Quality Management
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Doc Id: Business_Blueprint_PP_1.0
BUSINESS BLUEPRINT
KAY BOUVET ENGINEERING PVT.LTD.
MY SAP ERP IMPLEMENTATION PROJECT
PP MODULE
SANDESH L.BONDE
SAP Consultant-PP,
ADROIT INFOTECH PVT. LTD. PUNE.
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MR.KHANWILKAR
B.P.O.
K.B.E.P.L.
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MODULES TO BE IMPLEMENTED
NO.
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MODULE
1
PP MODULE
2
QM MODULE
3
SD MODULE
4
FI MODULE
5
MM MODULE
6
CO MODULE
7
PS MODULE
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CONTENTS
No.
Topic
Page numbers
Start
1.
PURPOSE
04
2
PRE REQUISITIES
04
3
ORGANIZATIONAL STRUCTURE
04
4
MATERIAL MASTER
07
A) BILL OF MATERIAL
09
B) WORK CENTER
11
C) ROUTING
15
5.
PRODUCTION PLANNING- DEMAND MANAGEMENT
19
6.
PRODUCTION PLANNING -MRP
20
7
MRP CONTROLLER
22
8
CAPACITY PLANNING
22
9
PRODUCTION PLANNING
25
10
PRODUCTION PROCESS EXECUTION
28
11
SAP PROCESS FLOW
31
12
PP STANDARD REPORT
32
13
ANNEXTURE 1
BUSINESS PROCESS OWNER’S ACCEPTANCE SIGN
OFF (BBP)
33
14
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1) PURPOSE:This document describes the proposed blue print for SAP Implementation at Kay Bouvet
Engineering Pvt. Ltd. (KBEPL). It outlines all the business processes associated within
the scope of implementation. The intent of the document is to define the TO-BE model
for the process for which an AS-IS study was conducted during the knowledge gathering
phase.
The production planning within SAP (PP) would encompass all activities relating to
Material Requirement Planning (MRP) and processing through production. It would
include master data maintenance and the controlling transactions needed for the same.
The document is a collaborative effort between the implementation team of Adroit
InfoTech Pvt.Ltd., Pune and the Core Team of Kay Bouvet Engineering Pvt. Ltd. The
document also represents the agreement of the core team to the proposed processes in
individual modules of the project and also of the deviations, where an agreement needs
to be reached on the process change. The blueprint aims to cover all the business
processes within the scope of the project and in case there are any processes which are
not covered for lack of clarity, better solution, etc these would be detailed as additions to
the blueprint as and when they are ready.
2) PRE- REQUISITIES:-
MASTER DATA & ORGANIZATIONAL DATA
We are required to have essential master and organizational data to perform the activity,
such as the data reflects the organization structure of K.B.E.P.L. and master data that
suits its operational focus.
Following are the lists of data required.
• Organizational Structure
•
Material Master
•
BOM
•
Work center.*9369*-3
•
Routing
3) ORGANIZATIONAL STRUCTURE:3.1 AS-IS AT KBEPL
At present no formal organizational structure exists at Kay Bouvet Engineering Pvt.Ltd.
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3.2 TO-BE AT KBEPL
KAY GROUP
CLIENT
KBEL
COMPANY CODE
B0
PRODUCTION PLANT
STORAGE LOCATION
Capacity
KB01
SL 01
WORK CENTER
EQUIPMENT
KB02
SL 02
KB03
SL 03
WC 01
WC 02
WC
03
EQ
EQ
EQ
COMPANY
A company is an organizational unit in accounting, which represents a business
organization according to the requirement of commercial law in a particular country. In
the SAP system, consolidation function in financial accounting is based on companies.
COMPANY
KAY GROUP
COMPANY NAME
KAY BOUVET ENGINEERING PVT.LTD.
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For Production Planning Module, Plant and Storage Locations are the one’s which are
relevant. Detailed Organization Structure would be covered in more detail in FI (Finance)
Module, MM (Material Management) Module and SD (Sales and Distribution) Module.
COMPANY CODE
•
Under the company, there will be 1 Company Code.
•
A company code is an organizational unit of external accounting for which a
complete, self contained set of accounting can be created. This includes the entry
of all transactions that must be posted and creation of all items for legal
individual financial statements, such as the balance sheet, profit and loss
statements.
•
The company code will be created in the system for KBEPL will be as under.
No.
Company Code
Name of the Company
1
KBEL
Kay Bouvet Engineering Pvt.Ltd.
PLANT
•
A plant is an organizational unit which subdivides an enterprise according to
production, procurement, maintenance and material planning.
•
It is the place where materials are produced or goods and services are provided.
•
A plant s assigned to company.
•
A plant also has following in SAP ERP:
•
An Address
A Language
A Country Assignment
A Work Day Calendar
A plant is assigned to company.
•
Purchasing
•
Organization and sales organizations are assigned to plants.
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No.
Plant Code
Name Of the Plant Code
1
KB01
KBEPL Unit I
2
KB02
KBEPL Unit II
3
KB03
KBEPL Unit III
STORAGE LOCATION
•
A location within a plant where inventory is stored.
•
In KBEPL following locations are decided for Logistics.
No.
