aco mm tbp 08 supply - manage deliveries requests-v1

To Be ProcessSupply – Manage deliveries requests

document.doc

Table of content

1.1 DOCUMENT UPDATES AND VALIDATIONS.......................................................................................................21.2 POINTS TO BE SOLVED................................................................................................................................... 2

2 SCOPE............................................................................................................................................................... 2

2.1 PROCESS SCOPE DESCRIPTION........................................................................................................................ 22.2 APPLICATION ARCHITECTURE (GLOBAL).........................................................................................................32.3 CROSS REFERENCES....................................................................................................................................... 3

3 PROCESS.......................................................................................................................................................... 4

3.1 CORE MODEL - PROCESS FLOW AND DESCRIPTION...........................................................................................43.1.1 Materials part of BOMs........................................................................................................................ 43.1.2 Materials not part of BOMs.................................................................................................................. 9

3.2 COUNTRY OR CUSTOMER SPECIFIC - PROCESS FLOW AND DESCRIPTION..........................................................133.2.1 Country specific process Flow – Spain...............................................................................................133.2.2 Country specific process Flow – France / Belgium / Spain.................................................................133.2.3 Country specific process Flow – Germany..........................................................................................133.2.4 Country specific process Flow – Italy.................................................................................................13

4 BUSINESS RULES.......................................................................................................................................... 13

4.1 CORE MODEL – BUSINESS RULES................................................................................................................. 134.2 COUNTRY OR CUSTOMER SPECIFIC – BUSINESS RULES..................................................................................14

4.2.1 Country specific process Flow – Germany..........................................................................................144.2.2 Country specific process Flow – Spain...............................................................................................14

5 KEY ELEMENTS OF SYSTEM IMPLEMENTATION...............................................................................15

5.1 CORE MODEL – KEY ELEMENTS OF SYSTEM IMPLEMENTATION.....................................................................155.1.1 Step 1 - Pre-requisites........................................................................................................................ 155.1.2 Step 2 – MRP results analysis............................................................................................................. 17

5.2 COUNTRY OR CUSTOMER SPECIFIC – KEY ELEMENTS OF SYSTEM IMPLEMENTATION......................................175.2.1 Country specific process Flow – France.............................................................................................17

5.3 SUMMARY.................................................................................................................................................. 17

6 ORGANIZATIONAL ROLES AND IMPACTS.............................................................................................18

7 APPLICATION SPECIFIC DEVELOPMENT REQUIREMENTS..............................................................18

8 KEY VOLUME & PERFORMANCE INDICATORS..................................................................................18

9 Added value for the Business and economical considerations............................................................................19

1 / 18 18/04/23 - 22:45


document.doc

1.1 Document updates and validations

UpdatesDate Version Author Comment

30/05/02 V0 JA Sanz Document creation15/06/02 V0 C. Hemery Document reading17/10/02 V1 C. Hemery V2 document creation14/11/02 V1 C. Hemery Including M. Sanchez del Rio remarks12/02/03 V1 C. Hemery Correction about Spain specific, on spare parts management18/01/05 V1 J.A. Sanz Document update24/08/05 V1 C. Choubard Document update (RO Italy)

ValidationsDate Version Validation

Resp.Comment

1.2 Points to be solved Ref. to To Be

Process

Open point description Action Plan to solve the point

Action plan Leader(Name)

Action plan Contributors

(Name)

Due Date for

resolution1 : Reorder release1.1 TBMM13 Printout message should not be

triggered automatically when the delivery schedule is updated by MRP

2 Scope2.1 Process scope description

This document describes Material Requirement Planning (MRP) functioning, the analysis and the validation of MRP results. It concerns all types of products, on all types of plants : glass plants, extrusion / encapsulation plants and Service Centers.

Out of scope- this document does not describe the content of each purchasing document category,Cf. TBMM11 Purchasing process : purchase requisitionCf. TBMM12 Purchasing process : contractCf. TBMM13 Purchasing process : scheduling agreementCf. TBMM14 Purchasing process : purchase orders- this document does not describe particularities of purchasing documents per purchasing processCf. TBMM15 Purchasing process : sub-contractingCf. TBMM17 Purchasing process : inter-company flowsCf. TBMM18 Purchasing process : intra-company flowsCf. TBMM20 Purchasing process : consignment flow

Transition periodNot relevant.

2 / 18 18/04/23 - 22:45


document.doc

2.2 Application architecture (global)

All the process phases described in this document : MRP pre-requisites, analysis and validation are performed in SAP.

