Val BBP PP Final

Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION
Production Planning
Business Process Blueprint
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SAP R/3 IMPLEMENTATION BUSINESS BLUEPRINT Production Planning
Prepared by Aniruddha Mukherjee
Checked by Vishal Rathore
Reviewed By
Approved By
Date
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Production Planning
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TABLE OF CONTENTS
OBJECTIVE OF BUSINESS BLUEPRINT PHASE.........................................................................................................................................................................................3
SCOPE OF BPBP DOCUMENT ..................................................................................................................................................................................................................6 PRODUCTION PLANNING IN SAP - OBJECTIVE ...............................................................................................................................................................................7 SECTION I .......................................................................................................................................................................................................................................................8 SECTION II....................................................................................................................................................................................................................................................12 ORGANIZATION STRUCTURE ..............................................................................................................................................................................................................12 OTHER MAJOR CONFIGURATION ......................................................................................................................................................................................................17 SECTION III ..................................................................................................................................................................................................................................................21 SECTION IV ..................................................................................................................................................................................................................................................78
SPECIAL ORGANIZATIONAL CONSIDERATIONS:.................................................................................................................................................................................80
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OBJECTIVE OF BUSINESS BLUEPRINT PHASE: This document is the outcome of the As-Is study, Discussion at Training and during the To-Be process and business process requirement analysis for the Vedanta Alumina Limited. Based on this As-Is coupled with inputs from the core team members during To-Be discussion, we arrived at the Business Processes, which are to be incorporated in the Business Blue Print. The aim of this document is to map the best business processes related to the Production Planning module in SAP ECC 5.0. This document is to be studied by core team members & process owners from Vedanta Alumina Limited. The preparation of this document is an essential precursor for prototyping and testing. The development work will start once process owners approval for this Blue Print is obtained followed by a corporate presentation to the senior management team, Vedanta Alumina Limited. This document will be used for configuring Production Planning module in SAP implementation. Document is based on discussions/presentations between representatives of VAL & PWC. In other words it contains 1. SAP Organization Model in context of existing business scenario and future requirements/issues as envisaged by VAL. 2. Mapping of business processes/issues brought forward by PwC & VAL, with SAP functionality. 3. Gaps & issues emerged during the discussion between VAL & PwC. 4. Business Process Flows mapped in SAP as per the scope defined.
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5. Closure of Mapping Phase and start of Piloting Phase of implementation.
A pictorial presentation of complete SAP implementation is depicted in the following page:
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SCOPE OF BPBP DOCUMENT The objective of this Blue Print presented to the Project Sponsor is to document the following: a) Business Requirements of VAL that need to be translated into SAP. SAP consultants team members on the basis of As-Is document, factory visit & discussions between PwC SAP consultants and VAL core team members have prepared this. SAP Gaps as identified by PwC Team with respect to the present scope of implementation and Business Requirements of VAL. Details of SAP New Business Process description supported by Process Flow diagram with respect to Different SAP process indicating the desired To be Processes / Business Blue Print.
b) c)
In order to bring the clarity and better understanding, the document has been divided in five sections: SECTION I: Scope of SAP Production Planning and Control module for the project. SECTION II: Organization structure. SECTION III: Master Data Management, As-Is and / To-Be Business processes, and Gaps identified for business processes as per SAP. SECTION IV: Appendix-Process ( SAP) Flow Diagrams.
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Production Planning in SAP - Objective To provide a Production Planning, execution, control and record maintenance system fully integrated with Finance, Costing, Materials Management, Sales & Distribution and Quality Management in order to achieve superior operational efficiency, cost reduction and profitability. The module also provides better handling of all business transaction, statutory compliance, EIS, and MIS for better decision-making management Control. This is achieved through the following components:

Integration into Process Planning and Control. Shop Floor Control in the R/3 System. Special Topics of Production. An Example of PO Processing. Creating a Process Order. Important Tasks within Process Order Processing. Confirming and Settling Process Orders.
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SECTION I Scope of Production Planning Module in VAL
PARTICULARS Master 1.1 General Master Records 1.1.1 Material Master 1.1.2 Material BOM 1.1.3 Resource 1.1.4 Recipe 1.1.5 Batch Production Planning and Procurement Planning 1.2.1 Sales and Operations Planning 1.2.2 Demand Management 1.2.3 Long-Term Planning 1.2.4 MPS 1.2.4 MRP
Alumina
Power
X X X X
X X X X
1.2
X (MM)
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PARTICULARS 1.3 Production 1.3.1 Discrete Production 1.3.2 Repetitive Manufacturing 1.3.3 Process Manufacturing 1.3.4 KANBAN 1.4 Inventory Management 1.4.1 Batch 1.4.2 Batch Search Strategy 1.4.3 Control Cycle 1.4.4 Serial Numbers Business 2.1 Production Planning and Procurement Planning 2.1.1 Market-Oriented Planning 2.1.1.1 Sales and Operations Planning 2.1.1.2 Forecast 2.1.1.3 Demand Management 2.1.1.4 Long-Term Planning 2.1.1.5 Master Production Scheduling 2.1.1.6 Material Requirements Planning
Alumina
Power
X (MM)
