DR. LAUTERBACH & PARTNER GMBH

Packaging Business Solutions

LP offer best-in class business solutions to packaging manufacturers supporting the industry specific end-to-end business process and enabling packaging companies to manage the entire value chain across business networks. LP packaging has been successful in many packaging businesses in Europe and beyond ranging from global enterprises to small business.

LP Packaging for End-to-End Business Process Solutions

LP packaging is a comprehensive industry solution based on the world leading mySAP ERP solution. LP packaging uses the broad configuration and customization capabilities of mySAP ERP and software add-on`s to deliver a solution which perfectly fits the packaging business requirements, increasing productivity and providing competitive advantage. Enterprise-wide integration is achieved through the JDF/JMF interface and numerous interfaces to the industries` technical systems. Software add-ons are fully compliant with SAP`s software development guidelines and do not modify the SAP code. LP packing operates at any time with the current version of the SAP software.

LP packaging is currently available for SAP ECC 5.0 and the associated SAP mill products. Best practices in the packaging industry developed, tried and tested for more than a decade in leading packaging companies across Europe allow for a fast, cost effective and low risk implementation of the world leading business software package. Best Practices are made available to the customer in his system at project start for presentation and training purposes along with a comprehensive Business process documentation comprising flow chart representations and detailed textual descriptions of the business processes, organizational units and roles.

Planning, Management, Financing and Data Collection through LP Packaging

LP packaging implements the following practices:

• product development
• printing forms production
• product specification
• product family related manufacturing paths
• tools and printing forms management
• costing of new products
• sales order management
• transportation planning
• industry specific planning processes
• planning and availability checks
• supply chain management
• detailed planning and scheduling
• reel management
• materials management and purchasing
• warehouse management and handling unit management
• production and completion confirmation processes
• cost, activity and results accounting
• finance
• quality management
• shop floor data collection and machine pre-setting through JDF/JMF interface

Business Process Representations

The following paragraphs give an overview of essential features and characteristics of the LP packaging best practices per business segment. Detailed descriptions of business processes and flow chart representations of the business processes are included in the delivery.

Product Development

- development order management
- specific support for development services
- electronic transfer of order queues to the development department
- recording of product development services without vouchers
- complete integration of servicing with material management
- resource planning
- invoicing out of development orders
- automatic analysis of development cost and revenues
- management of CAD drawings
- management of  detailed drawings
- management of the change history and where-used lists
- classification of CAD drawings
- retrieval of CAD drawings with reference to specification features
- system supported links to product, CAD layout, tool and version control
- visualization of CAD drawings
- traceability of CAD drawing
- interface to CAD system
- download of product features from sales orders

Printing Forms

- order management for printing form production
- specific support for printing form services
- electronic transfer of order queues
- recording of product development services without vouchers
- complete integration of servicing with material management, controlling and finance
- resource planning, detailing of services
- invoicing out of the printing form production order
- automatic analysis of printing form cost und revenues
- management of print layouts with reference to version and status
- management of change history
- classification of print layouts
- retrieval of print layouts with reference to customer item
- system supported links
- on-screen visualization of print layouts (PDF link)
- traceability of print layout versions per order
- structured colour specifications
- product specification print-out for external use
- automatic assignment of sort codes and gluing edge codes

Product Specification

- unambiguous product identification
- order independent and redundancy-free documentation
- assignment of version controlled printing layouts and CAD drawings
- change history
- print-out of the product specification (product sheet)
- archiving and labelling of important product documents and product records
- multi-level product hierarchy

Planning Of Product Family Related Manufacturing Paths

- configurable optimal routings per product family
- order related configuration
- assignment of components, production resources, instructions and inspection features to operations
- algorithms for automatic calculation of planned waste
- integrated version-controlled tool management and printing form management
- algorithms for automatic consideration of set-up times dependent on order variables
- algorithms for the automatic consideration of machine performance
- conversion factors for components and operations
- integration of ink specification, recipe management and ink consumption algorithms
- alternative routings and cross-plant routings
- external processing (subcontracting)
- single-level and multi-level routings for make-to-stock / make-to-order
- one-off and combined printing
- configurable routings for multi-part items
- pre-defined dependencies for typical product groups

Manufacturing, Purchasing and Maintenance of Tools and Printing Forms

- tool order management
- integration of tool management, material management, controlling, and finance
- invoicing of tool costs based on tool orders
- automatic analysis of tool cost per product family, customer and business area
- allocation of maintenance cost  in proportion to print order quantity
- version control of tools and printing forms
- link of technical documents to tools and printing forms
- tools master containing technical data
- maintenance notifications and maintenance orders, automatic availability check
- standardized tools purchasing process
- cylinder management (gravure printing, flexo printing)

Costing of New Products

- integration of costing of new products into sales, material management, production, controlling, finance
- configurable routing independent from individual products
- algorithms for optimizing blank dimensions
- automatic multi-level waste calculation accounting for various influencing factors
- automatic selection of operations and components based on user`s  parameter settings
- integrated tools costing, wear and tear costing
- calculation of freight and stock costs, sales reductions, rebates and discounts
- fast calculation of scaled quantities and technical alternatives
- pricing proposal based on specified target gross margin
- combination of multiple products in a single quotation
- automatic identification of quantity-dependent raw material prices
- manufacturing costs report and price analysis report
- generation of the product specification in the quotation document
- quotation tracing and control of success

