1. Wyeth’s Experiences with Handling Unit Management
Introduction
Wyeth’s Experiences with Handling Unit Management
Gregory Shannon
Wyeth SAP Core Team

2. Company Profile
Wyeth is a research-based global pharmaceutical company responsible for some of today’s most innovative medicines. Some of which include:
Premarin – Hormone replacement therapy
Prempro – Hormone replacement therapy
Effexor – Rheumatoid arthritis therapy
Protonix – Gastroesophageal Reflux Disorder
Prevnar – Pneumococcal vaccine

3. Company Profile (cont’d)
Wyeth also manufactures a large line of over-the-counter medications available at drug stores and supermarkets everywhere. Some of which include:
Advil family of products
Robitussin & Dimetapp elixirs
Caltrate
Preparation H
Centrum family of products

4. Business Environment
SAP was implemented in February of 2001 at a manufacturing plant in Puerto Rico. The implementation encompassed MM, PP-PI, Purchasing, Quality Management, and Warehouse Management. FI, PM, Finished stock, and MRO purchasing were already live.

5. Requirements
The Manufacturing plant ships Finished Stock to the distribution center, which in turns ships to the customer. There was a need to bar-code a label that is shipped from the Manufacturing plant to the DC.
Handling Unit
Manufacturing plant
Distribution Center
Customer

6. Requirements (cont’d)
The Distribution Centers have the requirement to perform Goods Receipt via an RF terminal into their external Warehouse Management systems.

7. Proposed Solution
Storage unit management did not meet the requirements because:
The SU number did not appear anywhere on the delivery.
The SU number disappeared once the stock entered the GI storage type.

8. Proposed Solution (cont’d)
Handling unit management met the desired requirements because:
The HU number gets packed into the outbound delivery.
At goods issue, it is possible to send the HU number via IDoc into the destination system.
The Handling unit number range could be different than the SU number range due to requirements of the destination systems.
The Handling unit number will never go away.

9. Structure PLANT SLOC SLOC SLOC SLOC WHSE. RM06 1000 1002 - HU 3000WM
WHSE.
RM1

10. Process – Setup Reqs. I
To activate Handling Unit management, the storage location must be designated as HU-managed. This means that all materials in the storage location must have an HU number assigned.
The partner storage location is a non-HU managed storage location into which quantities can be issued outside of HUM. It is also useful in unpacking, scrapping, and transfer postings.
In a WM environment, there must be a repacking storage type designated. Pallets cannot be unpacked from within their primary storage type. A Transfer Order must be created into a repacking storage type so that quantities can be unpacked.

11. Process – Setup Reqs. II
Master data requirements must be followed as well.
Packaging instruction – Piece of master data that tells the HU transaction codes how much of a material is packed into each Handling Unit.
WM II – The palletization information on the WMII view must be equal to the packaging instruction, or picking will become a problem.
Packaging material – When a handling unit is created, a finished material is packed onto an HU, which uses a packaging material (Such as PALLET, BOX, CARTON, etc.)

12. Process – GR Overview
Handling Units
created
(COWBPACK)
Handling Unit
Qtys. updated
(HU02)
Handling Units
received
(COWBHUWE)
Labels and TOs for put-away are automatically generated through configured print parameters. HU label SAPScript is defined as the HU slip in configuration.

13. Process – HU create
After Process Order release for a Finished good, the user runs transaction code COWBPACK. This transaction creates the handling unit numbers that will be assigned to the finished batch based on the order quantity. Each handling unit represents a full pallet of the finished material, with a single handling unit of less than a full pallet.
At this point, the system has only created the numbers to be assigned. Due to scrap factors, shortages, damages, etc., the number of HUs received will differ from what was actually created.
Master data: The Packaging instruction tells the COWBPACK program how many units per pallet.

14. Process – HU Change
If it is determined that a Handling Unit will be received for a quantity different from what it was originally created, the value must be adjusted prior to GR. Adjustment afterwards is a multi-step process.
The original pallet quantity must be unpacked, changed, repacked (all from the same screen), and saved.

15. Process – Goods Receipt
Once all of the necessary adjustments are made, the Goods receipt can take place. Business process in some plants is to receive pallet by pallet. Each GR creates a Transfer Order for put-away into the finished goods staging area. The user runs transaction code COWBHUWE to perform HU GR.
From the HU selection screen, all HUs that will not be received are “deleted” so that the next available HU can be received. This does not delete the HU, it only removes it from the selection screen.
Once the GR is posted, HU labels are generated as the put-away TOs are created.

16. Process – HU Delete
If any Handling Units will not be used (expected yield is several pallets less than what was created), it is good practice to delete the unused Handling Units.
Transaction HUMO is the Handling Unit Monitor. It reports on various statuses of a handling unit, whether it is received, where it is, what delivery it left on, etc.
From this screen, selected HUs can be deleted.

