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Quality Management System

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.


Date of issue : Reviewed by: Kishor Joshi Issue 1, Template Version : 1.0 Approved by : Atul Joshi

MR.KHANWILKAR B.P.O. K.B.E.P.L.


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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

MODULES TO BE IMPLEMENTED

NO.

MODULE

1 2 3 4 5 6 7

PP MODULE QM MODULE SD MODULE FI MODULE MM MODULE CO MODULE PS MODULE

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

CONTENTS
No. Topic Page numbers Start

1. 2 3 4

PURPOSE PRE REQUISITIES ORGANIZATIONAL STRUCTURE MATERIAL MASTER A) BILL OF MATERIAL B) WORK CENTER C) ROUTING

04 04 04 07 09 11 15 19 20 22 22 25 28 31 32 33 35

5. 6. 7 8 9 10 11 12 13 14

PRODUCTION PLANNING- DEMAND MANAGEMENT PRODUCTION PLANNING -MRP MRP CONTROLLER CAPACITY PLANNING PRODUCTION PLANNING PRODUCTION PROCESS EXECUTION SAP PROCESS FLOW PP STANDARD REPORT ANNEXTURE 1 BUSINESS PROCESS OWNERS ACCEPTANCE SIGN OFF (BBP)

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

3.2 TO-BE AT KBEPL

CLIENT

KAY GROUP

COMPANY CODE

KBEL

B0

PRODUCTION PLANT

KB01

KB02

KB03

STORAGE LOCATION

SL 01

SL 02

SL 03

Capacity

WORK CENTER

WC 01

WC 02

WC 03

EQUIPMENT

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.

Date of issue : Reviewed by: Kishor Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 For Production Planning Module, Plant and Storage Locations are the ones 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. 1

Company Code KBEL

Name of the Company 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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

No.
1 2 3

Plant Code KB01 KB02 KB03

Name Of the Plant Code


KBEPL Unit I KBEPL Unit II KBEPL Unit III

STORAGE LOCATION A location within a plant where inventory is stored. In KBEPL following locations are decided for Logistics.

No. 1 2 3 4 5 6

Storage Location KB11 KB12 KB13 KB14 KB15 KB16

Type of Storage Location FINISHED GOOD SEMI FINISHED GOOD SALES RETURN, REWORK & SUBCONTRACTING RAW MATERIAL GENERAL STORES SCRAP STORES

4) MATERIAL MASTER:-

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Quality Management System


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


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MMBE Stock Availability NO

MD61 Planning OR1


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MD02 Raw Material Availability


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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

NO ME21N Procurement MIGO PP SD MM MM QM Issue to Production Dept.

YES

Quality Check MB1C CO01 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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 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 BOMs 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.

Date of issue : Reviewed by: Kishor Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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:

Date of issue : Reviewed by: Kishor Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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.

Date of issue : Reviewed by: Kishor Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

WORK CENTER CODIFICATION

UNIT I O. MACHINE NAME (MACHINE SHOP) 1. 2 3. 4. 5. 6. 7 8 9 10 11 Horizontal Boring Machine, H160 Plaino Miller Machine, Heller Horizontal Boring Machine, Skoda Horizontal Boring Machine, H80 Vertical Turret Lathe,VTL Radial Drilling Machine,RDM5 Radial Drilling Machine, Universal Radial Drilling Machine, Lathe Machine,CL-6QMT Lathe Machine,CL-7QMT Shaper Machine

CODE 1HBMH160 1PMHELLR 1HBSKODA 1HBMCH80 1VTLATHE 1RDMRDM5 1RDMUNIV 1RDRILLM 1LM06QMT 1LM07QMT 1SHAPERM

NO. 1. 2 3. 4. 5. 6. 7 8 9 10 11

MACHINE NAME (FABRICATION SHOP) Welding Machine, TIG 01 Welding Machine, TIG 02 Welding Machine, CO2 01 Welding Machine, CO2 02 Plate Bending, Upto 15mm Shearing Machine,upto5mm Hand Gas Cutting Machine,1 Hand Gas Cutting Machine,2 Hand Gas Cutting Machine,3 Hand Gas Cutting Machine,4 Hand Gas Cutting Machine,5

CODE 1WMTIG01 1WMTIG02 1WMCO201 1WMCO202 1PBEND15 1SHEARM5 1HGCUT01 1HGCUT02 1HGCUT03 1HGCUT04 1HGCUT05

12 13

Vertical Sloting Machine,SL-9 Milling Machine

1VSMCSL9 1MILLING

12 13 14 15 16 17 18 19

Hand Gas Cutting Machine,6 Hand Gas Cutting Machine,7 Hand Gas Cutting Machine,8 Hand Gas Cutting Machine,9 Hand Gas Cutting Machine,10 Pug Machine,01 Pug Machine,02 Pug Machine,03

1HGCUT06 1HGCUT07 1HGCUT08 1HGCUT09 1HGCUT10 1PUGMC01 1PUGMC02 1PUGMC03

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

20

Electrodes Drying Oven

1OVEN001

UNIT II NO. 1. 2 3. 4. 5. 6. 7 8 9 10 11 12 13 14 MACHINE NAME (MACHINE SHOP) Radial Drill Machine,Imported01 Radial Drill Machine,Imported02 Stand Drill,01 Magnet Drill,01 Magnet Drill,02 Magnet Drill,03 Hand Drill,01 Hand Drill,02 Hydraulic Hack Saw Hyd. Pipe Bender Power Press Pipe Cutter Lathe Machine Sheet Cutter CODE 2RDRIL01 2RDRIL02 2SDRIL01 2MDRIL01 2MDRIL02 2MDRIL03 2HDRIL01 2HDRIL02 2HYHSW01 2HYPBD01 2PPRES01 2PCUTT01 2LATHEMC 2SHETCUT1 NO. 1. 2 3. 4. 5. 6. 7 8 9 10 11 12 13 14 MACHINE NAME (FABRICATION SHOP) Welding Transformers, 1 to 33 Welding Rectifier,01 Welding Rectifier,02 Pug Machines, 1 to 11 Hand Grinder (7), 1 to 14 Hand Grinder (4), 1 to 4 Table Grinder Shaft Grinder Straight Grinder Electrodes Drying Oven Heating Torch,01 Heating Torch,02 Plate Bending Machine CODE 2WTRAN01 to 2WTRAN33 2WRECT01 2WRECT02 2PUGMC01 to2PUGMC11 2HGRI701 to 2HGRI714 2HGRI401 to 2HGRI404 2TBGRI01 2SHGRI01 2STGRI01 2OVEN002 2HTORCH1 2HTORCH2 2PBENDMC

UNIT III DIVISION I NO. 1. 2 3. 4. 5. 6. MACHINE NAME (MACHINE) Lathe Machine,01 Lathe Machine,02 Lathe Machine,03 Lathe Machine,04 Lathe Machine,05 Lathe Machine,06 CODE 3LATHM01 3LATHM02 3LATHM03 3LATHM04 3LATHM05 3LATHM06 NO. 1. 2 3. 4. 5. 6. MACHINE NAME (FABRICATION) Welding Machines, 1 to 26 Pug Machines, 1 to 14 Profile Cutting Machine Grinders, 1 to 20 Plate Bending & Rolling Machine, 32 mm Plate Bending & Rolling Machine, 80 mm CODE 3WELDM01 to 3WELDM26 3PUGMC01 to 3PUGMC14 3PROFCM1 3GRIND01 to 3GRIND20 3PBEND32 3PBEND80
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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

7 8 9 10 11 12 13

Lathe Machine,07 Shaping Machine,01 Shaping Machine,02 Radial Drilling Machine,01 Radial Drilling Machine,02 Radial Drilling Machine,03 Hack Saw Machine

3LATHM07 3SHAPRE1 3SHAPRE2 3RDRIL01 3RDRIL02 3RDRIL03 3HACKS01

7 8 9 10 11 12 13

DIVISION II
NO. 1. 2 3. 4. 5. 6. 7 8 MACHINE NAME (MACHINE) Radial Drilling Machine ( COLB) Radial Drilling Machine (To Be Install) CODE 3RDRIL04 3RDRIL05 3BMFT180 3BMFB180 3BMFT110 3VTLATHM 3MMBHOLE 3CNCGMC

Boring Machine ( BFT 180) Boring Machine ( FB180 To Be Install) Boring Machine (BFT110 To BE Install) Vertical Turret Lathe ( To Be Install) Milling Machine (Make BHOLE) CNC Gas Cutting Machine ( 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 : Reviewed by: Kishor Joshi Issue 1, Template Version : 1.0 Approved by : Atul Joshi Page 16 of 36

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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

Work Center Formula Key

Routing Std. Value

Costs

Formula s
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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

EXAMPLE

Cost Center Production

Price

Activity Type RVE LAB

Work Center

Routing Formulas Std. Values Set up time Op.qty.*Labo r r time Op.qty.* Mach. time 1 Hr Op. 10

100Rs/Hr. 50RS/Hr.

Setup time Labor time

2 Hr 3 Hr

25RS/Hr.

MAC

Mach.time

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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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

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.