2.3 Cross references

TBPP05 Define the Planning ParametersTBPP13 Supply – Generate delivery requestsTBMM09 Purchasing process per material typeV2-TBMM11 Purchasing process – Purchase requisitionV2-TBMM12 Purchasing process – ContractsV2-TBMM13 Purchasing process – Scheduling agreementV2-TBMM14 Purchasing process – Purchase ordersV2-TBMM15 Purchasing process – Sub-contractingV2-TBMM17 Purchasing process – Inter-company flowsV2-TBMM18 Purchasing process – Intra-company flowsV2-TBMM20 Purchasing process – Consignment flow

3 / 18 18/04/23 - 22:45

SAP

Idocs, if Rawglass, PVB-Functionalinterlayers,

glass products

Flexnet

MRPcalculations

Reorder objects(purchasing documents)

Customer requirements

Production planning

MRP pre-requisites

Planning system

Detailedscheduling

EDI messages

Data

extraction

Data

integration


document.doc

3 Process

3.1 Core model - process flow and description

In any case, the process can be described as follows :

But in the detail of the process, we will distinguish two supply processes : the first one for materials part of BOMs, the second one for materials which are not part of BOMs.

3.1.1 Materials part of BOMs

Perimeter: This process concerns all the listed products below, which are included into the BOM

COMPONENTSCOMMON BENDING / TEMPERING

Raw Glass ConnectorSemi-finished products (HLB1) EXTRUSION / ENCAPSULATIONFinished products (FER1) Naked glassEnamel PolymerSilver paste SERVICE CENTERS *Primer Mirror pads (Raindetectors)

BENDING / LAMINATING Plastic ProfilesPVB Rubber parts (Rubber inserts & Rubber profiles)Functional interlayers Other plastic parts (Plastic inserts)Components for PVB/ Functional interlayers preparation : Heating network

Metallic parts

Components for PVB/ Functional interlayers preparation : Conducting line

Modules pre-assembly

Components for PVB/ Functional interlayers Connectors

4 / 18 18/04/23 - 22:45

OEM data specialist / SGSI / Country centraliser

Master data management

Local data specialist / SGSI / Country centraliser

Purchasing documentationmanagement

Automatic / Central planner / Demand Forecaster

Requirements

Automatic

MRP execution

MRP controller

MRP results analysis

MRP pre-requisites1

1 a

1 b

1 c

1 d

Logistic / Purchasing department

MRP results correction

2

3

Logistic / Purchasing department

Reorders release4


document.doc

preparation : ConnectorsMirror part* Pre-assembly in Spain : not only concern Service Centers, but also Aviles and Devisa plants.NB : components families listed above for Service centers are confirmed for Spain. The components are under the Devisas’s responsibility, there are no materials under the sub-contractors responsibility.

It concerns all types of plants : glass plants, extrusion / encapsulation plants and service centers.

3.1.1.1 Step 1 - Pre-requisites

Pre-requisites to this flow are also detailed in TBPP13 – Supply – Generate deliveries requests.

3.1.1.1.1 Step 1a - Master data

We will here list the required master data for MRP execution :Remark : For detailed content of material master and purchasing master data, please refer to : - TBMM02 - Material Master management for the fields to manage,- TBPP05 – Define the Planning Parameters for the rules per material master field.These documents also detail the material master management procedures.

MaterialThe following material types, included in BOMs, are created with MRP views in SAP :- FER1 for finished glass products or tradable semi-finished glass products,- STRA for components : raw glass, PVB/ Functional interlayers, …Remark : HLB1 products are also included in BOMs and relevant for MRP calculations, but as they are not externally supplied, they are not tackled in this document.

VendorsVendors are spread out into account groups.- Vendors for glass products are created either in account group GRP for group vendors (belonging to

Saint-Gobain) or KRED if they are external, such as sub-contractors.Remark : for cessions between companies which are both integrated in Sekurit Avenir solution, inter-company or intra-company flows are applied. In these case, vendors are also declared as customers for deliveries.

- Strategic products are purchased to strategic vendors – account group STRA. Purchasing prices for strategic products are negotiated by an international pilot purchaser.

In vendor master, there is one important data for MRP and purchases : the flag, at a purchasing organization level, which enables the automatic creation of purchase orders. Even if regular purchases are performed through scheduling agreements, this flag is set to enable, in case of ‘spot’ requirement, to transform automatically a purchase requisition into a purchase order.

Info-recordIt represents the result of the negotiation with the supplier. For a couple vendor / product, on a purchasing organization and / or a plant, the prices and delivery conditions are stored.Remark : for transfers between two plants of the same company, integrated in Sekurit Avenir solution, intra-company flow is applied. In this case, it consists in a goods transfer, no info-record is required.

Source-list

5 / 18 18/04/23 - 22:45


document.doc

The source-list is mandatory in order to fix the purchasing flow in automatic. When there are several possible suppliers the source-list defines, for a period of time, the best supplier for a product.It contains the purchasing document references (document number and item number) used for purchasing : scheduling agreement or contract.

Quota-arrangementQuota arrangements enable to manage procurement quotas (in percentage), for a period of time, if there are several possible suppliers for a product, on a plant. Quotas are possible for procurement types (internally supplied – production or purchase), and special procurement types (transfers) or vendors.

Bill of Material (BOM)The Bill of Material contains, for a finished product or a tradable semi-finished product, the list of required components. It enables MRP to determine, based on the finished product requirements, the components requirements.

3.1.1.1.2 Step 1b - Purchasing documentation

For all products concerned by this process, it was decided to use Scheduling Agreements for purchases.The required purchasing documentation for MRP execution is then, in addition to the purchase info-record, the scheduling agreement.

As detailed before, the scheduling agreement and the scheduling agreement item numbers are used in the source-list.The Scheduling agreement content is detailed in V2-TBMM13 Purchasing process – Scheduling agreement.Remark : for products managed in FLEXNET, the Scheduling agreement is sent via Idoc to FLEXNET, but purchasing prices should not be visible in FLEXNET.

3.1.1.1.3 Step 1c - Requirements

There are two sources for requirements : Customer requirements, and the Production Planning.

The Customer requirementsIn every sales document, sales orders and sales scheduling agreements, the customer requirements are filled in.For final customers, they are mainly integrated by EDI (Electronic Data Interchange) messages. But they can also be filled in manually, for Sekurit entities customers (cessions) which are not integrated into Sekurit Avenir solution for instance.There are firm and forecast requirements. For MRP, firm and forecast requirements are taken into account for final products shipped from sites delivering to the final customer (mainly service centers), reduced with the outstanding deliveries.Every central planner usually transmits customer requirements to all sites participating to the product supply chain.

The Production Planning (Detailed scheduling)Data about customer requirements are extracted from SAP to be integrated in each country detail scheduling system (for example, Ordocom for France).The detail scheduling calculations are performed in this external system, to establish for each plant (glass plants and extrusion / encapsulation plants) a production planning. Calculation periodicity: 1 week.This production planning is integrated into SAP automatically once a week : it will represent requirements.

3.1.1.1.4 Step 1d - MRP execution

6 / 18 18/04/23 - 22:45


document.doc

MRP is a global treatment at a plant level, it is triggered for all materials declared relevant for MRP calculations in master data. Its execution is planned weekly. MRP is executed plant per plant, beginning for service centers, ending for glass plants.

Remark : MRP execution is planned daily for the strategic components (materials included in the BOM), and daily for the other material types (ERSA, VERP, HIBE). Nevertheless, if a modification is noticed in planning, the local planner is free to decide, according to the modification importance, if the detailed scheduling has to be re-calculated and integrated into SAP, and consequently, if MRP should run on the concerned products.

MRP calculations take into account :- Requirements (Customer requirements or Production planning),- Master data, and all planning parameters filled in it,- Purchasing documentation if existing,- Forecast resources if existing,- Current stocks per product and per plant,To determine new resources if necessary.These forecast resources are updated in the desired purchasing document : Scheduling agreement in this case.

3.1.1.2 Step 2 - MRP results analysis

MRP analysis objectives are :1. Detect errors in MRP results : wrong vendor, unexpected resource document created. Errors are due to a

bad maintenance of master data and / or purchasing documentation.2. Detect problems in MRP results : delivery conditions maladjusted. Problems are due to a bad

maintenance of master data.3. Validate MRP results to release them towards our vendors.

Every product, per plant, is put under a MRP controller responsibility, who is in charge of MRP analysis and making master data be adjusted when necessary.For procured materials, the MRP controller is usually the person responsible for purchases :- for glass products, the logistic department,- for raw glass, either production or logistic department,- for PVB- Functional interlayers and Prelaminat, either production or logistic department,- for other strategic products, purchasing department.

The MRP is analyzed as often as it runs, i.e. daily for the strategic materials, and daily for the ERSA, VERP, HIBE material types. The MRP controller uses the collective list of products he is responsible for, to check every ‘moved’ product:- If the MRP controller detects an error or a problem, he gets in touch with the able person for master data

adjustment. Cf. following part 3.1.1.3 MRP results correction- If the MRP controller validates the result, he releases it towards our suppliers. Cf. part 3.1.1.4 Reorders

release.

3.1.1.3 Step 3 - MRP results correction

Two kinds of corrections might be required :1. Errors in MRP results: wrong vendor, unexpected resource document created.

Errors are due to a bad maintenance of master data and / or purchasing documentation.Cf. TBPP13 Supply – Generate deliveries requests.

7 / 18 18/04/23 - 22:45


document.doc

2. Problems in MRP results: delivery conditions maladjusted, stock level too high. The MRP result is not different from the expected result, procurement method should just be adjusted.Problems are also due to a bad maintenance of master data, but the result can be manually corrected to be released towards the vendor.