Storage Location
Type of Storage Location
1
KB11
FINISHED GOOD
2
KB12
SEMI FINISHED GOOD
3
KB13
SALES RETURN, REWORK & SUBCONTRACTING
4
KB14
RAW MATERIAL
5
KB15
GENERAL STORES
6
KB16
SCRAP STORES
4) MATERIAL MASTER:-
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Doc Id: Business_Blueprint_PP_1.0
•
The material maser contains all the information of the material that a company
procures produces, stores and sells.
•
The entire production process outlined for KBEPL can be described as follows:
I) Material planning through Customer Schedule.
II) Material Requirement Planning.
III)Production Execution.
IV) Dispatching.
PROCESS FLOW CHART AT KBEPL
VA01
Receiving
Sales Order
MMBE
Stock
Availability
NO
MD61
MD02
Planning
Raw Material
Availability
OR1
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Doc Id: Business_Blueprint_PP_1.0
NO
YES
ME21N
Procurement
MIGO
PP
Quality Check
MB1C
CO01
SD
MM
MM
Issue to
Production
Dept.
QM
Production
QA11
Quality Check
MB1C
Goods Ready
for Dispatch
VL01N
Delivery to
Sales Order
4 A) BILL OF MATERIAL
AS-IS AT KBEPL
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Every component either a finish good or semi-finish goods will have complex BOM.
TO-BE / SAP-PROCESS AT KBEPL
For KBEPL it would be a Multi-Level BOM structure.
4. A.1 SCOPE OF THE DOCUMENT
The Scope of the document is restricted to Creation, Change and Display of Bill of
materials for Finished Materials, Semi finished Materials.
4. A.2 GENERAL EXPLANATION
•
BOM is formally structure lists of components that makes of product or assembly.
•
The lists would contain object no. of each component, together with the quantity
and unit of measure.
4. A.3 EXPLANATIONS FUNCTIONS AND EVENTS
4. A.3.1 BUSINESS PROCESS DETAILS
BOM’s are used in their different forms in various situations where a finished
product is produced from several components parts or materials. The data stored
in the Bill of materials serves as basis for production planning activities such as
•
In material requirements planning (MRP) Bills of Material are used to
calculate procurement or in-house production quantities for materials.
•
In Production orders Bills of material are used for planning the issue of
materials.
• During Production order confirmation, the BOM is used to update finished
goods stock of the parent material and back flush actual consumption of
component material.
•
Stores personnel use the BOM goods issue of components for in-house or
sub-contracting applications.
•
Product costing uses the BOM to calculate the costs of materials required for
a specific product.
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4. A.3.2 BOM STRUCTURE
BOM Structures are of two types:1) Single-Level BOM structure.
2) Multi-Level BOM structure.
BOM Structure for KBEPL:-
•
For KBEPL it would be a Multi-Level BOM structure:-
Multi Level BOM
ASSEMBLY
Single-Level BOM
Single-Level
BOM
Item 1
Item 2
Item 3
Child Part
•
•
•
In KBEPL, BOM is having only one usage, i.e. it would be production BOM.
Every component either a Finished Good or a Semi Finished Good will have a
BOM.
BOM will have each component that goes into product and for which production
and planning dept. wants to plan.
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•
MRP will consider stock of raw material while net requirement calculation and MRP
controller decide whether the raw material can procure from outside or to crate
purchase order for the same.
REPORTING CONSIDERATIONS
•
•
•
CS11 – Explode BOM Level by Level
CS12 - Explode Multi level BOM
CS13 – Summarized Bill of Material
LIST OF BUSINESS PROCESS PROCEDURES (BPP)
•
•
•
•
•
CS01
CS02
CS03
CS20
–
–
–
–
Create Bill of Material
Change Bill of Material
Display Bill of Material
Mass Changes
B) WORK CENTER:-
AS-IS AT KBEPL
Labor and Machines are work centers. Capacity utilization of all machines is 100%
In all Plant shift is for 8.00 Hrs.
TO-BE / SAP-PROCESS AT KBEPL
Accordingly Capacity Category (labor or machine) will be used. Capacity Utilization of
each work center will be used as 100%.
Shift Timings of Work centers to be fixed according to plants (All shifts will be
maintained for each work center).
The creation, Change and Display of Work Centers will be done plant wise.
B.1 GENERAL EXPLANATION
•
•
•
All machines and labors will be created in SAP as work centers masters.
These masters will have the capacity availability details in terms of number of
shifts, shift sequences, work breaks, and the cost center data.
Following types of Work Centers would be created:
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1.Lathe Machines
2.Drilling Machines
3.Shaping Machines
4.Boring Machines
5.Bending Machines
6.Vertical Slotting Machine
7.Milling Machines
8.Hack Saw Machine
9. Welding Machine.
10.Plasma Cutting Machine
11.Shearing Machine
12.Hand Cutting Machine
13.Pug Machines
14.Oven
15.Profile Cutting Machine
16. Grinders.
DATA IN WORK CENTER WILL BE USE FOR
•
•
Scheduling: - Operation times and formulas entered in the work center, so that
the duration of an operation con be calculated.
Costing: - Required costing formulas are entered in the work center, so that the
costs of an operation can be calculated. A work center is also assigned to a cost
center.
THE WORK CENTER WOULD SERVE THE FOLLOWING PURPOSES VIZ.
•
•
•
•
•
•
To determine which machine or manpower is to be used in an operation.
To calculate costs and dates for an operation.
Work center can contain multiple types of capacity categories like Machine, Setup
and Labor.
Standard value key defined in the work centers will identify the parameters to be
captured. The typical standard values are setup time, machine time, labor time
etc. This can be maintained in Minutes etc.
Work centers will be assigned to a cost center and there will be activity types
defined in these cost centers. Activity types are evaluated for each cost center
and period with a charge rate that consists of a fixed portion and a variable
(work-related) portion. These activity types determine the charge rate with which
costing is to be carried out for internal standard values viz., machine hours, setup
time and labour hours defined in the controlling module.
The available capacity will be taken from the work centre in which is maintained
shift schedule and shift sequence.
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WORK CENTER CODIFICATION
UNIT I
O.
MACHINE NAME
(MACHINE SHOP)
CODE
NO.
MACHINE NAME
(FABRICATION SHOP)
CODE
1.
Horizontal Boring Machine,
H160
Plaino Miller Machine, Heller
1HBMH160
1.
Welding Machine, TIG 01
1WMTIG01
1PMHELLR
2
Welding Machine, TIG 02
1WMTIG02
1HBSKODA
3.
Welding Machine, CO2 01
1WMCO201
1HBMCH80
4.
Welding Machine, CO2 02
1WMCO202
5.
Horizontal Boring Machine,
Skoda
Horizontal Boring Machine,
H80
Vertical Turret Lathe,VTL
1VTLATHE
5.
Plate Bending, Upto 15mm
1PBEND15
6.
Radial Drilling Machine,RDM5
1RDMRDM5
6.
Shearing Machine,upto5mm
1SHEARM5
7
1RDMUNIV
7
Hand Gas Cutting Machine,1
1HGCUT01
8
Radial Drilling Machine,
Universal
Radial Drilling Machine,
1RDRILLM
8
Hand Gas Cutting Machine,2
1HGCUT02
9
Lathe Machine,CL-6QMT
1LM06QMT
9
Hand Gas Cutting Machine,3
1HGCUT03
10
Lathe Machine,CL-7QMT
1LM07QMT
10
Hand Gas Cutting Machine,4
1HGCUT04
11
Shaper Machine
1SHAPERM
11
Hand Gas Cutting Machine,5
1HGCUT05
12
Vertical Sloting Machine,SL-9
1VSMCSL9
12
Hand Gas Cutting Machine,6
1HGCUT06
13
Milling Machine
1MILLING
13
Hand Gas Cutting Machine,7
1HGCUT07
14
Hand Gas Cutting Machine,8
1HGCUT08
15
Hand Gas Cutting Machine,9
1HGCUT09
16
1HGCUT10
17
Hand Gas Cutting
Machine,10
Pug Machine,01
18
Pug Machine,02
1PUGMC02
19
Pug Machine,03
1PUGMC03
2
3.
4.
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1PUGMC01
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20
Electrodes Drying Oven
1OVEN001
UNIT II
NO.
MACHINE NAME
(MACHINE SHOP)
CODE
NO.
MACHINE NAME
(FABRICATION SHOP)
CODE
1.
2RDRIL01
1.
2RDRIL02
2
Welding Transformers,
1 to 33
Welding Rectifier,01
2WTRAN01 to
2WTRAN33
2WRECT01
3.
Radial Drill
Machine,Imported01
Radial Drill
Machine,Imported02
Stand Drill,01
2SDRIL01
3.
Welding Rectifier,02
2WRECT02
4.
Magnet Drill,01
2MDRIL01
4.
Pug Machines, 1 to 11
5.
Magnet Drill,02
2MDRIL02
5.
Hand Grinder (7”), 1 to 14
6.
Magnet Drill,03
2MDRIL03
6.
Hand Grinder (4”), 1 to 4
7
Hand Drill,01
2HDRIL01
7
Table Grinder
2PUGMC01
to2PUGMC11
2HGRI701 to
2HGRI714
2HGRI401 to
2HGRI404
2TBGRI01
8
Hand Drill,02
2HDRIL02
8
Shaft Grinder
2SHGRI01
9
Hydraulic Hack Saw
2HYHSW01
9
Straight Grinder
2STGRI01
10
Hyd. Pipe Bender
2HYPBD01
10
Electrodes Drying Oven
2OVEN002
11
Power Press
2PPRES01
11
Heating Torch,01
2HTORCH1
12
Pipe Cutter
2PCUTT01
12
Heating Torch,02
2HTORCH2
13
Lathe Machine
2LATHEMC
13
Plate Bending Machine
2PBENDMC
14
Sheet Cutter
2SHETCUT1
14
2
UNIT III
DIVISION I
NO.
MACHINE NAME
(MACHINE)
CODE
NO.
MACHINE NAME
(FABRICATION)
CODE
1.
Lathe Machine,01
3LATHM01
1.
Welding Machines, 1 to 26
2
Lathe Machine,02
3LATHM02
2
Pug Machines, 1 to 14
3.
Lathe Machine,03
3LATHM03
3.
Profile Cutting Machine
3WELDM01 to
3WELDM26
3PUGMC01 to
3PUGMC14
3PROFCM1
4.
Lathe Machine,04
3LATHM04
4.
Grinders, 1 to 20
5.
