2_pipes_master data_pp.doc

Master Data Document

Welspun Pipes and Steel of 24

Welspun-Pipes and Steel

SAP Implementation

Master Data DocumentPP Module

Version – V1.0

Date:


Contents

1. Material Master.......................................................................................................................................41.1. Define the Master............................................................................................................................41.2. Existing Codification logic.................................................................................................................51.3. Proposed Codification Logic.............................................................................................................61.4. Approach to Collect, Clean and collate the data in template..........................................................71.5. Data Upload Approach.....................................................................................................................81.6. Data availability and Testing Approach............................................................................................91.7. Post Go-Live Approach for Master Data Creation/Change/Delete..................................................9

2. Bill Of Material.........................................................................................................................................92.1. Define the Master............................................................................................................................92.2. Existing BOM Structure..................................................................................................................102.3. Proposed BOM Structure...............................................................................................................112.4. Approach to Collect, Clean and collate the data in template........................................................112.5. Data Upload Approach...................................................................................................................122.6. Data availability and Testing Approach..........................................................................................122.7. Post Go-Live Approach for Master Data Creation/Change/Delete................................................12

3. Bill Of Material.......................................................................................................................................133.1. Define the Master..........................................................................................................................133.2. Existing BOM Structure..................................................................................................................143.3. Proposed BOM Structure...............................................................................................................143.4. Approach to Collect, Clean and collate the data in template........................................................153.5. Data Upload Approach...................................................................................................................163.6. Data availability and Testing Approach..........................................................................................163.7. Post Go-Live Approach for Master Data Creation/Change/Delete................................................16

4. Routing...................................................................................................................................................174.1. Define the Master..........................................................................................................................174.2. Existing Routing Structure..............................................................................................................184.3. Proposed Routing Structure...........................................................................................................184.4. Approach to Collect, Clean and collate the data in template........................................................184.5. Data Upload Approach...................................................................................................................194.6. Data availability and Testing Approach..........................................................................................194.7. Post Go-Live Approach for Master Data Creation/Change/Delete................................................19

5. Work Center...........................................................................................................................................195.1. Define the Master..........................................................................................................................195.2. Existing Routing Structure..............................................................................................................215.3. Proposed Routing Structure...........................................................................................................215.4. Approach to Collect, Clean and collate the data in template........................................................215.5. Data Upload Approach...................................................................................................................225.6. Data availability and Testing Approach..........................................................................................225.7. Post Go-Live Approach for Master Data Creation/Change/Delete................................................22

6. Class And Characteristics.......................................................................................................................22



6.1. Define the Master..........................................................................................................................236.2. Existing Routing Structure..............................................................................................................236.3. Proposed Routing Structure...........................................................................................................246.4. Approach to Collect, Clean and collate the data in template........................................................246.5. Data Upload Approach...................................................................................................................246.6. Data availability and Testing Approach..........................................................................................256.7. Post Go-Live Approach for Master Data Creation/Change/Delete................................................25Process signoff...........................................................................................................................25



1. Material Master

1.1. Define the Master

Description: The material master record contains all information about the materials a company procures, manufactures, stores and ships. Material Master is maintained with the transaction code MM01 for create, MM02 for change and MM03 for display.

Requirement: In SAP, a material master record contains all the necessary data required to manage a material. Material master data includes a description of the material. Description may include things like size, weight, dimensions etc. Further, this also includes data relating to the control function i.e. MRP type, Production Scheduler, Procurement type, Industry sector, Material type etc. All the above data can be maintained directly by the user in SAP PP. In addition to this data, this can be directly maintained by the user. Further, the material master record also contains some data which is directly maintained by the SAP system.

Prerequisites: Before material master been created there are prerequisites for the same like to check for the existing material before creating a new material master, so that duplicity can be avoided. To check the existing Material, Material list can be checked with the transaction code MM60.

There are prerequisites for each screen in Material master, for example (part of KDS):

1) Basic Data: Base Unit of Measurement & Material group.2) MRP1/2/3/4: Plant and Storage Location3) Work Scheduling: Production Scheduler 4) Accounting: Organizational level & Valuation type.

Integration: Material master is used by all components in the SAP Logistics System. The integration of all material data in a single database object eliminates redundant data storage. In the SAP Logistics System, the data contained in the material master is required, for example, for the following functions:

1) In Purchasing for Ordering (MM)2) In Inventory Management for Goods Movement and Physical Inventory (MM)3) In Invoice Verification for posting Invoices (FI)4) In Sales and Distribution for Sales Order processing (SD)5) In Production Planning and Control for material requirements planning, scheduling,

and work scheduling (PP)6) In Quality Management for Quality check (QM).7) In Managing the Warehouses and Storage Location (WM)



Advantages:There are following advantages with the material master:

1) Improved overview2) Greater transparency3) Easier navigation.

1.2. Existing Codification logic

Bare Pipe (7 digits), Example H200001

H 2 00001L Longi PlantS Spiral I PlantQ ERW 6" PlantI ERW 6" IS PipeG ObsoleteH HFIW 16" PlantR Spiral II PlantT Spiral III PlantB PBM Plant IV PBM Plant II

A Spiral(LR)

Z HFW(LR)

D Double Joint(LR)

1 Raw Material2 Bare Pipe3 Coated Pipe4 Bare Pipe Supplied by Customer5 Coated Pipe, Customer Supplied

Bare Pipe6 Obsolete7 Bare Pipe R/M Supplied by Customer8 Obsolete

Running Serial number. (Manually Assign number)

Coated Pipe(9 digits), Example H30200001

H 3 02 00001L Longi PlantS Spiral I PlantQ ERW 6" PlantI ERW 6" IS PipeG ObsoleteH HFIW 16" PlantR Spiral II PlantT Spiral III PlantB PBM Plant IV PBM Plant IIA Spiral(LR)Z HFW(LR)D Double Joint(LR)

1 Raw Material2 Bare Pipe3 Coated Pipe4 Bare Pipe Supplied by

Customer5 Coated Pipe, Customer

Supplied Bare Pipe6 Obsolete7 Bare Pipe R/M

Supplied by Customer8 Obsolete

01 3lpe or 3lpp02 Internal coating (any type

of coating)03 CTE

04 Concrete weight coating06 Internal cement lining

07 Fusion bonded epoxy (FBE)

08 Zinc silicate primer + glass flake epoxy

09 Cte + glass flake epoxy10 External zinc silicate

primer11 External cte primer12 Zinc rich epoxy

primer(external)

Running Serial number. (Manually Assign number)

Coils and Plates( 7 digits), Example S100001

Logic starts with L1 for Longi plates, S1 for Spiral Coils and F1 for Fabri Plates.Balance 05 digits represent Sl. No.For example: L100001



S100001F100001.

1.3. Proposed Codification Logic

Proposed Material Codification for semi-finished and Finished Material.

Product Type + Product + Grade = PT + P + Q

Product Type

Product

Grade and Specification

Example,

Proposed Material Codification for Raw Material ( Coil, Slit Coil, Plate)



Product Type + Product + Grade + Dimension = PT + P + Q + D

Product Type

Product

Grade and Specification

Wall Thickness Range

Example,

Scrap and Slow Moving Materials



Example,

1.4. Approach to Collect, Clean and collate the data in template

Data can be collected from:1) Existing database tables into pre-defined templates (Existing database refers to the

legacy SAP system)2) Manual data collection into pre-defined templates.

The data can be downloaded from:1) SAP Standard Reports2) Customized reports developed (ABAP, BI etc.).3) SAP tables (e.g. MARA for material master, LFA1 for Vendor master etc.)4) Develop ABAP programs to extract data from SAP tables into templates.5) Templates in the form of XL sheets have been provided for data collection. Users

need to extract data into these templates.

Data cleansing, Data Cleaning or Data scrubbing is the process of detecting and correcting (or removing) the corrupt or inaccurate records from a record set, table, or database. Used mainly in database, the term refers to identifying incomplete, incorrect, inaccurate, irrelevant, etc. parts of the data and then replacing, modifying, or deleting this dirty data.

Data transformation allows the mapping of the data from its given format into the format expected by the appropriate application. This includes value conversions or translation


http://en.wikipedia.org/wiki/Dirty_data

http://en.wikipedia.org/wiki/Database

http://en.wikipedia.org/wiki/Table_(database)

http://en.wikipedia.org/wiki/Storage_record


functions, as well as normalizing numeric values to conform to minimum and maximum values.

Duplicate detection requires an algorithm for determining whether data contains duplicate representations of the same entity. Usually, data is sorted by a key that would bring duplicate entries closer together for faster identification.