17. Process – Summary
Goods receipt of Process orders using Handling Unit management is done with specific HU transaction codes. Attempting to use MIGO, MB31, etc. will result in error messages.
COWBPACK – Create HU
HU02 – Adjust HU prior to GR
COWBHUWE – Receive HU

18. Process – Example Ia Scenario:
A pallet was received, and a sample must be withdrawn from the existing HU quantity. The user must:
Create a TO to move the pallet into the repacking storage type.
Unpack the desired quantity (the unpacked quantity moves into the partner storage location), repack and save.
Create a TO to move the pallet back into the stocking storage type.
From the partner storage location, the quantity can be withdrawn via standard IM transactions.

19. Process – Example Ib Scenario:
A pallet was received, and a sample must be withdrawn from the existing HU quantity. The user must:
Post MB1a transaction to consume a quantity from HU-managed sloc. Instead of a material document, user gets a Delivery number.
Create Pick TO for this delivery number. A Pick HU is created. This is the new HU for the unpacked amount.
Confirm TO and Post goods issue on the delivery.
SAP transacts handling units with deliveries whenever possible.

20. Process – Example II Scenario:
An entire pallet must be withdrawn for scrapping or issuance to a cost center. The user must:
Create a TO to move the pallet into the repacking storage type.
Run transaction VLMOVE to consume via scrapping, cost center, etc.
VLMOVE takes the place of MB1a and MB1b for certain movements. This transaction can ONLY be used when moving a full Handling Unit.

21. Configuration Configuration settings required:
Storage location must be defined as HU-managed, and the partner storage location must be defined.
HU number range must be set.
WM parameters identified
Repacking storage type and bin
Assignment of SUT to the packaging material type
Control parameters for Pick HU creation

22. Recent Enhancements
After implementation at the Puerto Rico facility, the Richmond plant required some business changes:
HU labels were to generate upon HU creation, not GR.
Put-away TOs were to automatically confirm into the finished goods storage type.
Richmond finished goods were to be managed under the same warehouse number as the raw materials and components.

23. Process – Setup Reqs. III
All of the previous master data still needed to be set up, but in addition, condition records for the HU output also needed to be created. These records specified immediate print to a label printer, and were executed from the COWBPACK transaction.

24. Troubleshooting
There are some current issues that should be taken into consideration:
Packing onto a delivery: If a HU is incorrectly picked, a Pick HU may be inadvertently created. When this occurs, often the user will have to delete a delivery and restart the TO confirmation process. SAP will not allow re-picking of a HU any more than it allows re-picking of a TR once it is fully confirmed. However, with HUs, additional steps must be run to dis-associate the HU from the delivery before the delivery can be deleted.

25. Troubleshooting
There are some current issues that should be taken into consideration:
Full pallet removal: When storing Handling units in a Bulk storage type, take care to verify the master data on the packaging instruction with the WMII palletization data. Inconsistencies will result in more errors than with SUs.

26. Demo: HU Create
Enter the Process order and ENTER.

27. Demo: HU Create
The COWBPACK screen displays the information from the Process Order. The total process order quantity is accounted for. Notice that the last pallet will be a stump of 1,875 EA. Odds are good that the quantity will not be that exact number, so the final HU should be modified before GR is posted. Clicking Save will create the HUs.

28. Demo: HU display
By entering the Batch, the user will report on all HUs for a specific process order.
The system will give the user all HUs associated with the batch specified above. Since the process order equals the batch for a finished good, this is desirable.

29. Demo: HU Display Listed above are all of the HUs for a process order.
Clicking on the circled arrows will “expand” the screen output. That is, it will show the data on the white line, which does not initially appear on screen.
By printing this screen, the user will be able to provide the floor operators a list of all HUs that are expected for an order. If some numbers are not used, they can be noted on the output.
Output the document by clicking Print.
Listed above are all of the HUs for a process order.

30. Demo: HU Change
The screen above starts the transaction to change a Handling Unit quantity prior to Goods Receipt.
This transaction should be done before goods receipt to prevent the need for additional transactions post-GR.

31. Demo: HU Change
Enter the HU number in the proper field and press ENTER. This will show the material-specific information.
The user is changing the quantity that is packed on the HU. Since the operator has informed the user that the quantity is different from what the system thinks, this transaction is necessary.

32. Demo: HU Change
Select both the Handling Unit and the Material lines and click Empty (Unpack). Because the Handling unit was already “packed,” the user must unpack to change the quantity.
The HU must be Unpacked before changes to the quantity can be made.

33. Demo: HU Change
Once the HU is unpacked, enter the new stump quantity and click Pack. The changes can then be saved.
Enter the stump quantity in the Total quantity field, not the Partial.
Selecting both lines and clicking Pack assigns the quantity to the HU. Clicking Save updates the HU for good.

