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In the master recipe, the processes (list of operations/ a given
sequence/ task list) to be used for producing materials as well as the
resources and components required for production are defined.
A master recipe consists of a header and several operations,
each of which is carried out at a resource. An operation is subdivided into
phases.
A phase is an independent process step that contains the detailed
description of a part of the entire manufacturing process. Phases are carried
out at the primary resource of their superior operation.
At MYCOMPANY, we would create Master Recipe for semi-finished and
finished materials. At MYCOMPANY, the master recipe would consist of multiple
operations and phases (sub-operations).
The way phases are related to each other specifies the sequence of the
manufacturing process. Phase relationships can be sequential, parallel,
or overlapping.
A phase contains standard
values (Standard values are used in costing, scheduling, and capacity
planning to calculate costs, execution times, and capacity requirements) for
activities. These values serve to calculate dates, capacity requirements, and
costs.
Creation of Master Recipe
Process
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Description
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Process owner
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Triggering event
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Create Master
Recipe
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A fundamental
activity required for all types of film production.
The NPD Manager
would define a base quantity for the finished as well as semi-finished
products and corresponding to this base quantity would maintain the operating
time standards for the production. The NPD Manager would also select a
resource at which a particular operation could be performed.
In a recipe the
relationship between an operation (phase) and component allocation is also
defined. The NPD Manager would define components those would be issued
against an operation. This process is called Component Allocation.
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Manager NPD
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When SAP landscape
is being created or when a new material would be brought into production.
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Create Alternative
Recipe
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Since at MYCOMPANY,
similar type of products could be produced at more than one resource, in such
a case, multiple recipes would be created in the system, termed as
ALTERNATIVE recipe.
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Manager NPD
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When a base recipe
already exists and there are multiple ways methods or formulations existing
for the production of same product.
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At MYCOMPANY, the Manager NPD is currently
responsible for maintaining both the BOMs as well as routings (the task
list/recipe).
The NPD Development Master recipe will be created as shown below
Editing Master Recipe (To-Be Process)
Process
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Description
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Process owner
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Triggering event
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Edit Master Recipe
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The NPD Manager
may decide to edit a master recipe for a particular film if there were any
change in the formulation.
While editing a
recipe, the NPD Manager may edit the base quantity, the number of operations
or the component allocation.
The NPD Manager
may also edit a master recipe in case of new machine procurement. For example
if MYCOMPANY decides to scrap film line 1 in future and procure a new machine
film line 4 instead. In this scenario, master recipe would also be edited.
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Manager NPD
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Any
change in Master recipe has to be brought via CHANGE CONTROL initiated and
approved by QA. At MYCOMPANY, there are following possibilities because of
which the master recipe may be edited:
1.
Change in status i.e. from development (Created) to
Commercial (RELEASED GENERAL).
2.
Creation of a new resource (Installation of new
plant or equipment resulting in new standard values for a given task list).
3.
New BOM definition (new substitute or quantity structure).
4.
Changes in batch size.
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