ps bhel new plant bbp
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_____________________________________________________________________________________
•• ECC 6.0 Roll Out ProjectECC 6.0 Roll Out Pro ject
•• BBP PhaseBBP Phase
•• Module :- PSModule :- PS
Date Title Consultant BPO16.02.2010 BBP_PS Murali Mohan Muraleedharan
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BHEL SAP
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Table of Contents
I.Executive Summary:.......................................................................................................3
II.ESD Organizational Structure........................................................................................4
III.Organizational Elements:..............................................................................................4
IV.Master Data..................................................................................................................4
V.Business Processes:.....................................................................................................8
VI.SAP Solution:..............................................................................................................10
VII.Process Flow:............................................................................................................14
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S.No Activity Description
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I. Executive Summary:
The Electronics Division (EDN) of BHEL was formed in 1976, mainly to establish a strong base in
the areas of power and industrial electronics and supplement the company’s pioneering efforts inpower generation, transmission, industry and transportation sectors.
Making a modest beginning in 1976, the unit has registered continuous
and impressive growth, which is amply reflected in the fact that a large number
of power plants in the country today, are equipped with products and systems
made by BHEL-EDN. As reported by the ARC Survey for the year 2005, BHEL is
holding over 65 per cent of the Market share of DCS Supplies to Power Industry in India
(including hardware, software and services).
Technical collaborations with international leaders as well as BHEL-ElectronicsDivision’s relentless efforts and unwavering commitment to in-house solutions
have contributed to its rapid growth and suc cess. Despite stiff competition posed by the
world leaders and domestic private manufacturers, the unit has successfully maintained its growth
rate and become a major force to reckon with in power and industrial electronics.
Electronics Division has also been making pioneering efforts in Renewable Energy Sector by
commissioning Large-size Grid-Interactive as well as Stand-Alone Solar Power Plants, thus lighting
the lives of people living in remote parts of the country. The unit has also been making humble
contribution to Indian Space Programmes by fabricating Space Grade Solar Panels and Space
Quality Batteries for ISRO.
In recognition of its commitment to the quality systems and pro cedures, the unit
has been certified for ISO 9001 since July 1993. To fulfill its role of a responsible corporate citizen,
envisaging protection and conservation of the environment and ensuring that it’s products and
systems are also environment-friendly, BHEL has framed a Corporate Environment Management
Policy. Accordingly, the Electronics Division has become the first Electronics Industry in Bangalore
to get ISO 14001 Environment Management System certification and OHSAS 18001 certification. The
Electronics Division has established itself in the field of IT applications, using the state-of-art
technology systems, for communication, computing, networking and security requirement of the
organization in achieving its business goal. In this pursuit, the unit has been certified to ISO/IEC
27001:2005 Information Security Management System from STQC, Ministry of Communication
and Information Technology, Government of India.
BHEL has also joined United Nations' “Global Compact” and has committed tosupport the set of core values enshrined in its ten principles in the area of
Human Rights, Labour s, Environment and Anti-Corruption.
Electronics Division of BHEL is using SAP ECC 6.0 version in all product
groups in EDN. Different plants for different product groups have been
created in SAP. The Project oriented department involved in execution of
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the project Other departments are purchasing capital goods directly and
for this they can procure from out side if it is not available in plant.
Feasibility is done for the project before execution and once it is ok then
the orders are generated.
Presently projects are operating from EDN and BHEL wants to operate
from the ESD as well
II. ESD Organizational Structure
The New Plant should be capable of working on its own for the Businesstransaction. All the excise and accounting should be created for the plantaccount. Delivery of the FG should be from the new plant. All the Businessprocess of ESQP should be replicated to the New Plant.
III. Organizational Elements:
The Project System has no organizational structures of its own, incorporate it into the existing structure by making assignments to theorganizational units in Accounting and Logistics. It is this which enablesthe Project System to present data clearly and in many different ways.
Project system will use all modules Organizational elements likeFI/CO,MM,PP,PM
Company code:
Controlling Area
Business Area
Profit center
Cost center
Plant
IV. Master Data
Project Definition
WBS elements
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Network
Network activities
Activity elements
Milestones Material/BOM
To be able to carry out a project in its entirety, the project goals must be
precisely described and the project activities to be carried out must be
structured. A clearly and unambiguously structured project is the basis for its
planning, monitoring, control and success.
