Conquering Complex Product Certification in S/4 HANA

Jeanette Hogan, Carpenter Technology

Deloitte Consulting Contributors: Alicia Kelly, Lauren Thanasouras, Esha Ailani, Ekta Shah
SESSION CODE: 10711
Agenda

• Carpenter Technology Overview

• Manufacturing with SAP Classification Integration and Quality Management
• Business Certification Design Requirements – “One Face to the Customer”
• Certification Dashboard Solution: Functional and Technical Design Considerations
• Key Features and Functionality Highlights
• Scalability as Carpenter evolves with S/4 HANA in future rollouts
Carpenter’s SAP Custom Certification Solution
Certification for the highly engineered products manufactured by Carpenter Technology require
both standardization and customization.

Standardization
• The product certification responsibility lies within the manufacturing plant. The SAP
certification, developed to meet industry quality standards, promotes the standardization of
reporting results across the multiple business locations.
– Similar formats of Sales, Delivery, Production, and Quality data sections
– Global test names, Inclusion of Test Methods, Grouping of Quality Data, E-Sign
– Promote “One Face to the Customer”

Customization
• Unique customer requirements drive the need for customization in the selection and
placement of not only the test results but also the sales, production, and delivery data. The
SAP certification allows for this customization by utilizing grouping of data, certification
statements, and data selections.
– Selection of multiple names and addresses for sold to and ship to
– Inclusion of selected batch characteristics such as country of origin, production date and specifications;
– Grouping of test results and certifications statements as defined by the customer.
Carpenter Technology Overview
Who is Carpenter?

Carpenter Technology Corporation is a leading producer and distributor of premium specialty alloys, including titanium
alloys, nickel and cobalt based superalloys, stainless steels, alloy steels and tool steels. Carpenter’s high-performance
materials and advanced process solutions are an integral part of critical applications used within the aerospace,
transportation, medical and energy markets, among other markets. Building on its history of innovation, Carpenter’s
powder technology capabilities support a range of next-generation products and manufacturing techniques, including
additive manufacturing and 3D Printing.
Carpenter End-Use Market Participation
Carpenter is a Specialty Alloys Manufacturing Company
Customer purchase options
• Product forms are selected and MTO/MTS
options chosen to meet lead time and order
quantity requirements.
• A small portion of product portfolio is general
inventory.
• All other products are manufactured to
customer specific requirements.
• May require up to 50 different specifications
including customer specific and industry
standards
Manufacturing with
SAP Classification Integration and
Quality Management
Manufacture Semi-Finished Stocking Points

• Semi-finished (ZSEM) stocking points allow for larger quantity production and
shorter lead times. Testing limits are designed to meet multiple customer and
industry requirements.
• Each intermediate production step is a discrete part number in SAP
Traceability of Specification Identification and Quality Testing

Finished Good Batch Characteristics

• Flows through the ZSEM levels
• Specification identity, revision level
and date
• Batch Number
• Heat Number
• Site of manufacture
• Date of manufacture
• Other specific manufacturing details
Test Plans on the ZSEM levels within
standard SAP QM
Product Certification Requirements –
“One Face to the Customer”
Key Design Requirements for Product Certification
Draft Capability
• Allow the Product Certification process to begin while product is in final stages of production

Visibility
• Dashboard to view backlog and Certification ID status
• Consolidation of certification for child (split) production orders
• View of Finished Good batch lineage

Data Selection
• Discrete selection of tests, inspection methods and batch characteristics from any of the
ZSEM or ZFIN levels within the hierarchy
• Select Sales and Delivery data elements

Placement of Data Elements

• Create groupings for test results and certification statements
• Placement of inspection and test methods per grouping or MIC
• Addition of certification statements, instruction codes/free text, to any grouping
E-Sign & Delivery Certification Requirements
Delivery Update after E-Sign
• E-Sign capability to freeze Quality sections and apply signature of authorized Carpenter
Certification Representative
• Addition and placement of Sales and Delivery information after E-Sign

