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Vedanta Alumi na Ltd. Product ion Planni ng Page 1 of 1

SAP ECC 5.0 I MPLEMENTATI ON Business Process Bluepr in t Version No 1.2

CONFIDENTIAL

SAP R/3 IMPLEMENTATION

BUSINESS BLUEPRINT

Production Planning

Prepared by Checked by Reviewed By Approved By DateAniruddha Mukherjee Vishal Rathore

PDF created with pdfFactory trial version www.pdffactory.com
http://www.pdffactory.com/http://www.pdffactory.com/


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TABLE OF CONTENTSOBJECTIVE OF BUSINESS BLUEPRINT PHASE.........................................................................................................................................................................................3SCOPE OF BPBP DOCUMENT ..................................................................................................................................................................................................................6 PRODUCTION PLANNING IN SAP - OBJECTIVE...............................................................................................................................................................................7 SECTION I .......................................................................................................................................................................................................................................................8 SECTION II....................................................................................................................................................................................................................................................12 ORGANIZATION STRUCTURE ..............................................................................................................................................................................................................12 OTHER MAJOR CONFIGURATION ......................................................................................................................................................................................................17 SECTION III..................................................................................................................................................................................................................................................21 SECTION IV ..................................................................................................................................................................................................................................................78 SPECIAL ORGANIZATIONAL CONSIDERATIONS:.................................................................................................................................................................................80



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OBJECTIVE OF BUSINESS BLUEPRINT PHASE:

This document is the outcome of the As-Is study, Discussion at Training and during the To-Be process and business process requirement analysisfor the Vedanta Alumina Limited.

Based on this As-Is coupled with inputs from the core team members during To-Be discussion, we arrived at the Business Processes, which are tobe incorporated in the Business Blue Print. The aim of this document is to map the best business processes related to the Production Planningmodule in SAP ECC 5.0. This document is to be studied by core team members & process owners from Vedanta Alumina Limited. The preparationof this document is an essential precursor for prototyping and testing. The development work will start once process owners approval for this BluePrint is obtained followed by a corporate presentation to the senior management team, Vedanta Alumina Limited.

This document will be used for configuring Production Planning module in SAP implementation. Document is based on discussions/presentations

between representatives of VAL & PWC. In other words it contains

1. SAP Organization Model in context of existing business scenario and future requirements/issues as envisaged by VAL.

2. Mapping of business processes/issues brought forward by PwC & VAL, with SAP functionality.

3. Gaps & issues emerged during the discussion between VAL & PwC.

4. Business Process Flows mapped in SAP as per the scope defined.



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5. Closure of Mapping Phase and start of Piloting Phase of implementat ion.

A pictorial presentation of complete SAP implementation is depicted in the following page:



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SCOPE OF BPBP DOCUMENT

The objective of this Blue Print presented to the Project Sponsor is to document the following:

a) Business Requirements of VAL that need to be translated into SAP.

SAP consultants team members on the basis of As-Is document, factory visit & discussions between PwC SAP consultants and VAL

core team members have prepared this.b) SAP Gaps as identi fied by PwC Team with respect to the present scope of implementation and Business Requirements of VAL.

c) Details of SAP New Business Process description supported by Process Flow diagram with respect to Different SAP process

indicating the desired To be Processes / Business Blue Print.

In order to bring the clarity and better understanding, the document has been divided in five sections:

SECTION I: Scope of SAP Production Planning and Control module for the project.

SECTION II: Organization structure.

SECTION III: Master Data Management, As-Is and / To-Be Business processes, and Gaps identified for business processes as per SAP.

SECTION IV: Appendix-Process ( SAP) Flow Diagrams.



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Production Planning in SAP - Objective

To provide a Production Planning, execution, control and record maintenance system fully integrated with Finance, Costing, MaterialsManagement, Sales & Distribution and Quality Management in order to achieve superior operational efficiency, cost reduction and profitability.

The module also provides better handling of all business transaction, statutory compliance, EIS, and MIS for better decision-making managementControl. This is achieved through the following components:

Integration into Process Planning and Control.

Shop Floor Control in the R/3 System.

Special Topics of Production.

An Example of PO Processing.

Creating a Process Order.

Important Tasks within Process Order Processing.

Confirming and Settling Process Orders.



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SECTION I

Scope of Production Planning Module in VAL

PARTICULARS Alumina Power

Master

1.1 General Master Records

1.1.1 Material Master X X1.1.2 Material BOM X X1.1.3 Resource X X1.1.4 Recipe X X1.1.5 Batch

1.2 Production Planning and Procurement Planning1.2.1 Sales and Operations Planning1.2.2 Demand Management X1.2.3 Long-Term Planning1.2.4 MPS

1.2.4 MRP X X (MM)



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1.3 Production1.3.1 Discrete Production1.3.2 Repetitive Manufacturing1.3.3 Process Manufacturing X X

1.3.4 KANBAN1.4 Inventory Management

1.4.1 Batch1.4.2 Batch Search Strategy

1.4.3 Control Cycle1.4.4 Serial Numbers

Business2.1 Production Planning and Procurement Planning

2.1.1 Market-Oriented Planning2.1.1.1 Sales and Operations Planning2.1.1.2 Forecast

2.1.1.3 Demand Management X2.1.1.4 Long-Term Planning2.1.1.5 Master Production Scheduling2.1.1.6 Material Requirements Planning X X (MM)



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2.1.1.7 Evaluations: Logistics Information System X X

2.1.2 Sales Order Oriented Planning2.1.2.1 Master Production Scheduling

2.1.2.2 Material Requirements Planning2.1.2.3 Evaluations: Logistics Information System

2.1.3 Consumption-Driven Planning MM MM2.1.3.1 Forecast2.1.3.2 Material Requirements Planning X X2.1.3.3 Evaluations: Logistics Information System X X

2.2 Production2.2.1 Process Manufacturing

2.2.1.1 Process Order Creation X X2.2.1.2 Material Staging2.2.1.3 Capacity Requirements Planning X X

2.2.1.4 Process Order Execution X X2.2.1.5 Evaluation and Mass Processing X X2.2.1.6 Evaluations: Logistics Information System2.2.1.7 Replenishment Stock Transfer with Reservation X X



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2.2.1.8Replenishment Stock Transfer with Direct TransferPosting X X

2.3 Inventory Management MM2.3.1 Goods Movements

2.4.1.1 Reservation X X2.4.1.4 Goods Receipt X X2.4.1.5 Stock Transfers / Trans. Postings X X2.4.1.6 Goods Issue X X

2.3.2 Physical Inventory & Cycle Counting MM2.4.2.1 Physical Inventory X (MM)

Cross-Application Components3.1 Classification System X X

3.1.1 Characteristics X X3.1.2 Classes X X3.1.3 Classification X X



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Section II

Organization Structure

Plants

The plant is an operating area or branch within a company. The plant is assigned to a single company code. A plant has its own material masterdata. You can maintain data at plant level for the following views on a material master record in particular: MRP, Purchasing, Storage, Workscheduling, Production resources/tools, Forecasting, Quality management, Sales, Costing. Among this, views in bold would be used in case ofVedanta Alumina Ltd.

As per discussion with Finance & Materials, there will be only fourCompany Code (1000,2000,3000,4000) and four plants (Non-Virtual) will becreated which may be as follows:

PRODUCTION PLANT DESCRIPTION

1000 VAL Alumina Plant

2000 VAL Power Plant

3000 VAL Smelter Plant



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Storage Locations

Storage location is an organizational unit allowing the differentiation of material stocks within a plant. All data referring to a particular storagelocation is stored at storage location level. This applies mainly to storage location stocks.

Several storage locations can be assigned to a plant.

The logical and physical storage locations will be configured to track the inventory in the shop floor. The configuration of the storage locations willbe done according to the physical or the logical movement of materials in the shop floor. The detailed discussion on storage locations will come inthe plant specific documentation.

Proposed Storage Locations for plant relevant for PP.

Alumina Plant (1000)

STORAGE LOCATIONS DESCRIPTION

To Be submitted by MM



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Power Plant (2000)

STORAGE LOCATIONS DESCRIPTION

To Be submitted by MM



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Main Resources in Alumina Plant

RESOURCES DESCRIPTION

Calcinations Unit Hydrate is Calcined into Alumina.

Hydrate Unit Alumina as Hydrate is Obtained.

Process Caustic UnitUnit where Process Caustic may becaptured as WIP.

Note: The Resource of caustic may not used on day-to-day basis. It may be used at the end of the month to capture WIP for Caustic and that too

would be used if any other work around is not found at realization and integration testing phase. PwC s Suggestion is to manage WIP through ageneralist approach.



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Main Resources in Power Plant

RESOURCES DESCRIPTION

Power Resource for power Plant.



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Other Major Configuration

Factory Calendar

Every Plant will be having a factory calendar with details of the working days and the holiday schedule. The Factory calendar will be named as Aland PO for Process and Power plants respectively. Periods and the Fiscal Year will be from April March.

Holiday Calendar

Every Plant will be having a hol iday calendar with details of the holidays as public and other holidays, either as fixed or a moving day in a year. TheFactory calendar will be named as Al and PO for Process and Power plants respectively. Periods and the Fiscal Year will be from April March.

Material Groups

The functional grouping of the materials for reporting and analysis. It can be used to restrict the scope of analysis and searching specificallymaterial master record via search help.

MRP Group

If we are going for different process order types for Alumina (finished materials), power (raw materials for process plant) etc, and then MRP groupcan be created. Material type assignment has to done on one to one basis. One plant may have more than one MRP group. The number of MRPgroup to be finalized in the Realization phase.



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MRP Type

For material those would be planned on the basis of manufacturing requirement would be planned through Classical MRP. For these type ofmaterial MRP type PD would be used in general. Based on this requirement planned Order would be generated in the system for finished product.Raw Materials would be planned through consumption based planning. Relevant information related to Re-order point and safety stock would beprovided in the material master record.

Lot-sizing Procedure

Using this system should calculate the Order quantity for planned order. It is consumed from material planning. We would use Lot-for-Lot OrderQuantity in general (EX).

MRP Controllers

It specifies the group or the number of the controller responsible for Material requirement planning in your organization (Plant or Company). Thematerial, which is relevant for material requirement planning, should be assigned to a MRP controller



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Order Types for Alumina Plant

ORDER TYPE DESCRIPTION

AL Order Type for Alumina.

HY Order Type for Hydrate.

NAOH Order Type for Caustic.

Note: The Order type of caustic may not used on day-to-day basis. It may be used at the end of the month to capture WIP for Caustic and that toowould be used if any other work around is not found in realization phase or integration testing phase. PwC s Suggestion is to manage WIP througha generalist approach.

Order Types for Power Plant

ORDER TYPE DESCRIPTION

POW Order Type for Power.



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To-Be Processes

Production Planning Processes

The Business Blue Print is divided into various sections as defined by the different processes as discussed during to-be and Expectation from SAP.These processes are:

Finished Product Planning. Raw Materials Planning.

Consumables Planning. Production Scheduling. Capacity Evaluation.

Order Execution. Goods Movement.

Cost Analysis. Report Analysis.

To carry out these processes, certain Masters are required to be maintained prior to carry out the Transactions and Reports. This master is listed

below with explanation text. These Masters are created before Go-Live through Mass data upload process. They are fixed or constant in nature.The system would access these master data while the user will be carrying out transaction on day-to-day basis. So from user point of view also itmandatory to understand the relevant or organization specific master data in detail so that actual business process is replicated into the system interms of data and hence phenomenal purity.



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Section III

Sl.No.

Process Name Mode Process Description/remarksGap(Y/N)

Remarks

1.0

Process Plant-Logistics GeneralData

1.1 Batch Management

Fullysystemsupported

The manufacturing mode of VAL is a typical case of processmanufacturing scenario. Here, batch tracking is not possiblephysically. So production in SAP as well as in reality wont becaptured through batches.

N

1.2MaterialClassification


Material Classification can be done with the standard materialclassification system in SAP (Class Type 001). This will allowbetter search.

N



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1.3

ClassificationCreation/change ofClass andCharacteristics


Characteristic is a property that describes and differentiates

objects.

Example: length, colour, weight, etc.

Class is an assembly of characteristics that can be attributed to aproduct (or to several similar products). It can also be defined as agrouping of similar products according to common characteristics

Example Pump class, Boiler class etc.

N

1.4

MRP Profile

Fully

systemsupported

If the order types are more than one, profiles will help inmaintaining some controlling data. (i.e., automatic selection of

order type during manual order creation).

N



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1.5Procurement Type


This would help the system to identify the procurement type for theparticular material. We use E for produced goods, F for externalprocurement and X for both type of procurement.

N

1.6Strategy Group


For Material Produced In-House we need to maintain Strategy 11for semi-finished product i.e., Make to stock and GrossRequirement planning.

N

1.7

Availability CheckFullysystem

supported

Based on this system checks the availability. In Vedanta we woulduse checking rule 01 for all semi-finished and finished product.This is used for accumulating the total requirement on daily basis.Any other availability check to be introduced can be considered at

Realization stage.

N



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Remarks

2.0

Process Plant-Product DataManagement

2.1Maintain MaterialMaster


Material master for Finished and Semi finished goods. MaterialClassifications may be used. Views such as Basic data 1, BasicData 2, MRP 1, MRP 2, MRP 3, MRP 4 and work scheduling (asand when required basis). For example: for raw material therewont be any Work Scheduling View.

N

2.1.1Create MaterialMaster


Create relevant views for each material and give the values ofrespective fields.

N

2.1.2Change MaterialMaster


Change values of settings as necessary in the material master canbe done anytime, but frequent change is not recommended.

N



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Sl.No.


Remarks

2.1.3Display MaterialMaster.


View settings without changing. This purely for read only purpose. N

2.2Maintain Bills ofMaterial


Create and change, as necessary, master data for Bills of Material.Standard BOM will be created and saved in the system. In case ofProcess manufacturing scenario, this can be done along withrecipe itself.

N

2.2.1Create Bills ofMaterial


Create BOMs for all materials produced in-house. In case ofProcess manufacturing scenario, this can be done along withrecipe itself.

N

2.2.2Change Bills ofMaterial


Change values of settings as necessary. In case of Processmanufacturing scenario, this can be done along with recipe itself.

N



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Remarks

2.2.3Display Bills ofMaterial


View settings without changing. This is purely Read Only view forBOM.

N

2.3 Maintain ResourceFullysystemsupported

Create and change, as necessary, master data for Resource. AllResource shall be attached to a Cost Centre. Processing Unitcapacity categories may be used for a Resource. However datarelated to Resource category and Capacity category may bechanged at the time of realization depending on the simulation testresult.

N

2.3.1 Create ResourceFullysystemsupported

Create Resource for all processing facilities in the plant withcapacity categories of Processing Unit. This would capture logicalplace of operation under a plant and at the same time collect thecosting data generated out of activity consumption. Every resourceis assigned to a cost centre.

N



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2.3.2 Change ResourceFullysystemsupported

This process would enable the user to capture any enhancedfunctionality in future. It can be used to change any existing fieldvalue apart from resource category and capacity category. Anyextra capacity category can be introduced by using the

functionality.

N

2.3.3 Display ResourceFullysystemsupported

View settings without changing. This is used for viewing the masterdata in Read only mode.

N

2.4 RecipeFully

systemsupported

Create and change, as necessary, master data for Recipe.The entire standard recipe will be created in the system for all theplants and material combination. Control Key PI01 can be used upwhile creating the Recipe. However, if required, separate controlkey can be created at time of realization phase.

N



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2.4.1 Create Recipe.Fullysystem

supported

Create Recipe for all materials produced in-house. The respectiveoperations, their phases, internal relations, material assignmentsare to be mentioned .The standard values for operations can alsobe mapped through this functionality. Control keys like PI01, and

PI05 may be used depending on the business processesintegrated along with the operations.

N

2.4.2 Change RecipeFullysystemsupported

Change values of settings as necessary. Any change in theprocess can be mapped in future through this transaction.

N

2.4.3 Display Recipe.Fullysystemsupported

View settings without changing and in Read Only mode.N

2.4.4 In-Process Inspection Fullysystem

Recipe will have In-Process Inspection Characteristics (Managedby the QM module). This is not under the Purview of current scope

N



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Remarks

supported of the project.

2.5 Production VersionFullysystemsupported

Its a combination of BOM and Recipe. So in case of recipe it is

mandatory to maintain Production version. Functionalities relatedto Lot size, alternative BOM etc can be captured through this.Multiple production versions might be there for a material. It can belocked or Unlocked on as and when required basis.

N

2.5.1Create Productionversion


At the time of recipe creation system prompts to maintainProduction version. Multiple production versions are only usedwhen more than one production line is there. Here in Vedanta onlyone production version would be created.

N

2.5.2Change Productionversion


Data related to production version can be changed at anytime. IfNew BOM is to be attached keeping the existing one in the systemwith the same recipe, one production version is generated and theprevious one is locked in changed mode.

N



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Sl.No.


Remarks

2.5.3

Display production

version

Fully

systemsupported

This is for displaying purpose read only mode. N

Process Plant- Production Planning.

3.0Process Plant-ProductionPlanning (PP-PI)

DemandManagement

Fully

systemsupported

Planning cycle will start from demand management. TheProduction Strategy would be Make to stock. GrossRequirement Planning will be used.

Planned independent requirements are used to perform DemandManagement functions. A planned independent requirementcontains one planned quantity and one date, or a number ofplanned independent requirements schedule lines, that is, oneplanned quantity split over time according to dates.

N



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Sl.No.


Remarks

3.1 View Demand

Fully

systemsupported

Demand on monthly scale can be viewed from planned

independent requirement. The Requirement for finished product isfed into the system, which will be considered at the time MRP run.

N

3.1.1Create PIR


Create demand for standard finished product in the system basedon the Rough-cut Planning idea. For Vedanta, this should not bemore than the maximum production capacity since production istotally based on Utilization of Full Plant capacity. It is not driven bysales. Down time of five days can be taken into account in PIR sothat time for opportunity based maintenance or annualmaintenance (Shut down type) can be taken in

To account in production planning in advance.

N

3.1.2 Change PIR Fullysystem

If any change is required in PIR, this process can be used .If MRPelements are not already converted, change would be directly

N



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Remarks

supported taken into account in the stock/requirement list. For affecting theexisting planned Order, MRP has to be run once again.

3.1.3 Display PIR

Fully

systemsupported

View the Planned independent requirement in display mode. N

3.1.4 Production Strategy


Make to stock production-planning strategy will be used for theProcess plant. This has been decided pertaining to actualphilosophy of production, which is not based on sale requirement.Basic idea is full utilization of plant capacity. Requirement type LSFand/ BSE can be used to meet such requirement.

N

3.1.5Staggered periodSplit


The requirement of PIR can be split further into smaller periods

(Ex. Months into weeks or weeks into days). On the basis of thesame PIR can be generated further. Hence Planned Orders can besplit automatically for smaller periods. We can use our own periodsplitting key to split the requirement into smaller periods.

N



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Sl.No.


Remarks

4.1Run MRP on material Fully

systemsupported

Activate Materials Planning for all materials at Plant to deriveGross requirements. This transfers the demand created by the PIRfor dependent planning for the BOM items.

N

4.2 Total PlanningFullysystemsupported

Total planning covers the planning of all the materials that arerelevant for requirements planning and includes the BOMexplosion for materials with a bill of material.

You can use total planning for a single plant or you can use thescope of planning to control whether the total planning run isexecuted on a multi-plant level

4.3ViewStock/Requirementlist


View Stock /requirements list to check stock position in terms ofMRP elements. All the PIR, planned order and Production Orders (if not delivered) would be displayed along with ATP ,safety stock( ifany ) , existing Stock ( if any). User will be able to see the most

N



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Sl.No.


Remarks

updated information related to Material Requirement.

4.4 Stock overview

Fully

systemsupported

View Stock overview as and when required. System enables the

user to check stock available for the stock items at various areas ofthe organization.

N

4.5 MRP ListFullysystemsupported

Functionality relevant to MRP i.e., all MRP elements can beviewed from time to time. It will show the conditions of Stock orRequirement at time of last MRP run.

4.6 Planned Order


Proposal to manufacture after MRP execution is generated trough-planned order. It can be viewed from stock/ Requirement list.

Planned Orders are converted to process order before the start ofprocess in the shop floor. N



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Sl.No.


Remarks

5.0Process Plant-Capacity Planning

The economic use of resources is an objective for many areas of acompany. The component "Capacity Planning" is available in theSystem for this purpose.

N

5.1 Capacity EvaluationFullysystemsupported

Company can use capacity evaluations to analyse capacity loadsin your company. You can adjust the analyses for each useraccording to the planning level, planning horizon and the area ofresponsibility. Available capacities and capacity requirements canbe selected according to various criteria and cumulated using anyperiod split you choose.

N

6.0Process Plant-Process Execution

To manufacture products in the shop floor as per the Recipe andBill of Material (Material BOM)

N

6.1 Process OrderFullysystemsupported

Process orders are used for the production of materials or forrendering of services in a specific quantity on a specific date. Theyenable the planning of resources, control of process ordermanagement, and specify the rules for account assignment andorder settlement.

N



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Sl.No.


Remarks

Actual confirmation to shop floor to go ahead with manufacturing.This can be obtained from Planned order. Other wise for anyoffline requirement Process Order can also be created manually.

6.2Create/ ChangeProcess Order


Creating a process order is not a stand-alone process. ProcessOrder is created from stock/Requirement list. But system allowscreation of process Order separately. It is generally done beforethe commencement of manufacturing. The quantity to be producedunder such a process Order has to be mentioned clearly. Thescheduling of process order that has to be followed really for shopfloor happens at this phase and system schedules the processorder. For Vedanta forward scheduling is recommended asscheduling type.

N

6.3 Check MaterialAvailability


Process order consumes materials (Semi-finished / Raw). The

Materials have to be issued to the Process Orders Or will have tobe back flushed. Logically these materials have to be available insystem before the commencement of process. System woulddisplay missing part list (if any). For Vedanta System will

N



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Sl.No.