Depending on the type of project and the emphasis in project monitoring,
Structure the project in the Project System using the structures work
breakdown structure (WBS) and/or networks. Structures for example WBS
and networks allow size and reuse structures and sequences of events in the
projects.
Each project starts with the definition and classification of the structures
required for processing and the incorporation of these into the existing
enterprise structure.
Once the decision is taken from the top management to go-head for any
project, the project planner will carry out detailing of the project structure. This
includes Work breakdown structure (henceforth referred as “WBS”), Work
breakdown structure elements (WBSE), Network and Network activities.
Milestones and material component planning will be done in WBS/Activity, as
required.
The Steps involved in creating the project structure are described below:
1. Project Management will start preparing the project structure. Project
builder, a tool in SAP Project system, will be primarily used for creating
the project structure.
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2. Project coding mask has to be Maintain in the Customization for a
particular profile, In Each Coding we will define the no of levels the work
has to be broken down.
Project Coding Mask- ES/0001-XX-XX-XX
3. Project Definition will be created; the coding used will remain
your Project Number.
4. Choose Suitable “Project Profile”. All the default values like Controlling
area, company code, Plant, planning profiles, Budget Profiles and other
important project parameter, which are customized, will get defaulted on
the screen through these profiles.( Most of the defaulted values can be
changed in the project during project creation, before saving it for the first
time).
5. Once the project definition is created, the Work break down structure is
prepared. A hierarchy of Work breakdown elements (WBSE) will be created. The
structure will primarily have One WBS at 1st Level. The actual costs will be
captured against the lower level of WBS elements. These WBS elements will be
planning elements as well as Account assigned elements so that planning and
actual cost can be posted on those WBS Elements. The top level WBS element
will be a ”billing” element where all the total budget, plans, actual costs and
revenue can be collected covering the entire project.
1. Department is having the Start date and End date of the Project and based on
forward scheduling the system given the end date of the project.
2. The Individual object such as WBS elements, Network, Network activities, Activity elements, milestones and Material components if any
can be selected from template area and dropped on the project definition on
the project builder. It is recommended to first create the Work break down
structure for the project. Later the Project WBS should be expanded to the
required level by selecting the network and network activity. Project structure
can also contain WBS without any activities and network.
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3. Network is nothing but flow of activities, so the Network will hold group of
Activities. Network is required for planning, analyzing, controlling and monitoring
schedules, dates and resources at the Activity Level. Activities are to be
maintained for each Network. Relationships are to be maintained for eachActivity, depending on the requirement user can consider Finish- Finish (FF),
Start- Start (SS), Start- Finish (SF) & Finish -Start (FS) Relationships.
• The Project oriented department involved in execution of the project aremainly Make to order projects.
• Feasibility is done for the project before execution and once it is ok thenthe orders are in place.
• Presently already these projects are operating from EDN Plant and BHEL
wish to operate the same projects from another plant too i.e. ESD.
Customer Expectations:
BHEL wants to monitor the progress of ESD plant Projects through PS.
BHEL also want to follow the process of Project Execution and Maintenance
Details of Process TO BE mapped in SAP:
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V. Business Processes:
Sl.No
BHEL ESD BUSINESSPROCESS
SAP Sub ProcessMODULE
1. Registering Sales Inquiry Sales Inquiry Creation
Monitoring of status of Inquiry
Monitoring of Due date forsubmission through Inquiry List
PS
2. Quotation for Projectorder
Creation of Quotation withreference to Inquiry.