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PARTICULARS 2.1.1.7 2.1.2 Evaluations: Logistics Information System
Alumina X X
Power
2.2
Sales Order Oriented Planning 2.1.2.1 Master Production Scheduling 2.1.2.2 Material Requirements Planning 2.1.2.3 Evaluations: Logistics Information System 2.1.3 Consumption-Driven Planning 2.1.3.1 Forecast 2.1.3.2 Material Requirements Planning 2.1.3.3 Evaluations: Logistics Information System Production 2.2.1 Process Manufacturing 2.2.1.1 Process Order Creation 2.2.1.2 Material Staging 2.2.1.3 Capacity Requirements Planning 2.2.1.4 Process Order Execution 2.2.1.5 Evaluation and Mass Processing 2.2.1.6 Evaluations: Logistics Information System 2.2.1.7 Replenishment Stock Transfer with Reservation
MM X X
MM X X
X X X X X
X X X X X
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PARTICULARS 2.2.1.8 2.3
Alumina Replenishment Stock Transfer with Direct Transfer Posting X MM X X X X MM X (MM) X X X X
Power X
Inventory Management 2.3.1 Goods Movements
2.4.1.1 Reservation 2.4.1.4 Goods Receipt 2.4.1.5 Stock Transfers / Trans. Postings 2.4.1.6 Goods Issue 2.3.2 Physical Inventory & Cycle Counting 2.4.2.1 Physical Inventory Cross-Application Components 3.1 Classification System 3.1.1 Characteristics 3.1.2 Classes 3.1.3 Classification
X X X X
X X X X
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Section II Organization Structure Plants The plant is an operating area or branch within a company. The plant is assigned to a single company code. A plant has its own material master data. You can maintain data at plant level for the following views on a material master record in particular: MRP, Purchasing, Storage, Work scheduling, Production resources/tools, Forecasting, Quality management, Sales, Costing. Among this, views in bold would be used in case of Vedanta Alumina Ltd. As per discussion with Finance & Materials, there will be only four Company Code (1000,2000,3000,4000) and four plants (Non-Virtual) will be created which may be as follows: PRODUCTION PLANT 1000 2000 3000 DESCRIPTION VAL Alumina Plant VAL Power Plant VAL Smelter Plant
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Storage Locations Storage location is an organizational unit allowing the differentiation of material stocks within a plant. All data referring to a particular storage location is stored at storage location level. This applies mainly to storage location stocks. Several storage locations can be assigned to a plant. The logical and physical storage locations will be configured to track the inventory in the shop floor. The configuration of the storage locations will be done according to the physical or the logical movement of materials in the shop floor. The detailed discussion on storage locations will come in the plant specific documentation. Proposed Storage Locations for plant relevant for PP. Alumina Plant (1000) STORAGE LOCATIONS To Be submitted by MM DESCRIPTION
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Power Plant (2000) STORAGE LOCATIONS To Be submitted by MM DESCRIPTION
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Main Resources in Alumina Plant RESOURCES Calcinations Unit Hydrate Unit Process Caustic Unit DESCRIPTION Hydrate is Calcined into Alumina. Alumina as Hydrate is Obtained. Unit where Process Caustic may be captured as WIP.
Note: The Resource of caustic may not used on day-to-day basis. It may be used at the end of the month to capture WIP for Caustic and that too would be used if any other work around is not found at realization and integration testing phase. PwC s Suggestion is to manage WIP through a generalist approach.
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Main Resources in Power Plant RESOURCES Power DESCRIPTION Resource for power Plant.
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Other Major Configuration Factory Calendar Every Plant will be having a factory calendar with details of the working days and the holiday schedule. The Factory calendar will be named as Al and PO for Process and Power plants respectively. Periods and the Fiscal Year will be from April March. Holiday Calendar Every Plant will be having a holiday calendar with details of the holidays as public and other holidays, either as fixed or a moving day in a year. The Factory calendar will be named as Al and PO for Process and Power plants respectively. Periods and the Fiscal Year will be from April March. Material Groups The functional grouping of the materials for reporting and analysis. It can be used to restrict the scope of analysis and searching specifically material master record via search help. MRP Group If we are going for different process order types for Alumina (finished materials), power (raw materials for process plant) etc, and then MRP group can be created. Material type assignment has to done on one to one basis. One plant may have more than one MRP group. The number of MRP group to be finalized in the Realization phase.
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MRP Type For material those would be planned on the basis of manufacturing requirement would be planned through Classical MRP. For these type of material MRP type PD would be used in general. Based on this requirement planned Order would be generated in the system for finished product. Raw Materials would be planned through consumption based planning. Relevant information related to Re-order point and safety stock would be provided in the material master record. Lot-sizing Procedure Using this system should calculate the Order quantity for planned order. It is consumed from material planning. We would use Lot-for-Lot Order Quantity in general (EX). MRP Controllers It specifies the group or the number of the controller responsible for Material requirement planning in your organization (Plant or Company). The material, which is relevant for material requirement planning, should be assigned to a MRP controller
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Order Types for Alumina Plant
ORDER TYPE AL HY NAOH
DESCRIPTION Order Type for Alumina. Order Type for Hydrate. Order Type for Caustic.
Note: The Order type of caustic may not used on day-to-day basis. It may be used at the end of the month to capture WIP for Caustic and that too would be used if any other work around is not found in realization phase or integration testing phase. PwC s Suggestion is to manage WIP through a generalist approach.
Order Types for Power Plant ORDER TYPE POW DESCRIPTION Order Type for Power.
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To-Be Processes Production Planning Processes The Business Blue Print is divided into various sections as defined by the different processes as discussed during to-be and Expectation from SAP. These processes are: Finished Product Planning. Raw Materials Planning. Consumables Planning. Production Scheduling. Capacity Evaluation. Order Execution. Goods Movement. Cost Analysis. Report Analysis.
To carry out these processes, certain Masters are required to be maintained prior to carry out the Transactions and Reports. This master is listed below with explanation text. These Masters are created before Go-Live through Mass data upload process. They are fixed or constant in nature. The system would access these master data while the user will be carrying out transaction on day-to-day basis. So from user point of view also it mandatory to understand the relevant or organization specific master data in detail so that actual business process is replicated into the system in terms of data and hence phenomenal purity.
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Section III Sl. No. Process Name Process PlantLogistics General Data Mode Process Description/remarks Gap (Y/N) Remarks
1.0
1.1
Batch Management
Fully system supported
The manufacturing mode of VAL is a typical case of process manufacturing scenario. Here, batch tracking is not possible physically. So production in SAP as well as in reality wont be captured through batches.
1.2
Material Classification
Material Classification can be done with the standard material classification system in SAP (Class Type 001). This will allow better search.
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Sl. No.
Process Name
Mode
Process Description/remarks
Gap (Y/N)
Remarks
Characteristic is a property that describes and differentiates objects. Classification Creation/change of Class and Characteristics Fully system supported Example: length, colour, weight, etc. Class is an assembly of characteristics that can be attributed to a N product (or to several similar products). It can also be defined as a grouping of similar products according to common characteristics Example Pump class, Boiler class etc.
1.3
1.4
MRP Profile
If the order types are more than one, profiles will help in maintaining some controlling data. (i.e., automatic selection of order type during manual order creation).
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Process Name
Mode Fully system supported
Gap (Y/N)
Remarks
1.5
Procurement Type
This would help the system to identify the procurement type for the N particular material. We use E for produced goods, F for external procurement and X for both type of procurement.
1.6
Strategy Group
For Material Produced In-House we need to maintain Strategy 11 for semi-finished product i.e., Make to stock and Gross Requirement planning.
1.7 Based on this system checks the availability. In Vedanta we would use checking rule 01 for all semi-finished and finished product. This is used for accumulating the total requirement on daily basis. N Any other availability check to be introduced can be considered at Realization stage.
Availability Check
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Process Name
Mode
Gap (Y/N)
Remarks
2.0
Process PlantProduct Data Management
2.1
Maintain Material Master
Material master for Finished and Semi finished goods. Material Classifications may be used. Views such as Basic data 1, Basic Data 2, MRP 1, MRP 2, MRP 3, MRP 4 and work scheduling (as and when required basis). For example: for raw material there wont be any Work Scheduling View.
2.1.1
Create Material Master
Fully system supported Fully system supported
Create relevant views for each material and give the values of respective fields.
2.1.2
Change Material Master
Change values of settings as necessary in the material master can N be done anytime, but frequent change is not recommended.
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Process Name
Gap (Y/N)
Remarks
2.1.3
Display Material Master.
View settings without changing. This purely for read only purpose.
2.2
Maintain Bills of Material
Create and change, as necessary, master data for Bills of Material. Standard BOM will be created and saved in the system. In case of N Process manufacturing scenario, this can be done along with recipe itself.
2.2.1
Create Bills of Material
Create BOMs for all materials produced in-house. In case of Process manufacturing scenario, this can be done along with recipe itself.
2.2.2
Change Bills of Material
Change values of settings as necessary. In case of Process manufacturing scenario, this can be done along with recipe itself.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
2.2.3
Display Bills of Material
View settings without changing. This is purely Read Only view for BOM.
2.3
Maintain Resource
Create and change, as necessary, master data for Resource. All Resource shall be attached to a Cost Centre. Processing Unit capacity categories may be used for a Resource. However data N related to Resource category and Capacity category may be changed at the time of realization depending on the simulation test result.
2.3.1
Create Resource
Create Resource for all processing facilities in the plant with capacity categories of Processing Unit. This would capture logical N place of operation under a plant and at the same time collect the costing data generated out of activity consumption. Every resource is assigned to a cost centre.
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Sl. No.
Process Name
Mode
Process Description/remarks This process would enable the user to capture any enhanced functionality in future. It can be used to change any existing field value apart from resource category and capacity category. Any extra capacity category can be introduced by using the functionality.
Gap (Y/N)
Remarks
2.3.2
Change Resource
2.3.3
Display Resource
View settings without changing. This is used for viewing the master N data in Read only mode.
2.4
Recipe
Create and change, as necessary, master data for Recipe. The entire standard recipe will be created in the system for all the plants and material combination. Control Key PI01 can be used up N while creating the Recipe. However, if required, separate control key can be created at time of realization phase.
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Process Name
Mode
Process Description/remarks Create Recipe for all materials produced in-house. The respective operations, their phases, internal relations, material assignments are to be mentioned .The standard values for operations can also be mapped through this functionality. Control keys like PI01, and PI05 may be used depending on the business processes integrated along with the operations.
Gap (Y/N)
Remarks
2.4.1
Create Recipe.
2.4.2
Change Recipe
Change values of settings as necessary. Any change in the process can be mapped in future through this transaction.
2.4.3
Display Recipe.
View settings without changing and in Read Only mode.
2.4.4
In-Process Inspection Fully system supported
Recipe will have In-Process Inspection Characteristics (Managed N by the QM module). This is not under the Purview of current scope of the project.
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Sl. No.
Process Name
Mode supported
Process Description/remarks of the project.
Gap (Y/N)
Remarks
2.5
Production Version
Its a combination of BOM and Recipe. So in case of recipe it is mandatory to maintain Production version. Functionalities related to Lot size, alternative BOM etc can be captured through this. N Multiple production versions might be there for a material. It can be locked or Unlocked on as and when required basis.
2.5.1
Create Production version
At the time of recipe creation system prompts to maintain Production version. Multiple production versions are only used N when more than one production line is there. Here in Vedanta only one production version would be created.
2.5.2
Change Production version
Data related to production version can be changed at anytime. If New BOM is to be attached keeping the existing one in the system N with the same recipe, one production version is generated and the previous one is locked in changed mode.
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Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
2.5.3
Display production version
This is for displaying purpose read only mode.
Process Plant- Production Planning. 3.0 Process PlantProduction Planning (PP-PI) Planning cycle will start from demand management. The Production Strategy would be Make to stock. Gross Requirement Planning will be used. Planned independent requirements are used to perform Demand Management functions. A planned independent requirement contains one planned quantity and one date, or a number of planned independent requirements schedule lines, that is, one planned quantity split over time according to dates.
Demand Management
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Process Name
Mode
Gap (Y/N)
Remarks
3.1
View Demand
Demand on monthly scale can be viewed from planned independent requirement. The Requirement for finished product is N fed into the system, which will be considered at the time MRP run.
3.1.1
Create PIR
Create demand for standard finished product in the system based on the Rough-cut Planning idea. For Vedanta, this should not be more than the maximum production capacity since production is totally based on Utilization of Full Plant capacity. It is not driven by N sales. Down time of five days can be taken into account in PIR so that time for opportunity based maintenance or annual maintenance (Shut down type) can be taken in To account in production planning in advance.
3.1.2
Change PIR
If any change is required in PIR, this process can be used .If MRP elements are not already converted, change would be directly taken into account in the stock/requirement list. For affecting the
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Sl. No.
Process Name
Mode supported
Process Description/remarks taken into account in the stock/requirement list. For affecting the existing planned Order, MRP has to be run once again.
Gap (Y/N)
Remarks
3.1.3
Display PIR
View the Planned independent requirement in display mode.
3.1.4
Production Strategy Fully system supported
Make to stock production-planning strategy will be used for the Process plant. This has been decided pertaining to actual philosophy of production, which is not based on sale requirement. N Basic idea is full utilization of plant capacity. Requirement type LSF and/ BSE can be used to meet such requirement.
3.1.5
Staggered period Split
The requirement of PIR can be split further into smaller periods (Ex. Months into weeks or weeks into days). On the basis of the same PIR can be generated further. Hence Planned Orders can be N split automatically for smaller periods. We can use our own period splitting key to split the requirement into smaller periods.
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Sl. No.
Process Name
Mode
Process Description/remarks With the reorganization function, you can delete planned independent requirements for which there are no sales orders in the database. You can delete the planned independent requirements history.
Gap (Y/N)
Remarks
3.1.6
Reorganization of PIR
4.0
Material Requirement Planning
The main function of material requirements planning is to guarantee material availability, that is, it is used to procure or produce the requirement quantities on time both for internal purposes and for sales and distribution. This process involves the monitoring of stocks and, in particular, the automatic creation of procurement proposals for purchasing and production. In doing so, MRP tries to strike the best balance possible between

Optimising the service level and Minimizing costs and capital lockup.
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Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
4.1
Run MRP on material
Activate Materials Planning for all materials at Plant to derive Gross requirements. This transfers the demand created by the PIR N for dependent planning for the BOM items.
4.2
Total Planning
Total planning covers the planning of all the materials that are relevant for requirements planning and includes the BOM explosion for materials with a bill of material. You can use total planning for a single plant or you can use the scope of planning to control whether the total planning run is executed on a multi-plant level
4.3
View Stock/Requirement list
View Stock /requirements list to check stock position in terms of MRP elements. All the PIR, planned order and Production Orders ( N if not delivered) would be displayed along with ATP ,safety stock( if any ) , existing Stock ( if any). User will be able to see the most
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Sl. No.
Process Name
Mode
Process Description/remarks updated information related to Material Requirement.
Gap (Y/N)
Remarks
4.4
Stock overview
View Stock overview as and when required. System enables the user to check stock available for the stock items at various areas of the organization.
4.5
MRP List
Functionality relevant to MRP i.e., all MRP elements can be viewed from time to time. It will show the conditions of Stock or Requirement at time of last MRP run.
4.6
Planned Order
Proposal to manufacture after MRP execution is generated troughplanned order. It can be viewed from stock/ Requirement list. Planned Orders are converted to process order before the start of N process in the shop floor.
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Sl. No. 5.0
Process Name Process PlantCapacity Planning
Mode
Gap (Y/N)
Remarks
The economic use of resources is an objective for many areas of a company. The component "Capacity Planning" is available in the N System for this purpose.
5.1
Capacity Evaluation
Company can use capacity evaluations to analyse capacity loads in your company. You can adjust the analyses for each user according to the planning level, planning horizon and the area of responsibility. Available capacities and capacity requirements can be selected according to various criteria and cumulated using any period split you choose. To manufacture products in the shop floor as per the Recipe and Bill of Material (Material BOM)
6.0
Process PlantProcess Execution
6.1
Process Order
Process orders are used for the production of materials or for rendering of services in a specific quantity on a specific date. They N enable the planning of resources, control of process order management, and specify the rules for account assignment and order settlement.
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Sl. No.
Process Name
Mode
Process Description/remarks Actual confirmation to shop floor to go ahead with manufacturing. This can be obtained from Planned order. Other wise for any offline requirement Process Order can also be created manually.
Gap (Y/N)
Remarks
6.2
Create/ Change Process Order
Creating a process order is not a stand-alone process. Process Order is created from stock/Requirement list. But system allows creation of process Order separately. It is generally done before the commencement of manufacturing. The quantity to be produced under such a process Order has to be mentioned clearly. The N scheduling of process order that has to be followed really for shop floor happens at this phase and system schedules the process order. For Vedanta forward scheduling is recommended as scheduling type.
6.3
Check Material Availability
Process order consumes materials (Semi-finished / Raw). The Materials have to be issued to the Process Orders Or will have to be back flushed. Logically these materials have to be available in system before the commencement of process. System would display missing part list (if any). For Vedanta System will
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Sl. No.
Process Name
Mode
Process Description/remarks configured in such a way that system should raise warning if the material is not available. But decision-making should be at the level of user whether the Process Order could be processed after such missing part.
Gap (Y/N)
Remarks
6.4
Release Production Order
Process Order Release is carried out on verge of production initiation. In Vedanta this release procedure should be manual i.e., N user has to release the Process Order every time Production is initiated against a new Process Order.
