BMBC

ERP Lot Track & Trace Capability
for Foods Companies
Steve Twinney
Director, Deloitte Consulting
GMA/FPA Food Supplier Best Practices Conference
October 2,3 2007
Agenda
¾ Food Supply Chain and

linkages to ERP
¾ Sample Track & Trace
Scenario and Demo
(using SAP)
2
©2007 Deloitte. All rights reserved
The Supply Chain and linkages to ERP
Supply Chain
Inside
Manufacturing WHSE Retail
Input Consumer
Providers Processor Processor 3rd Food
Plant A Plant B Party Service
WHSE
Track/Trace Window
Scope of a manufacturers track &

trace responsibilities
3
©2004 Deloitte Consulting L.P. ©2007 Deloitte. All rights reserved
Material Movement Transactions
Dry
Dry Raw
Raw
Goods
Goods Material
Material
Stock
StockRoom
Room Coolers
Coolers
Processing Finished
Finished
ProcessingWork
Work WIP
WIP Packing
PackingWork
Work Goods
Area
Area Coolers Area Goods
Coolers Area Freezers
Freezers
Finished
Finished
Goods
Goods
Coolers
Coolers
4
Material Movements – ERP Transactions
P.O. Receipts Dry

Dry Raw
Raw
Goods
Goods Material
Material
Stock
StockRoom
Room Coolers
Coolers
Supplier
Returns Stock Transfers
Finished
Finished
Processing
ProcessingWork
Work WIP
WIP Packing
PackingWork
Work Goods
Goods
Area
Area Coolers
Coolers Area
Area Freezers
Freezers
Component
Component
Issues Transfers
Transfers Issues
Finished
Finished
Production Goods
Production Goods
Receipts Coolers
Coolers
(WIP) Receipts
(FG) Sales
Order
Transfers Shipments
Physical Count
Adjustments
5
Expanding Search Cone
Finished Good C
MFG Lot #5
Customers
Customer #1
Sub-assembly A MFG Lot #6
Raw Material X MFG Lot #1

Finished Good B
Customer #2
MFG Lot #2 Customer #3

PURCH Lot #1 MFG Lot #7
Customer #4
PURCH Lot #2 Sub-assembly B
PURCH Lot #3 MFG Lot #3 Finished Good D
Public Whs’
Vendor 3rd Pty
MFG Lot #9
WHS
Return to Vendor
6
Finished Good C
MFG Lot #5
Customers
Customer #1
Sub-assembly A MFG Lot #6
Raw Material X MFG Lot #1

Finished Good B
Customer #2
MFG Lot #2 Customer #3

Customer #4
PURCH Lot #2 Sub-assembly B
PURCH Lot #3 MFG Lot #3 Finished Good D
Public Whs’
Vendor 3rd Pty
MFG Lot #9
WHS
Return to Vendor
7
Sub-assembly A
Raw Material X Customers
MFG Lot #4
PURCH Lot #1 Finished Good C Customer #1
MFG Lot #5
Customer #2
Sub-assembly B MFG Lot #2
PURCH Lot #3 Customer #3
MFG Lot #6
PURCH Lot #4 Finished Good B Customer #4
PURCH Lot #5
MFG Lot #3
Vendor
PURCH Lot #6
Return to Vendor
8
Sub-assembly A
Raw Material X Customers
MFG Lot #4
PURCH Lot #1 Finished Good C Customer #1
MFG Lot #5
Customer #2
Sub-assembly B MFG Lot #2
PURCH Lot #3 Customer #3
MFG Lot #6
PURCH Lot #4 Finished Good B Customer #4
PURCH Lot #5
MFG Lot #3
Vendor
PURCH Lot #6
Return to Vendor
9
Analyzing Lot Track/Trace Information
Central tool, which

enables users to
gain extensive
access to
information
relevant to
batches.
Designed as one-
screen-transaction.
Flexible selection of lots on the basis of material-, lot-, stock-,

Shelf-Life-Data - as well as classification-data (e.g. characteristics
like viscosity or density, status of classification).
10
Sample Track Trace Scenario and Demo
SAP’s Batch Management Cockpit
11
Sample Bill of Materials (BOM)
Frozen
Chocolate Chip
Cookie Dough
16 oz
Semi-Finished Packaging Materials
Chocolate Chip
Cookie Dough Liner
Flour
Label
Sugar
Chocolate Chips
Box
Butter
12
Situation-Solution Analysis
CONTAMINATED
CUSTOMER RECALL
BATCH OF FLOUR
Vendor notifies about Contaminated batch of flour
Identify contaminated flour batch purchase order
Identify process orders that used contaminated batch of

flour
( semi-finished and finished goods)
Identify sales orders with products that used contaminated
batch
Match customers using the sales orders
Recall contaminated batch of final product
Check existing inventories of contaminated flour

(raw material, semi-finished and finished goods)
13
Multilevel BOM – Transaction CS11
14
Batch Information Cockpit – Transaction BMBC
Example: Defective Batch # B125
15
BMBC- Top-Down Analysis for Batch # B125
Purchase order
16
BMBC- Bottom-Up Analysis for Batch # B125
Process Orders and Batches of Semi-Finished and Finished goods
17
Sales Orders and Batches of Finished goods
18
BMBC- Top-Down Analysis for Batch # B125
Stock Transport Order
19
Delivery Detail
20
BMBC- Legend
21
22

BMBC

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ERP Lot Track & Trace Capability

for Foods Companies

¾ Food Supply Chain and

Scope of a manufacturers track &

P.O. Receipts Dry

Raw Material X MFG Lot #1

MFG Lot #2 Customer #3

Raw Material X MFG Lot #1

MFG Lot #2 Customer #3

Central tool, which

Flexible selection of lots on the basis of material-, lot-, stock-,

SAP’s Batch Management Cockpit

Semi-Finished Packaging Materials

Vendor notifies about Contaminated batch of flour

Identify contaminated flour batch purchase order

Identify process orders that used contaminated batch of

Recall contaminated batch of final product

Check existing inventories of contaminated flour

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