Sales Order Processing

- independent sales and production orders
- configurable sales order positions, stock items, trading goods and sets
- sales order entry
- automatic order generation via EDI
- order generation with reference to contracts; contract processing
- support of pricing
- integrated order calculation; price analysis
- sales statistics and sales history
- call-off management related to sales orders
- identification of sales order positions
- automated invoicing of delivered goods
- returns and credit note processing
- integration with finance

Transportation Planning and Shipping

- automated generation of delivery-due lists
- overview of finished good stock and planned production dates
- integrated transportation planning for combining deliveries into shipping orders
- freight calculation based on freight tables
- shipping order management, order tracing and order accounting
- printout of delivery and transport documents, customs handling
- integration with finance

Business Process Management

Industry Specific Planning Processes

- Pre-planning of critical materials and bottleneck capacities
- Pre-structuring of the production plan
- Order calculation and sales price calculation
- Automatic generation of production orders per sequence

Planning and Availability Checks

- Automatic reservation of materials combined with availability check
- Generation of purchase requisitions and automatic transfer to purchasing
- Automatic material requirement planning for stock material
- Automatic reservation of capacity requirements, graphical and tabular views of capacity loads, combining of production orders, concurrent resource planning
- Automatic transfer of planned production orders to scheduling
- Automatic availability checks for tools, printing inks, ok-to-print
- Pre-production of semi finished goods/make-to-stock production
- Cross-company and inter-company business

Supply Chain Management

- SCM agreements with customers and suppliers
- Presetting of electronic data interchange (EDI) for standard messages
- EDI capability (excluding EDI-converters to non-SAP systems / different SAP data models)
- Scheduling agreement / forecast delivery schedule
- Vendor managed inventory, consignment stock
- Costing, valuation and results analysis for SCM finished goods and product families
- Finance integration

Scheduling

- Integrated scheduling with graphical user interface
- Automatic planning processes, sorting of production orders
- Automatic availability checks for material, tools and ok-to-print
- Automatic warning when exceeding confirmed delivery dates
- Release of production orders, display of released order queue at production terminal
- Capability to interconnect to machine data capture systems
- Splitting of production orders and automatic dispatching of remaining quantity

Material Management

- General coding concept, material classification
- Purchasing with purchase requisitions, contracts, purchase order, etc.
- Customer`s claims processing, debit notes
- Design of purchasing organisations independent of company codes
- EDI capabilities, SCM agreements with suppliers
- Purchasing statistics and vendor evaluation
- Batch management and batch tracing
- Warehouse management, automatic inventory record keeping

Warehouse and Handling Unit Management

Handling Units (HUs) are groupings of material representing real units like reels, covering boxes, pallets etc. Every HU has a unique Id. Full traceability of the material flow from the supplier to the customer is available. HU management is basis of machine-readable material identification.

- Maintenance and unique identification of packaging units
- Inventory management by batches and storage units
- Purchasing with purchase requisitions, contracts, purchase order
- Barcode control of material movements per packaging unit 
- Warehouse management, stock removal / stock placement strategies

Production and Completion Confirmation

- Full integration of production
- Event-driven completion confirmation
- Warnings at impending under delivery or over delivery exceeding fixed tolerances
- Unscheduled tasks, ad hoc external order processing, cross-plant production, material movements and supplies
- Rework and excess work, manufacturing of replacements, sorting orders
- Capability to include: in-process inspections, inspection characteristics, quality inspections
- Batch related goods issue and backflushing
- Automatic posting of tool strokes / rotations
- Special production orders for mixed colours
- Production information system

Cost Accounting and Results Analysis (Controlling)

- Customised costing sheet (full cost) and calculation of contribution margin
- Costing of quotations, sales order costing
- Results analysis
- Pre- and post-calculation of service orders
- Information system displaying variances
- Integration of cost centre controlling and financial accounting
- Preconfigured industry specific information system

Finance

- Presetting of master data
- General ledger- balance analysis, automatic clearing, reporting, closing, and planning
- Accounts payable
- Accounts receivables
- Banks- Incomings, outgoings, data medium exchange
- Fixed assets- Acquisition and retirement, depreciation, value corrections, reporting, integration in cost centre accounting
- Integration of financial accounting in controlling (CO), materials management (MM), production (PP), sales (SD) and customer services (CS).

Quality Management

- Fully integrated quality management functionality, GMP compatible, auditable
- Defect evaluation lists
- Test equipment management
- Planning and processing of goods receipt inspections, laboratory tests, in-process and final inspections
- Automatic generation of quality notifications
- Evaluation of inspection orders and customer complaints, defect statistics

Product Specification

Parameter controlled product specification including the documentation of product features required by and guaranteed to the customer.

Technical Documentation Interface

Export of SAP documents like samples and printing layouts with reference to document type, number, description, version, status and customer instructions into technical systems like CAD, image editing, packing line and robots.

JDF/JMF Interface

- JDF / JMF support
- order reference for machine pre-settings
- production data collection
- machine data collection
- electronic job ticket
- display of linked documents