tobe pp05 shopfloorexecution
TRANSCRIPT
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SAP-TO BE Process
NAWPP005Shop Floor Control
PRODUCTION PLANNING
er!"0
!#"0$"%00&
STATEMENT OF CONFIDENTIALITY / DISCLAIMER
This document is the property of Critor! Inc" No prt of this document sh## $e
reproduced! stored in retrie%# system! or trnsmitted $y ny mens! e#ectronic!
mechnic#! photocopyin&! recordin&! or other'ise 'ithout prior 'ritten permission from
Critor! Inc"
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Table of Contents
T')le o* Contents
! Shop Floor Control"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""#
1.1 AS IS Process............................................................................................................................................3
1.2 Core to Be Process....................................................................................................................................5
1.3 Changes to Existing Organization...........................................................................................................1
1.! "escri#tion of I$#ro%e$ents an& 'e( )etrics........................................................................................1
1.5 *otes on +,rther I$#ro%e$ents..............................................................................................................1
1.- +,nctional "eficit an& )etho& to e$o%e That.......................................................................................1
1./ Interface e0,ire$ent.............................................................................................................................1
1. S(ste$ Config,ration Consi&erations.....................................................................................................1
1. +ile Con%ersion Consi&erations...............................................................................................................1
1.1 An( re#orts re0,ire& relate& to c,rrent b,siness #rocess.......................................................................11.11 An( &oc,$ento,t#,t 4o,l& be #rinte& for this b,siness #rocess...........................................................1
1.12 A,thorization Consi&erations...................................................................................................................11
1.13 En& ser Training e0,ire$ents.............................................................................................................11
1.1! Process +lo4 Chart.................................................................................................................................12
% SAP St'n+'r+ Reports""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""!,
# Csto. De/elop.ents"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""!
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! Shop Floor Control
TO-BE Doc.ent
For SAP R3# I.ple.ent't1on 't Ne( Allen)err4 (ors"
"ate7 13..2-
Sr. *o of TO BE &oc,$ent *A8PP5
ef. Sr. *o. Of AS6IS &oc,$ent Pro&,ction Exec,tion
*a$e of B,siness Process7 Sho# +loor Control
)o&,le7 Pro&,ction Planning S,b $o&,le7 Sho# +loor Control
9ersion no of &oc,$ent7 1. "ate7 13..2-
9ersion )anage$ent This "oc,$ent is s,b:ect to change control. E%er( change of the &oc,$ent has to n&ergo changecontrol #roce&,re an& has to be registere& in the follo4ing table
ers1on Ch'n2e Prep're+ B4 D'te
!"0 An'nth R'6 !#"0$"%00&
!"! AS IS Process
Production Execution
Production Execution
Creation of Production Order
In NAW no production order concept is adopted presently.
The product wise daily plan is released to Production by PPC for each machine in every
production line.
The Daily Production Plan is generally within the months plan.
The release of Daily plan is Production Order for the Production Department.
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Material Staging
Raw materials are moved to respective machines in trolleys or trays by PPC.
After the operation is performed the material is moved to Paring !ay waiting for movement
to ne"t machine for ne"t operation in the other Production #ine.
There are different Paring !ays for different operations
Production Confirmation
Production is confirmed after all the operations by putting paint mar on the product .
Goods receipt from Production
$inal products% after final inspection% are handed over to $inished &oods 'tores by PPC on
Production Credit 'lip made manually.
atc!es for manufactured Products
(eat treatment code is punched on products depicting year% month% )* and charge number.
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!"% Core to Be Process
Pro+ct1on or+er De*1n1nt1on7
A #ro&,ction or&er &efines 4hich $aterial is to be #ro&,ce&; at 4hich location; at 4hat ti$e; 4hich
operatioand how much wor is re+uired. ,t also defines which !O-% Routing is to be used .
The wor processes within a company are e"ecuted using orders.
