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:

• You classify materials Fruit juice and Fruit premix as well as the fruit premix batches using a batch class that contains characteristics Fruit content and Acid content.

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.

• You classify material Lemon juice and its batches with a batch class that contains characteristic Acid content.

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.

• For batch determination, you define a batch search strategy that contains the selection criteria Expiration date and Fruit content for material Fruit premix and a batch search strategy that contains the selection criteria Expiration date and Acid content. The batch search strategy you define for the lemon juice allows batch determination based on a proportion quantity, this means, based on the absolute acid content.

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:

1. You create a process order for an order quantity or fruit juice quantity of 500 l for example.
2. The system calculates the following:
• The required fruit premix quantity in proportion to the fruit juice quantity
• The required water quantity and the required absolute acid content in the lemon juice using the formulas

Since no batches have been selected, it uses the data from the material item (line 4).

As a result, the following data is displayed:

1. You carry out batch determination for the Fruit premix component. The system finds two batches with identical expiration dates. You use the following batches:
• One batch with a quantity of 200 L, a fruit content of 10 %, and an acid content of 3 %
• One batch with a quantity of 100 L, a fruit content of 15 %, and an acid content of 2 %

You adjust the original quantity in the totals record of the material item accordingly.

1. You manually start product quantity calculation. The system makes the following adjustments one after another:
1. It calculates the fruit juice quantity using the formula.
2. It updates the absolute acid content of the lemon juice and the required water quantity using the formulas.

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:

1. You carry out batch determination for the Lemon juice component. You use a batch quantity with an absolute acid content of 6 LA and a percent acid content of 25 %.
2. You start material quantity calculation again. The system again updates the quantity of water using the formula and the batch data available now.

The following result is displayed: