SM Extension at Hyundai Uses SAPConsole

Session 4009

Joe Preski – Hyundai Transleadjoep@translead.com

Jim Farkas – The Baer Groupjfarkas@baergroup.com

SM Extension Uses SAPConsole

• Presentation Today– Engagement Overview– Service Management– SAPConsole– Lessons Learned– Further Reading

• Q&A

Engagement Overview

• Hyundai Translead– The Business– The ERP Suite– Business Drivers

• Extension Methodology– ValueSAP– Enterprise Structure– Implementation Guide

(IMG) Replication– “Greenfield” Challenges

Hyundai Translead

• Enterprise Situation– Parent is Hyundai Motors…

• Material from Hyundai Mobis

– Business Unit is Hyundai Translead• HQ (FI, CO and MM-Pur) and Sales in San Diego• Manufacturing in Tijuana, Mexico

– 2 existing plants– 1 new plant completed construction 10/02 at go-live

• IT in San Diego and Tijuana• Logistics (Import/Export responsibilities)

– US, Mexico, Korea– NAFTA compliance

Hyundai Translead

Hyundai Translead

Hyundai Translead

• Business Drivers for Extension– “Surprise” project– Less than 20 weeks to have up and running

• Plant layout and IT infrastructure design (MW, tele, drops, etc)• Build plant and buy additional real estate• Team building and implementation• Hardware landscape upgrade and migration• English, Korean, Spanish, SAP-ese

– Leverage existing application – Not to interfere with other plants (2,500 people)– Limited IT resources plus The Baer Group

• Business Drivers for Scanning– Vision of Project/Plant Manager and IT Department– Speed and accuracy– Model for back-fit at other plants

Hyundai Translead

• Core modules in place– Went live July 1998– FI, CO, SD, MM, WM, PP, PM, QM– Very novel cross-border link to San Diego data center

• Service Management (SM) to be all new– Need for SM Flexibility vs. PP repair orders– Need for causal data history

• SD channels are new• MM/WM data and scanning new• Of 60 new users, only 6 started with SAP

experience

Extension Methodology

• ValueSAP (formerly ASAP)

Extension Methodology

• Enterprise Structure– New Company Code– Same + new material types– Separate MRP (Super user)– Warehouse storage types different– Movement types similar– Order types unique– FI and CO same some unique reports

Extension Methodology

• Implementation Guide (IMG) Replication

Extension Methodology

• “Greenfield” Challenges– Users?– Details?– Material?– Core

Storage?– Training?– Etc…

Salvage MaterialProcesses

Material Inventory

Production RequirementsPlan and MRP

Cores InCore Inspection

and Storage

Pre-Productioncleaning andpreparations

Rel

eas

e to

Rem

anu

fact

ue

Disassemble,clean and inspect

failed parts

Pull Parts,reassemble and

test

Finished Goods Out

Test and return toshippingcontainer

Container lotsprepared for

shipping to PDC

Core ReturnChecklist - Yellow

Core ReturnChecklist - White

Cores Received atCore WarehouseReceiving Dock

Move toInspect

Area

Open Containerand Inspect Coreand remove CoreReturn Checklist

(2-part).

Create“DeductionReason” for

missingcomponents

Create ServiceRequest to captureDealer, VIN Data,

CustomerComplaint text...

Send“Missing

Components” list to

HMA/HMC/KIA

WM-MoveContainerwith Core

to Slocusing

movementtype 311

Storage of CoresTo Pre-

prod

end

Create/UpdateMaterial, Serial #

for each Core

Second WarrantyInspection Routine

Yes,Reman by TM

Post GoodsReceipt (GR)

Using MovementType 101 (incl

Ser#)New

Create Core Info Sheet[in SAP at this point]

and Component PartsLabel w/Bar Codes

Create ContainerLabel w/Bar Code

(2 sets)

Vinyl Pouch w/wire

Output fmIW56/IW52

InsertVinyl

Pouchand affix

ContainerLabel #1

OptionalSIMPLEscanner

WM ScanStation

IQ01 or IQ04 MB01/Ref to PO

New or RemanCore? Reman

Output frmIW56/IW52

Create [in SAP at thispoint] Label w/Bar

Codes for VB and TC.

MB1B

MMBE/MB03

Reman by TM?

No, Remanby others

Service Management (SM)

• Unique Business Processes– Core Logistics– Forecast of

Repair Materials– Production and

Material Inductions

Service Management (SM)

• Core Logistics• Service Notification and Service Order• Time-frame as long as 2 years• Data to enhance quality programs• Warranty program statistics

• Competition • Korean manager• Did in Korea w/o computer!

Core repairables

Component tagging

Service Management (SM)

• Forecast of Repair Materials– Master Data – Demand Planning– Safety Stock Levels– MRP

Service Management (SM)

• Production and Material Inductions– RF Scanning

Scanning Line Pick Lists

Finished Goods to Ship

SAPConsole

• Concept• Execution

– Hardware• Access points• Server• Scanner (Handheld computers)

– Software• Telnet services• SAPConsole• SAP R/3 Applications

SAPConsole

• Concept

Application Server

RF front end (Windows NT)

RFTerminal

RFTerminal

RFTerminal

RFController

I/O

Interface

Engine

Translation Data

Connection

SAPConsole

• Execution– Hardware

• Access points• Server• Scanner (Handheld computers)

Server Hardware on Site

SAPConsole

• Execution– Software

• Telnet services• SAPConsole• SAP R/3 Applications

Lessons Learned

• System migration along with extension means extra days• Overview vs. detailed actual processes can lead to changes• Business process owners and users; can’t live without them!• Mexican radio frequencies for handhelds• Tag printer settings and default label length• Challenging Import/Export time frames

– Process; 90 day delivery lead times– Project; 2 weeks for customs clearances– Project; x? hours for each border crossing

• Cultural diversity demands• Computer literacy/confidence challenges• MM upload from questionable legacy data, time• CBP vs MRP vs Demand Planning vs Actual usage service parts

Further Reading

• SAP Console Installation Guide (Ver 2)• Georgia Soft Works www.georgiasoftworks.com

• SAP Mobile Data Entry

Questions and Answers

• Business Drivers?

• SAPConsole?

• Service Management (SM)?

Thank you for attending!Please remember to complete and return your evaluation form following this session.

Session Code: 4009

“SM Extension at Hyundai Uses SAPConsole”