In any case, the MRP controller gets in touch with the able person for master data (and especially MRP views maintenance) / purchase documentation adjustment.- For glass products (material type FER1), the OEM data specialist is warned and provided with the

correct values,- For raw glass (material type STRA), the local master data maintainer is warned and provided with the

correct values,- For PVB-Functional interlayers, enamel and silver paste, mirror pads, tungsten wires and polymers

(material type STRA), the central SGSI master data manager is warned and provided with the correct values

- For other strategic products, such as connectors and pre-assembly parts (material type STRA), the national master data manager (or the purchaser directly) is warned and provided with the correct values.The organization should be set.

If the MRP result can be corrected manually to be released to the vendor, prior to master data adjustments, the MRP controller changes directly data in the purchasing document, but informs the Production department of the modification.The delivery schedule can be changed manually to adjust schedules quantities, delivery dates.

If master data adjustments are performed quickly enough, once these adjustments have been performed, MRP can be run manually on the concerned product(s). The result then takes into account master data adjustments, the MRP result is analyzed again and if it is correct, can be released (transmitted to the vendors).

3.1.1.4 Step 4 - Reorders release

For all products concerned by this process, it was decided to use Scheduling Agreements for purchases.So, when the MRP result is a procurement requirement, one or several schedule lines are created or updated in the scheduling agreement delivery schedule.

Once the MRP results have been analyzed and corrected if necessary, the delivery schedule is confirmed by the purchaser :- if quantities and dates determined by MRP are correct, the message for printout can be created- if quantities or dates should be adjusted, they are adjusted manually and then, the message for printout

can be created

When manual adjustments are performed in the delivery schedule, they will not be changed by the next MRP execution.- If the requirement is superior to the previous requirement, a new schedule line is created to complete the

resource,- If the requirement is inferior to the previous requirement, nothing is changed in the delivery schedule.When no manual adjustments are performed in the delivery schedule, if requirements are changed, the next MRP execution updates the delivery schedule.

Remark for Raw Glass managementEvery week, when requirements are sent to SGG, SGG confirms the delivery schedules. If SGG encounters a problem to deliver the required product, a derogation demand is transmitted to SGS to deliver another

8 / 18 18/04/23 - 22:45


document.doc

product. When a substitution is agreed between SGG and SGS, the purchaser should change manually the scheduling agreement to :- delete the delivery schedule on the first required product for the corresponding date,- create the item in the scheduling agreement for the substitution product (if it was not received yet),- create the delivery schedule for the substitution product.Substitution products are not determined by MRP calculations.

The Delivery schedule content is detailed in V2-TBMM13 Purchasing process – Scheduling agreement.

3.1.2 Materials not part of BOMs

Perimeter : This process concerns all the other products not included into the BOM but managed in stock.It concerns, for example :- Thinner,- Lubricant and Silica,- Acetylene,- Plastic separators, polystyrene protections, metallic pieces for ribbon and ribbon, …- Cutting, drilling and soldering tools,- …

It only concerns glass plants and extrusion / encapsulation plants.

3.1.2.1 Step 1 - Pre-requisites

3.1.2.1.1 Step 1a - Master data

We will here list the required master data for MRP execution :Remark : The detailed content of material master and purchasing master data is detailed in : - TBMM02 - Material Master management for the fields to manage,- TBPP05 – Define the Planning Parameters for the rules per material master field.These documents also detail the material master management procedures.

MaterialThe following material types, not included in BOMs but managed in stocks (in quantity and in value), are also created with MRP views in SAP :- ERSA for spare parts,- HIBE for consumable parts,- VERP for packing materials,- Some remaining STRA for strategic materials.Requirements for these products are calculated based on a reorder point or a safety stock.

Remark : in addition to the purchases recurrence, other rules are taken into account to determine whether a product is managed in stocks, such as- life cycle of the product (if consumption does not occur in the same month than the goods receipt),- value.Products which are not managed in stocks are not relevant for MRP calculations.

9 / 18 18/04/23 - 22:45

Definitions :- Safety stock : defines a minimum stock quantity, to satisfy an unexpectedly high demand in the

coverage period. Safety stocks are not adjusted dynamically with the demand.- Reorder point : defines a threshold quantity for materials managed on consumption-based MRP. If the

stock falls below this quantity, the system flags this material for requirement planning. The reorder point can represent a safety stock + a quantity necessary during the delivery time.

-


document.doc

VendorsVendors are spread out into account groups.- External vendors are created in account group KRED.- [For exceptions, strategic products are purchased to strategic vendors – account group STRA]

In vendor master, there is one important data for MRP and purchases : the flag, at a purchasing organization level, which enables the automatic creation of purchase orders. Even if regular purchases are performed through scheduling agreements, this flag is set to enable, in case of ‘spot’ requirement, to transform automatically a purchase requisition into a purchase order.