Project Quotation against theSales Inquiry for the execution of the Project
PS
3. Sales Order ByMarketing Department.
Issuance of initial Sales Order withreference to quotation – PS to be
subsequently issued
PS
4. Creation Of Project Project structure for Make TOrder Projects
PS
5. Issuance Of BOM’s andPR from Projects
Issuance of BOMs , PRs andProduction orders from Projectsystems
Creation of Material componentfor WBS
PS
6. Monitoring Of activities
In the Projects meansdeliverables or BOM’s
Monitoring of activities in Project
systems:
Engineering activities
Material Procurement
Manufacturing / testing
Shipping and Billing
PS
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7. Sales Order delivery WBS element / Material elementto be delivered
PS
8. Delivery relatedbilling.
Outbound delivery from SD PS
9. PGI from Projectsystem
PGI for shop items (Movement281)
Statistical GR for PR items fromproject systems to enable billingof PR items
PS
10. Picking and Packing.Picking based onnative SAP
transactions. Packinginvolves native SAPtransaction of generating handlingunit and furtherprocess based on‘developments’
Picking and packing in projectsystems
Generation of packing list from
project systems
PS
11. Short shipment fromPROJECT SYSTEMS
Creating short-shipmentmaterial as a separate activityat relevant deliverable WBSlevel
Creation of separate Sales
order (short-shipment type)
PS
12. Third Party Materialto Shop duringexecution
Changes to Sales order (PS) andconsequential changes of Projectsystems for changing a 3 rd partymaterial into shop material
PS
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VI. SAP Solution:
No.BUSINESS PROESSS
STEPS /BPP NUMBER
INPUT DATA / SPECIALINFORMATION
TRCODE
OUTPUT RESULT Improvement
1 Project – Create
Provide the Project: ES/1234 and selectthe Profile according tothe requirement andWBS: ES/1234-SH1
CJ20N Project Creation
2 WBS – CreatePROJECT DEF: ES/1234PROJECT PROFILE:ES CJ91
WBS Active WBS Created - ES
3 Network – CreateProject : ES/1234
Network Type : PS04 CJ20N
Valid Until:01.01.2010
Network Created :4000635
4 Create Project CostPlan
Project : ES/1234
And do the cost plan inPPB
CJ20N
Valid Until:01.01.2010
Project ES/1234 Costed – Material + ActivityCosting
5 Create ProjectRevenue Plan
Project : ES/1234WBS - ES/1234-SH1-76
VA01
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and do the revenueplanning in PPB
Valid Until:
01.01.2012
Project ES/1234Revenue Plan
Completed BY CreatingSale Order : 12345
6
Project Budgeting –Copy Revenue andCost Plan to BHELBudget Version(Original) – Version11
Project : ES/1234Source : Version 0
Target : Version 11CJ9FS
Execute Revenue and Costplan transferred toBudget Version for
reporting purpose.
7 Budget Planning Project : ES/1234
CJ30
Execute CJ3B Transaction
Copy 100 % of planned cost asBudget. BudgetDocument0100000003posted.
8 Supplement Budget
Project : ES/1234WBS: ES/1234-SH1-76-01Amount : 50,000 INR
CJ36
Execute CJ3B Transaction
Supplement BudgetPosted :100000005document posted.
9Create Project Sale
Order
WBS - ES/1234-SH1-76VA01
Project Sale Order
Created
10Create ProjectPurchaseRequisition.
Project : ES/1234Network Order :12345
CJ20NProject PurchaseRequisition Created: 1234567
11 Material Transfer Project’s/1234 CN33 Material
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Network:ES/1234/SH1-0001Materail:E1000
Transferred
12Create ProjectPurchase Order
Project : ES/1234Network Order :4000635 ME21N
Project PurchaseOrder Created :1234567
13
Create GoodsReceipt
Project PurchaseOrder : 1234567
MIGO Material DocumentCreated : 1234567
14
Perform Order
Related/ DeliveryRelated Billing –Project Billing
Sale Order Number:
31001535Invoices Doc Type:ZPBL
VF01Billing DocumentCreated : 2345678
15Display Line ItemActual Report
Project : ES/1234CJI3
Line item ActualReport Displayed
16
Display Cost Report- Plan BasedHierarchical Report :Plan/Actual/Commitment/Rem.Plan/Assigned
Project : ES/1234S_ALR
_87013533
Report Displayedwith correct values
17
Display Cost Report- Plan BasedHierarchical Report :Actual/Commitment/
Total/Plan in COArea Currency
Project : ES/1234S_ALR
_8701
3542
Report Displayedwith correct values
18
Display Project
Structure InformationSystem Report
Project : ES/1234Select Project Cost andProject Revenue andAccruals
CN41
Report Displayedwith correct values
19 Perform – Actual Project : ES/1234 CJ44 Report Executed
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OverheadCalculation onProject –
with correct values
20
Perform - ResultAnalysis ( IndivProcessing)
Project : ES/1234KKA2
Results Analysis –Report Executedand resultsreviewed by user.