1.5. Data Upload Approach

Data can be uploaded to the system by various methods in SAP, for example:1) LSMW: The LSMW (Legacy System Migration Workbench) is a tool based on SAP

software that supports single or periodic data transfer from non-SAP to SAP systems (and with restriction from SAP to SAP system). Its core functions are:

a. Importing legacy data from PC spreadsheet tables or sequential filesb. Converting data from its original (legacy system) format to the target (SAP)

formatc. Importing the data using the standard interfaces of SAP (IDoc Inbound

processing, Batch Input, Direct Input)By means of standard transfer programs: a wide range of master data (e.g. G/L accounts, customer master, vendor master, material master, bills of material) and transaction data (e.g. financial documents, sales orders)

2) BDC: BDC stands for Batch Data Communication and is also referred to as Batch Input. It is a technique for mass input of data by simulating user inputs in screens of existing transactions. There are two main methods of BDC, these are:

a. Call Transaction Using (CTU)b. Batch Input Session (BI session)

3) BAPI: A Business Application Programming Interface (BAPI) is a precisely defined interface providing access to processes and data in business application systems such as R/3. BAPIs are defined as API methods of SAP business object types. These business object types and their BAPIs are described and stored in the Business Object Repository (BOR). A BAPI is implemented as a function module that is stored and described in the Function Builder.

1.6. Data availability and Testing Approach

Data availability and testing approach should be 25% at the time of Unit Testing and the same should be 75% at the time of Integration Testing.

1.7. Post Go-Live Approach for Master Data Creation/Change/Delete

A separate team needs to be recruited for the maintenance of masters & the master’s updation should be done centrally in order to avoid the duplication.

2. Bill Of Material


http://help.sap.com/saphelp_46c/helpdata/en/a5/3ec8534ac011d1894e0000e829fbbd/content.htm


http://en.wikipedia.org/wiki/Algorithm


2.1. Define the Master

Description:

BOM contains list of components that make up a product or assembly. The list contains the object

number of each component, together with the quantity and unit of measure. BOM is maintained with the transaction code CS01 for create, CS02 for change and CS03 for display.

Requirement:

BOMs are used in their different forms in various situations where a finished product is assembled from several component parts or materials. Depending on the industry sector, they can also be called recipes or lists of ingredients and so on.

They contain important basic data for numerous areas of a company, for example:

MRP Material provisions for production Product costing Plant maintenance

Prerequisites: 1) Material Master

Integration:

A material requirements planning (MRP) department explodes bills of material on a certain date to calculate cost-effective order quantities for materials.

A work scheduling department uses bills of material as a basis for operation planning and production control.

A production order management department, uses bills of material to plan the provision of materials.

The data stored in bills of material is also used in other activities in a company such as:

Sales orders

As an aid to data entry. You can also create and maintain a BOM specifically for a sales order (variant configuration).

Reservation and goods issue

As an aid to data entry



Product costing

To calculate the costs of materials required for a specific product

Advantages:

This simultaneous use of BOM data in different areas of a company illustrates the advantage of a system based on integrated application components. Links between application components facilitate continuous data exchange between different application areas, giving all users access to the latest data at all times.

2.2. Existing BOM Structure

At present simple BOM is used. Base Unit of Measure tonBase quantity is

2.3. Proposed BOM Structure

Super BOM,


Data can be collected from:



1) Existing database tables into pre-defined templates (Existing database refers to the legacy SAP system)

2) Manual data collection into pre-defined templates.

The data can be downloaded from:1) SAP Standard Reports2) Customized reports developed (ABAP, BI etc.).3) SAP tables (e.g. MARA for material master, LFA1 for Vendor master etc.)4) Develop ABAP programs to extract data from SAP tables into templates.5) Templates in the form of XL sheets have been provided for data collection. Users need to

extract data into these templates.


Data transformation allows the mapping of the data from its given format into the format expected by the appropriate application. This includes value conversions or translation functions, as well as normalizing numeric values to conform to minimum and maximum values.



Data can be uploaded to the system by various methods in SAP, for example:1) LSMW: The LSMW (Legacy System Migration Workbench) is a tool based on SAP software

that supports single or periodic data transfer from non-SAP to SAP systems (and with restriction from SAP to SAP system). Its core functions are:

a. Importing legacy data from PC spreadsheet tables or sequential filesb. Converting data from its original (legacy system) format to the target (SAP) formatc. Importing the data using the standard interfaces of SAP (IDoc Inbound processing, Batch

Input, Direct Input)By means of standard transfer programs: a wide range of master data (e.g. G/L accounts, customer master, vendor master, material master, bills of material) and transaction data (e.g. financial documents, sales orders)


a. Call Transaction Using (CTU)b. Batch Input Session (BI session)3) BAPI: A Business Application Programming Interface (BAPI) is a precisely defined interface

providing access to processes and data in business application systems such as R/3. BAPIs








are defined as API methods of SAP business object types. These business object types and their BAPIs are described and stored in the Business Object Repository (BOR). A BAPI is implemented as a function module that is stored and described in the Function Builder.




A separate team needs to be recruited for the maintenance of masters & the master’s updating should be done centrally in order to avoid the duplication.

