erp md report
TRANSCRIPT
1
P/L (IT) HOD DIRECTOR MD
PROD MAT QC DEVP TECH FIN HR ADMIN GP
ERP OVERVIEW
1. CUSTOMER PLAN
2. DISPATCH
3. RECEIPTS
4. TAXATION
• QR Barcode Invoice
• Customer trim in based auto invoicing
• FG & SFG Inventory
• PDA based POP
• Sales Return
SALES
• Multi level BOM
• Model wise - car value analysis
• Introducing LTP & STP
• D+2 Planning
• Automatic purchase schedule by STP
• Kanban & Lean Management
BOM
PPC
• Inventory Levels - R/M, LP, CKD,
• Automated PO schedule
• Lean Inventory through Purchase scheduling
• Systemised CKD costing
• Barcode (PDA) based Material Transfer
MATERIALS/ PURCHASE
• Cost History
• Internal Cost/Management Accounting
• WIP STOCK Monitor
• Statistical Process Control (SPC)
• 4M Calculation
COSTING/ PRODUCTION
• Kiosk based Quality POP
• DCR & CounterMeasure
• Inline, Incoming & Customer PPM
• Vendor Performance Rating
QUALITY CONTROL
• Employee Portal
• Reporting Portal
•Budgeting
•Online Reports and Approval
• Supplier Portal Like VAATZ
PORTALS
KE
Y F
UN
CT
ION
AUGPROTO AUGDEMO
1. CAR BOM
2. MATERIAL BOM
3. DLY/ MTHLY/ YRLY PLAN’G
4. EASIER PLANNING MODEL
JUNPROTO JULDEMO
1. PURCHASE REQUEST
2. PURCHASE PLANNING
3. WAREHOUSE
4. CKD SUB MODULE
JULPROTO JULDEMO
1. COST CENTERS
2. PRODUCT COSTING
3. WIP STOCK
4. PRODUCTION PLAN’G - 4M
JULPROTO SEPDEMO
1. INLINE QC
2. INCOMING QC
3. FINAL INSPECTION
4. PPM CALCULATION
5. VENDOR QC
JULPROTO SEPDEMO
1. WORK FLOW
2. APPROVAL SYSTEM
3. VENDOR QC
4. VENDOR PO & PAYMENT
OCTPROTO NOVDEMO
3
CFT MEETING SCHEDULE & SCOPE
CFT Meeting Schedule
BOM Production Material Purchase Costing Quality TM Sales HR Reporting Vendor MIS
Meeting 1 11-Jun 18-Jun 25-Jun 09-Jul 02-Jul 16-Jul 23-Jul 30-Jul 06-AugRequirement will be
collected during the
discussion with CFT on
other Modules
Meeting 2 13-Jun 20-Jun 27-Jun 11-Jul 04-Jul 18-Jul 25-Jul 01-Aug 08-Aug
Meeting 3 15-Jun 22-Jun 29-Jun 13-Jul 06-Jul 20-Jul 27-Jul 03-Aug 10-Aug
Meeting 4 20-Jun 27-Jun 04-Jul 18-Jul 11-Jul 25-Jul 01-Aug 08-Aug 16-Aug
Meeting 5 06-Jul 06-Aug 31-Jul 31-Jul 03-Sep 12-Sep 27-Sep 30-Aug 16-Oct 15-Oct 19-Oct 08-Nov
Level Meeting Scope
1 • Application Flow Confirmation
• Requirement Collection templates will be shared
• Process Function and Activity Identification
• Risk Area Identification
• 1st level BR Identification
• Master Data Identification
2 • Data Element Identification
• Integration BR Identification
• Master Data Confirmation
• New Process Changes Identification
3 • Proposed Model Presentation
• Feedback Session
4 • Feedback Incorporation
• Final Proto Type Presentation
5 • Application Module Demo
CFT Meeting Schedule & Methodology
A SNAPSHOTA Snapshot
Application flow
Confirmation
Req. Collection Templates
sharing
Process Function &
Activity Identify
Risk Area Identify
1st Level Business
Risk Identify
Master Data
IdentifyMeeting 1
Proposed Model
Presentation
Feedback Session
Incorporation of feedback
Final Proto type
presentation
Application Module Demo
Data Element Identification
Integration Business
Rules
Master Data Conformation
Identifying New Process
ChangesMeeting 2
Meeting 3
Meeting 4
Meeting 5
Milestones
Jan Feb March April May June July August Sep Oct Nov Dec
2012
2013
CALENDAR – MODULE DEMOMILESTONES AT A GLANCE
EXAMPLE TEXT
MILESTONES – MODULE WISE DEMO
6
CALENDAR – CFT SCHEDULEJune 2012
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
WEEK 1 1 2 3
WEEK 2 4 5 6 7 8 9 10
WEEK 3 11 12 13 14 15 16 17
WEEK 4 18 19 20 21 22 23 24
WEEK 5 25 26 27 28 29 30
WEEK 6
AS IS – SYSTEM STUDY and REAL TIME GAP ANALYSISby Leiten Team
Execution Plan for All ModulesProject
Kick Off
Meeting
BOM, PPC
CFT Meet
BOM ,PPC
FLOW CONFIRM
BOM ,PPC
TO BE
PRESENT
PRODUCTION
CFT MEET
PRODUCTION FLOW CONFIRM
BOM, PPC -PROTO
PRODUCTION
TO BE
PRESENT
MATERIAL
CFT MEET
MATERIAL
FLOW CONFIRM
PRODUCTION PROTO
MATERIAL
TO BE PRESENT
7
CALENDAR - CFT SCHEDULEJuly 2012
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
WEEK 1 1
WEEK 2 2 3 4 5 6 7 8
WEEK 3 9 10 11 12 13 14 15
WEEK 4 16 17 18 19 20 21 22
WEEK 5 23 24 25 26 27 28 29
WEEK 6 30 31
COSTING FLOW CONFIRM
MATERIAL- PROTO
SALES
CFT
MEET.
COSTING
CFT MEET
TM
CFT MEET
QUALITY
CFT MEET
PURCHASE
CFT Meet
PURCHASE
FLOW CONFIRM
COSTING- PROTO
QUALITY FLOW CONFIRM
PURCHASE -PROTO
TM
FLOW CONFIRM
QUALITY -PROTO
PURCHASE
TO BE
PRESENT
QUALITY
TO BE
PRESENT
TM
TO BE PRESENT
COSTING
TO BE
PRESENT
CALENDAR – CFT SCHEDULEJuly2012
8
CALENDAR - CFT SCHEDULEAugust 2012
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
WEEK 1 1 2 3 4 5
WEEK 2 6 7 8 9 10 11 12
WEEK 3 13 14 15 16 17 18 19
WEEK 4 20 21 22 23 24 25 26
WEEK 5 27 28 29 30 31
WEEK 6
SALES FLOW CONFIRM
TM - PROTO
HRM
CFT MEET
HRM FLOW CONFIRM
SALES - PROTO
HRM- PROTO
REPORTINGVENDOR PORTALTO BE
HRM
TO BE
PRESENT
CALENDAR – CFT SCHEDULEAugust 2012
ERP – DATA FLOW
MANUFACTURING
BOM MANAGEMENT
PPC/MRP
COSTING
PRODUCTION / SHOP FLOOR
TECHNICAL AND MAINTANENCE
11
BOM TFT
A Permanent Task Force Team (TFT) is necessary to maintain BOM in ERP.
Director
Development
I/C Person
Daimler
I/C Person
HMI
I/C Person
AL Nissan
Production(Routing)
Purchase(Purchase Price)
Finance(Ledger Code)
Approver
Initiator
Supporter
Creator IT Person& TL
Re
qu
est to
Cre
ate
Ma
ste
r, BO
M
Info
rmatio
n to
oth
ers
afte
r cre
atin
g B
OM
B.O.M.
12
A Bill of Materials (BOM) is a detailed list of all parts and subassemblies that are required to build a specific product, including the quantity necessary for each unit produced.
Bill of Material - Definition
BOM Data Entry Screen BOM Tree View
B.O.M.
B.O.M.
BOM Creation Process
Development Person
& Manager
Master & BOM
Person (IT)IT Team Leader Process Description Output
Responsibility &
Approval
1.Deliver information about new
development or new ECO
(Developer delivers sourcing list, BOM
application form to IT person in-charge of
Master)
BOM Change
Application
&
Sourcing List
Developmen
t Member
& Manager
2.Check for Consistency and
Completeness after receiving BOM
application form and sourcing list.