34. Demo: HU Change Running HUMO again reveals the updated HU quantity.
Clicking on the circled arrows will “expand” the screen output. That is, it will show the data on the white line, which does not initially appear on screen.
The displayed HUs can now be received without any further changes.
Running HUMO again reveals the updated HU quantity.

35. Demo: HU Receipt
By clicking Propose HU, the system will display all un-received Handling Units. The user may or may not want to receive all of the displayed HUs.
The COWBHUWE transaction will receive any unprocessed handling units. This transaction can be done multiple times for a process order. At WPC, this transaction is run pallet by pallet.

36. Demo: HU Receipt
By selecting the unwanted HUs and clicking Delete rows, the user can elect to not receive the HUs. They will disappear from the screen.
NOTE: The Handling Unit number will NOT be deleted by clicking Delete rows. All that button does is remove the HU from the screen.

37. Demo: HU Receipt Clicking Save will post the inventory into IM and WM.
At the completion of this step, there should be inventory in both IM and WM for this material/batch. The TO does not print out because it is not needed.
Clicking Save will post the inventory into IM and WM.

38. Demo: HU Delete
After Goods Receipt, the Handling Unit Monitor looks like this.
Clicking on the circled arrows will “expand” the screen output. That is, it will show the data on the white line, which does not initially appear on screen.
The screen above shows the handling units that are received. Notice that the value for Object key has changed. The received HUs appear with a 12, and the un-received appear with a 09. Since the floor has informed the user that there are no additional HUs to be received, the two un-received HUs can be deleted. To accomplish this, select both lines and click Delete selected HUs.
NOTE:
Performing this task is not required as part of the process, nor does it affect inventory in any way. It is desirable from a clean-up perspective that this transaction be performed. If it is not, the potential exists that the unused HU labels may output if transaction VL74 is run without a process order specified.

39. Demo: Master Data Packaging Instruction:
This data element applies to Finished Goods. A Packaging instruction tells the system how much of a material gets packed onto a pallet. This is accessed when performing transaction COWBPACK.
The Target quantity information MUST correspond to the Warehouse Management II view of the material master. The reason for this is as follows:
At Goods Receipt of a FERT (COWBHUWE), the packed quantity is viewed. This data comes from the packaging instruction.
At TO create from GR, the Warehouse Management II view is accessed. The put-away TO will be created with this value and not look at the packaging instruction at all.
If the quantities are not equal, the situation must be investigated. Which value is correct?

40. Demo: Master Data Packaging Instruction Determination:
This setting is necessary to assign the instruction to the material. It looks like it should already be assigned, but when COWBPACK is run, it looks here to see a link.
Storage section:
This is a setting that is accessed at put-away for a material. Based on the setting in the material master (see slide 277), the system will determine whether or not a material can be placed in a bin.
Picking area:
Storage section is to put-away as Picking area is to picking. This data element is primarily used in the splitting of Transfer orders.
Storage bin type:
This is often just PL for pallets, but in some Bulk storage storage types, this can be used to determine how deep a storage bin can be. This field, combined with the bulk storage indicator on the material master (see slide 277) determines how many pallets of a material can be placed.
Verif. Field:
This field is used in the RF process. This will normally be the same value as the storage bin itself. In the scenario shown above, the value is different because the barcode vendor did not create the labels properly. Since the information shown above is what the RF device reads when the bin is scanned, that must be populated in this field to get the RF to work properly.
Total capacity:
Determines how many units can fit in the bin. Units is defined in configuration, and can be a pallet, box, drum, etc.
Utilization:
This tells the user how full the bin is.
No. of quants:
This shows how many pallets are in the bin. If the bin goes 4 deep, and there are 8 pallets in the bin, the logical assumption is that the material master setting is “2” for Bulk storage indicator. See slide 277 to check.

41. Questions??? Gregory Shannon Wyeth Pharmaceuticals 484-563-3070
Storage section:
This is a setting that is accessed at put-away for a material. Based on the setting in the material master (see slide 277), the system will determine whether or not a material can be placed in a bin.
Picking area:
Storage section is to put-away as Picking area is to picking. This data element is primarily used in the splitting of Transfer orders.
Storage bin type:
This is often just PL for pallets, but in some Bulk storage storage types, this can be used to determine how deep a storage bin can be. This field, combined with the bulk storage indicator on the material master (see slide 277) determines how many pallets of a material can be placed.
Verif. Field:
This field is used in the RF process. This will normally be the same value as the storage bin itself. In the scenario shown above, the value is different because the barcode vendor did not create the labels properly. Since the information shown above is what the RF device reads when the bin is scanned, that must be populated in this field to get the RF to work properly.
Total capacity:
Determines how many units can fit in the bin. Units is defined in configuration, and can be a pallet, box, drum, etc.
Utilization:
This tells the user how full the bin is.
No. of quants:
This shows how many pallets are in the bin. If the bin goes 4 deep, and there are 8 pallets in the bin, the logical assumption is that the material master setting is “2” for Bulk storage indicator. See slide 277 to check.