Remarks

configured in such a way that system should raise warning if thematerial is not available. But decision-making should be at thelevel of user whether the Process Order could be processed aftersuch missing part.

6.4Release ProductionOrder


Process Order Release is carried out on verge of productioninitiation. In Vedanta this release procedure should be manual i.e.,user has to release the Process Order every time Production isinitiated against a new Process Order.

N

6.5Confirm ProductionOrder


This is for Confirming actual completion of production for an order,either partial or final. Also actual yield, scrap, time taken, andgoods movements will be confirmed.

N

6.6Confirmationcancellation

Partiallysystemsupported

It is possible to cancel data previously confirmed. Every completionconfirmation entered in the system can be cancelled. Thus, if youentered three confirmations for a phase, you can also cancel three

P



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Sl.No.


Remarks

confirmations and all confirmations automatically created by them.

6.7Issue Materials &Components


For Posting goods issued for Production, this functionality will be

used. This will ensure the total consumption for production.Movement type used for this process is 261. For any return ofgoods issue, movement type 262 will be used.

Unplanned materials can also be issued for a process order.

N

6.8 By-product receiptFullysystemsupported

Any by-product should also be taken as a component (-ve qty) intothe BOM of in-house produced materials and that by-product willbe receipt into the stock at the time of confirmation. Standard SAPmovement type is 531. For Vedanta Red Mud Can be taken as byProduct /Waste.

6.9Receive ProducedMaterials

Fullysystem

Goods Receipt for produced goods is captured through thisfunctionality. After Goods receive store will be updated in

N



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Sl.No.


Remarks

supported inventory. Generally 101 is standard SAP movement type throughwhich goods receipt against production is captured.

6.10 View Cost

Fully

systemsupported

The Planned vs. actual costs can be viewed after all issues and

activities are completed in the process Order changemode/display mode.

6.11

Technical Closure(TECO)


Once the process order is confirmed fully i.e., desired yield isconfirmed in terms of Goods movement and activity confirmation isalso done along with, it has to be declared Technically complete.The entire reservation list pending (if any) for the Process Order isdeleted after this activity by the system itself.

N



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Sl.No.


Remarks

7.0 ReportsFullysystemsupported

Reports are generated in the SAP system based on theinformation fed on day-to-day basis. This enables the user to takedecision related to business.

N

7.1 Stock OverviewFullysystemsupported

It can be used to view Stocks for different material taking Plant andstorage location as additional selection criteria.

N

7.2Extend materialviews


It shows the historical data related to material extension at differentpoint of time.

N

7.3

List of material

Storage locationassignment.


Shows the exhaustive list for materialstorage locationassignment.

N



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Sl.No.


Remarks

7.4 Material ListFullysystemsupported

Shows Detail of a material on basis of selection criteria like plant,material, material type, material group and created by.

N

7.5Material list with priceand inventory values


Gives the detail of standard price, Per unit price, Currency Key etc.N

7.6 Resource ListFullysystemsupported

Gives detail of resources.N

7.7 Cost Centreassignment.

Fully

systemsupported

Shows the details assignment of cost centres to Resources. N



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Remarks

7.8 Resources CapacityFullysystemsupported

Shows the capacity records (Master) for different resources listwise.

N

7.9Where used list-Resource


Lists the different recipes where resources are used.N

7.10Where Used List -Material


Lists of material Used into different BOM.N

7.11 Stock/Requirementlist-collective display

Fully

Systemsupported

Gives the stock /requirement scenario for a MRP area or plant N



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Sl.No.


Remarks

7.12

Multi level OrderReport

FullySystemsupported

Gives multilevel order report for Process Order with differentinformation.

N

7.13Missing Part Info-System


Gives the list of missing parts on plant. Material and differentselection criteria for plant.

N

7.14

Stock/Requirementlist


Shows the detail scenario of stock or requirement scenario.N

7.15

Collective Display of

Planned Order.

FullySystem

supported

Can display the planned orders collectively on the basis of MRP

controller, Material and production version.

N



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Remarks

7.16MRP List


Functionality relevant to MRP i.e., all MRP elements can beviewed from time to time. It will show the conditions of Stock orRequirement at time of last MRP run. This is of static type.

N

7.17

MRP List CollectiveDisplay


Same as previous, only it can be displayed MRP area wise.N

7.18Process OrderInformation System


Gives the detail of the information regarding process Ordermanagement.

N

7.19Process OrderIndividual list display.


Gives the detail of the information regarding process Ordermanagement object wise.

N



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Remarks

7.20Resource analysis


Gives plant wise analysis of resources.N

7.21Operation analysis


Gives the shop floor information operation wise.N

7.22Material Analysis


Shop floor material analysis information.N

7.23 Process OrderAnalysis

Fully

Systemsupported

Shop floor analysis for Process Order. N



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7.24Product CostAnalysis


Shop floor Product cost analysis.N

7.25Exception analysis

FullySystemsupported Exception analysis at material, plant and Process Order Level.

N

7.26Capacity Planning


Resource Load Analysis.N

7.27 Capacity Planning

Fully

Systemsupported

Process Order Level. N



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Resource Overload Analysis.N

7.29Resource View

FullySystemsupported Enhanced capacity evaluation-resource wise.

N

7.30Order View


Enhanced capacity evaluation-Order wise.N

7.31 MaterialConsumption

Fully

Systemsupported Material Consumption analysis.

N



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7.32Capacity PlanningTable


Capacity Planning table- Process Order View.N

7.33Material to be costed.


