bbp production

Production PlanningBusiness Blue Print

DOCUMENT TITLE : BUSINESS BLUEPRINT

MODULE : PRODUCTION PLANNING

DATE CREATED : 7TH JUNE 2009

AUTHOR :

VERSION MANAGEMENT

S NO VERSION NO DATE CREATED REMARKS

DRAFT 1 7TH JUNE 2009

SIGN OFF

NAME ROLE ACTION SIGNATURE

PAGE 1 OF 23

MR.YOGESH / MR.ABHIJIT

CONTROL TECH SAP CONSULTANT

DELIVER

MIRACLE AUTO PVT.LTD DELIVER

PROJECT MANAGER (MAPL) REVIEW

MR.SATISH JADHAVPROJECT MANAGER (CONTROL

TECH)REVIEW

BUSINESS PROCESS OWNER SIGNOFF


Table of ContentsOrganisational Data....................................................................................................................................3

Master Data..............................................................................................................................................11

Business Processes..................................................................................................................................14

Materials Management Processes Overview........................................................................................14

List of Business Processes...................................................................................................................25

Materials Management High Level Process Diagram:..........................................................................25

Business Process:.................................................................................................................................26

Gaps.........................................................................................................................................................85

Development / Enhancement................................................................................................................85

Reports..................................................................................................................................................85

Forms....................................................................................................................................................86

Interface................................................................................................................................................86

Pending / Open Issues..............................................................................................................................86

Appendix - QADB......................................................................................................................................86

Appendix – Report and Forms Formats....................................................................................................87

Appendix – Development Specifications...................................................................................................87

Appendix - Reviewers comments.............................................................................................................87

PAGE 2 OF 23


Organisational Data

Plant

A Plant is an organizational unit used to document goods stored in distribution centres and stores for the purposes of inventory management, and to model the associated business processes, such as goods receipt, physical inventory and goods issue.

A Plant is an independent unit that has its own Inventory Management and orders its own stock

Store is a location in which goods are put on sale to the consumer.

A store is assigned one purchasing organization and one sales area (sales organization, distribution channel and division) and thereby also a distribution chain, to which the store belongs and which is used primarily for inter company billing purposes. The store must be authorized to receive goods from the sales area to which the supplying distribution centre belongs. If it is to be possible for merchandise to be transferred from one store to another, then the recipient store must also be authorized to receive goods from the sales area to which the supplying store belongs.

Each distribution centre is assigned a purchasing organization (and, if required, a sales area) for determining warehouse transfer prices and units of measure.

Each site belongs to exactly one company code.

LIST OF PLANT THAT ARE FINALISED ARE AS FOLLOWS:

2-WHEELERS

3-WHEELERS

PAGE 3 OF 23

S NO

CODE CATEGORYDESCRIPTIO

N

1 PAT1MANUFACTURING PLANT

TALEGAON

2 PAC1MANUFACTURING PLANT

CHAKAN

3 PAR1MANUFACTURING PLANT

RANJANGAON

S NO

CODE CATEGORYDESCRIPTIO

N

1 AAS1MANUFACTURING PLANT

SURAT

2 AAB1MANUFACTURING PLANT

BARODA


Storage Location

A Storage Location is an organizational unit that allows you to differentiate between various types of stock in a site. Stocks of an Material can be managed within a site in different Storage Locations to differentiate, for example, between the stock stored for returns, promotions and cross-docking. Storage Locations are intended to represent warehouses or areas in a warehouse.

To reflect the complex warehouses that are typical in retailing, each Storage Location can be divided into warehouse numbers, Storage types and Storage bins using the Warehouse Management System. Storage Locations are then used to represent areas in a warehouse. This differentiation between stocks is therefore of most relevance to distribution centres.

If stock is to be managed on an Material basis, Storage Locations must be used.

STORAGE LOCATIONS FOR PLANT – PLT1 (TALEGAON)

S NO STORAGE LOCATION DESCRIPTION

1 SLTR RAW MATERIAL

2 SLTS SEMI-FINISHED

3 SLTQ QUALITY

4 SLTJ REJECTION

5 SLTA ASSEMBLY

6 SLTF FINISHED GOODS

STORAGE LOCATIONS FOR PLANT – PLC1 (CHAKAN)


1 SLCR RAW MATERIAL

2 SLCS SEMI-FINISHED

3 SLCQ QUALITY

4 SLCJ REJECTION

5 SLCA ASSEMBLY

6 SLCF FINISHED GOODS

STORAGE LOCATIONS FOR PLANT –PLR1 (RANJANGAON)

PAGE 4 OF 23


1 SLRR RAW MATERIAL

2 SLRS SEMI-FINISHED

3 SLRQ QUALITY

4 SLRJ REJECTION

5 SLRA ASSEMBLY


STORAGE LOCATIONS FOR PLANT – AAS1 (SURAT)


1 SLSR RAW MATERIAL

2 SLSS SEMI-FINISHED

3 SLSQ QUALITY

4 SLSJ REJECTION

5 SLSA ASSEMBLY

6 SLSF FINISHED GOODS

STORAGE LOCATIONS FOR PLANT – AAB1 (BARODA)

S NO *STORAGE LOCATION DESCRIPTION

1 SLBR RAW MATERIAL

2 SLBS SEMI-FINISHED

3 SLBQ QUALITY

4 SLBJ REJECTION

5 SLBA ASSEMBLY

6 SLBF FINISHED GOODS

*First two digit indicates storage location, third digit indicates plant and forth digit indicates material descriptions

PAGE 5 OF 23

MAPL

Miracle Auto P.Ltd

Pune Auto P.Ltd.

(PAPL)

Ahemdabad

Auto.P.Ltd.

(AAPL)

Talegaon

(PAT1)

Chakan

(PAC1)

Ranjangaon

(PAR1)

Surat

(AAS1)

Baroda

(AAB1)

comp01, 07/06/09,

l. edit


.

PAGE 6 OF 23

PAT1

TALEGAON

PATR

RAW MATERIAL

PATS

SEMIFINISHED

PATQ

QUALITY

PATJ

REJECTION

PATA

ASSEMBLY

PATF

FINISHED GOODS

PAC1

CHAKAN

PACR

RAW MATERIAL

PACS

SEMIFINISHED

PACQ

QUALITY

PACJ

REJECTION

PACA

ASSEMBLY

PACF

FINISHED GOODS

PATR

RANJANGAON

PARR

RAW MATERIAL

PARS

SEMIFINISHED

PARQ

QUALITY

PARJ

REJECTION

PARA

ASSEMBLY


PAGE 7 OF 23

AATS

SURAT

AASR

RAW MATERIAL

AASS

SEMIFINISHED

AASQ

QUALITY

AASJ

REJECTION

AASA

ASSEMBLY

AASF

FINISHED GOODS

AATB

BARODA

AABR

RAW MATERIAL

AABS

SEMIFINISHED

AABQ

QUALITY

AABJ

REJECTION

AABA

ASSEMBLY

AABF

FINISHED GOODS


Master Data

Material Master

The Material master contains data on all the individual Materials that a company purchases, sells or produces. An Material master record includes information such as the unit of measure and the description of the Material. An Material master record includes information such as the unit of measure and the description of the Material.