Print Capability
• Print capability at any point in the process

Template
• Template capability to capture customer certification requirements

Standardization
• Standardized forms across sales and certification documents – “One Face to the Customer”
Certification Dashboard Solution:
Functional & Technical Design Considerations
Functional Design Considerations
Standard SAP Quality Certification functions served as the starting point for Carpenter’s Product
Certification Blueprint design sessions. Key Functional Design Considerations include:

• Design a much more dynamic end-user application without requiring pre-defined templates to be created
or linked to multiple ABAP form layouts for their customer/material combinations

• Collecting the certifiable test result data for a Finished Good that are stored across various inspection
processes throughout the manufacturing and procurement transactions for Carpenter, including test results
logged at other Carpenter plants
• Collecting all of this information programmatically rather than requiring users to build the
lineage for each certification profile eliminated duplicate data entry and provided a system
controlled data repository for each Order/Batch

• We kept the SAP Best Practice approach in mind when designing for the requirement around needing to
add notes/comments to the forms.
• Did not allow users to make uncontrolled, direct form updates
• Introduced the “Free-text statement” concept while ensuring attachment of Cert documents to
delivery line items occur only from within the Cert Dashboard transaction
Technical Design Considerations
Other process teams had enhancements to key objects such as Sales Orders, Production Orders,
Logistics applications, and customer facing forms including labels and shipping paperwork.

• To ensure the Certification Dashboard program logic and the actual Product Certification document were
consistent across the huge integrated platform, the technical developers programmed many Cert
Dashboard functions in an integrated manner which drove the overall efficient design for Carpenter.

• Key Technical Integration Designs for the Cert Dashboard include:

• Sales Order customer text statements selected by the Customer Service Organization can be flagged
as relevant for Certification which automatically flows through to the Cert Statement feature for the
Certification Representative to review or pass through to the form.
• Goods Receipt confirmations from Production as well as Goods Receipts on Purchase Orders for
Finished Goods (only) triggers the Cert Dashboard Request in the Backlog.
• Including the Cert forms in the automatic printing of logistics paperwork based on various rules and
logic per Customer or Delivery Type.
• A custom Cert field was configured on the Delivery Header to block the Shipment transaction from
being completed until Cert forms are attached for each batch picked on the delivery.
Technical Design Considerations (cont.)
• Key technical integration designs for the Cert Dashboard include:
• To provide robust transparency and audit traceability, custom tables on the backend log and track
the User ID and date-stamp for when the Cert document is created or changed, as well as separately
tracking when it is E-Signed and by whom.
• Carpenter is leveraging the SAP Content Server model for several designs including Product
Certification.
• Each time a Cert is re-generated with refreshed/revised data, a new output is attached to the
delivery line item and uploaded on the web-based internal content server.
• The custom output type that was configured to support the Cert form being auto-printed gets
a new corresponding output on the delivery item.
Key Features and Functionality Highlights
Certification Dashboard: Process Flow

Material is Cert line item, containing Cert form is built by users

produced and information specific to the batch designing the layout,
received off of a
Production Order received off of a production order, is encompassing Quality and
into Quality dropped into the Cert Backlog Production data into the draft
Inspection Stock design as required

Cert is E-signed, and material is

released from Quality Inspection Stock by
posting Usage Decision

Batch is picked/packed for an Cert Supporter adds the

SAP Delivery by Shipping
Department. Shipping Department Delivery and Sales information,
communicates the delivery number and attaches the Cert form to
to the Cert Department. the Delivery to complete.
Certification Dashboard: Functional Areas

• Initial entry screen to allow users to narrow down

criteria of the material to be certified
Selection Screen • 3 types of certification supported
• Original Cert Documents
• Re-cert Documents
• Legacy Cert Documents
Full customization
• Status management provides visibility to Cert and to meet customer
product progress requirements
Cert Backlog while maintaining
• Certification serialization
standards across
• Overview screen displays all relevant information to
organization
users to quickly identify line items

• Ability to create and edit all form inputs encompassed

under 3 tabs
Cert Builder • Quality Data
• 4 sections to support catalog grouping
• Sales Data
• Production Data
• Delivery Data
• Allows for test results, statements, batch and material
characteristics to be surfaced
Certification Dashboard: Function Header Bar

Launch the Cert Builder to review the

If you have saved a template during a previous transaction, you
Hierarchy Display List, make edits to the form
can select a new Cert ID with the status of NYS and then click on
layout, perform data selections, and print
Copy from Template to adopt that template into this Cert.
preview the current document.