6.5
Confirm Production Order
This is for Confirming actual completion of production for an order, N either partial or final. Also actual yield, scrap, time taken, and goods movements will be confirmed.
6.6
Confirmation cancellation
Partially system supported
It is possible to cancel data previously confirmed. Every completion P confirmation entered in the system can be cancelled. Thus, if you entered three confirmations for a phase, you can also cancel three
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Sl. No.
Process Name
Mode
Process Description/remarks confirmations and all confirmations automatically created by them.
Gap (Y/N)
Remarks
6.7
Issue Materials & Components
For Posting goods issued for Production, this functionality will be used. This will ensure the total consumption for production. Movement type used for this process is 261. For any return of goods issue, movement type 262 will be used. Unplanned materials can also be issued for a process order.
6.8
By-product receipt
Any by-product should also be taken as a component (-ve qty) into the BOM of in-house produced materials and that by-product will be receipt into the stock at the time of confirmation. Standard SAP movement type is 531. For Vedanta Red Mud Can be taken as by Product /Waste.
6.9
Receive Produced Materials
Goods Receipt for produced goods is captured through this functionality. After Goods receive store will be updated in inventory. Generally 101 is standard SAP movement type through
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Process Name
Mode supported
Process Description/remarks inventory. Generally 101 is standard SAP movement type through which goods receipt against production is captured.
Gap (Y/N)
Remarks
6.10
View Cost
The Planned vs. actual costs can be viewed after all issues and activities are completed in the process Order change mode/display mode.
Technical Closure (TECO) Once the process order is confirmed fully i.e., desired yield is confirmed in terms of Goods movement and activity confirmation is also done along with, it has to be declared Technically complete. N The entire reservation list pending (if any) for the Process Order is deleted after this activity by the system itself.
6.11
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Process Name
Gap (Y/N)
Remarks
7.0
Reports
Reports are generated in the SAP system based on the information fed on day-to-day basis. This enables the user to take decision related to business.
7.1
Stock Overview
It can be used to view Stocks for different material taking Plant and N storage location as additional selection criteria.
7.2
Extend material views
It shows the historical data related to material extension at different N point of time.
7.3
List of material Storage location assignment.
Shows the exhaustive list for material- storage location assignment.
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Process Name
Gap (Y/N)
Remarks
7.4
Material List
Shows Detail of a material on basis of selection criteria like plant, material, material type, material group and created by.
7.5
Material list with price and inventory values
Gives the detail of standard price, Per unit price, Currency Key etc.
7.6
Resource List
Gives detail of resources.
7.7
Cost Centre assignment.
Shows the details assignment of cost centres to Resources.
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Process Name
Gap (Y/N)
Remarks
7.8
Resources Capacity
Shows the capacity records (Master) for different resources list wise.
7.9
Where used listResource
Lists the different recipes where resources are used.
7.10
Where Used List Material
Lists of material Used into different BOM.
7.11
Stock/Requirement list-collective display
Fully System supported
Gives the stock /requirement scenario for a MRP area or plant
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Version No 1.2
Sl. No.
Process Name
Mode Fully System supported
Gap (Y/N)
Remarks
7.12
Multi level Order Report
Gives multilevel order report for Process Order with different information.
7.13
Missing Part InfoSystem
Gives the list of missing parts on plant. Material and different selection criteria for plant.
7.14
Stock/Requirement list
Fully system supported Fully System supported
Shows the detail scenario of stock or requirement scenario.
7.15
Collective Display of Planned Order.
Can display the planned orders collectively on the basis of MRP controller, Material and production version.
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Version No 1.2
Sl. No.
Process Name
Mode
Process Description/remarks Functionality relevant to MRP i.e., all MRP elements can be viewed from time to time. It will show the conditions of Stock or Requirement at time of last MRP run. This is of static type.
Gap (Y/N)
Remarks
MRP List 7.16
7.17
MRP List Collective Display
Same as previous, only it can be displayed MRP area wise.
7.18
Process Order Information System
Gives the detail of the information regarding process Order management.
7.19
Process Order Individual list display.
Gives the detail of the information regarding process Order management object wise.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
7.20
Resource analysis
Gives plant wise analysis of resources.
7.21
Operation analysis
Gives the shop floor information operation wise.
7.22
Material Analysis
Shop floor material analysis information.
7.23
Process Order Analysis
Shop floor analysis for Process Order.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
7.24
Product Cost Analysis
Shop floor Product cost analysis.
7.25
Exception analysis
N Exception analysis at material, plant and Process Order Level.
7.26
Capacity Planning
Resource Load Analysis.
7.27
Capacity Planning
Process Order Level.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
7.28
Capacity Planning
Resource Overload Analysis.
Resource View 7.29
N Enhanced capacity evaluation-resource wise.
7.30
Order View
Enhanced capacity evaluation-Order wise.
7.31
Material Consumption
N Material Consumption analysis.
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Process Name
Gap (Y/N)
Remarks
7.32
Capacity Planning Table
Capacity Planning table- Process Order View.
7.33
Material to be costed.
Display of material to be costed.
7.34
Result of Costing run.
Analyse or compare material cost estimates.
7.35
Price Vs. Cost Estimate.
Analyse or compare Material Cost Estimates.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
7.40
Costed Multi level BOM
Multi level BOM: Value /Amount/Status
7.41
Cost components
Analyse cost component split for planned cost: cost component
8.0
Power PlantLogistics General Data
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Process Name
Mode
Gap (Y/N)
Remarks
8.2
Batch Management
The manufacturing mode of VAL is a typical case of process manufacturing scenario. Here, batch tracking is not possible N physically, neither it is required. So production in SAP as well as in reality wont be captured through batches in case of power plant. Material Classification can be done with the standard material classification system in SAP (Class Type 001). This will allow better search.
