Blue Print PP

Download Blue Print PP

Post on 11-Apr-2015

7.365 views

Category:

Documents

5 download

Embed Size (px)

TRANSCRIPT

Phosphorus India Ltd

103

Phosphorus India Ltd

PROJECT MANAGER

Mr.MODULEFICO MM PP SD : : : :

EXPERTSMr. Gokul Mr. Y. M. Reddy Mr. Krishna Mohan

PROJECT CO-ORDINATORMR.SRINIVASA REDDY FI-CO Mrs. Meenakshi MM Mr. Arvind Mr. Venu SD Mr. GiriPrasad Mr. Madhav

VERTICAL LEADMR.MILIND RAHANGDALE PP Mr. N.Gulhane Mr. G. Ravikumar Mr. Jawar Mr. Srikanth HR Mr. Mortin Mr. Suresh Miss. Sangeeta Miss. Bindi Priya

104

Phosphorus India Ltd

TABLE OF CONTENTS1. INTRODUCTION 2. PURPOSE 3. SCOPE 4. BUSINESS BENEFITSa) GENERAL b) PP-RELATED

5. ORGANIZATIONo GENERAL EXPLANATION o NAMING CONVENTION o DEFINITION OF ORGANIZATIONAL UNITS CLIENT COMPANY CODE PLANT STORAGE LOCATION

I. II. III. IV.

6. BUSSINESS PROCESS OVERVIEW OF PIL 7. CROSS-APPLICATION/CENTRAL ORGANIZATIONAL UNITSa) CALENDAR b) UNITS OF MEASUREMENT

8. MATERIAL GROUPING - FINISHED PRODUCT AND SEMI-FINISHED PRODUCTSa) PRODUCT LIST B) Material Types

9. BOM 9.1 BOM TYPESo o o o o MULTIPLE BOM VARIANT BOM BOM USAGE GROUP BOM BOM GROUP

9.2 ITEM CATEGORYa) RECURSIVE BOM b) CO PRODUCTS / BY PRODUCTS c) ALT ITEM CATEGORY GROUP

9.3 ESSENTIAL PRODUCTION SCRAP 9.4 GENERAL DATA FOR BOMa) b) c) d) REQUIREMENTS / EXPECTATIONS GENERAL EXPLANATIONS NAMING / NUMBERING CONVENTIONS DESCRIPTIONS OF IMPROVEMENTS

105

Phosphorus India Ltd

e) DESCRIPTION OF FUNCTIONAL DEFECTS f) APPROACHES TO COVERING FUNCTINAL DEFECTS

g) AUTHORIZATION & USER ROLES 10. MASTER DATAa) b) c) d) PRODUCTION PLANNING MATERIAL REQUIREMENT PLANNING PRODUCTION CONTROL CAPACITY PLANNING & SCHEDULING

11. WORK CENTERA) PERSON RESPONSIBLE FOR THE WORK CENTER B) CAPACITY C) SHIFT AND SHIFT SEQUENCE

d) WORK CENTERS IN PIL 12. ROUTING INTRODUCTION 13. PRODUCTION PLANNINGSALES & OPERATIONS PLANNING DEMAND MANAGEMENT

14. MATERIAL REQUIREMENT PLANNING- MRPa) MRP CONTROLLER b) PRODUCTION PLANNING AND PROCUREMENT PLANNING

15. PLANNED ORDERS PROCESSING 16. SHOP FLOOR CONTROLa) b) c) d) e) PRODUCTION ORDER CREATION PRODUCTION ORDER RELASE PRODUCTION ORDER CONFRMATION PRINTOUT OF PRODUCTION ORDER REPORT

17. REPETITIVE MANUFACTURING 18. REPORTS 19. ANNEXURE I 20. ANNEXURE II 21. GAPSa) IDENTIFICATION OF GAPS b) ADDRESSING OF GAPS

106

Phosphorus India Ltd

23. IntroductionPhosphorus India Ltd is a corporate giant in the Agrochemical and Industrial Chemicals sector in India and has major presence The Specialty Chemicals (Insecticide, Fungicides, herbicides, fumigants and rodenticides) Caustic Chlorine White Phosphorus Industrial Chemicals Captive Power Generation of 48.5 MW The group has major products in the Insecticide, Herbicide, Vidicide, Fumigant, and Industrial Gases. Apart from this, the group also has manufacturing facilities in UK, USA, China and Argentina. Phosphorus India Limited today, has the widest range of generic agrochemical and other chemical intermediates. Over and above, good markets in India, these agrochemicals are exported to more than 100 countries in the world.

24.

PURPOSE

The purpose of the Business Blueprint is to document the detailed System and Business Process Requirements, and to implement the SAP R/3 System. This document summarizes the proposed decisions associated with implementation as they relate to the configuration of SAP.

25.

SCOPE7.1 MASTER DATA Material master Bill of material Work center Routing Sales & Operations Planning Demand management

The Implementation Scope includes the following SAP R/3 Sub-Modules in Production Planning:

7.2 PRODUCTION PLANNING 7.3 MATERIAL REQUIREMENT PLANNING 7.4 CAPACITY PLANNING & SCHEDULING 7.5 PRODUCTION CONTROL Order Control Goods movement Confirmation

107

Phosphorus India Ltd

26.