Display of material to be costed.N

7.34 Result of Costing run.FullySystemsupported

Analyse or compare material cost estimates.N

7.35 Price Vs. CostEstimate.

Fully

Systemsupported

Analyse or compare Material Cost Estimates. N



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7.40Costed Multi levelBOM


Multi level BOM: Value /Amount/StatusN

7.41Cost components


Analyse cost component split for planned cost: cost component N

8.0

Power Plant-Logistics GeneralData



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8.2 Batch Management


The manufacturing mode of VAL is a typical case of processmanufacturing scenario. Here, batch tracking is not possiblephysically, neither it is required. So production in SAP as well as inreality wont be captured through batches in case of power plant.

N

8.3MaterialClassification


Material Classification can be done with the standard materialclassification system in SAP (Class Type 001). This will allowbetter search. N

8.4

ClassificationCreation/change ofClass and

Characteristics

Fullysystem

supported

Characteristic is a property that describes and differentiatesobjects.

Example: length, colour, weight, etc.

Class is an assembly of characteristics that can be attributed to a

product (or to several similar products). It can also be defined as agrouping of similar products according to common characteristics

Example Pump class, Boiler class etc.

N



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8.5MRP Profile


If the order types are more than one, profiles will help inmaintaining some controlling data. (i.e., automatic selection oforder type during manual order creation).

N

8.6Procurement Type


This would help the system to identify the procurement type for theparticular material. We use E for produced goods, F for externalprocurement and X for both type of procurement.

N

8.7 Availability CheckFullysystemsupported

Based on this system checks the availability. In Vedanta we woulduse checking rule 01 for all semi-finished and finished product.This is used for accumulating the total requirement on daily basis.Any other availability check to be introduced can be considered atRealization stage.

N



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9.0Product DataManagement

9.1Maintain MaterialMaster


Material master for Finished and Semi finished goods. MaterialClassifications may be used. Views such as Basic data 1, BasicData 2, MRP 1, MRP 2, MRP 3, MRP 4 and work scheduling ( asand when required basis ). For example: For raw material therewont be any Work Scheduling View.

N

9.1.1Create MaterialMaster


Create relevant views for each material and give the values ofrespective fields.

N

9.1.2Change MaterialMaster

Fully

systemsupported

Change values of settings as necessary in the material master canbe done anytime, but frequent change is not recommended. N



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9.1.3Display MaterialMaster.


View settings without changing. This purely for read only purpose. N

9.2Maintain Bills ofMaterial


Create and change, as necessary, master data for Bills of Material.Standard BOM will be created and saved in the system. In case ofProcess manufacturing scenario, this can be done along withrecipe itself.

N

9.2.1Create Bills ofMaterial


Create BOMs for all materials produced in-house. In case ofProcess manufacturing scenario, this can be done along withrecipe itself.

N

9.2.2Change Bills ofMaterial


Change values of settings as necessary. In case of Processmanufacturing scenario, this can be done along with recipe itself.

N



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9.2.3Display Bills ofMaterial


View settings without changing. This is purely Read Only view forBOM.

N

9.3 Maintain ResourceFullysystemsupported

Create and change, as necessary, master data for Resource. AllResource shall be attached to a Cost Centre. Processing Unitcapacity categories may be used for a Resource. However datarelated to Resource category and Capacity category may bechanged at the time of realization depending on the simulation testresult.

N

9.3.1 Create ResourceFullysystemsupported

Create Resource for all processing facilities in the plant withcapacity categories of Processing Unit. This would capture logicalplace of operation under a plant and at the same time collect thecosting data generated out of activity consumption.

N

9.3.2 Change Resource Fullysystem

This process would enable the user to capture any enhancedfunctionality in future. It can be used to change any existing field

N



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supported value apart from resource category and capacity category. Anyextra capacity category can be introduced by using thefunctionality.

9.3.3 Display ResourceFullysystemsupported

View settings without changing. This is used for viewing the masterdata in Read _only mode.

N

9.4 Maintain RecipeFullysystemsupported

Create and change, as necessary, master data for Recipe.The entire standard recipe will be created in the system for all theplants and material combination. PI01 can be used up whilecreating the Recipe.

N

9.4.1 Create Recipe.Fullysystemsupported

Create Recipe for all materials produced in-house. The respectiveoperations, their phases, internal relations, material assignmentsare to be mentioned .The standard values for operations can alsobe mapped through this functionality. Control keys like PI01, PI22

N



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and PI05 may be used depending on the business processesintegrated along with the operations.

9.4.2 Change Recipe

Fully

systemsupported

Change values of settings as necessary. Any change in theprocess can be mapped in future through this transaction.

N

9.4.3 Display Recipe.Fullysystemsupported

View settings without changing and in Read Only mode.N

9.5 Production VersionFullysystem

supported

Its a combination of BOM and Recipe. So in case of recipe it ismandatory to maintain Production version. Functionalities relatedto Lot size, alternative BOM etc. Multiple production version might

be there for a material. It can be locked or Unlocked on as andwhen required basis.

N



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9.5.1Create Productionversion


At the time of recipe creation system prompts to maintainProduction version. Multiple production versions are only usedwhen more than one production line is there. Here in Vedanta onlyone production version would be created.

N

9.5.2Change Productionversion


Data related to production version can be changed at anytime. IfNew BOM is to be attached keeping the existing one in the systemwith the same recipe , one production version is generated and theprevious one is locked in changed mode.

N

9.5.3Display productionversion

Fullysystem

supported

This is for displaying purpose read only mode.

N



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Process Plant- Production Planning.

10.0ProductionPlanning (PP-PI)

10.1 Production Strategy


Make to stock production-planning strategy will be used for theProcess plant. This has been decided pertaining to actualphilosophy of production, which is not based on requirement. Basicidea is full utilization of plant capacity. Requirement type LSF and/BSE can be used to meet such requirement. For Power plant thisfunctionality is used if and only if long term planning is done.