Creation of Production order refers to
*hat is to be produced
*hen production has to tae place
*hat are all the components needed to produced and consumed for the specified
+uantity *hat are the PRTs re+uired to complete the order
Pro+ct1on Or+er cre't1on h's to *ollo( the proce+re7
A routing is selected/ its operations and se+uences are transferred to the Production
order. The !ill of -aterials is e"ploded and the items in the !ill of -aterial are transferred to
the Production order. Availability chec of components in stoc .
Availability chec for Production resource tools.
Reservations are generated for !ill of -aterial items held in stoc.
As the -RP is run the Planned order would be generated as per the P,Rs0plannedindependent re+uirements1.
$inished products will be received in the stoc by confirming the final operation in the
routing The planned costs for the order are generated.
Production Order can be created with reference to a material and a planned order. ,n
case of creation of Production orders through planned order% the system will allow forindividual% partial or collective conversions of planned orders.
When ' Pro+ct1on or+er 1s cre'te+8 the s4ste. cop1es /'r1os .'ster +'t' onto 1tsel*7
"outing# The system checs for the routing and copies the routing of the material
ill of Material# The system checs for the !O-s% which fall within the validity
date.*henever production order is created by conversion of a planned order% the!O- that is used for planning by the system will automatically get copied into order.,n case this needs to be changed 0where the norms for planning and e"ecution isdifferent1 this has to be manually changed by the user.
!efore releasing the Production order and starting production% the system has an
option to chec whether all the material components assigned to a Production order
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are available on the calculated re+uirements dates. These availability checs can betriggered either automatically or manually and can be carried out at plant or atstorage location level.
,f any components are not available in the stocs% system will create a missing partslist and an error message will be issued to the users.
Pro+ct1on or+er con*1r.'t1on7
After creation and releasing a production order% the user confirmation
process has to be performed.. As a part of Production Order confirmation% the system shall allow for
updating the production control related information vi2.% +uantity ofproduction% activity data 0actual $i"ed time% actual 3ariable time% start 4 endtime% dates for individual operations within each production order .'ystem
will calculate the activities based on the confirmation +uantity and thenorms. This calculated figures for each of the activities will be displayed onthe confirmation screen and will be changed only if re+uired.
As mentioned earlier% creation of Production order results in creation of
materials reservations. ,f the material consumed is less than the planned+uantity% it is important that the open reservations are closed. The openreservations are considered as 5Demand elements for which material hasto be provided. (ence it is important to close the material reservations thatare no more relevant..
*ith a confirmation we would be able to specify
The +uantity in an operation that was produced as yield% scrap and
the +uantity to be rewored
(ow much wor was actually done
*hich wor center was used for the operation
*ho carried out the operation
B'tch 9'n2e.ent7
During the production confirmation the material that are being activated with batch
management needs to be assighned with the batch number.This batch number will
be updated e+uivalent to the production order number.
,n )A* batches are assigned after heat treatment%in which a code with e"ternal
numbering will be used .
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There are fe4 #rocess that are being highl( reco$$en&e& as a #art ofStan&ar& 3
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Important fields to )e maintained for NAW#
Material Master9 !ac flush indicator has to be maintained 6:6Always !ac
flush
Wor* center9 control ey6
PP;:6need to be maintained for raw materials
PP;
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Process flo+ c!art #
)o
yes
C'r1tor Con*1+ent1'l P'2e $
Con%ersion of #lanne& or&er
into #ro&,ction or&er
Confir$ation of #ro&,ction
or&ers
A%ailabilit( chec>)issing #arts list
#rocessing
?,alilt( stoc>
nrestricte& stoc>
elease of #ro&,ction or&er
@oo&s $o%e$ent an&
Technical co$#letion of or&er.