Material Type

Material types group together Materials with the same attributes. When you create an Material master record, you must assign it to a single Material type. The Material type you choose determines:

Whether the Material number can be assigned internally by the system or externally by the user Number range interval to which the Material number belongs

Whether the stocks are managed on a value basis and/or on a quantity basis

User departments whose data you can maintain for Materials of this Material type

S NO MATERIAL TYPE

DESCRIPTION NUMBER RANGES PRICE CONTROL

1 FERT FINISHED PRODUCT 9001 - Standard price

2 HALB SEMI-FINISHED PRODUCT

5001 / 3001 - Moving Average Price

3 ROH RAW MATERIALS 1001 / 2001 - Moving Average Price

PAGE 8 OF 23

comp01, 07/06/09,

Material Master


Planning and processing of production process =============================================================

Module Name: Production Planning Version : 1.0 Date 07/06/09

Process Owner: Facilitator : Satish Jadhav

=============================================================

Make-to-Stock Production

The scenario Make-to-Stock (MTS) Production focuses on:

Company process runs on Make to stock (strategy no 10).

Sales-order-independent production using MTS (Make-to-stock) production / production order processing.

Planned independent requirements

Production triggered by a production plan

Make-to-stock production - Two-level-production for subassembly and finished part

Use of production versions

Optional enhancement: Serial number for finish product

Optional enhancement: External processing

Optional enhancement: Batch management processing

References to different procurement scenarios for raw materials

The product manufactured anonymously and delivered to the warehouse is a Finished Good MTS.

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PAGE 10 OF 23


Business Process:

Miracle Auto P. Ltd is a 2 Wheeler & 3 Wheelers manufacturing company and sales product in Indian domestic market. Miracle Auto P. Ltd sales their Product direct from their plant. There is one scenario used in company which is making to Stock. (Net requirement planning scenario) where warehouse stock is is taken in consideration.

PP1. Make To Stock Production Process.

- There are two Product Group Managers in Miracle Auto P. Ltd. One for Two wheeler plant (PAPL) and another for three wheeler plant (AAPL). They plan Production activities as per net requirement, They schedule monthly production activities. It is required because they receives the net requirement on monthly basis. It helps them to Plan for quarterly production activities. There is monthly meeting with management where they agreed on production plan for the month. Product Manager receives net requirement (Planned Independent Requirement) for the month from marketing. Then they plan production activities for the month and hands them over to respective departments.

- Production manager runs MRP and as per MRP result. He make purchase requisition / capacity requirement.

- Then production incharge makes and release production order, after production of material he confirm order and then material pass through quality inspection.

- If any quality related problems found then rework operation done on material and it again goes through quality inspections. If everything is ok in quality inspection result, then quality department issue material clearance report to respective department.

- Then Final confirmation is done by production incharge and post material to the Finished Goods Store.

PAGE 11 OF 23


Post FG to FG Store. (SAP)

Final Confirmation (SAP)

Production Incharge

Quality Confirmation Report. (SAP)

Quality Inspection Test

Quality Inspector

Make Production. (SAP)

Release Production Order (SAP)

Production Incharge

Create Purchase Requisition (SAP)

MRP Run (SAP)

Production Manager

Plan Independent Requirement(SAP)

Plan reqmt. For month

Collect net reqmt. From Marketing

Monthly Meeting

Product Manager

PAGE 12 OF 23


Process Overview Table

Process step External process reference

Business condition

Business role Trans-action code

Expected results

Monthly Meeting Production Planning & Review

Make to Stock (Net Reqmt. Scenario)




Creating Planned Independent Requirements

Product Manager MD61 Independent Requirements for finished product is created For Monthly Basis.

Material Requirements Planning at Plant Level

Production Manager

MD02 Independent requirements for finished product were planned.

Evaluation of the Stock/Requirement List

The requirements planning has been carried out

Production Manager

MD04 Stock/requirements situation for the planned materials is analyzed

Create Production Order Production Incharge

MD04 / CO41 Planned order for In-House Parts has been converted to production order

Material Staging for Production

Production Incharge

MF60 All materials, needed for the production order were moved from various storage locations to the production storage

PAGE 13 OF 23



Business condition


Expected results

location

Releasing Production Order for Production

Production Incharge

CO05N production order has been released

Material Staging for final Assembly

Repeat processing of process step “Material Staging for Production”

Production Incharge

MF60 All materials, needed for the production order were moved from various storage locations to the production storage location