Select 2+ Cert ID’s that are from the same Leading Production Order
OR from the same Purchase Order/Material, and click Consolidate
to merge the data into a single Cert Document.
Note: Cert Supporter MUST review the data ahead of time to verify
if Certs can be consolidated prior to consolidation.
Error Checking:
- Prevents batches originating from different
Leading (Parent) orders to be consolidated
- Information sets can be grouped for holistic view
of the material
Certification Dashboard: Function Header Bar (cont.)

Refresh the Cert Backlog

List to see new Cert ID’s, When it’s time to sign the Cert Document, click this button to
new or revised data, or apply user’s digital signature to the form.
Production, Sales, and
review the latest status of a Delivery information,
Cert ID Once E-Signed, the signature cannot be undone and the
as well as free text,
Quality Data Tab of the Cert Builder is locked for editing for
can still be adjusted!
Inspection data
This flexibility
supports certifications
that need to be sent
Once Shipping provides a Delivery Number that is ready for
from distribution
the Cert to be attached for shipment, click this button and
A single cert line item centers.
enter the Delivery Number to link to the Cert ID.
can be added to
The Cert Builder screen will open, and certain data can be multiple deliveries if a
selected/maintained and then the Cert can be automatically batch is filling
attached to the Delivery multiple orders
Certification Consolidation: Error Message Examples
Certification Dashboard: Fiori Theme Screen Designs
 Certification Dashboard: Quality Data Tab
Four (4) sub-screens make up the foundation for development of the Cert Form Quality
information
1st ALV Sub-Screen: Groups
Purpose: Add all groups to this section where test related data will
be assigned within the Cert form
• Group names can be dictate by plant users
• Every group must be assigned an Inspection point from a
linked inspection lot, as well as given a Sequence ID.
• Inspection characteristic results of chosen points populate 2nd
ALV.
• Multiple Points → 1 Group as well as 1 Point → Multiple
Groups
3rd ALV Sub-Screen: Cert Instruction Codes
Purpose: Add pre-loaded certification statements to the Cert Form
• Ability to re-utilize standard required statements
• Integrates with Template function to readily access statements
specific to customer, material, etc.
• Statements can be added to any of the groups selected in 1st
ALV
2nd ALV Sub-Screen: Inspections
Purpose: Test results linked to the selected inspection lots/points to
1st ALV are displayed to be grouped and ordered for form output
• Inspection characteristics of one point can span multiple
groups
• Additional data elements such as Test Standard and Inspection
method
• Unit of Measurement Conversion
• Origin of Testing Location
4th ALV Sub-Screen: Free Text Statements
Purpose: Add any ad-hoc free text statements to be surfaced on
form output
• Section can be edited even after cert is E-signed
• Statements can be added to any of the groups selected in 1st
ALV
Certification Dashboard: Fiori Theme Quality Data Screen Design
 Certification Dashboard: Sales Data Tab
Two (2) key features integrate with Sales Orders information to surface data for Make-to-Order.*
Cert Texts from Sales Order
Purpose: Allows user to check notes regarding certification requirements as well as select statements that must appear on the form
• Two types of Cert Texts…
– ZEXT: Actual statements that must be printed on the document
– ZINT: Notes added by Customer Service that are relevant when certifying product

Sales Order Data Attributes

Purpose: Data elements can be sequenced and passed to the form output
• Attributes
– Sales Order number
– Sales Order Line Item
– Customer Name
– Customer Number *Make-to-Stock
– Phone Number scenario
– Customer Material Number handled via
• Partner Types delivery
– Sold-To Party information
– Ship-To Party
– Bill-To Party
– Cert-To Party
 Certification Dashboard: Production Data Tab
Five (5) primary features to provide full picture of product from procurement through pack
(A) Standard Production Data Attributes
Purpose: Pre-defined data elements can be sequenced and passed to the form
output to display in desired order
• Group checkboxes to control form placement of the batch characteristic
data
– Batch Header Level: Check the Group field to display batches
individually with all their pertinent data (underneath each batch #)
– Batch Characteristic Level: Check the Group field(s) to display batch
data grouped at a consolidated level