Date of issue : Reviewed by: Kishor Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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
Issue 1, Template Version : 1.0 Approved by : Atul Joshi Page 21 of 36

Date of issue : Reviewed by: Kishor Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 LIST OF BUSINESS PROCESS PROCEDURES (BPP) MD01 MD02 MD03 MD20 MD04 MD05 MD16 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

MD14 Individual conversion of planned orders


MD15 Collective conversion of planned orders MDUM Convert Planned order into Purchase requisitions

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 : Reviewed by: Kishor Joshi Issue 1, Template Version : 1.0 Approved by : Atul Joshi Page 23 of 36

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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.
Date of issue : Reviewed by: Kishor Joshi Issue 1, Template Version : 1.0 Approved by : Atul Joshi

requirements

are

Page 24 of 36

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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 Issue 1, Template Version : 1.0 Page 25 of 36 work center than move Reviewed by: Kishor Joshi Approved by the planned order to : Atul Joshi other work center or material and ideas in this document. No material should be Confidentiality Clause: Adroit InfoTech reserves the copyright on all change the whole without reproduced in any form (electronic or written), in part or production the express consent of Adroit InfoTech. The contents of this document are strictly confidential and should not beof thatwith any other company without the prior permission of Adroit InfoTech. dates shared planned order
Date of issue :

Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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.

Date of issue : Reviewed by: Kishor Joshi

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Page 27 of 36

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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. Selection of Production version

If no production version (Valid BOM, Routing automatically copied to production order)

Maintain Routing Master Data i.e. Operation time in each operation, components.

Availability check during production order creation

Maintain Work Center Master Data.ie. individual capacity, capacity utilization, Factory calendar, Linkage to cost center.

Decision for production order creation with missing parts/capacity

No

Yes
Date of issue :

Production Reviewed by: Kishor Joshi Approved by : Atul Joshi order creation Confidentiality Clause: Adroit InfoTech reserves the copyright& Release of on all material and ideas in this document. No material should be reproduced in any form (electronic or written), in part or whole orders. express consent of Adroit InfoTech. The contents of this without the
document are strictly confidential and should not be shared with any other company without the prior permission of Adroit InfoTech.

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0 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 cant do the rest of the costing activities.
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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

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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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

TECO-Completed

. 12) PP STANDARD REPORTS:-

Sr.No. 1

Report Name Order Information System

Report Description The order information system is a tool for shop floor control with a reporting function for production orders and planned orders. Existing stock overview Dynamic Listing of current stock

T-Code COOIS CO28

2 3 4 5 6

Stock Overview Stock / Requirement List Order Progress Report Missing Part Information System Material Consumption

MMBE MD04 CO46

Missing Part List Check This report can be used for analyzing the actual material usage against plan in manufacturing process. Standard material report Report on Multi-Level BOM Responsible for giving information related to Bill of Materials. Comparison of BOM between two Materials

CO24 MCRE

7 8 9

Material List BOM Explosion Where-Used List Material

MM60 CS12 CS15

10 11

Order Information System: Order View Report Collective Display of Planned Orders

CO26 MD16

ANNEXURE 1 PROCESS MAPPING FOR PP


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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 Demand Manage ment Productio n Planning Require customer order including drawing. MRP Run Production Schedules will be created 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. Goods issue Item consumption entry Confirmation Order MD61 D/C MRP Controller SAP Drawing required Codification required Set of operations Create BOM Create Work Center Create Routing CS01 CR01 CA01 D/C D/C D/C MRP Controller MRP Controller MRP Controller SAP SAP SAP

MD02

D/C

MRP Controller

SAP

Capacity Planning

Check the capacity load on each machine. Sales order

CM01

D/C

MRP Controller

SAP

Productio n/Work order creation

CO01

D/C

MRP Controller

SAP

Productio n process execution

Production/ Work Order

CO11 MB31

D/C

MRP Controller

SAP

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Issue 1, Template Version : 1.0 Approved by : Atul Joshi

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Quality Management System


Doc Id: Business_Blueprint_PP_1.0

settlement Technically Completion (TECO)

BUSINESS PROCESS OWNERS ACCEPTANCE SIGN OFF (BBP)


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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. 1 2 3 Name Mr. Uday Gidaveer Mr.Sawant Mr. Kaushal Designation Production In charge Production In charge Production In charge Date Signature

K.B.E.P.L. MANAGEMENT REPRESENTATIVE Sr.No. 1 2 Name Mr.P.B.Khanwilkar Mr.Manish Ojha Designation V.P. Project Manager Date Signature

ADROIT INFOTECH MANAGEMENT REPRESENTATIVE Sr.No. 1 2 Name Mr.Kishor Joshi Mr.Ravindranath KC Designation Delivery Manager Project Manager Date Signature

INFORMATION PREPARED AND PROPOSED BY Sr.No. 1 Name Mr.Sandesh Bonde Designation SAP-PP Consultant Date Signature

Date of issue : Reviewed by: Kishor Joshi

Issue 1, Template Version : 1.0 Approved by : Atul Joshi

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