Info-recordIt represents the result of the negotiation with the supplier. For a couple vendor / product, on a purchasing organization and / or a plant, the prices and delivery conditions are stored.

Source-listThe source-list is mandatory in order to fix the purchasing flow in automatic. When there are several possible suppliers the source-list defines, for a period of time, the possible best supplier for a product.It contains the purchasing document references (document number and item number) used for purchasing : scheduling agreement or contract.

Quota-arrangement When necessary, Quota arrangements enable to manage procurement quotas (in percentage), for a period of time, if there are several possible suppliers for a product, on a plant. Quotas are possible for procurement types (internally supplied – production or purchase), special procurement types (transfers) or vendors.

3.1.2.1.2 Step 1b - Purchasing documentation

Within products not included in the BOM, products for which purchases are recurrent are managed in stocks. Purchases are performed using Scheduling Agreements.The required purchasing documentation for MRP execution is then, in addition to the purchase info-record, the scheduling agreement.

As detailed before, the scheduling agreement / the contract and the scheduling agreement item / contract item numbers are used in the source-list.

The Scheduling agreement content is detailed in V2-TBMM13 Purchasing process – Scheduling agreement.The Contract content is detailed in V2-TBMM12 Purchasing process – Contract.

Scheduling agreementScheduling agreements are defined for a period and for a target quantity. Products requirements are formalized in schedule lines fulfilled by the MRP.

ContractContracts (especially for purchasing material) are defined for a period and for a target quantity or a target value. This functionality is used in Germany where the MRP is based on contracts for ordering the materials.

3.1.2.1.3 Step 1c - Requirements

Requirements are calculated based on safety stocks or reorder points (material master, MRP views). The analysis is performed comparing the stock level to forecast resources and workshop demands.

10 / 18 18/04/23 - 22:45


document.doc

In France (Chantereine), Belgium and Germany, workshop demands are in the system, in stock reservations.In Spain, Italy, Portugal and in France (Noyon and Aniche), workshop demands are not in the system: manual demands are performed.

There are several sources for requirements, depending on the plant and purchasing department organization:- MRP type reorder point, the MRP creates purchase requisitions in order to adjust the stock situation

by product,- Reorder the stocks regarding the reservation (manually for France and Belgium and automatically for

Germany link with PM module) created by the work center, the stocks are equal to 0 and when a reservation is created a purchase requisition is generated.

3.1.2.1.4 Step 1d - MRP execution

MRP is a global treatment at a plant level, it is triggered for all materials declared relevant for MRP calculations in master data. Its execution is planned in two modes :- Daily. It only scans the materials moved since the last treatment. A ‘moved’ material is a material which

underwent a stock movement and / or a new requirement.MRP is executed plant per plant, beginning for service centers, ending for glass plants.

- Weekly. It scans the complete database for each plant to review each material situation, even if no movement was performed on the product.

MRP calculations take into account :- Requirements (Reservation …),- Master data, and all planning parameters filled in it,- Purchasing documentation if existing,- Forecast resources if existing,- Current stocks per product and per plant,To determine new resources if necessary.These forecast resources are updated in the desired purchasing document : either a purchase requisition, a purchase requisition referring to a contract, or a scheduling agreement.

3.1.2.2 Step 2 - MRP results analysis

MRP analysis objectives are :1. Detect errors in MRP results : wrong vendor, unexpected resource document created. Errors are due to a

bad maintenance of master data and / or purchasing documentation.2. Detect problems in MRP results : delivery conditions maladjusted. Problems are due to a bad

maintenance of master data.3. Validate MRP results to release them towards our vendors.

Every product, per plant, is put under a MRP controller responsibility, who is in charge of MRP analysis and making master data be adjusted when necessary.For procured materials, the MRP controller is usually the person responsible for purchases (Purchasing Department).

The MRP is analyzed as often as it runs, i.e. daily. The MRP controller uses the collective list of products he is responsible for, to check every ‘moved’ product :- If the MRP controller detects an error or a problem, he gets in touch with the able person for master data

adjustment. Cf. following part 3.1.2.3 MRP results correction- If the MRP controller validates the result, he releases it towards our suppliers. Cf. part 3.1.2.4 Reorders

release.

11 / 18 18/04/23 - 22:45


document.doc

3.1.2.3 Step 3 - MRP results correction

Two kind of corrections might be required :1. Errors in MRP results : wrong vendor, unexpected resource document created.

Errors are due to a bad maintenance of master data and / or purchasing documentation.2. Problems in MRP results : delivery conditions maladjusted, stock level too high. The MRP result is not

different from the expected result, procurement method should just be adjusted.Problems are also due to a bad maintenance of master data, but the result can be manually corrected to be released towards the vendor.Master data and purchase documentation concerned are the ones listed above.