(B) Additional Characteristic Data Attributes

Purpose: New data elements can be added ad-hoc, sequenced and passed to the
form output to display in desired order
• Click create icon to add as many new rows to list as needed
• Navigate to the dropdown box of newly added rows to select characteristics
– Standard search features to find both material and batch
characteristics
 Certification Dashboard: Production Data Tab
(C) Print - Production Order Number
Purpose: For Cert IDs that have been consolidated into a single cert, the Child
production orders are listed out for selection
• Note: Sequence ID must be assigned to production order attribute to
enable this selection

(D) Print - Batches

Purpose: For Cert IDs that have been consolidated into a single cert, the batches
are listed out for selection
• Checkbox de-selection provides ability to remove batch from Cert form in the
event consolidation occurred incorrectly

(E) Print – Spec IDs

Purpose: Specification IDs listed out to be selected and passed to Cert form
• Spec IDs are pulled from the batch level
• Users can de-select checkboxes for Spec IDs if the product is not to be
certified to a given spec standard
 Certification Dashboard: Delivery Data Addition Process
Delivery number is to be provided by the Shipping Department to complete the Cert form.
Step 1: Select the Cert Line to add a Delivery number
Step 2: Click ‘Add Delivery’ button
Step 3: Enter Delivery Number and click Enter button
– Note if the batch tied to the Cert Line item is not on the
Delivery document, an error message will be generated
Step 4: On the Delivery Data Tab, sequence the given
data attributes and click Save
– Delivery Number
– Delivery Line Item
– Customer PO Number
– Customer PO Date
– Planned GI Date
– Lading Number
– Net Weight
Step 5: Click ‘Attach to Delivery’ button
– Note that a confirmation message will confirm the Cert
form has been added to the Delivery Output
Scalability for Cert Dashboard as
Carpenter evolves with S/4 HANA
Certification Dashboard: Future Rollouts and Improvements
Carpenter will continue to rollout the robust S/4 HANA platform to the remaining PEP companies
as well as to the SAO division in the future. The Cert Dashboard solution for Carpenter was
designed with expansive scalability in mind to allow sales, manufacturing and data management
organizations to grow and refine core processes, while keeping Cert Dashboard flexible enough to
accommodate and scale with those changes.
• Examples of these scalable solutions are:
• Design and implement a complex, custom Carpenter Customer/Product Certification Profile
Template to store ALL settings in all tabs/fields by Material, Spec ID, and/or Customer
• Can be automatically created/saved for future use during the creation of a Cert (no pre-
defined profiles required up front before Cert generation).
• Direct integration with Carpenter’s future Material/Order Spec solution design.
• Auto-Cert functionality for materials that do not require end-user form creation.
• Custom test result inheritance across Orders even if Order is not within the Batch/Order Lineage.
• Supports mill-industry processes where testing at a higher level reduces redundant testing to
be performed as well as eliminates the risk for skewing test results just for Certification
• Certification Reports built directly in S/4 HANA with new configurable buttons added to the
Dashboard to optimize the end user experience
SAP Certification Benefits to Carpenter

• Standardized forms to promote “One Face to the Customer”

• Common data elements across the sites to meet the customer and industry quality
standards such as ISO and AS9100.

• Visibility into the order hierarchy and the capability to pull in Test Results from any
ZSEM or ZFIN production level.

• Capability for customer specific templates to insure consistency in test result

groupings and certification statements.

• Elimination of key stroke errors with the flow of material batch characteristics to
certification
 Thank you for attending my session!
For questions, contact me at:
jhogan@cartech.com

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Conquering Complex Product Certification in S/4 HANA

Jeanette Hogan
Carpenter Technology Corporation
SESSION CODE: 10711
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