naw

SAP-TO BE Process
NAWPP005
Shop Floor Control
PRODUCTION PLANNING

Ver1.0
13.09.2006

STATEMENT OF CONFIDENTIALITY / DISCLAIMER

This document is the property of Caritor, Inc. No part of this document shall be
reproduced, stored in a retrieval system, or transmitted by any means, electronic,
mechanical, photocopying, recording, or otherwise without prior written permission from
Caritor, Inc.

Table of Contents

Table of Contents
1

Shop Floor Control.................................................................................................................................3

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14

AS IS Process............................................................................................................................................3
Core to Be Process....................................................................................................................................5
Changes to Existing Organization...........................................................................................................10
Description of Improvements and Key Metrics........................................................................................10
Notes on Further Improvements..............................................................................................................10
Functional Deficit and Method to Remove That.......................................................................................10
Interface Requirement.............................................................................................................................10
System Configuration Considerations.....................................................................................................10
File Conversion Considerations...............................................................................................................10
Any reports required related to current business process.......................................................................10
Any document/output would be printed for this business process...........................................................10
Authorization Considerations...................................................................................................................11
End User Training Requirements.............................................................................................................11
Process Flow Chart.................................................................................................................................12

SAP Standard Reports..........................................................................................................................14

Custom Developments.........................................................................................................................17

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1 Shop Floor Control

TO-BE Document
For SAP R/3 Implementation at New Allenberry works.
Date: 13.09.2006
Sr. No of TO BE document

NAWPP005

Ref. Sr. No. Of AS-IS document

Production Execution

Name of Business Process: Shop Floor Control

Module: Production Planning

Sub module: Shop Floor Control

Version no of document: 1.0

Date: 13.09.2006

Version Management This Document is subject to change control. Every change of the document has to Undergo change
control procedure and has to be registered in the following table
Version

Change

1.0

Prepared By
Ananth Raj

Date
13.09.2006

1.1 AS IS Process
Production Execution

Production Execution
Creation of Production Order
In NAW no production order concept is adopted presently.
The product wise daily plan is released to Production by PPC for each machine in every
production line.
The Daily Production Plan is generally within the months plan.
The release of Daily plan is Production Order for the Production Department.

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Material Staging
Raw materials are moved to respective machines in trolleys or trays by PPC.
After the operation is performed the material is moved to Parking Bay waiting for movement
to next machine for next operation in the other Production Line.
There are different Parking Bays for different operations
Production Confirmation
Production is confirmed after all the operations by putting paint mark on the product.
Goods receipt from Production
Final products, after final inspection, are handed over to Finished Goods Stores by PPC on
Production Credit Slip made manually.
Batches for manufactured Products
Heat treatment code is punched on products depicting year, month, NW and charge number.

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1.2 Core to Be Process

Production order Definintion:
A production order defines which material is to be produced, at which location, at what time, which
operatioand how much work is required. It also defines which BOM, Routing is to be used .
The work processes within a company are executed using orders.
Creation of Production order refers to
What is to be produced?
When production has to take place?
What are all the components needed to produced and consumed for the specified
quantity?
What are the PRTs required to complete the order?
Production Order creation has to follow the procedure:
A routing is selected; its operations and sequences are transferred to the Production
order.
The Bill of Materials is exploded and the items in the Bill of Material are transferred to
the Production order.
Availability check of components in stock .
Availability check for Production resource tools.
Reservations are generated for Bill of Material items held in stock.
As the MRP is run the Planned order would be generated as per the PIRs(planned
independent requirements).
Finished products will be received in the stock by confirming the final operation in the
routing
The planned costs for the order are generated.
Production Order can be created with reference to a material and a planned order. In
case of creation of Production orders through planned order, the system will allow for
individual, partial or collective conversions of planned orders.
When a Production order is created, the system copies various master data onto itself:
Routing: The system checks for the routing and copies the routing of the material
Bill of Material: The system checks for the BOMs, which fall within the validity
date.Whenever production order is created by conversion of a planned order, the
BOM that is used for planning by the system will automatically get copied into order.
In case this needs to be changed (where the norms for planning and execution is
different) this has to be manually changed by the user.
Before releasing the Production order and starting production, the system has an
option to check whether all the material components assigned to a Production order

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are available on the calculated requirements dates. These availability checks can be
triggered either automatically or manually and can be carried out at plant or at
storage location level.
If any components are not available in the stocks, system will create a missing parts
list and an error message will be issued to the users.

Production order confirmation:

After creation and releasing a production order, the user confirmation
process has to be performed..
As a part of Production Order confirmation, the system shall allow for
updating the production control related information viz., quantity of
production, activity data (actual Fixed time, actual Variable time, start / end
time, dates for individual operations within each production order .System
will calculate the activities based on the confirmation quantity and the
norms. This calculated figures for each of the activities will be displayed on
the confirmation screen and will be changed only if required.
As mentioned earlier, creation of Production order results in creation of
materials reservations. If the material consumed is less than the planned
quantity, it is important that the open reservations are closed. The open
reservations are considered as Demand elements for which material has
to be provided. Hence it is important to close the material reservations that
are no more relevant..
With a confirmation we would be able to 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

Batch Mangement:
During the production confirmation the material that are being activated with batch
management needs to be assighned with the batch number.This batch number will
be updated equivalent to the production order number.
In NAW batches are assigned after heat treatment,in which a code with external
numbering will be used .

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There are few process that are being highly recommended as a part of
Standard R/3 Production module for the closure of production order .

TECO
DLV

Technical Completion of a Production Order

Technical completion means ending a production order from a logistical viewpoint.