N

11.0

Material

RequirementPlanning

The main function of material requirements planning is toguarantee material availability, that is, it is used to procure orproduce the requirement quantities on time both for internal

purposes and for sales and distribution. This process involves themonitoring of stocks and, in particular, the automatic creation ofprocurement proposals for purchasing and production.



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In doing so, MRP tries to strike the best balance possible between

Optimising the service level and

Minimizing costs and capital lockup.

For power plant planning would be done either throughConsumption based planning (MM) or Long term Planning. Butfor Refinery Classical MRP (Deterministic) PP andconsumption based (MM), both can be used.

11.1Run MRP on material Fully

systemsupported

For power plant planning would be done either throughConsumption based planning or Long term Planning. But forRefinery Classical MRP (Deterministic) PP and consumptionbased (MM), both can be used.

N

11.2 Total PlanningFullysystemsupported

Total planning covers the planning of all the materials that arerelevant for requirements planning and includes the BOMexplosion for materials with a bill of material.



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You can use total planning for a single plant or you can use thescope of planning to control whether the total planning run isexecuted on a multi-plant level.For power plant planning would bedone either through Consumption based planning ( MM ) or Longterm Planning. But for Refinery Classical MRP (Deterministic) PP

and consumption based (MM), both can be used.

11.3ViewStock/Requirementlist


View Stock /requirements list to check stock position in terms ofMRP elements. All the PIR, planned order and Production Orders (if not delivered) would be displayed along with ATP ,safety stock( ifany ) , existing Stock ( if any). User will be able to see the mostupdated information related to Stock/Requirement list. For powerplant planning would be done either through Consumptionbased planning (MM) or Long term Planning. But for RefineryClassical MRP (Deterministic) PP and consumption based(MM), both can be used.

N



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11.4 Stock overviewFullysystemsupported

View Stock overview as and when required. System enables theuser to check stock available for the stock items at various areas ofthe organization.

N

11.5 MRP ListFullysystemsupported

Functionality relevant to MRP i.e., all MRP elements can beviewed from time to time. It will show the conditions of Stock orRequirement at time of last MRP run. For power plant planningwould be done either through Consumption based planning(MM) or Long term Planning. But for Refinery Classical MRP(Deterministic) PP and consumption based (MM), both canbe used.

11.6 Planned Order

Fully

systemsupported

Proposal to manufacture after MRP execution is generated trough-planned order. It can be viewed from stock/ Requirement list.

Planned Orders are converted to process order before the start ofprocess in the shop floor.For power plant planning would be doneeither through Consumption based planning (MM) or Long termPlanning. But for Refinery Classical MRP (Deterministic) PP and

N



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consumption based (MM), both can be used.

12.0 Capacity Planning The economic use of resources is an objective for many areas of acompany. The component "Capacity Planning" is available in theSystem for this purpose.

N

12.1 Capacity EvaluationFullysystemsupported

Company can use capacity evaluations to analyse capacity loadsin your company. You can adjust the analyses for each useraccording to the planning level, planning horizon and the area ofresponsibility. Available capacities and capacity requirements canbe selected according to various criteria and cumulated using anyperiod split you choose.

N

13.0 Process ExecutionTo manufacture products in the shop floor as per the Recipe andBill of Material (Material BOM)

N



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13.1 Process OrderFullysystemsupported

Process orders are used for the production of materials or forrendering of services in a specific quantity on a specific date. Theyenable the planning of resources, control of process ordermanagement, and specify the rules for account assignment andorder settlement.Actual confirmation to shop floor to go ahead with manufacturing.This can be obtained from Planned order. Other wise for anyoffline requirement Process Order can also be created manually.

N

13.2Create/ ChangeProcess Order


Creating a process order is not a stand-alone process. It isgenerally done before the commencement of manufacturing. Thequantity to be produced under such a process Order has to bementioned clearly. The scheduling of process order that has to befollowed really for floor happens at this phase and systemschedules the process order. For Vedanta forward scheduling is

recommended as scheduling type.

N



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13.3Check Material

Availability

Fully

systemsupported

Process order consumes materials (Semi-finished / Raw). TheMaterials have to be issued to the Process Orders Or will have tobe back flushed. Logically these materials have to be available insystem before the commencement of process. System woulddisplay missing part list (if any). For Vedanta System willconfigured in such a way that system should raise warning if thematerial is not available. But decision-making should be at thelevel of user whether the Process Order could be processed aftersuch missing part.

N

13.4Release ProductionOrder


Process Order Release is carried out on verge of productioninitiation. In Vedanta this release procedure should be manual i.e.,user has to release the Process Order every time Production isinitiated against a new Process Order.

N

13.5Confirm ProductionOrder


This is for Confirming actual completion of production for an order,either partial or final. Also actual yield, scrap, time taken, andgoods movements will be confirmed.

N



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13.6 Confirmationcancellation Partiallysystemsupported

It is possible to cancel data previously confirmed. Every completion

confirmation entered in the system can be cancelled. Thus, if youentered three confirmations for a phase, you can also cancel threeconfirmations and all confirmations automatically created by them.

P

13.7Issue Materials &Components


For Posting goods issued for Production, this functionality will beused. This will ensure the total consumption for production.Movement type used for this process is 261. For any return ofgoods issue, movement type 262 will be used.

Unplanned materials can also be issued for a process order.

N

13.8 By-product receiptFullysystemsupported

Any by-product should also be taken as a component (-ve qty) intothe BOM of in-house produced materials and that by-product willbe receipt into the stock at the time of confirmation. Standard



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movement type is 531.For reversal 532 may be used.