3. Routing

3.1. Define the Master A routing is a description of which operations (process steps) have to be carried out and in which order to produce a material (product).

Description:

A routing is composed of a header and one or more sequences. The header contains data that is valid for the whole routing. A sequence is a series of operations. Operations describe individual process steps, which are carried out during production (see Routing graphic)

A routing is identified by its group and group counter.

Routing is maintained with the transaction code CA01 for create, CA02 for change and CA03 for display.

Requirement:

A routing is used as a source for creating a production order or a run schedule header by copying.


MRP




Material provisions for production Product costing Plant maintenance

Prerequisites: 1) Material Master2) Work Center

Integration:

Capacity Rquirement Planning, Product Costing

Advantages:

3.2. Existing Routing Structure

There is no grouping of routing; each material will have separate group

3.3. Proposed Routing Structure

Super Routing

This Super Routing will have all the operations used in producing the product of any diameter and wall thickness, and TDC. While choosing dimension and TDC for the product, required operations get selected with the help of dependency. Operation time is determined based on Welspun mill capacity norms.

The super routing would have all stations of the plant irrespective of, whether you use it or not in the production process. The routing will have non variant operation, which will always be used. And some operations are optional and are used based on technical or customer requirement.




Data can be collected from:3) Existing database tables into pre-defined templates (Existing database refers to the legacy

SAP system)4) Manual data collection into pre-defined templates.












a. Call Transaction Using (CTU)








b. Batch Input Session (BI session)6) BAPI: A Business Application Programming Interface (BAPI) is a precisely defined interface

providing access to processes and data in business application systems such as R/3. BAPIs are defined as API methods of SAP business object types. These business object types and their BAPIs are described and stored in the Business Object Repository (BOR). A BAPI is implemented as a function module that is stored and described in the Function Builder.





4. Work Center

4.1. Define the Master Operations are carried out at a work center.Description:

Work centers are business objects that can represent the following real work centers, for example:

Machines, machine groups

Production lines

Assembly work centers

Employees, groups of employees

Routing is maintained with the transaction code CR01 for create, CR02 for change and CR03 for display.

Requirement:

Together with bills of material and routings, work centers belong to the most important master data in the R/3 production planning and control system. Work centers are used in task list operations and work orders. Task lists are for example routings, maintenance task lists,




inspection plans and standard networks. Work orders are created for production, quality assurance, plant maintenance and for the Project System as networks.

Prerequisites: Standard Value Key, formula for scheduling, capacity requirement and costing

Integration:


Advantages:

Data in work centers is used for

Scheduling

Operating times and formulas are entered in the work center, so that the duration of an operation can be calculated.

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.

Capacity planning

The available capacity and formulas for calculating capacity requirements are entered in the work center.

Simplifying operation maintenance

Various default values for operations can be entered in the work center

4.2. Existing Work Center Structure

4.3. Proposed Work Center Structure



Example,













5. Class And Characteristics

5.1. Define the Master In the classification system, characteristics describe the properties of objects. The values of a characteristic specify these properties.

Description: For example, Characteristic pipe_dia has the values '609.6 mm', '914.4 mm', and '406.4 mm'. While classifying a pipe, use this feature of pipe as, characteristic to specify the pipe_dia of the pipe.

Classification is maintained with the transaction code CL01 for create, CL02 for change and CL03 for display.

Requirement:

A routing is used as a source for creating a production order or a run schedule header by copying.


MRP Material provisions for production Product costing Plant maintenance

Prerequisites: 3) Material Master4) Work Center

Integration:


Advantages:

5.2. Existing Routing Structure

In existing system, variant class is not used because this class is used only when we adopt variant configuration



5.3. Proposed Class and Characteristics Structure

Each product will have a class, and its class type would be 300.

Characteristics are named in such way that the short name would get us an idea what feature the character is representing.




The data can be downloaded from:16) SAP Standard Reports17) Customized reports developed (ABAP, BI etc.).18) SAP tables (e.g. MARA for material master, LFA1 for Vendor master etc.)



19) Develop ABAP programs to extract data from SAP tables into templates.20) Templates in the form of XL sheets have been provided for data collection. Users need to

























Process signoff

ROLE NAME SIGNATURE

Process Owner Mr. Manoj Jain

Core Team Lead Mr. Alok Shrivastava

Core Team Member Mr. Anand Routh

Core Team Member Mr. Kirti

Consulting Team Lead Mr Tuhin Subhra Das

Consulting Team Member Mr Mardan Ali

Consulting Team Member Mr Umesh Kumar


2_pipes_master data_pp.doc

Documents

material master data

data upload approach

data availability

necessary data

live approach

testing approach

material master record

new material master