Capacity Leveling Production Planner

CM28 capacity is levelled and production version is selected

Printing Shop Floor Papers (Finished Good) (optional)

Shop Floor Specialist

CO02 Shop floor papers have been printed

Confirming Assembly Activities

Production Order is released

Shop Floor Specialist

CO11N Assembly Order for finished product has been confirmed

Quality Check Quality Inspector

Rework Processing (Work-in-Process) for Finished Product (optional)

Rework Processing (Work-in-Process) (202)

See Rework scenario

See Rework scenario

See Rework scenario

Rework is executed; Rework operation is inserted in production order

Quality Confirmation Quality Confirmation Report

Quality Inspector Quality of the product has been confirmed

External Processing (optional)

PP Subcontracting

See PP- Subcontracting



Production order operation is processed

PAGE 14 OF 23



Business condition


Expected results

(External Processing)

scenario scenario scenario externally

Final Confirmation Production Incharge

CO11N final confirmation of the last operation has been carried out

Posting Goods Receipt for Production Order

Serial number assignment

Production Incharge

MIGO the goods receipt for the production order is posted

Period End Closing (only once a month)

Period end closing “general” Plant (181)

See period end closing scenario




Bill of material is a comprehensive, formally structured list of the components that makes up a product or assembly. The list contains a description and object Number for each component, together With the quantity and unit of measure.BOMs and routings contain important basic or master data for integrated materials management andproduction control. In the design department, new products are designed to be suitable forproduction, as well as for their intended function. In this product phase, drawings and a list of all therequired parts, the bill of material (BOM), are produced.

BOMs can be found in various forms wherever finished products or semi-finished products areproduced from several component parts or materials. Depending on the industry sector, they mayalso be called:

PAGE 15 OF 23


. Recipe lists

. Ingredients lists

Definition of a BOM

Bill Of Material For 9150 ( Pulser 150cc Red )

PAGE 16 OF 23

9150

(Pulser 150 Red)

5150

Engine

(1 Nos)

5001

Chasis Assembly

(1 Nos)

5002

Wheel Assembly

(2 Nos)

5301

Light Assembly

(2 Nos)

5401

Mirror Assembly

( 2 Nos )

5501

Wires Kit

(1 Nos)

5601

Seat For Pulser

(1 Nos)

5701

Saree Guard

(1 Nos)

5801

Shock Absorbers

(4 Nos )

5901

Battery

(1 Nos)

5149

Crank Case

(1 Nos)

1201

Gear

(1 Nos)

1401

Crank Shaft

(1 Nos)

1001

Tyre Pulser

(1 Nos)

1101

Rim Pulser

(1 Nos)

1301

Crank case Casting

(2 Nos)

Work-Centres :

A work center is a location where a particularoperation is executed.

The following can be defined as work centers:

Individual work center -Automatic lathe 17Work center group -Lathe shopProduction line -Band 9Individual person -P. SmithGroup of people -Pool 12

Work centers are used in task lists (routings, standard networks, inspection plans, maintenance task lists, rough-cut planning profiles) and in orders to identify where the work is going to be performed.A work center is a location where the capacity of production resources is consumed by activitiesperformed in the manufacture of products.Work centers can be used as capacity collectors for internal and external suppliers (externalprocessing).

( PAR1 ) Ranjangaon

Surface Grinding M/cWCRSG2

CNC MachiningWCRCN2

Sand casting machine 1 WCRSC2

DescriptionsCode

Put crank case over this assembly

WERCC2

Gear shaft assembly machine

WERGS2

Prod. of Engine-2 Wheelers

Cylindrical Grinding M/cWCRCG2

Surface Grinding M/cWCRSG3

CNC MachiningWCRCN3

Sand casting machine 1WCRSC3

DescriptionsCode

Put crank case over this assembly

WERCC3

Gear shaft assembly machine

WERGS3

Prod. of Engine-3 Wheelers

Cylindrical Grinding M/c WCRCG3

Prod. of CrankCase-2 Wheelers Production of CrankCase-3 Wheelers

PAGE 17 OF 23

RoutingsA routing describes a production process.Operation 10 Pre-assembly

PAGE 18 OF 23

20 Checking 30 Final assemblies 40 Checking 50 Deliveries

The routing defines the operations (sequence of activity) to be performed as well as:Where the work is performedHow long the work should takeWhat materials to use for each operationWhat special tools, jigs, etc. are to be used