In any case, the MRP controller correct the values.

Once master data have been adjusted, MRP can be run manually, on the concerned product(s). The result then takes into account master data adjustments, the MRP result is analyzed again and if it correct, can be released (transmitted to the vendors).

3.1.2.4 Step 4 - Reorders release

Within products not included in the BOM, we will distinguish two types :- Products for which purchases are recurrent are managed in stocks. Purchases are performed using

Scheduling Agreements.When the MRP result is a procurement requirement, one or several schedule lines are created or changed in the scheduling agreement delivery schedule.

- Products for which purchases are not recurrent are not managed in stocks – so they are not relevant for MRP calculations, purchases are performed using purchase orders.

Once the MRP results have been analyzed and corrected if necessary, reorder object (delivery schedule or purchase requisition) is confirmed by the purchaser :- if quantities and dates determined by MRP are correct,

- the message for printout can be created for scheduling agreement,- the purchase requisition can be transformed into a purchase order – the message for printout is

created automatically.- if quantities or dates should be adjusted, they are adjusted manually and then,

- the message for printout can be created for scheduling agreement,- the purchase requisition can be transformed into a purchase order – the message for printout is

created automatically.

When manual adjustments are performed in the reorder object, they will not be changed by the next MRP execution.- If the requirement is superior to the previous requirement, a new reorder object is created to complete

the resource,- If the requirement is inferior to the previous requirement, nothing is changed in the delivery schedule.When no manual adjustment are performed in the reorder object, if requirements are changed, the next MRP execution updates the reorder object.

The Delivery schedule content is detailed in V2-TBMM13 Purchasing process – Scheduling agreement.The Purchase Requisition content is detailed in V2-TBMM11 Purchasing process – Purchase requisition.The Purchase order content is detailed in V2-TBMM14 Purchasing process – Purchase order.

3.2 Country or customer specific - process flow and description

12 / 18 18/04/23 - 22:45


document.doc

3.2.1 Country specific process Flow – Spain

3.2.2 Country specific process Flow – France / Belgium / Spain

Specificity : Spare parts with high value (material type ERSA)The products concerned are spare parts with a high value, for which the Purchasing Department consults maintenance technicians to determine if purchasing is necessary. These products are not relevant for SAP MRP calculations.A report exists (Report name : MRP type ND, transaction ZA03) : it lists products for which current stock ≤ reorder point. This report is transmitted to maintenance technicians who decide whether a purchase should be triggered or a part should be repaired or if no procurement is necessary.

3.2.3 Country specific process Flow – Germany

Specificity : ContractsThis functionality is used in Germany where the MRP is based on contracts for products purchases. About 90% of the materials of the warehouse are purchased through a contract. This functionality allows, after validation of the results, to transform all the purchase requisitions generated by the MRP into purchase orders linked to the contract and to sent by fax to the suppliers those documents.

Monthly, a specific job runs for calculating the forecasts for spare parts materials based on the past consumption (the last 12 months). The results gives the forecasts consumption for the coming month and generate by the MRP the correspondent requirements by materials, the master data on the MRP view is specific for the planification type ‘V2’ and the use of the Forecasting view by material.

3.2.4 Country specific process Flow – Italy In order to get a synthetic view on the MRP results and to be able to get a printout of these results (via Download in excel), a specific report had been developed (transaction ZM189). This report contains for each material the usable stock, the quantity in purchase requisition, and the quantity scheduled.

4 Business Rules4.1 Core model – Business rules

Planning horizonsTwo functional horizons are defined :- Mid-term horizon : it is the longer horizon on which forecasts are less reliable, but which enable to work

on a longer horizon. The time-frame is the month.- Detailed scheduling horizon : it is the horizon on which requirements are considered as firm. It lasts

from 1 to 3 months, and the time-frame is the day.

Two horizons can also be defined in the system :- Planning horizon : it is the longer horizon on which MRP (Material Requirement Planning) will run. It

is defined to 6 months.- Planning time fence : it is the horizon on which MRP result is considered as fix, this result is not

changed by the next MRP run.

Planning horizons depend on product families :

13 / 18 18/04/23 - 22:45


document.doc

Planning time fence Planning horizonGlass products : finished and tradable semi-finished products

1 week 6 months

Raw glass 2 days + time of transport 6 monthsPVB / Functional interlayers 1 week 6 monthsEnamel, Silver paste and connectors

1 month 6 months

Other components Defined per product 6 months

Products management For glass products, raw glass – material type FER1 -, PVB / Functional interlayers, enamel, silver

paste, connectors and other components in BOM (Bill of Material) – material type STRA, it is defined that they are managed in stock. They are relevant for MRP calculations, based on the production planning.

