Using Business Information Warehouse (BW) for EHS ReportingSession 3501

Carolyn Redeker, Mike Kabjian, Vinod Narayan

Agenda

• Project Drivers• Business Requirements• Reporting Strategy• Reporting Example• BW Challenges• Conclusion

Project Drivers

• Need for single EHS reporting system– Both production & sales data– Reports tailored to regulatory

requirements• Opportunity

– Company moving to SAP• Sales system went live late 2002• Production systems now being developed

– EHS Product Safety module fit requirements

Expected Benefits

• Time saving

• Increased accuracy

• Consistent data across many reports

• Framework for future reports

Business Requirements Company

• The Clorox Company makes a wide range of consumer products

– Laundry Products

– Water filters

– Plastic bags, wraps, and containers

– Auto Care

Business Requirements Company

– Insecticides

– Home Care Products

– Charcoal

– Food products

Business Requirements Company

• Core value: ‘doing the right thing’– Regulatory compliance is critical– Accurate regulatory reporting is key to

compliance

Business Requirements Regulations

Sales and Production based reporting• FIFRA

– Production reports– Sales-based fees and assessments– Export labeling

• TSCA 12B– Export notification

Business Requirements Regulations

• SARA 313– Toxic Release Inventory

• VOC monitoring– State and federal reports of VOC sales

• Recycled resin content– Plastic packages– Trash bags

Business Requirements – Clorox systems environment

• Patchwork legacy systems– Regulatory reporting has been largely manual– Painful to ensure we have all data

• In process of SAP implementation– Order-to-cash process went live last year– Manufacturing systems going live this year– EHS implementation going live with

Manufacturing systems

Business Requirements – Software

• SAP 4.6c• EHS 2.7b• BW 2.1c with upgrade to 3.1

– Reports designed for BW 2.1c– System will be upgraded to 3.1 before

go-live

What is SAP-BW?

Business Content predefined information models, (InfoSources, InfoCubes, Queries) predefined extractors for many R/3 and non R/3 applications (but not EHS)

SAP Data Warehousing Solution R/3 and non-R/3 data extraction automated central control

R/3 other

Information Analysis user interface based on Excel user can tailor information drilldown capability

Why BW?

• Data warehouse– Historical data available for analysis

• More flexible than ABAP reports– Allows various levels of aggregation– Fewer BW reports required for same

output• Outputs data in spreadsheet format• Could produce formatted reports

– not in current scope

Reporting Strategy• ABAP used to monitor alignment of EHS and

Material Master data• BW used for all regulatory reports

– TSCA export notifications feasible for EHS’s MSDS shipping process, but too small to justify effort.

• BW cube for each implementation area– Procurement– Inventory– Deliveries– Production– Invoices

BW Reporting Example

BW Reporting Example

• Quantity of 1,3,4 tri-methylbenzene in all annual shipments (deliveries) from an automotive plant.

• Used to support Toxic Release Inventory (TRI) reporting

Caveats

• Very small subset of overall TRI solution

• Goal is to provide a “mass balance” via several different BW reports– What comes in (purchase orders)– What’s produced (production orders)– What goes out (deliveries)– What stayed (inventory)

More Caveats

• Lots of Clorox-specific assumptions– Custom properties tree– Bill of materials used extensively– Specialized EHS substances and data

structure

Expected Result

Delivery data for EHS regulated substancesReporting period: 1/1/04 - 12/31/04Regulatory list: TRIPlant: U0A8

List substance name CAS NumberTotal chemicaldelivered (lbs)