Lathe Machine,05
3LATHM05
5.
6.
Lathe Machine,06
3LATHM06
6.
Plate Bending & Rolling
Machine, 32 mm
Plate Bending & Rolling
Machine, 80 mm
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3GRIND01 to
3GRIND20
3PBEND32
3PBEND80
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7
Lathe Machine,07
3LATHM07
7
8
Shaping Machine,01
3SHAPRE1
8
9
Shaping Machine,02
3SHAPRE2
9
10
Radial Drilling Machine,01
3RDRIL01
10
11
Radial Drilling Machine,02
3RDRIL02
11
12
13
Radial Drilling Machine,03
Hack Saw Machine
3RDRIL03
3HACKS01
12
13
DIVISION II
NO.
MACHINE NAME (MACHINE)
CODE
1.
Radial Drilling Machine ( COLB)
3RDRIL04
2
Radial Drilling Machine
3RDRIL05
3.
Boring Machine ( BFT 180)
3BMFT180
4.
Boring Machine ( FB180 To Be Install)
3BMFB180
5.
Boring Machine (BFT110 To BE Install)
3BMFT110
6.
Vertical Turret Lathe ( To Be Install)
3VTLATHM
7
Milling Machine (Make BHOLE)
3MMBHOLE
8
CNC Gas Cutting Machine ( To Be Install)
3CNCGMC
(To Be Install)
REPORTING CONSIDERATIONS
• CR08 – Work Center Hierarchy Report
• CR06 – Work Center Assignment to Cost Centers
• CR07 – Work Center Capacities
• CR60 – Work Center information system
LIST OF BUSINESS PROCESS PROCEDURES (BPP)
• CR01 – Creation of Work Center
• CR02 – Change of Work Center
• CR03 – Display of Work Center
• CR21 – Create Work Center Hierarchy
• CR22 – Change Work Center Hierarchy
• CR23 – Display Work Center Hierarchy
• CA85 – Replace
• CA80 – Work Center Where used list
C) ROUTING:Date of issue :
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AS-IS AT KBEPL
For manufacturing one component, various machines are used; multiple work center
assignments are there.
TO-BE / SAP-PROCESS AT KBEPL
While creating the production order user can select the routing by selecting the
production version which contains that routing number.
C.1 GENERAL EXPLANATION
•
•
•
A routing is a description of which operations have to be carried out in which
order to produce a material which can be a Finish Product or a Semi-Finish
Product to be manufactured in-house.
Routing contains information about the work centers where the individual work
steps are carried out.
Routing also contains the planned times for carrying out the operations (standard
values).
C.2 ROUTING WOULD ALSO SERVE THE FOLLOWING PURPOSES VIZ.
For work scheduling which uses routing as a basis for operation planning and production
control. The routing thus answers the questions like:
• Where the production is done?
• How long it will take?
• What are the materials and tooling required?
•
•
•
•
Components required for operation will be attached to operation as per BOM
norms.
System will automatically group all the routings of a material under a group
number and this group number will be internal number generated by the system.
Operation unit will be maintained in the units on which the output is measured
and monitored and hence it will vary from operation to operation in a routing.
Any additional information on operation, routing will be maintained at the
respective long text area.
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•
All manufactured items will have
production) created in the system.
routings
(detailed
routing
for
discrete
REPORTING CONSIDERATIONS
• CA51 – List of Routings for product/plant
• CA60 – Display Changes
• CA80 – Work Center Where Used List
LIST OF BUSINESS PROCESS PROCEDURES (BPP)
• CA01 – Creation of Routing
• CA02 – Change of Routing
• CA03 – Display of Routing
• C223 – Create Production version
C.3 COST CENTER
DEFINITION
A cost center is part of an organization that does not produce direct profit and adds to
the cost of running a company.
Cost Center
Price
Activity
Type
Costs
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Work
Center
Formula
Key
Routing
Std. Value
Formula
s
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EXAMPLE
Cost Center Production
Activity
Type
Price
Work Center
Routing
Formulas
Std. Values
Set up time
1 Hr
Labor time
Op.qty.*Labo
r r time
2 Hr
Mach.time
Op.qty.*
Mach.
time
3 Hr
100Rs/Hr.
RVE
Setup time
50RS/Hr.
LAB
25RS/Hr.
MAC
Op.
10
Costs
SET= 1 Hr.* 100 Rs./Hr.=100 Rs.
LAB= 2 pcs.*2 Hr.* 50 Rs./Hr.=200 Rs.
MAC=2 Pcs.*3 Hr.*25 Rs./Hr.=150 Rs.
ACTIVITY TYPE
•
•
A unit in a controlling area that classifies the activities performed in a cost center.
Activity types in production cost centers are machine hours or finished units.
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•
•
•
•
•
Work centers only have an available capacity on working days. In order to
calculate the available capacity, a factory calendar has to be maintained, in which
the working days are defined.
You define the work start, work finish and break times for all work centers in a
shift definition.
In shift sequences, you maintain the sequence of individual shift definitions for all
shift sequences.
The cost center that you want to assign the work center must exist and belong to
the same controlling area as the work center plant.
At KBEPL we would be defining 3 Activity Types: 1) Machine, 2) Setup, 3) Labour
5) PRODUCTION PLANNING-DEMAND MANAGEMENT:5.1 AS-IS AT KBEPL
•
•
•
•
•
•
•
•
Schedule from the customer is on the basis of planning for the Production.