Routing For Crank Case

30 minCylindrical Grinding110

30 minBoring100

10 minTapping90

10 minDrilling80

20 minSurface Grinding70

30 minMilling On CNC60

10 minEjection50

45 minCooling 40

15 minPouring Aluminum into mold30

30 min.Aluminium Foundry.20

20 min.Preparation Of Mold 10

TimeOperationsCode

PAGE 19 OF 23

Routing For 3 Wheeler

20 min.Insert Light Assembly.40

10 min.Insert Seat.50

30 min.Insert Handle.60

10 min.Insert Meter.70

10 min.Insert Mirror.80

40 min.Insert Hood.90

25 min.Insert Wires Kit.30

30min.Insert Wheel Assembly.20

20 min.Chasis Engine Assembly.10

TimeOperationsCode

Gaps NO GAPS FOUND IN PRODUCTION PLANNING PROCESS

Development / EnhancementPROVIDE THE LIST AND CHARACTERISTICS OF DEVELOPMENT.

NO DEVELOPMENT REQUIREMENTS FROM BUSINESS.

PROGRAM NAME

TRANSACTION CODE

INPUT PARAMETERS

OUTPUT DESCRIPTION OF TRANSACTION

RELATED SUB PROCESS NUMBER

* PLEASE INCLUDE THE DEVELOPMENT LOGIC AND SPECIFICATION IN THE ATTACHMENT

ReportsPROVIDE THE LIST AND CHARACTERISTICS OF CUSTOMISED REPORTS THAT IS NOT STANDARD/

CUSTOMISED.

CUSTOMISED REPORT REQUIREMENTS FROM BUSINESS

REPORT NAME INPUT PARAMETERS DESCRIPTION OF REPORT / FORM

COMMENT

QUALITY CONFIRMATION

QUALITY TESTS RESULTS IT SHOWS PRODUCTION QUALITY STATUS

REQUIREMENT IS NOT CLEAR

PAGE 21 OF 23

* PLEASE INCLUDE THE REPORT FORMAT IN THE ATTACHMENT

FormsPROVIDE THE LIST AND CHARACTERISTICS OF CUSTOMISED FORMS THAT IS NOT STANDARD/

CUSTOMISED.

CUSTOMISED FORM REQUIREMENTS FROM BUSINESS

FORM NAME INPUT PARAMETERS DESCRIPTION OF REPORT / FORM RELATED SUB PROCESS NUMBER

PRODUCTION ORDER PRODUCTION ORDER CONFIRMATION

NOT YET FINALISED

* PLEASE INCLUDE THE FORM FORMAT IN THE ATTACHMENT

InterfaceDESCRIBE AND PROVIDE DIAGRAMS OF ANY INTERFACES TO AND FROM EXTERNAL APPLICATIONS

NO INTERFACE FROM EXTERNAL APPLICATIONS.

Pending / Open Issues

Issue DetailsArea Expected

ClosureTarget Date

Actual Closure

Impact Remarks

1.2.

Appendix - QADB

Appendix – Report and Forms Formats

Appendix – Development Specifications

PAGE 22 OF 23

Appendix - Reviewers commentsPROVIDE COMMENTS FROM THE REVIEWERS:

CommentsName

DateConsultant

remark

PAGE 23 OF 23

bbp production

Documents

storage types

stock store

storage bins

different storage locations

supplying store

sales area sales organization

list of business processes

warehouse management