1,3,4-trimethylbenzene2-ethyl-1-hexanolPropylene oxide

108-67-9104-76-775-56-9

28,432 lbs22,764 lbs 5,121 lbs

Overall Structure

1,3,4Trimethylbenzene

Solvent

Formula

Automotive Product24/8oz

Automotive Product48/4oz

Automotive Product24/12oz

EHS Structure

1,3,4Trimethylbenzene

Solvent

List substanceTRI, RQ 25,000 lbsThreshold 1.0

Raw substance3% 1,3,4 Trimethylbenzene

SolventRaw Material (ROH)Base unit: 1 pound

EHS

MM

MM Alloc. 1:1

Solvent

Formula

Automotive Product24/12oz

Finished material (FERT)BOM quantity: 40 cases

Semi-finished material (HALB)BOM quantity: 20 gallons

Raw Material (ROH)Base quantity: 1 pound

Plant: U0A8

Bill of Material Structure

General Assumptions

• Reporting is plant-specific

• Data typically summarized for a year

• Data reported on component level - 1,3,4 trimethylbenzene

• Must report in pounds !! !@*%!

Assumption 1

• Accurate list substance data maintained

Assumption 2

• Accurate raw substance data maintained

Assumption 3

• Conversion factors maintained for all relevant materials in BOM structure– Conversion to pounds (i.e. cases to

pounds or gallons to pounds)

Assumption 4

• Bill of material maintained accurately.

LabelFormula

WaterClosure

Step 1

• Transfer EHS master data to BW using custom ABAP program

SUBID SUBCAT NAME CASNUMLS0003 LIST_SUB 1,2,4 Trimethylbenzene 95-63-6

Step 2

• Transfer EHS and BOM composition data using custom ABAP program

PLANT MATNR AMT_MAT LIST_SUB LBS_LISTU0A8 168 1 case LS0003 0.054 lbsU0A8 176 1 case LS0003 0.023 lbs

Step 3

• Transfer transaction data and combine with composition data

DELIVERY MATNR QUANTITY LIST_SUB LBS_LIST800345 168 45 cases LS0003 2.43 lbs800457 168 80 cases LS0003 4.32 lbs800756 176 50 cases LS0003 1.15 lbs

Step 4

• Regulatory expert executes BW query with desired parameters

• BW query summarizes data and adds necessary ‘attributes’

List substance name CAS NumberTotal chemicaldelivered (lbs) RQ_MFG

1,3,4-trimethylbenzene2-ethyl-1-hexanolPropylene oxide

108-67-9104-76-775-56-9

28,432 lbs22,764 lbs 5,121 lbs

25,000 lbs25,000 lbs25,000 lbs

Challenges in Implementing BW

for EH&S

IndustrySource Data

Pricing

B2B

R/3 (HELM)

CRM

DataIntegration

andCleansingProcess

Data Warehouse

SCM

HR

External

InformationAccess

Metadata

Reporting

Web Reporting

Data mining

DATA CAPTURE• Transaction and master data source

systems identified

• Data cleansed

• Data extraction procedures/methods identified

DATA RETRIEVAL• Query created and executed

using BeX Analyzer

• selection criteria entered

• Data retrieved from cubes

• Report presented in Ms Excel

DATA STORAGE• Data model created/maintained

• Data extracted from source system and loaded

• Data transformed and stored in infocubes

BW Schematic

BW Challenge

No Standard Business Content from SAP for EH&S

• Piggy Back approach for transaction data by using Business Content extractors for Delivery, Billing, Purchasing, Production & inventory.

• Substance Master data loaded through generic extractor created from infoset.

Business Content DataSources

for Transaction Data

DeliveryBilling

InventoryProductionPurchasing

Generic Datasource for Substance Master Data

BW Challenge Resolution

BOM Explosion from finished product material to list substance level.

Finished Product

Raw Material Raw Material Label Material

Raw Mat. Substance

Listed Component

Listed Component

BW Challenge

• Create an ODS to capture the BOM structure. The ODS would also store the percentage of component in a higher Level item

• The ODS is populated by a generic datasource created from an Infoset Generic Datasource

Based on ABAP Program

BOM ExplosionODS

BW

R/3

BW Challenge Resolution

Exploding a single line of transaction data into multiple lines corresponding to quantities &

amounts for listed materials

BW Requirement

Deliv Doc Item Material Raw Mat Listed Mat.