8.3
Material Classification
Characteristic is a property that describes and differentiates objects. Classification Creation/change of Class and Characteristics Fully system supported Example: length, colour, weight, etc. Class is an assembly of characteristics that can be attributed to a N product (or to several similar products). It can also be defined as a grouping of similar products according to common characteristics Example Pump class, Boiler class etc.
8.4
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Process Name
Mode
Process Description/remarks If the order types are more than one, profiles will help in maintaining some controlling data. (i.e., automatic selection of order type during manual order creation).
Gap (Y/N)
Remarks
8.5
MRP Profile
8.6
Procurement Type
This would help the system to identify the procurement type for the particular material. We use E for produced goods, F for external N procurement and X for both type of procurement.
8.7
Availability Check
Based on this system checks the availability. In Vedanta we would use checking rule 01 for all semi-finished and finished product. This is used for accumulating the total requirement on daily basis. Any other availability check to be introduced can be considered at N Realization stage.
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Sl. No. 9.0
Process Name Product Data Management
Mode
Gap (Y/N)
Remarks
9.1
Maintain Material Master
Material master for Finished and Semi finished goods. Material Classifications may be used. Views such as Basic data 1, Basic Data 2, MRP 1, MRP 2, MRP 3, MRP 4 and work scheduling ( as and when required basis ). For example: For raw material there wont be any Work Scheduling View.
9.1.1
Create Material Master
Create relevant views for each material and give the values of respective fields.
9.1.2
Change Material Master
Change values of settings as necessary in the material master can N be done anytime, but frequent change is not recommended.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
9.1.3
Display Material Master.
View settings without changing. This purely for read only purpose.
9.2
Maintain Bills of Material
Create and change, as necessary, master data for Bills of Material. Standard BOM will be created and saved in the system. In case of N Process manufacturing scenario, this can be done along with recipe itself.
9.2.1
Create Bills of Material
Create BOMs for all materials produced in-house. In case of Process manufacturing scenario, this can be done along with recipe itself.
9.2.2
Change Bills of Material
Change values of settings as necessary. In case of Process manufacturing scenario, this can be done along with recipe itself.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
9.2.3
Display Bills of Material
View settings without changing. This is purely Read Only view for BOM.
9.3
Maintain Resource
Create and change, as necessary, master data for Resource. All Resource shall be attached to a Cost Centre. Processing Unit capacity categories may be used for a Resource. However data N related to Resource category and Capacity category may be changed at the time of realization depending on the simulation test result. Create Resource for all processing facilities in the plant with capacity categories of Processing Unit. This would capture logical place of operation under a plant and at the same time collect the costing data generated out of activity consumption.
9.3.1
Create Resource
9.3.2
Change Resource
This process would enable the user to capture any enhanced functionality in future. It can be used to change any existing field value apart from resource category and capacity category. Any
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Production Planning
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Sl. No.
Process Name
Mode supported
Process Description/remarks value apart from resource category and capacity category. Any extra capacity category can be introduced by using the functionality.
Gap (Y/N)
Remarks
9.3.3
Display Resource
View settings without changing. This is used for viewing the master N data in Read _only mode.
9.4
Maintain Recipe
Create and change, as necessary, master data for Recipe. The entire standard recipe will be created in the system for all the plants and material combination. PI01 can be used up while creating the Recipe.
9.4.1
Create Recipe.
Create Recipe for all materials produced in-house. The respective operations, their phases, internal relations, material assignments are to be mentioned .The standard values for operations can also be mapped through this functionality. Control keys like PI01, PI22
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Production Planning
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Sl. No.
Process Name
Mode
Process Description/remarks and PI05 may be used depending on the business processes integrated along with the operations.
Gap (Y/N)
Remarks
9.4.2
Change Recipe
Change values of settings as necessary. Any change in the process can be mapped in future through this transaction.
9.4.3
Display Recipe.
View settings without changing and in Read Only mode.
9.5
Production Version
Its a combination of BOM and Recipe. So in case of recipe it is mandatory to maintain Production version. Functionalities related to Lot size, alternative BOM etc. Multiple production version might be there for a material. It can be locked or Unlocked on as and when required basis.
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Production Planning
Page 58 of 58
Version No 1.2
Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
9.5.1
Create Production version
At the time of recipe creation system prompts to maintain Production version. Multiple production versions are only used N when more than one production line is there. Here in Vedanta only one production version would be created.
9.5.2
Change Production version
Data related to production version can be changed at anytime. If New BOM is to be attached keeping the existing one in the system N with the same recipe , one production version is generated and the previous one is locked in changed mode.
This is for displaying purpose read only mode. 9.5.3 Display production version Fully system supported N
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Production Planning
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Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
Process Plant- Production Planning. 10.0 Production Planning (PP-PI) Make to stock production-planning strategy will be used for the Process plant. This has been decided pertaining to actual philosophy of production, which is not based on requirement. Basic idea is full utilization of plant capacity. Requirement type LSF and/ N BSE can be used to meet such requirement. For Power plant this functionality is used if and only if long term planning is done.
10.1
Production Strategy Fully system supported
11.0
Material Requirement Planning
The main function of material requirements planning is to guarantee material availability, that is, it is used to procure or produce the requirement quantities on time both for internal purposes and for sales and distribution. This process involves the monitoring of stocks and, in particular, the automatic creation of procurement proposals for purchasing and production.
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Production Planning
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Sl. No.
Process Name
Mode
Process Description/remarks In doing so, MRP tries to strike the best balance possible between

Gap (Y/N)
Remarks
Optimising the service level and Minimizing costs and capital lockup.
For power plant planning would be done either through Consumption based planning (MM) or Long term Planning. But for Refinery Classical MRP (Deterministic) PP and consumption based (MM), both can be used. For power plant planning would be done either through Consumption based planning or Long term Planning. But for Refinery Classical MRP (Deterministic) PP and consumption based (MM), both can be used.