For components which are not in BOMs, there is a ‘best practice’ rule. Cf. TBMM02 - Material Master management. Nevertheless, as in Sekurit V1 material management for this type of components was decided by each purchasing manager, this best practice is not compulsorily followed. Some will be managed in stock and relevant for MRP calculations based on safety stock or reorder point, others will not be managed in stock and relevant for MRP calculations.

4.2 Country or customer specific – Business Rules

4.2.1 Country specific process Flow – Germany

Specificity : ContractsPurchases are submitted to the following rules :- if the purchase order refers to a contract, it is transmitted automatically by fax to the vendor,- if the purchase order does not refer to a contract

if the purchase amount is inferior to 2 500 €, it is transmitted automatically by fax to the vendor, if the purchase amount is superior to 2 500 €, it is printed to be validated by the purchasing

department manager.

4.2.2 Country specific process Flow – Spain

Specificity : Spare parts (material type ERSA)For spare parts, the planification is not based on reorder point but on past consumption for MRP calculations. A special planification type G3. is used, to analyze consumption on a past period (the period is defined in material master, per product and per plant) and calculate an average consumption.In the material master, the Plant-specific material status from MM/PP view is then set to G3.

5 Key elements of system implementation5.1 Core model – Key elements of system implementation

Here will be detailed steps relevant for system implementation.

5.1.1 Step 1 - Pre-requisites

5.1.1.1 Step 1a - Master data

14 / 18 18/04/23 - 22:45


document.doc

MaterialAll data maintained in material master are detailed in TBMM02 - Material Master management, including MRP data.

For products managed in FLEXNET, material master are sent to FLEXNET via ZMATMAS idoc :- Material type FER1 for finished glass products or tradable semi-finished glass products,- Material type STRA + Division 30 for raw glass,- Material type STRA + Division 40 for PVB/ Functional interlayers.For products managed in SAP directly, no idoc is sent to FLEXNET :- Material type STRA + Division ≠ 30 or 40 for strategic products not managed in FLEXNET,- Material type ERSA for spare parts,- Material type HIBE for consumable parts,- Material type VERP for packing materials.

ZMATMAS idoc is created automatically by a treatment which scans material creation and modification.

VendorsAll data maintained in vendor master are detailed in TBMM03 – Vendor Master data.

For vendors used in FLEXNET for receiving, vendor master are sent to FLEXNET via ZCREMAS idoc :- Branch 001 for transport vendors,- Branch 002 for glass vendors (glass products, finished and tradable semi-finished products),- Branch 003 for raw glass vendors,- Branch 004 for PVB / Functional interlayers vendors.For vendors used in SAP directly, no idoc is sent to FLEXNET :- Branch ≠ 001 or 002 or 003 or 004.

ZCREMAS idoc is created automatically by a treatment which scans vendor master creation and modification.

Info-recordAll data maintained in info-records are detailed in TBMM04 - Purchasing Master Data.Info-records are not sent to FLEXNET.

Source-listAll data maintained in info-records are detailed in TBMM04 - Purchasing Master Data.Info-records are not sent to FLEXNET.

Quota-arrangementAll data maintained in info-records are detailed in TBMM04 - Purchasing Master Data.Info-records are not sent to FLEXNET.

5.1.1.2 Step 1b - Purchasing documentation

Scheduling agreementAll data maintained in vendor master are detailed in TBMM13 - Purchasing Process - Scheduling Agreement.

For scheduling agreements used in FLEXNET for receiving, scheduling agreement data are sent to FLEXNET via BLAORD idoc. This idoc is created automatically when a message type XNEU is created in the purchasing document.XNEU message type determination is based on the following access sequence to maintain condition master data – these master data are maintained by the CDC, with menu path :

15 / 18 18/04/23 - 22:45


document.doc

Logistics Materials Management PurchasingMaster data Messages Outline AgreementAccess sequence : Condition : Doc type + Purchasing group

Condition : Doc type + Purchasing OrganizationCondition : Doc type

ContractAll data maintained in vendor master are detailed in TBMM12 - Purchasing Process - Contracts.Contracts are not sent to FLEXNET.If contracts are used, purchase orders are created referring to the contract and are sent to FLEXNET. This will be detailed in TBMM14 - Purchasing Process – Purchase orders.

Remark : purchase orders created but not referring to contracts are also sent to FLEXNET.

5.1.1.3 Step 1c - Requirements

A customizing is necessary to set plants parameters for MRP (Material Requirement Planning). The following parameters are accessible :- Number ranges

for planned orders, reservations, dependant requirements, purchase requisitions, MRP lists and simulative dependant requirements.