Regulation List Mat qty

9000 100 M1 R1 C1 TRI 30

9000 100 M1 R1 C2 VOC 40

9000 100 M1 R2 C3 TSCA 30

R/3 Transaction data

Deliv Doc Item Material Qty

9000 100 M1 100

BW Challenge

In the update rules for the infocube, determine all the components of the material by doing a lookup on the BOM explosion table. Split the key figures (quantities & amounts) into the corresponding quantities for the components.

R/3 Delivery Item Datasource

BOM ExplosionODS

R/3

EH&S Delivery Cube

Update Rules

Comm Structure

BW Challenge Resolution

Handling key figures at different levels of granularity in one Infocube – Finished Product, Raw Material & Listed Substance key figures

Deliv Doc

Item Finished Product

Raw Mat

Listed Substance

Finished Product qty

Raw Mat qty

Listed Subst qty

9000 100 M1 R1 C1 100 50 30

9000 100 M1 R1 C2 100 50 20

Material Qty

M1 200

Raw Material

Qty

R1 100

Listed Substance Qty

C1 30

C2 20

Cube Structure

BW Challenge

1. Finished Product and Raw Material quantities are stored in separate key figures2. When reporting on Listed substances, the listed substance key figure is used.

Such queries are always filtered by Regulation3. When reporting on Finished Products or Raw Materials the corresponding key

figures are used. All three key figures are never used simultaneously in one query

Deliv Doc

Item Finished Product

Raw Mat

Listed Subst.

Reg List

Listed Subst qty

RawMat qty

MatQty

9000 100 M1 R1 C1 TRI 30 0 0

9000 100 M1 R1 C2 VOC 20 0 0

9000 100 M1 R1 0 50 0

9000 100 M1 0 0 50

Finished Product

Qty

M1 50

Raw Material

Qty

R1 50

Finished Product Report

Raw Material Report

BW Challenge Resolution

F1

Raw 1 Raw 2

Comp 1 Comp 2

F1

Raw 1 Raw 3

Comp 1 Comp 3

BOM Structure 05/01/2003 BOM Structure 05/15/2003

Doc# Item Mat Qty

9000 100 F1 100

Doc# Item Mat Qty

9000 100 F1 80

Handling changes in BOM structure after a transaction document (for e.g. delivery) has been created but not closed. This leads to a situation in which changes to the delivery document are based on the new structure leading to data discrepancy in BW.

BW Challenge

R/3 Delivery ItemDatasource

R/3

EH&S Delivery Cube

BOM ExplosionODS

Deliv Item ODS

Logic in Update rules to make sure document is Closed before loading

to cube

BW

BW Challenge Resolution

BW Challenge

Co-existing and removing dependencies with existing delivery, billing, production,

procurement & inventory cubes in the BW production environment. This is particularly

relevant because we share extractors & datasources with them.

BW Challenge Resolution

• Data is loaded into an intermediate ODS before update rules are applied in order to delink from the existing cube and also improve load performance. R/3 Delivery Item

Datasource

EH&S Delivery Cube

BOM ExplosionODS

Deliv Item ODS

Existing Cube inProduction

Lessons Learned• Get all the input

– EHS reporting touches many modules– Check assumptions with process experts in all

areas

• 80/20 rule– Don’t design for exceptions that happen 1% of the

time.

• Focus on the data, not the regulatory form– The data is the biggest user need.

• Don’t try to do it all in one report. – Provide options for cross-checking and validation.

Conclusions

• We have designed a system that accomplishes our objectives.– Coherent source for regulatory reports– Report data sorted by regulation– Easier for regulatory experts to do their

jobs well.

• Business processes will be key to ensure data and reporting integrity

Thank you for attending!Please remember to complete and return your evaluation form following this session.

Session Code:3501