If errors are found, Return the paper to
developer,
Sourcing list and BOM change application
form must have Material details & other
required information about that.
BOM Change
Application
Master
Person (IT)
3. IT Team Leader verifies BOM
application form and sourcing list.
IT Team
Manager
4.In accordance with BOM application
form, Create Material Master & BOM
BOM Change
Information
IT Team
Member
(Master)
5.The IT member is responsible to
create Master and BOM informs to related
teams about the creation / change in
BOM.
Other team members should check the
BOM Module that the BOM is updated as
requested
IT Team
Member
Concerned
Team
Members
Information of New
Development /EO Change
NO
1
Yes
Rewritie sourcing list/Check BOM & Educate
Error
NO
MASTER & BOM Creation
InformCompletion of BOM Creation
[Development,Materials,Sales,Cost
]
2
45
3
Invalid Sourcing List
[Return]
Receive inquiry of
BOM creation & Approval
Review BOM Change
Application Form &
Approval
Yes
BOM & PPC / MRP
Key Functions
1. YEARLY PLAN ( JAN – DEC)
2. MONTHLY PLAN (QUARTERLY)
3. DAILY PLAN (D+2)
Features
PPC / MRP
Introducing LTP & STP
Improved D+2 Planning
Automatic Purchase Schedule through STP
Kanban, Lean Production & Lean Inventory
Yearly Material Procurement Planning
Yearly Capacity Planning
Yearly Sales Planning
Delivery
PRODUCTION
Key Functions
1. PROCESS MASTER
2. MACHINE MASTER
3. PRODUCTION ROUTING MASTER
4. PRODUCTION PLANNING -4M CALCULATION
5. WIP STOCK
Features
PRODUCTION
WIP Stock Monitor
Statistical Process Control (SPC) at all shops
Daily Production Planning through D+2 System
Mould History Card (ISO, 5-Star requirement)
Shop-Line-Machine concept for effective costing
Calculation of Capacity Plan, Productivity, OEE
Integration with Tech Maintenance for 100% uptime
Machine wise UPH, UPMH calculation
4M Calculation
PRODUCTION
Key Functions
1. COST CENTERS
2. COST ELEMENTS
3. COST ESTIMATION
4. PRODUCT COSTING
Features
COSTING
Manages Internal Cost/Management Accounting
Activity based Costing
Cost History
Automation of Supplementary/ Retro Invoicing
Key Functions
1. MAINTENANCE SCHEDULE
2. ASSET MANAGEMENT
3. SPARES MAINTENANCE
4. ENERGY MANAGEMENT
Features
TECHNICAL & MAINTANANCE
Maintenance Scheduling & Reminders
Preventive and Predictive Maintenance
Reducing MTBF through Continuous alerts
M/C Breakdown Analysis
Spares maintenance
Asset Tracking
EB Reading, Diesel Accounting
Key Functions
1. MATERIAL PURCHASE PLANNING
2. PURCHASE REQUEST & APPROVALS
3. SUPPLIER MANAGEMENT
4. WAREHOUSE MANAGEMENT
5. CKD SUB MODULE
Features
MATERIALS & PURCHASE
Inventory Levels - R/M, LP, CKD, BO
Vendor Rating / Performance
Calculating ITR and Purchase/Sales ratio
Barcode (PDA) based Material Transfer
Crate / Trolley Accounting
Automated PO schedule
Rate Master creation through Approval system.
Lean Inventory through Purchase scheduling
Vendor Stock Monitoring
Automated GR (GR through Vendor Portal)
Systemised CKD costing
Systemised billing process for Transporters
Control on Purchase Returns (Qty, Payment)
CKD
MATERIALS & PURCHASE
Calculating ITR
Automatic Material Costing system
Automatic PO as Per Production Planning
Online PO Approval
Vendor Stock Monitoring System
Automatic Data Upload to SAP
Automated CKD Costing System
Direct Link with Korean HO & Downloading Packing List
FIFO based
CKD Issue
Automatic GR through Vendor
Portal
Barcode Based GRN
Trolley & Pallet Accounting System
Automatic BOM based Material
Scheduling
Barcode (PDA) based Material Issue
Centralized Stock Monitoring System
Flaw less Stock Transfers
PURCHASE
MATERIALS
WAREHOUSE
MATERIALS & PURCHASE
MATERIALS & PURCHASE
Key Functions
1. INLINE QC - REWORK, REJECTION
2. INCOMING QC - REWORK, REJECTION
3. FINAL INSPECTION -REWORK, REJECTION
4. PPM CALCULATION.
5. VENDOR QC MANAGEMENT
Features
QUALITY
Inline, Incoming & Customer PPM calculation
Kiosk based Quality POP
Online SPC to send SMS for production quality issues
Defect Content Report & Countermeasure from Vendor
Systemised Debit Advice for rejection
Interlink with Vendor Portal for Rework / Rejection PPM
Vendor Performance Rating
Key Functions
1. CUSTOMER PLAN
2. DISPATCH SUB MODULE
3. RECEIPT SUB MODULE
4. TAXATION SUB MODULE
Features
SALES
QR Barcode – Sales Invoice
Trim – in based Auto Invoice
PDA based POP
Effective D+2 planning system to avoid customer line stop
Proper accounting of Sales Return
Complete capturing of Warranty claim, Cost of Poor Quality
Systemised working of Transport Billing
Crate/ Trolley Accounting
SALES
SHOPFLOOR
Key Functions
1. ATTENDANCE SYSTEM
2. PAYROLL SUB MODULE
3. TRAINING SUB MODULE
4. APPRAISAL SUB MODULE
5. EMPLOYEE DATA BANK
Features
HUMAN RESOURCE
Centralized Attendance monitoring system
Integrated Pay Roll system
HR Training History Module
Audit compliances
All EIS Reporting
Leave Approval thru Reporting Portal
Key Functions
1. APPROVAL SYSTEM
2. WORK FLOW SYSTEM
Features
REPORTING AND APPROVAL PORTAL
Budgeting ( Needs integration with Finance Module)
Integrated Online Report Approval with All Modules in ERP
Leave Application Approval
Purchase Rate Master Approval
Sales Rate Master Approval
New BOM creation Approval
BOM Modification Approval
Business Trip Approval / Report
Other Approvals
Sharing Company Policy / Process
Key Functions
1. QUALITY
2. PURCHASE
Features
VENDOR PORTAL
Advance Shipment Notice (ASN) with Barcode
Purchase Order and Delivery Schedule
GR Inward and Payment Tracking
Quality Tracking, DCR and Counter Measure Action
PPM Status
Performance Rating
Key Functions
1. INTEGRATED WITH ALL MODULES
2. DASHBOARD REPORTING
3. GRAPHICAL REPORTS
4. TRENDS
5. PLANNING
Features
EXECUTIVE INFORMATION SYSTEM
Direct on-line access to relevant information
Timely and Accurate
Dashboard Reports, Analysis and Graphs
Identifies Trends
Measures Performance
Daily Manpower Summary
Daily Absent Ratio
OT Analysis
ITR Trend
Purchase/Sales ratio
Planning Analysis
PPM Status
Top 10 - Worst parts
Sales Trend
Purchase Trend
SALES
HUMAN RESOURCE
• Integrated Attendance Monitoring
• Integrated Pay Roll System• Training History • Appraisal Sub Module• Employee Data Bank
QUALITY
• Customer Plan• Item Configuration• Delivery Schedule• PDA based POP• Sales Return• Crate/Trolley
Management
• Incoming QC• Inline QC• Final Inspection (FG)• PPM Calculation• Vendor Quality
Management
MANUFACTURING
• BOM Management• PPC/MRP• Costing• Quality Control – Inline• Production Control• Capacity Planning• Technical and
Maintenance
MATERIALS
• Warehouse Management• Movements & Transactions• Costing• Quality Control – Incoming• PDA based Inventory
Management• CKD Management
PURCHASE
• Purchase Scheduling• Purchase Orders• Sub Contracting• Costing• Goods Receipt• Accounts Payable
ERP INTEGRATION MODELCORE MODULES - SNAPSHOT
ERP (EIS)
VENDORPORTAL
Reporting & Approval Portal
QC
QUALITY
PRProduction
PPCProductionPlanning &
Control
BOM
HRHuman Resource
MPSMaterials, Purchase &
Stores
COCosting
SDSales
TMTech & Main
EISExecutive Information System
FI
IL
IC
EMPLOYEEPORTAL
ERP INTEGRATION MODEL