- Master data MRP controller : number of the MRP controller or group of MRP controllers responsible for

planning material requirements Special procurements Scheduling margin key : key that the system uses to determine the floats required for scheduling

an order- Planned orders

Conversion planned orders > purchase requisitions : number of planned orders proposed by the collective conversion function for converting planned orders into purchase requisitions

Checking rule for the availability check- Reporting

Run-time statistics : frequency of reporting Grouping periodsThe indicator is used for creating period totals in the current

stock/requirements list and in the MRP list - Planning run

External procurement : default values for purchasing and MRP, per plant Rescheduling: Part of the planning area, starting from the end of the replenishment lead time

(the system calculates the end of the replenishment lead time by the planning date + number of days for the replenishment lead time), in which the system checks in the net requirements calculation whether firmed or fixed receipt elements (purchase orders, production orders, firmed planned orders, and so on) should be rescheduled in. The rescheduling horizon is calculated in workdays.

Planning horizon: part of the planning area, where a planning file entry is made for the net change planning in the planning horizon. The planning horizon is calculated in workdays.

Available stock: determines stocks included in the net requirements calculation. Error processing : determines the maximum number of purchase order proposals per date and the

substitute MRP controller/group for requirements planning Item numbers : determines the item number of the purchase requisition and of the stock transfer

reservation Order start in past : determines if the start date of order proposals are allowed in the past.

Customizing of plant parameters for MRP is performed by PP module.

16 / 18 18/04/23 - 22:45


document.doc

5.1.1.4 Step 1d - MRP execution

MRP execution is automatic : a job is planned at the required frequency, with selection variants per plant.MRP is first executed on service centers (where customers requirements are integrated), then on extrusion / encapsulation plants and eventually on glass plants.

For strategic materials in the BOM the execution is done weekly.The materials not included in the BOM and the material type ERSA, HIBE, VERP the execution is done daily.

5.1.2 Step 2 – MRP results analysis

The MRP controller uses the collective list of products he is responsible for, using transaction MD06.For every product, he has a direct access to the detailed MRP result.

5.2 Country or customer specific – Key elements of system implementation

5.2.1 Country specific process Flow – France

Specificity : material typesThe special material type ROH is used in France for spare parts, due to a problem encountered during the roll-out in 1998.

Since the go-live Sekurit Avenir, the material type ROH disappears of the scope. Now the materials ROH are dispatch in their real nature of product (Spare parts – ERSA, Consumables – HIBE, Packaging – VERP).

5.3 Summary

Action Transac. / data

Comments

1. Pre-requisites1a – Master data

MM03XK03ME13ME03MEQ3

Display material masterDisplay vendor masterDisplay info-recordDisplay Source-listDisplay Quota Arrangement

1b – Purchasing documentation

ME33LME33K

Display Scheduling agreementDisplay Contract

1c – Requirements1d – MRP execution MD02

MD03MRP manual execution : single item, multi-levelMRP manual execution : single item, mono-level

2. MRP results analysis MD06 Collective display of MRP list3. MRP results correction MM02

ME01MEQ1

Change material masterMaintain Source-listMaintain Quota arrangement

4. Reorders release ME32L / ME38ME22

Change Scheduling agreement / Maintain scheduling agreement scheduleChange Purchase Order

IMMM009 Define plantsIMMM014 Maintain all plant parametersIMMM021 Activate MRP for plantsIMMM024 Define MRP controllers

17 / 18 18/04/23 - 22:45


document.doc

6 Organizational roles and impacts

MRP (Material Requirement Planning) application In Sekurit Avenir V1, in SAP, MRP calculations for glass products are based on customer

requirements only. For other components, in SAP, MRP is only based on reorder point or safety stock. For raw glass, PVB / Functional interlayers, enamel, silver paste and connectors, purchases were based on production planning but calculated outside SAP.

In Sekurit Avenir V2, MRP calculations will be based, for every product included in BOMs, on customer requirements and production planning, in SAP. So, the MRP analysis will be different.

Master data Procedures for master data management are reviewed within Sekurit Avenir V2. Master data

maintenance becomes globally more centralized, and especially for strategic products – except raw glass – included in BOMs. So, when, the MRP controller detects a master data problem, he will have to contact the master data manager.

Strategic products included in BOMs in Sekurit Avenir V2 are not compulsorily maintained as STRA material types. So, for some products, it will be necessary to change its material type.

Profiles managementImpact of use of Scheduling Agreement and Contracts on user profiles should be worked out.

7 Application specific development requirements

Report : MRP type NDThis query was developed for France, but is also used in Belgium and Spain.It is available in SAP, with Menu path :

Logistics Materials management Specifique SGSF MRP type NDTransaction ZA03.

Report: “report for MRP synthetic analysis”This report had been developed especially on the requirement of Italian users.It’s available in SAP with the transaction ZM189

8 Key volume & performance indicators

9 Added value for the Business and economical considerations

18 / 18 18/04/23 - 22:45

aco mm tbp 08 supply - manage deliveries requests-v1

Documents