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!"# Ch'n2es to E;1st1n2 Or2'n1
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!"$ F1le Con/ers1on Cons1+er't1ons
*I=
!"!0 An4 reports re>1re+ rel'te+ to crrent )s1ness process
*I=
!"!! An4 +oc.ent3otpt (ol+ )e pr1nte+ *or th1s )s1ness process
*I=
!"!% Athor1
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!"!, Process Flo( Ch'rt
F12re !7 Pro+ct1on Or+er Cre't1on
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F12re %7 Goo+s Isse to Pro+ct1on Or+er
S12n-o** ?Appro/'l@ *or th1s +oc.ent7
N'.e o* Te'. .e.)ers7 Or2'n1
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% SAP St'n+'r+ Reports
SAP St'n+'r+ Reports
Sl No7 Report Descr1pt1on Select1on Cr1ter1' Otpt
1 Stoc> O%er%ie4 ))BE )aterial; Plant D Storage location Stoc> Stat,s at each storagelocation
2 )aterial =ist ))- )aterial; Plant; )aterial T(#e D)aterial @ro,#
)aterial )aster "etails
3 )issing Parts Infor$ation =istCO2! Plant fro$ Selection fro$eser%ationsF D )P Controller fro$Selection fro$ Or&erF 4ith Profile for)aterial 9ie4
Shortage =ist
! Pro&,ction Or&er Infor$ationS(ste$ COOIS
L1st7 Ite.
Gea&er
Profile Stan&ar&
)aterial
Pro&,ction Or&er
Pro&,ction Or&er T(#e
)P Controller
Selection stat,s Profile or
S(ste$ Stat,s
L1st7 Ite.
Profile Stan&ar&
)aterial
Pro&,ction Or&er
Pro&,ction Or&er T(#e
)P Controller
Selection stat,s Profile or
S(ste$ Stat,s
L1st7 Con*1r.'t1ons
Profile Stan&ar&
Pro&,ction Or&er
=ist of Or&ers base& onSelection Criteria
=ist of Or&ers base& onSelection Criteria; 4ith $aterialco$#onents
=ist of Or&ers base& onSelection Criteria; 4ithconfir$ation &etails
=ist of Or&ers base& onSelection Criteria; 4ith @oo&sIss,e D ecei#t &etails
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SAP St'n+'r+ Reports
Sl No7 Report Descr1pt1on Select1on Cr1ter1' Otpt
Pro&,ction Or&er T(#e
)P Controller
Selection stat,s Profile or
S(ste$ Stat,s
L1st7 Doc.ente+ Goo+s
9o/e.ent
Profile Stan&ar&
Pro&,ction Or&er
Pro&,ction Or&er T(#e
)P Controller
Selection stat,s Profile or
S(ste$ Stat,s
5 PT 8here ,se& in Tas> =ist CA/ Pro+ct1on resorces3Tools
)aterial
Plant
T1.e
'e( "ate
T's L1st
T(#e +ro$
Stat,s for$
sage fro$
Plant
Planner @ro,# fro$
9'ter1'l
+ro$ )aterial n,$ber
PT 8here ,se& list 4ith all&etails .
- PT sages in or&er Pro+ct1on resorces3Tools
)aterial
Plant
Or+er Select1on
Plant
It 4ill gi%e PT ,sages co,nter
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SAP St'n+'r+ Reports
Sl No7 Report Descr1pt1on Select1on Cr1ter1' Otpt
Pro&,ction Sche&,ler
)P controller gro,#
Or&er t(#e
Sche&,le start &ate
Sche&,le& &eli%er( &ate
Or&er
)aterial
Person in charge
Selection #rofile stat,s
/ )CP/ 6 8or> Center Wor Center8 pl'nt8 per1o+ 8or> Center
)CP1 6 O#eration Oper't1on8 pl'nt8 per1o+ O#eration
)CP5 6 )aterial 9'ter1'l8 pl'nt8 per1o+ )aterial
1 )CP3 6 Pro&,ction Or&er Pro+ct1on Or+er8 pl'nt8 per1o+ Pro&,ction Or&er
11 )CE 6 )aterial Cons,$#tion 9'ter1'l Cons.pt1on8 pl'nt8
per1o+
)aterial Cons,$#tion
12 )CI 6 Pro&,ct Costs 9'ter1'l 8 pl'nt8 per1o+ Pro&,ct Costs
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# Csto. De/elop.ents
Pr1nt Re>1re.ents
Sl No7 Report Descr1pt1on Select1on Cr1ter1' Otpt
De/elop.ent Re>1re.ents
Sl No7 Report Descr1pt1on Select1on Cr1ter1' Otpt
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