13.9 Receive ProducedMaterials

Fully

systemsupported

Goods Receipt for produced goods is captured through this

functionality. After Goods receive store will be updated ininventory. Standard movement type 101. For reversal 102 may beused.

N

13.10 View CostFullysystemsupported

The Planned vs. actual costs can be viewed after all issues andactivities are completed in the process Order changemode/display mode.

13.11

Technical Closure

(TECO)

Fully

systemsupported

Once the process order is confirmed fully i.e., desired yield isconfirmed in terms of Goods movement and activity confirmation is

also done along with, it has to be declared Technically complete.The entire reservation list pending (if any) for the Process Order isdeleted after this activity by the system itself.

N



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14.0 Reports

14.0 ReportsFullysystemsupported

Reports are generated in the SAP system based on theinformation fed on day-to-day basis. This enables the user to take

decision related to business.

N

14.1 Stock OverviewFullysystemsupported

It can be used to view Stocks for different material taking Plant andstorage location as additional selection criteria.

N

14.2Extend materialviews


It shows the historical data related to material extension at differentpoint of time.

N

14.3List of materialStorage locationassignment.


Shows the exhaustive list for materialstorage locationassignment.

N



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14.4 Material ListFullysystemsupported

Shows Detail of a material on basis of selection criteria like plant,material, material type, material group and created by.

N

14.5Material list with priceand inventory values


Gives the detail of standard price, Per unit price, Currency Key etc.N

14.6 Resource ListFullysystemsupported

Gives detail of resources.N

14.7

Cost Centre

assignment.

Fully

systemsupported Shows the details assignment of cost centres to Resources. N



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14.8 Resources CapacityFullysystemsupported

Shows the capacity records ( Master) for different resources listwise.

N

14.9Where used list-Resource


Lists the different recipes where resources are used.N

14.10Where Used List -Material


Lists of material Used into different BOM.N

14.11

Stock/Requirement

list-collective display

Fully

Systemsupported Gives the stock /requirement scenario for a MRP area or plant N



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14.12

Multi level OrderReport


Gives multilevel order report for Process Order with differentinformation.

N

14.13Missing Part Info-System


Gives the list of missing parts on plant. Material and differentselection criteria for plant.

N

14.14

Stock/Requirementlist


Shows the detail scenario of stock or requirement scenario.N

14.15

Collective Display ofPlanned Order.

FullySystem

supported

Can display the planned orders collectively on the basis of MRP

controller, Material and production version.

N



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14.16MRP List


Functionality relevant to MRP i.e., all MRP elements can beviewed from time to time. It will show the conditions of Stock orRequirement at time of last MRP run. This is of static type.

N

14.17

MRP List CollectiveDisplay


Same as previous, only it can be displayed MRP area wise.N

14.18Process OrderInformation System


Gives the detail of the information regarding process Ordermanagement.

N

14.19 Process OrderIndividual list display.


Gives the detail of the information regarding process Ordermanagement object wise.

N



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14.20Resource analysis


Gives plant wise analysis of resources.N

14.21Operation analysis


Gives the shop floor information operation wise.N

14.22Material Analysis


Shop floor material analysis information.N

14.23

Process Order

Analysis

Fully

Systemsupported Shop floor analysis for Process Order. N



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14.24Product CostAnalysis


Shop floor Product cost analysis.N

14.25Exception analysis

FullySystemsupported Exception analysis at material, plant and Process Order Level.

N



Resource Load Analysis.N

14.27

Capacity Planning

Fully

Systemsupported Process Order Level. N



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Resource Overload Analysis.N

14.29Resource View

FullySystemsupported Enhanced capacity evaluation-resource wise.

N

14.30Order View


Enhanced capacity evaluation-Order wise.N

14.31

Material

Consumption

Fully

Systemsupported Material Consumption analysis. N



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14.32Capacity PlanningTable


Capacity Planning table- Process Order View.N

14.33Display Material to becosted.


Display of material to be costed.N

14.34 Result of Costing run.FullySystemsupported

Analyse or compare material cost estimates.N

14.35

Price Vs. Cost

Estimate.

Fully

Systemsupported Analyse or compare Material Cost Estimates. N



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14.40Costed Multi levelBOM


Multi level BOM: Value /Amount/StatusN

14.41Cost components


Analyse cost component split for planned cost: cost componentN



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SECTION IV

Process Plant: ( SAP Flow Diagram)

Release

CreateDemand

Raise PIR Run MRP

PurchaseRequisition

Integrationwith MM

Planned Order

Convert Planned

Order to Process

Order/ProcessOrder Creation

SchedulingCapacity

AvailabilityCheck

Integration

With PM

Material

AvailabilityCheck

Integrationwith MM

Calculation of

Planned cost atthe time ofsaving

Integration

with FI-CO

Goods IssueagainstProcess

ProcessOrderConfirmation

Integration

With FI-COand MM

Accounting Document,

Material Document andControlling documentGenerated.

GoodsReceived

UsageDecision(QM

Integration)

Ready For

Delivery(SDIntegration

TechnicalCompletionof Order

Closing



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Power Plant:

Release

Process Order Creation

SchedulingCapacity

AvailabilityCheck

Integration

Material

AvailabilityCheck

Integrationwith MM

Calculation of

Planned cost atthe time ofsaving

Integration

with FI-CO

Goods Issue

againstProcess

ProcessOrderConfirmation

IntegrationWith FI-CO

and MM

Accounting Document,

Material Document and

Controlling documentGenerated.

Goods

Received

Technical

Completionof Order

Closing



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val_bbp_pp_final

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