At times they also receive Customer Order instead of the Schedule; hence they
are using that Customer Order as a reference for production planning.
Scheduling is done on the basis of customer order which can be monthly /
Quarterly.
Schedule is then forwarded to the Purchase Dept. who is triggering the
Procurement Cycle for Raw material / Semi-finish components / Bought-Out-Parts
(BOP) etc. And meanwhile the BOP are received the PPC Department is prepares
the monthly production schedule for each item at FG level for all these
requirements. This gives a day wise item wise schedule for delivery of the FG.
The detailed Monthly production schedule is then circulated to all the concerned
departments in the plant for their necessary action.
When PPC makes the monthly production plan they manually ensure that the plan
is as per the capacity of the plant.
Purchase Dept. also schedules the delivery with the Vendor based on this
schedule received from Customer.
Raw material and other required components for the production is received at
production to initiate the production activity.
5.2 TO-BE / SAP-PROCESS AT KBEPL
•
•
•
•
Production schedules will be created by the system based on the base of PIR
input in the demand management.
Requirements would be entered in Demand Management. The demand
management is the process of entering the requirements of a material that needs
to be produced for future sales.
Customer orders received will be entered in the Sales Module and the data
transfer to Production Planning module is done by the system.
The requirements will be entered for a finished Product. The system considers the
requirements entered in the demand management as the requirement quantities.
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•
•
Based on the strategy selected for a material, the system considers other
elements like Sales order, stock etc before arriving at the net quantity that needs
to be produced.
Parameters like Plant, Requirements type (which will be based on the strategy),
For Net requirement planning (LSF), planning period etc. will be made as default
for each user who creates the demand.
REPORTING CONSIDERATIONS
• MD63 – Display Independent Requirements
LIST OF BUSINESS PROCESS PROCEDURES (BPP)
•
•
•
MD61 – Create Independent Requirements
MD62 – Change Independent Requirements
MD73 – Display Total Requirement
6) PRODUCTION PLANNING-MATERIAL REQUIREMENT PLANNING.
6.1 AS-IS AT KBEPL
•
•
Presently KBEPL is doing the Material Requirement Planning manually.
They will collect the norms from Quality Management and the same will be
circulated to Material management with order quantity and having time to time
follow up with stores people as per planning.\
TO-BE / SAP-PROCESS AT KBEPL
•
•
•
Planning procedures automatically generate order proposals to purchasing and to
production. SAP planning procedures can be divided into Material Requirements
Planning.
The main function of Material Requirements Planning is to give the guarantee of
material availability to the shop floor.
The output of MRP may either be procured or produced.
SOME SALIENT FEATURES OF MRP INCLUDE
•
•
•
•
Planned Orders, Schedule lines and Purchase requisitions are generated.
The production or procurement quantity shall be based on the lot sizing
procedure specified for that material in the material master. In order to meet
these requirements, MRP calculates procurement quantities and dates as well as
plans the corresponding procurement elements.
The procurement element in the planning run is the planned order or, for external
procurement, the purchase requisition. Both the procurement elements are
internal planning elements that can be changed, rescheduled or deleted at any
time.
If a material is produced in-house, the system also calculates the dependent
requirements, that is, the quantity of components required to produce the
finished product or the assembly, by exploding the BOM. If a material shortage
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•
•
exists, planned orders are created at every BOM level to cover proposed
requirements.
For external procurement, the system then converts these planned procurement
elements into exact schedule lines set against schedule agreements. Materials
that are procured externally trigger the purchasing procedure.
The quantities made available by production or by external procurement are
placed in stock and or managed by inventory management.
and are managed by Inventory Management.
CARRYING OUT THE MRP RUN
•
•
•
•
•
•
•
•
MRP shall always be run at multi-level.
This essentially means that the system explodes the Bill of Material for a material
and generates dependent requirements for assemblies and components.
These components are also planned to cover dependent requirements.
If the components also have BOMs, the system explodes these BOMs also and
plans the components.
The system repeats this process until all BOM levels have been exploded.
While BOM explosion is carried out, the system will check for the status and
validity of the BOM and shall consider only the specific BOM with active status
and which falls within the defined validity period.
In specific cases where the dependent material schedule finish date falls later
than the start date of its higher level material, the system will show exception
messages at the MRP list of the dependent material The user shall manually
reschedule the higher-level material production to suit the schedule of the
dependent material. All materials will be grouped as per the department (as per
MRP controller) using the specific material so as to enable each group to view
stock situations of materials relevant to their department. However, MRP shall be
run at the material level or Plant level only.
The systems shall assign number ranges for planned orders at each plant. If
Minimum and Maximum lot size specifies for material in the material master and
the system will create planned order quantities within the above range. In case
where the net requirement exceeds the maximum lot size, the system will create
multiple planned orders.
The possible values which are envisaged to be used in MRP run are:
• Processing key-NETCH
• Create purchase requisition-1,2,3
• Delivery schedules-Schedule lines
• Create MRP list-MRP list
• Planning mode-Normal mode
• Scheduling-Lead time scheduling.