KEY BUSINESS BENEFITSa) General

The SAP System will provide the following Key Business Benefits:

SAP will provide Access to Real-Time, On-Line Information with timely processing. SAP will offer stronger, more robust Reporting Tools. SAPs Integrated Database eliminates the need for data replication and stand-alone systems, decreasing the chance for human errors. This will reduce non-value-added work while improving overall data integrity and give broader information access. SAP is Packaged Software, which is readily scalable. As such, the SAP software will serve as a facilitator of future growth.

b) PP-RelatedEntire Production Planning and Control process will be captured for the first time in a computerized SAP R/3 system. Part numbers for semi-finished product defined, so that stock valuation at various WIP stages can be done through SAP. Material requirement planning will be performed through a much accurate MRP run process in SAP. Material will be planned from the raw materials till the finished product stage. For the Material Type Production resources, consumables and tools, consumption based planning will be undertaken. Planned Scrap outcome of the production process will be accounted through the SAP system automatically and back-flushed to Scrap store. Capacity planning, Production scheduling with the PIL Shift sequence will be performed through SAP. Product Costing to be obtained through SAP. Standard SAP reports will be generated for all production processes. All the Work Centers in PP are assigned to Cost center. All the production costs will automatically get accumulated in the cost centers. All the PP master data will be loaded on to the system resulting in generation of the planned costs of the production processes. Actual production can be confirmed in the system, which will generate the actual costs. Variance in the planned and actual costs can be identified and the desired improvements can be effected in order to improve and further control the production process. This is only possible through the integration of the various modules.

27.

ORGANIZATION

SAP an organizational structure consists of the following units: The client is the top level of the organizational level. Several company codes can be assigned to one client. In turn, several plants can be assigned to a company code, and several storage locations assigned to a plant. Plants must always be consecutively numbered for all company codes. Consequently, plants assigned to different company codes cannot have the same number. However, the numbers of storage locations can be repeated, as long as they are assigned to different plants.

108

Phosphorus India Ltd

Plant: An organizational unit serving to subdivide an enterprise according toproduction, procurement, maintenance, and material planning aspects. It is a place where either material is produced or goods and services provided. Storage location: An organizational unit allowing differentiation between the various stocks of a material in a plant.

7.1 CORPORATE STRUCTURE Phosphorus India Ltd Group of companies comprises of twoCompanies

Company code 1: Phosphorus India Ltd Unit-1 (PIL1) Company code 2: Phosphorus India Ltd Unit-2 (PIL2)

109

Phosphorus India Ltd

We will go for SAP Implementation in PIL01 Company.

PIL Group of Comp.

PIL Unit-1 Vapi

PIL Unit-2 Ankleshw ar

CPP Plant

Freon Plant

ISOPROT URON Plant with 2 Prod. Line

TCAC Plant

ZNP Plant

ALP Plant

RMS

FGS

Con. Store

Scrap Store

RMS

FGS

Con. Store

Scrap Store

Semi-Finish Storage

Semi-Finish Storage

110

Phosphorus India Ltd

Plants: 1. PIL Unit-1 Plant Name a. CPP Plant

Located At Vapi Products CPP (Chloropyriphos) SAP Nomenclature CPPP

CPP Plant

CPP ChloropyriphoPlant Name b. Freon Plant Products Freon-22 Freon-12 SAP Nomenclature FREP

Freon Plant

Prod. Line for Freon-22Plant Name c. ISO Plant Products Isoproturon

Prod. Line for Freon-12SAP Nomenclature ISOP

ISOP Plant

ISOPROTURON

111

Phosphorus India Ltd

Storage Locations:1. PIL Unit-1 Sl. No 01 02 03 04 05 06 07 08 09 10 11 12 ISOP FREP Plant CPPP Located At Vapi Description Raw Material storage Spare parts storage Finished Products storage Scrap storage Raw Material storage Spare parts storage Finished Products storage Scrap storage Raw Material storage Spare parts storage Finished Products storage Scrap storage Nomenclature in sap S110 S120 S130 S140 S210 S220 S230 S240 S310 S320 S330 S340

112

Phosphorus India Ltd

28.

Business Process Overview of PIL GroupForecast/ Demand

Planning

Production

Procurement

PIL Unit-1

PIL Unit-2

Depot-1

Depot-3

Sales

Sales & Distribution

FinanceInvoicing

Collection

113

Phosphorus India Ltd

29. CROSS-APPLICATION/CENTRAL ORGANIZATIONAL UNITSa) General ExplanationAn organizational unit serving subdivides an enterprise according to production, procurement, maintenance, and material planning aspects. It is a place where either material is produced or goods and services provided. All data that is valid for a particular plant, as well as for the storage locations belonging to it, is stored at plant level. This includes, for example, MRP data and forecast data.

b) Naming ConventionIt is being proposed that the following number of plants will be created CPP Plant Code- CPPP FREON Plant Code- FREP ISOPROTURON Plant Code- ISOP

c) Definition of Organizational UnitAn organizational unit serving subdivides an enterprise according to production, procurement, maintenance, and material planning aspects. It is a place where either material is produced or goods a