11.1
Run MRP on material
11.2
Total Planning
Total planning covers the planning of all the materials that are relevant for requirements planning and includes the BOM explosion for materials with a bill of material.
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Production Planning
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Sl. No.
Process Name
Mode
Process Description/remarks You can use total planning for a single plant or you can use the scope of planning to control whether the total planning run is executed on a multi-plant level. For power plant planning would be done either through Consumption based planning ( MM ) or Long term Planning. But for Refinery Classical MRP (Deterministic) PP and consumption based (MM), both can be used.
Gap (Y/N)
Remarks
11.3
View Stock/Requirement list
View Stock /requirements list to check stock position in terms of MRP elements. All the PIR, planned order and Production Orders ( if not delivered) would be displayed along with ATP ,safety stock( if any ) , existing Stock ( if any). User will be able to see the most updated information related to Stock/Requirement list. For power N plant planning would be done either through Consumption based planning (MM) or Long term Planning. But for Refinery Classical MRP (Deterministic) PP and consumption based (MM), both can be used.
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Sl. No.
Process Name
Process Description/remarks View Stock overview as and when required. System enables the user to check stock available for the stock items at various areas of the organization.
Gap (Y/N)
Remarks
11.4
Stock overview
11.5
MRP List
Functionality relevant to MRP i.e., all MRP elements can be viewed from time to time. It will show the conditions of Stock or Requirement at time of last MRP run. For power plant planning would be done either through Consumption based planning (MM) or Long term Planning. But for Refinery Classical MRP (Deterministic) PP and consumption based (MM), both can be used.
11.6
Planned Order
Proposal to manufacture after MRP execution is generated troughplanned order. It can be viewed from stock/ Requirement list. Planned Orders are converted to process order before the start of N process in the shop floor. For power plant planning would be done either through Consumption based planning (MM) or Long term Planning. But for Refinery Classical MRP (Deterministic) PP and
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Sl. No.
Process Name
Mode
Process Description/remarks consumption based (MM), both can be used.
Gap (Y/N)
Remarks
12.0
Capacity Planning
The economic use of resources is an objective for many areas of a company. The component "Capacity Planning" is available in the N System for this purpose.
12.1
Capacity Evaluation
Company can use capacity evaluations to analyse capacity loads in your company. You can adjust the analyses for each user according to the planning level, planning horizon and the area of responsibility. Available capacities and capacity requirements can be selected according to various criteria and cumulated using any period split you choose. To manufacture products in the shop floor as per the Recipe and Bill of Material (Material BOM)
13.0
Process Execution
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Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
13.1
Process Order
Process orders are used for the production of materials or for rendering of services in a specific quantity on a specific date. They enable the planning of resources, control of process order management, and specify the rules for account assignment and N order settlement. Actual confirmation to shop floor to go ahead with manufacturing. This can be obtained from Planned order. Other wise for any offline requirement Process Order can also be created manually.
13.2
Create/ Change Process Order
Creating a process order is not a stand-alone process. It is generally done before the commencement of manufacturing. The quantity to be produced under such a process Order has to be mentioned clearly. The scheduling of process order that has to be followed really for floor happens at this phase and system schedules the process order. For Vedanta forward scheduling is recommended as scheduling type.
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Sl. No.
Process Name
Mode
Process Description/remarks Process order consumes materials (Semi-finished / Raw). The Materials have to be issued to the Process Orders Or will have to be back flushed. Logically these materials have to be available in system before the commencement of process. System would display missing part list (if any). For Vedanta System will configured in such a way that system should raise warning if the material is not available. But decision-making should be at the level of user whether the Process Order could be processed after such missing part.
Gap (Y/N)
Remarks
13.3
Check Material Availability
13.4
Release Production Order
Process Order Release is carried out on verge of production initiation. In Vedanta this release procedure should be manual i.e., N user has to release the Process Order every time Production is initiated against a new Process Order.
13.5
Confirm Production Order
This is for Confirming actual completion of production for an order, N either partial or final. Also actual yield, scrap, time taken, and goods movements will be confirmed.
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Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
13.6
Confirmation cancellation
Partially system supported
It is possible to cancel data previously confirmed. Every completion confirmation entered in the system can be cancelled. Thus, if you P entered three confirmations for a phase, you can also cancel three confirmations and all confirmations automatically created by them.
13.7
Issue Materials & Components
For Posting goods issued for Production, this functionality will be used. This will ensure the total consumption for production. Movement type used for this process is 261. For any return of goods issue, movement type 262 will be used. Unplanned materials can also be issued for a process order.
13.8
By-product receipt
Any by-product should also be taken as a component (-ve qty) into the BOM of in-house produced materials and that by-product will be receipt into the stock at the time of confirmation. Standard
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Sl. No.
Process Name
Mode
Process Description/remarks movement type is 531.For reversal 532 may be used.
Gap (Y/N)
Remarks
13.9
Receive Produced Materials
Goods Receipt for produced goods is captured through this functionality. After Goods receive store will be updated in inventory. Standard movement type 101. For reversal 102 may be used.
13.10
View Cost
The Planned vs. actual costs can be viewed after all issues and activities are completed in the process Order change mode/display mode.
13.11
Technical Closure (TECO)
Once the process order is confirmed fully i.e., desired yield is confirmed in terms of Goods movement and activity confirmation is also done along with, it has to be declared Technically complete. N The entire reservation list pending (if any) for the Process Order is deleted after this activity by the system itself.
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Sl. No.
Process Name
Mode
Gap (Y/N)
Remarks
14.0 Reports Fully system supported Reports are generated in the SAP system based on the information fed on day-to-day basis. This enables the user to take decision related to business.