The net requirements calculation is carried out in MRP in the planning run after the
planning file check and at plant level. The system checks whether it is possible to cover
requirements with the plant stock and fixed receipts already planned. In the case of a
shortage the system creates a procurement proposal.
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LIST OF BUSINESS PROCESS PROCEDURES (BPP)
•
•
•
•
•
•
•
MD01
MD02
MD03
MD20
MD04
MD05
MD16
•
MD14 – Individual conversion of planned orders
•
•
MD15 – Collective conversion of planned orders
MDUM – Convert Planned order into Purchase requisitions
–
–
–
–
–
–
Total Planning Run (Plant Level)
MRP Run (Single Item Multi Level)
MRP Run (Single Item Single Level)
Create Planning file entry
Display / Stock requirements situation
Display MRP List
Collective display of planned orders
List of Transaction Codes related for Long Term Planning:
•
•
•
•
•
•
MS31
MS32
MS33
MS01
MS02
MS04
–
–
–
–
–
–
Create Planning Scenario
Change Planning Scenario
Display Planning Scenario
Total Planning Run (For Long Term Planning)
MRP Run, Single Item Multi Level (For Long Term Planning)
Stock Requirement List (Long Term Planning)
7) MRP CONTROLLER:7.1 AS-IS AT KBEPL
•
At present the MRP is run by the respective Department, whosoever is in the
need of the material.
7.2 TO-BE / SAP-PROCESS AT KBEPL
We shall be defining an MRP Controller.
• Any material which takes part in Material Requirement Planning will be assigned
to a MRP Controller.
• The Heads of different sections would be the MRP controllers of their respective
MRP areas.
• The identification of the MRP controllers in the SAP system is through a three digit
numeric code.
• For that purpose, the proposed naming convention of the respective heads will be
as follows:
001
002
003
8) CAPACITY PLANNING:Date of issue :
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AS-IS AT KBEPL
Production in Charge is checking the availability of machines & manpower capacity.
Weekly preparation of plan on the basis of monthly plan for each machine, and
displaying the same. (Fine tuning on daily basis for urgencies)
As per production plan, machine load is calculated. Based on this man power
requirement is generated. If short for the plan, check for overtime to meet the plan.
TO-BE / SAP-PROCESS AT KBEPL
For each planned order/Production order, system will generate the capacity load on that
machine, which can be viewed at any point of time. For checking the manpower
capacity, manpower will be defined as work center of capacity category labor.
Accordingly as per the availability of machine, user will convert the planned order into
production order, selecting the suitable production version which contains the routing
number in which that work center is used.
As per the weekly plan, requirements will be given in the system in demand
management on weekly basis for a whole month together at the beginning of the month.
And MRP will be run on the basis of this weekly plan once in a month (at the beginning
of the month).MRP Will be run on the Plant level.
8.1 PROCESS REQUIREMENT
•
•
•
Check the Capacity Load on each work center
According to the load on each machine do the Production Planning
Long term capacity planning to check the available manpower and machines. And
on the basis of this make a decision of either procuring new machine or
manpower
8.2 SCOPE OF THE DOCUMENT
The scope of this document is to check the capacity load on each work center and
according to the Production planning.
8.3 PROCESS FLOW
8.3.1. GENERAL EXPLANATION
The economic use of resources is an objective for many areas of a company. The
component Capacity Planning (PP-CRP) is available for this purpose.
Capacity planning comprises the following partial components:
CAPACITY EVALUATION
In the capacity evaluation, available capacity and capacity
determined and compared with each other in lists or graphics.
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are
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CAPACITY LEVELING
The objectives of capacity leveling are:
•
•
Optimal capacity commitment
Selection of appropriate resources in most applications, you can use two types of
planning table (graphical and tabular versions) to display the capacity situation
and to carry out capacity leveling.
EXPLANATIONS FUNCTIONS AND EVENTS
BUSINESS PROCESS DETAILS
Capacity planning supports planning in all its phases:
• long-term rough-cut planning
• medium-term planning
• short-term detailed planning
8.3.2 PROCESS FLOW
Requirements given in
demand management
for finished materials
MRP PLANNING
RUN (PLANT LEVEL)
Planned Order created
with capacity load on
work center mentioned
in routing of that
material
Check the total load on
that machine
If load is more on any
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the plannedApproved
order to
other
work
center
or
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change
the
reproduced in any form (electronic or written),
in part
or production
whole without the express consent of Adroit InfoTech. The contents of this
document are strictly confidential and should
not beof
shared
any other company without the prior permission of Adroit InfoTech.
dates
thatwith
planned
order
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REPORTING CONSIDERATIONS
•
•
•
•
CM01- Work Center Load
CM02 – Orders
CM50 – Work Center View
LIST OF BUSINESS PROCESS PROCEDURES
•
•
CM21 – Planning Table (Graphical)
CM22 - Planning Table (Tabular)
9) PRODUCTION PLANNING:AS-IS AT KBEPL
Production is based on sales order qty.
TO-BE / SAP-PROCESS AT KBEPL
For the machining/fabrication after receiving the material will be reserved for the
processing (as per schedule) through the manual created production order (Work
Order).After that user will book the actual production of that material against that
production order.
T-Code: - CO01 /COOIS
9.1 PROCESS REQUIREMENT
Order from on the basis of detailed planning and shop floor execution. All the
intermediates and final product manufacturing will have an order to control its execution.
The document covers details about following for orders all leve
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•
•
•
•
•
•
•
Order creation(Conversion from planned Order or manual creation)
Lot Size (Production Planned Quantity)
Selection of Order type (Separate Order Types for each Plant)
Selection of production version (Different Production version for different Routing)
Order Release (Approval for Production Order Execution)
Inspections lot generation
Material availability check
Using the order it is expected to control the above said process in shop floor. The Major
expectations from having an order would be
• Scheduling
• Capacity requirements analysis
• Material Reservation
• Controlling goods movements
• Booking quantities produced and activities used
• Tracking the cost
9.2 SCOPE OF THE DOCUMENT
The Scope of the document is to create the production orders for Semi finished and
finished products
ORDER TYPES
•
•
Production order with specific order type will be created for each business
process, as per requirement. For each Production Plant, separate Order types will
be created. Each Order Types will have the different number range.
Production Order of forming Material will be created manually. For rework this
also separate order type will be created to differentiate it with other orders.
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9.2.1 PRODUCTION ORDER DESIGN FLOW
Production order
from R/3 MRP
Planned order
w.r.t.material/Production
Scheduler/Plant
Maintain
production
B.O.M.
If no production
version (Valid BOM,
Routing automatically
copied to production
order)
Selection of
Production
version
Maintain Routing
Master Data i.e.
Operation time in each
operation,
components.
Maintain Work Center
Master Data.ie.
individual capacity,
capacity utilization,
Factory calendar,
Linkage to cost center.
Availability check
during production
order creation
Decision for
production order
creation with
missing
parts/capacity
No
Yes
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Production
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Joshi
order
creation
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REPORTING CONSIDERATIONS
•
•
•
COOIS – Production Order Information system
MB25 – Material Reservation list
CO24 – Missing Part list
LIST OF BUSINESS PROCESS PROCEDURES (BPP)
•
•
•
•
•
•
•
MD04 CO01 MD04 CO02 CO03 CO40 –
CO41 –
Stock/Requirement list
Production order Creation
Plan order to Production order creation directly.
Production order change
Production order Display
From Planned Order
From Planned Order (collectively)
10) PRODUCTION PROCESS EXECUTION:Execution of each production stage is controlled by its orders. The Step involved in
Production order execution are listed below
• Goods issue
• Production Execution start
• Item consumption entry
• Confirmation
• Order settlement
• Technically Completion (TECO)
10.1 SCOPE OF THE DOCUMENT
The scope of this document is of execution of production order for manufacturing of
Semi Finished Good & Finished Good.
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10.2
PROCESS FLOW
GENERAL EXPLANATION
A Production order defines which material is to be produced, at which location, at what
time and how much work is required. It also defines which work centers are to be used
and how the order costs are to be settled.
GOODS ISSUE
Before you can start producing a material, all the necessary material components have
to be issued from stock via goods issues. The delivery to stock of the manufactured
material is documented in the system via a goods receipt. Both types of goods
movement trigger the following transactions in the system:
• A material document is created to record the goods movement.
• The stock quantities of the material are updated.
• The stock values are updated in the material master record and the
stock/consumption accounts are updated.
ORDER CONFIRMATION
A confirmation documents the processing status of orders, operations, sub- operations
and Individual capacities. It is an instrument for controlling orders.
With a confirmation you specify
•
The quantity in an operation that was produced as yield, scrap and the quantity
to be reworked
•
How much work was actually done
•
Which work center was used for the operation
•
Who carried out the operation
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After confirmation of production order, following activities takes place in system
• A reduction in the capacity load on the resource
• An update of the costs, based on the confirmed data
• An update of the order vs. production, such as times or order status
• Yield quantity, scrap qty, reason for variance accounting.
• Goods Receipt and Goods Issue
ORDER SETTLEMENT
When a production order is settled, the actual costs incurred for the order are settled to
one or more receiver cost-objects (for example, to the account for the material
produced).
TECHNICALLY COMPLETION OF ORDER
• Technical completion is the completion of a Production order from the logistics
point of view. It is also used when termination of an order is to be done
prematurely, or if the order was not properly executed and want to delete open
requirements of the order (for example, reservations, and capacity
requirements).
• Technically completion of order is necessary from costing point of view. Unless
and until order is technically complete, costing person can’t do the rest of the
costing activities.
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•
Technical completion of order is possible to do in mass.
11) SAP PROCESS FLOW:Logistics General
Production Planning
Master Data
Material
Create Material
Change Material
Display Material
Bill of Material
Create BOM
Change BOM
Display BOM
Work Center
Create Work Center
Change Work Center
Display Work Center
Routing
Create Routing
Change Routing
Display Routing
MRP
MRP Run
Total MRP
Single item Multiple Level
MRP List
Stock Requirement List.
Planned Order
Individual conversion to
production order
Collective conversion
production order.
Production Order
Production Order
Create
Change
Release
Order
Confirmation
Production
Confirmation
Partial Confirmation
Final Confirmation
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TECO-Completed
.
12) PP STANDARD REPORTS:-
Sr.No.
Report Name
Report Description
T-Code
1
Order Information System
COOIS
CO28
2
Stock Overview
The order information system is
a tool for shop floor control with
a reporting function for
production orders and planned
orders.
Existing stock overview
3
Stock / Requirement List
Dynamic Listing of current stock
MD04
4
Order Progress Report
5
Missing Part Information System
Missing Part List Check
CO24
6
Material Consumption
MCRE
7
Material List
This report can be used for
analyzing the actual material
usage against plan in
manufacturing process.
Standard material report
8
BOM Explosion
Report on Multi-Level BOM
CS12
9
Where-Used List Material
Responsible for giving
information related to Bill of
Materials. Comparison of BOM
between two Materials
CS15
10
Order Information System:
Order View Report
Collective Display of Planned
Orders
11
MMBE
CO46
MM60
CO26
MD16
ANNEXURE 1 – PROCESS MAPPING FOR PP
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Approved by : Atul Joshi
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reproduced in any form (electronic or written), in part or whole without the express consent of Adroit InfoTech. The contents of this
document are strictly confidential and should not be shared with any other company without the prior permission of Adroit InfoTech.
Quality Management
System
Doc Id: Business_Blueprint_PP_1.0
D – Direct fit, W – Work around, N – Not in SAP, C – Customization
ACTIVITY
STEP
DATA INPUT
DATA
OUTPUT
T-CODE
IN SAP
FITN
ESS
D/W
/N/C
RESPONSIBILITY/
AUTHORIZATION
R
E
M
A
R
K
S
PROCESSING
SYSTEM (SAP,
NON-SAP)
Material
Master
Bill of
Material
Work
Center
Routing
Drawing
required
Codification
required
Set of
operations
Create BOM
CS01
D/C
MRP Controller
SAP
Create
Work Center
Create Routing
CR01
D/C
MRP Controller
SAP
CA01
D/C
MRP Controller
SAP
Productio
n
Planning
Require
customer
order
including
drawing.
MRP Run
Production
Schedules will
be created
MD61
D/C
MRP Controller
SAP
Material
Availability
(either
procured or
produced)
Weekly
preparation of
plan on the
basis of
monthly plan
for each
machine
Actual
production
of
that
material
against
that
production
order.
MD02
D/C
MRP Controller
SAP
CM01
D/C
MRP Controller
SAP
CO01
D/C
MRP Controller
SAP
Goods issue
Item
consumption
entry
Confirmation
Order
CO11
MB31
D/C
MRP Controller
SAP
Demand
Manage
ment
Capacity
Planning
Check the
capacity
load on
each
machine.
Productio
n/Work
order
creation
Sales order
Productio
n process
execution
Production/
Work Order
Date of issue :
Reviewed by: Kishor Joshi
Issue 1, Template Version : 1.0
Page 34 of 36
Approved by : Atul Joshi
Confidentiality Clause: Adroit InfoTech reserves the copyright on all material and ideas in this document. No material should be
reproduced in any form (electronic or written), in part or whole without the express consent of Adroit InfoTech. The contents of this
document are strictly confidential and should not be shared with any other company without the prior permission of Adroit InfoTech.
Quality Management
System
Doc Id: Business_Blueprint_PP_1.0
settlement
Technically
Completion
(TECO)
BUSINESS PROCESS OWNER’S ACCEPTANCE SIGN OFF (BBP)
Date of issue :
Reviewed by: Kishor Joshi
Issue 1, Template Version : 1.0
Page 35 of 36
Approved by : Atul Joshi
Confidentiality Clause: Adroit InfoTech reserves the copyright on all material and ideas in this document. No material should be
reproduced in any form (electronic or written), in part or whole without the express consent of Adroit InfoTech. The contents of this
document are strictly confidential and should not be shared with any other company without the prior permission of Adroit InfoTech.
Quality Management
System
Doc Id: Business_Blueprint_PP_1.0
The Business Blue print (BBP) proposed by Business Process Consultant based on the
information given by KBEPL representative in the ‘As Is’ workshops conducted. The
proposed solution covers all the existing business requirement of KBEPL developed based
on best practice functionalities supported by SAP. This document will be the base for
configuring SAP for Production system.
INFORMATION APPROVED BY
Sr.No.
Name
Designation
1
Mr. Uday Gidaveer
Production In charge
2
Mr.Sawant
Production In charge
3
Mr. Kaushal
Production In charge
Date
Signature
Date
Signature
Date
Signature
Date
Signature
K.B.E.P.L. MANAGEMENT REPRESENTATIVE
Sr.No.
Name
Designation
1
Mr.P.B.Khanwilkar
V.P.
2
Mr.Manish Ojha
Project Manager
ADROIT INFOTECH MANAGEMENT REPRESENTATIVE
Sr.No.
Name
Designation
1
Mr.Kishor Joshi
Delivery Manager
2
Mr.Ravindranath KC
Project Manager
INFORMATION PREPARED AND PROPOSED BY
Sr.No.
Name
Designation
1
Mr.Sandesh Bonde
SAP-PP Consultant
Date of issue :
Reviewed by: Kishor Joshi
Issue 1, Template Version : 1.0
Page 36 of 36
Approved by : Atul Joshi
Confidentiality Clause: Adroit InfoTech reserves the copyright on all material and ideas in this document. No material should be
reproduced in any form (electronic or written), in part or whole without the express consent of Adroit InfoTech. The contents of this
document are strictly confidential and should not be shared with any other company without the prior permission of Adroit InfoTech.