Example: Calculations Using Physical Batch Quantities
Scenario
You want to use a fruit premix with varying fruit and acid content to produce a fruit juice whose fruit content is always 5 % and whose acid content is always 2 %.
The fruit premix batches are selected according to their expiration date. You can use different batches whose expiration dates are close together in one order but each batch is always used up completely.
You want to adjust the fruit content of the fruit juice by mixing water into it. The acid content, on the other hand, is adjusted by adding lemon juice with the different lemon juice batches having different acid contents themselves.
Realization
Entries in Batch Management
You define active ingredient management with the following specifications:
In material Fruit juice, you define the fruit content of 5 % and the acid content of 2 % you want to obtain.
In material Fruit premix, you define 10 – 20 % as the allowed fruit content and 1 – 4 % as the allowed acid content. In the batches, you enter the actual fruit and acid contents.
In the material, you enter 20 – 30 % as the allowed interval for the acid content. In the batches, you enter the actual acid content.
In addition, you assign the proportion unit LA (liters of acid) to the material, which you can use to enter the absolute acid content of a specific quantity of lemon juice.
Entries in the Master Recipe and Bill of Material (BOM)
In the BOM, you enter the required component quantities with reference to a base quantity of the product Fruit juice. For the fruit premix that is to be used as complete batches, you enter the required physical quantity in the BOM. Since the lemon juice is to be used depending on its acid content, you plan it in the proportion unit Liters of acid. This means that you do not enter the physical quantity of the lemon juice but the required absolute acid content instead.
The quantities and the characteristic values of material classification are transferred to the Material Quantity Calculation screen in the master recipe. The following data is displayed, for example:
Calculating the Product Quantity
The product quantity in the order is determined by the available fruit premix quantity. For this reason, the system must calculate the fruit juice quantity as follows:
Fruit juice qty |
= |
Absolute fruit content in fruit premix / Intended fruit content in fruit juice |
You can calculate the absolute fruit content of the fruit premix as follows in the master recipe:
Absolute fruit content |
= |
Fruit premix qty * Percent fruit content in fruit premix |
For the system to be able to correctly calculate the fruit content after the batch determination and maybe even a batch split in the order, it must calculate the product sum of all fruit premix batches. For this reason, you must enter the following formula for the fruit juice:
CPSM(004;002) / [001,002] |
Calculating the Lemon Juice Quantity
To obtain the intended acid content of the fruit juice, you must balance variations in the percent acid content of the fruit premix. For this reason, you must adjust the lemon juice quantity. This adjustment is not in proportion to the product quantity.
The following applies for the calculation of the absolute acid content of the lemon juice required:
Absolute acid content |
= |
Intended absolute acid content in the fruit juice – absolute acid content in the fruit premix | |
= |
Fruit juice qty * intended percent acid content - absolute acid content in the fruit premix |
You can calculate the absolute acid content of the fruit premix as follows in the master recipe:
Acid content of fruit premix |
= |
Fruit premix qty * Percent acid content in fruit premix |
For the system to be able to correctly calculate the acid content after the batch determination and maybe even a batch split in the order, it must calculate the product sum of all fruit premix batches. For this reason, you must enter the following formula for the acid content:
[001,001] * [001,003] - CPSM(004;003) |
Calculating the Water Quantity
To obtain the intended fruit content of the fruit juice, you must balance variations in the fruit content of the fruit premix. This means that you must adjust the quantity of water. The following relationship applies:
Water qty |
= |
Fruit juice – Fruit premix qty – Physical qty of lemon juice |
You can calculate the physical quantity of the lemon juice as follows in the master recipe:
Lemon juice qty |
= |
Absolute acid content in lemon juice / Percent acid content |
For the system to be able to correctly calculate the lemon juice quantity after the batch determination and maybe even a batch split in the order, it must, however, calculate the quotient sum of all lemon juice batches. For this reason, you must enter the following formula for the water:
[001,001] – [004,001] - CQSM(006;003) |
Process During Order Processing
In the order, the material data is processed as follows:
Since no batches have been selected, it uses the data from the material item (line 4).
As a result, the following data is displayed:
You adjust the original quantity in the totals record of the material item accordingly.
Since no batches have been selected for the lemon juice, the system uses the data of the material item (line 8 of the graphic below) to calculate the quantity of water.
The following data is displayed:
The following result is displayed: