHEP

3rd Party Warehouse

56727Trop


in WMS(SHP)

ManualQTG

*Including IRP

TCode On


FB


RT

ManualTrop Rail

RT

Genesis Inventory

Accounting


(VTTS/LIPS)

POCs On





Create STO

STO CREATED



Final

(BSEG)

TCode Off

Trans Opt.

ETMOptimized?

(VTTS/LIPS)

Process Step

FB

TBL Off


M



(SHP)


Post Goods Receipt

RT



Shipment Processor

VL02N

TBL On

IF On

FB

Create STR using

Rail Load Builder




RT

1UP Reviewed

RTF

B

Vessel Check-in

RT

POCs Off

VL32N/MIGO

(VTTS/LIPS)


Draft

FB

FB

ZV02



RT

Phoenix

FB

FG STO Processor

NB

Rate Shipment


generated(SHP)

Acct On

EPROOn

Delivery Processor


NB

RT

Receive Product

IF Off

(BSEG)


New Interface


Acct Off

BIL Reviewed


RT

(VTTS/LIPS)


(RECV)

EPRO Off

RT



(SHP)

Xref

VL01N/VT01N


and Shipment

RT

(BSEG)

GenesisInventory

Accounting


ME21N

Legacy Interface

(VTTS/LIPS)








25619SHPMNT

62352ZSHPT_ASN


EDI ADMIN EAM P2P


118

Q&A