21
Purchase IndentCreation, ShopManufacturingProductConsumption
Project : ES/0633Network Type : PS02Material : SUITE:CJF07 CJ20N
Purchase IndentCreation, ShopManufacturingProductConsumption –Completed.
22 Create Project withrunning sequencenumber
WBS: ES CJ20N
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VII. Process Flow:
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CUSTOMER
CUSTOMER ORDER
CUSTOMER ORDERTO BUSINESSORDER
RECEIPT OF INTERNALORDERS BY EDN
RECEIPT OF INTERNALORDERS BY ESD
COMMERCIAL
PMC
NETWORK
WBS
COMMERCIAL
PMC
CUSTOMER ORDERTO BUSINESS ORDER
PROJECTDEF
ACTIVITY
DELIEVERABLES FOREXECUTION
MRP
RUN
WBSRESERVATIONS
PR ORDERS DEL TOWBS STK
PLANNEDORDERDS
PROD ORDERS
GR
SALESDELIVERY
SALES ORDER
PROD EXECUTION
BILLING
PIR’S FOR PROC
GRPROC FROMMM
MAKE TO RDER ITEMS
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By Using a sales order, all costs and revenues involved for an order item are
assigned collectively to the item.. You can change the proposal manually. The
requirements type is determined on the basis of the MRP group and the
strategy group in the material master record.
The bill of material transfer component makes it easier to assign material
components to network activities and make this information up-to-date.
Assign bill of material (BOM) items to a network activity manually by
exploding the BOM and then change the BOM,
Assign a very large number of components and can assign components
during the design phase and expect to have to make several changes tothe BOMs.
BOM transfer function to assign individual BOM items to network
activities, the system creates a logical link using a references point.
Unlike the manual assignment of single components, you can
automatically update subsequent BOM changes in the network activity.
If any changes happens in quantities or the material description in a BOM
automatically transfer these changes to the network as well as to the
corresponding purchase requisitions and reservations.
Items from several types of bills of material such as:
Material BOMs
Sales order BOMs
WBS BOMs
WBS BOMs are mainly used together with Production lots. They are bills of
Material that are valid only for a particular WBS element.
Note : If WBS BOMs using with the Project System, it is not necessary to create
production lots)
BOMs from external systems, select activities from all the networks in a project
you can also assign BOM items that do not have a reference point.
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set this status, the WBS elements should be having created or released system status.
This TECO status allows
• Assigning networks to the WBS element.
• Post actual costs
• Transfer actual costs
You can cancel the technically completed status. In this case the system sets the
Released status.
Closed (CLSD) status is set for those work breakdown structure or WBS element that
has been completed from both a logistic and an accounting point of view. The Closed
status can be set if the project definition or the WBS element have either the Released
or the technically completed status. The CLSD status prohibits
• Assigning networks, production orders or CO orders to the WBS element.
• Posting actual costs to the WBS element
You can cancel the closed status. In this case the system sets the technically
completed status.
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CUSTOMER
CUSTOMER ORDER
CUSTOMER ORDERTO BUSINESSORDER
RECEIPT OF INTERNALORDERS BY EDN
RECEIPT OF INTERNALORDERS BY ESD
COMMERCIALPMC
COMMERCIALPMC
CUSTOMER ORDERTO BUSINESS ORDER
PROJECTDEF
WBS
ACTIVITY
NETWORK
MRPRUN
MR’S wrt to
BOM
SALES ORDER
SALESDELIVERY
BILLING
SPARE ITEMS
Material BOM
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PROJECTDEF
WBS
NETWORK
ACTIVITY
ManualCreation of
PR’s
PO
STATISTICALGR
ORDERRELATED
BILLINGBILLING
THITD PARTY ITEMS