This function is usually used, if the execution of an order has to be stopped
prematurely or if the order could not be executed in the required manner and
open requirements for the order (reservations, capacities) should be deleted.

The following actions are executed if an order is set to Technically

complete.
The order is not relevant for MRP planning
Reservations are deleted
Capacity requirements are deleted
Purchase requisitions for external operations or non-stock materials are
deleted
The order and its operations receive the system status Technically
Completed (TECO)
If an order is technically complete, you cannot change it. The fields in the order
are displayed but cannot be changed. You can however cancel technical
completion, for instance if order data has to be changed.
After technical completion you can still make postings for the order. For
instance, material withdrawal or a confirmation can be posted if they were
previously forgotten
DELIVERY COMPLETED :
The Status is manually activated for the change in status of the delivery .

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Important fields to be maintained for NAW:

Material Master: Back flush indicator has to be maintained -1-Always Back
flush
Work center: control key PP01-need to be maintained for raw materials

PP03-need to be maintained for all other type,Fert,Halb

In PP01 there is no auto GR maintained as this control key is used in

Raw materials.
In PP03 auto GR is used as it is required for production confirmation.
Batch management is active with external numbering.
Production order types:
PP01- NAW normal production
PP03 NAW Rework process

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Process flow chart :

Conversion of planned order

into production order

Availability check

No
Missing parts list
processing

yes

Release of production order

Confirmation of
orders

production

Goods
movement
and
Technical completion of order.

Qualilty stock

Unrestricted stock

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1.3 Changes to Existing Organization

Production order concept is being introduced in NAW .

1.4 Description of Improvements and Key Metrics

System will give all information about
production orders,
capacity available,

avavilability check for materials and PRT,

missing parts in the production order if any

Cost can be captured based on the production order.

1.5 Notes on Further Improvements

NIL

1.6 Functional Deficit and Method to Remove That

NIL

1.7 Interface Requirement

NIL

1.8 System Configuration Considerations

Specific setting is required for order type dependent parameter and Specific setting is
required for PRT quantity calculation.

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1.9 File Conversion Considerations
NIL

1.10 Any reports required related to current business process

NIL

1.11 Any document/output would be printed for this business process

NIL

1.12 Authorization Considerations

NIL

Business Roles

Number of Users

Business Manager

Operations Manager

Master Production Scheduler / MRP Controller

Planning Engineers

Nil

Shop floor supervisor

Nil

1.13 End User Training Requirements

Business User Segments

Number of Users

Type of Transaction

Geographical Location

Business Manager

Display, Reports

NAW ,Faridabad

Operations Manager

Display, Change, Reports

NAW ,Faridabad

Master Production Scheduler / MRP

Controller

Display, Change, Reports

NAW ,Faridabad

Planning Engineers

Nil

Create, Change, Display

NAW ,Faridabad

Shop floor supervisor

Nil

Display

NAW ,Faridabad

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1.14 Process Flow Chart

Figure 1: Production Order Creation

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Figure 2: Goods Issue to Production Order

Sign-off (Approval) for this document:

Name of Team members:

Organization / Bus. Unit

Mr M P Joshi

NAW

Mr A Sen

NAW

Mr.S C Jain

NAW

Mr N M Ogra

NAW

Ananth Raj (Consultant PP QM)

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Signature

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2 SAP Standard Reports

SAP Standard Reports

Sl No:

Report Description

Selection Criteria

Output

01

Stock Overview (MMBE)

Material, Plant & Storage location

Stock Status at each storage

location

02

Material List (MM60)

Material, Plant, Material Type &

Material Group

Material Master Details

03

Missing Parts Information List

(CO24)

Plant from Selection from

Reservations & MRP Controller from
Selection from Order with Profile for
Material View

Shortage List

04

Production Order Information

System (COOIS)

Caritor

List: Item

Header

Profile (Standard)

Material

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

List of Orders based on

Selection Criteria
List of Orders based on
Selection Criteria, with material
components

List: Item

Profile (Standard)

Material

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

List: Confirmations

Profile (Standard)

Production Order

Confidential

List of Orders based on

Selection Criteria, with
confirmation details

List of Orders based on

Selection Criteria, with Goods
Issue & Receipt details

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SAP Standard Reports
Sl No:

Report Description

Selection Criteria

05

PRT Where used in Task List (CA70)

Production Order Type

MRP Controller

Selection status Profile or

System Status

List: Documented Goods

Movement

Profile (Standard)

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

Production resources/Tools

Material

Plant

PRT Usages in order

Type From

Status form

Usage from

Plant

Planner Group from

Material
From Material number

Production resources/Tools

Material

Plant

It will give PRT usages counter

Order Selection

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Key Date

Task List

06

PRT Where used list with all

details .

Time

Output

Plant

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SAP Standard Reports
Sl No:

Report Description

Selection Criteria

Production Scheduler

MRP controller group

Order type

Schedule start date

Scheduled delivery date

Order

Material

Person in charge

Selection profile status

Output

07

MCP7 - Work Center

Work Center, plant, period

Work Center

08

MCP1 - Operation

Operation, plant, period

Operation

09

MCP5 - Material

Material, plant, period

Material

010

MCP3 - Production Order

Production Order, plant, period

Production Order

11

MCRE - Material Consumption

Material Consumption, plant,

period

Material Consumption

12

MCRI - Product Costs

Material , plant, period

Product Costs

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3 Custom Developments

Print Requirements
Sl No:

Report Description

Selection Criteria

Output

Development Requirements
Sl No:

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Report Description

Selection Criteria

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Output

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