14.0
Reports
14.1
Stock Overview
It can be used to view Stocks for different material taking Plant and N storage location as additional selection criteria.
14.2
Extend material views
It shows the historical data related to material extension at different N point of time.
14.3
List of material Storage location assignment.
Shows the exhaustive list for material- storage location assignment.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.4
Material List
Shows Detail of a material on basis of selection criteria like plant, material, material type, material group and created by.
14.5
Material list with price and inventory values
Gives the detail of standard price, Per unit price, Currency Key etc.
14.6
Resource List
Gives detail of resources.
14.7
Cost Centre assignment.
Shows the details assignment of cost centres to Resources.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.8
Resources Capacity
Shows the capacity records ( Master) for different resources list wise.
14.9
Where used listResource
Lists the different recipes where resources are used.
14.10
Where Used List Material
Lists of material Used into different BOM.
14.11
Stock/Requirement list-collective display
Gives the stock /requirement scenario for a MRP area or plant
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.12
Multi level Order Report
Gives multilevel order report for Process Order with different information.
14.13
Missing Part InfoSystem
Gives the list of missing parts on plant. Material and different selection criteria for plant.
14.14
Stock/Requirement list
Fully system supported Fully System supported
Shows the detail scenario of stock or requirement scenario.
14.15
Collective Display of Planned Order.
Can display the planned orders collectively on the basis of MRP controller, Material and production version.
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Production Planning
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Sl. No.
Process Name
Mode
Process Description/remarks Functionality relevant to MRP i.e., all MRP elements can be viewed from time to time. It will show the conditions of Stock or Requirement at time of last MRP run. This is of static type.
Gap (Y/N)
Remarks
MRP List 14.16
14.17
MRP List Collective Display
Same as previous, only it can be displayed MRP area wise.
14.18
Process Order Information System
Gives the detail of the information regarding process Order management.
14.19
Process Order Individual list display.
Gives the detail of the information regarding process Order management object wise.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.20
Resource analysis
Gives plant wise analysis of resources.
14.21
Operation analysis
Gives the shop floor information operation wise.
14.22
Material Analysis
Shop floor material analysis information.
14.23
Process Order Analysis
Shop floor analysis for Process Order.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.24
Product Cost Analysis
Shop floor Product cost analysis.
14.25
Exception analysis
N Exception analysis at material, plant and Process Order Level.
14.26
Capacity Planning
Resource Load Analysis.
14.27
Capacity Planning
Process Order Level.
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Page 75 of 75
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.28
Capacity Planning
Resource Overload Analysis.
Resource View 14.29
N Enhanced capacity evaluation-resource wise.
14.30
Order View
Enhanced capacity evaluation-Order wise.
14.31
Material Consumption
N Material Consumption analysis.
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.32
Capacity Planning Table
Capacity Planning table- Process Order View.
14.33
Display Material to be costed.
Display of material to be costed.
14.34
Result of Costing run.
Analyse or compare material cost estimates.
14.35
Price Vs. Cost Estimate.
Analyse or compare Material Cost Estimates.
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Production Planning
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Sl. No.
Process Name
Gap (Y/N)
Remarks
14.40
Costed Multi level BOM
Multi level BOM: Value /Amount/Status
14.41
Cost components
Analyse cost component split for planned cost: cost component
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Page 78 of 78
Version No 1.2
SECTION IV
Process Plant: (SAP Flow Diagram) Purchase Requisition Create Demand Integration with MM Convert Planned Order to Process Order/Process Order Creation Integration With PM Integration with MM
Raise PIR
Run MRP
Planned Order
Scheduling
Capacity Availability Check
Material Availability Check
Ready For Delivery (SD Integration
Usage Decision (QM Integration) Technical Completion of Order
Goods Received
Process Order Confirmation
Goods Issue against Process Order. Accounting Document, Material Document and Controlling document Generated.
Calculation of Planned cost at the time of saving
Release
Closing
Integration With FI-CO and MM
Integration with FI-CO
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SAP ECC 5.0 IMPLEMENTATION Power Plant:
Production Planning
Page 79 of 79
Version No 1.2
Integration With PM Process Order Creation Scheduling
Integration with MM Material Availability Check
Capacity Availability Check
Closing
Technical Completion of Order
Goods Received
Process Order Confirmation Integration With FI-CO and MM
Goods Issue against Process Accounting Document, Material Document and Controlling document Generated.
Calculation of Planned cost at the time of saving
Release
Integration with FI-CO
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Production Planning
Page 80 of 80
Version No 1.2
Special Organizational Considerations: Different Grades of Bauxites and coal would be treated as single material. Neither it would be batch managed nor separate material code would be maintained for that. It will be managed through Moving Average price. In Refinery only three Resources might be there. There will be no In Process Inspection. Red Mud should be treated as Waste. Process Order would be created for a month for refinery. At the end of every month Process Order would be reconciled. Demand for Alumina should be generated on monthly scale. Confirmation of process Order of refinery will be done shift wise/Daily basis. In power plant consumption would be posted based on the actual Production. Reading of meters at the end of power plant may be taken into account.
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Production Planning
Page 81 of 81
Version No 1.2
Only one saleable item is there Alumina. Hydrate wont be sold. For power plant DM water would be considered as activity and would be directly booked to cost centre on a certain frequency. For power plant process order should be created on daily basis. Plant shall have only one resource. Process Order confirmation in power plant would be done on daily basis.
For power & steam one PO will be generated on daily basis. Distribution rule of power & steam will be posted on daily basis per process
order (manually). All the raw materials will be planned by consumption based planning and that will be taken care by MM.
------ End ------
CONFIDENTIAL

Val BBP PP Final

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Vedanta Alumina Ltd.

SAP ECC 5.0 IMPLEMENTATION

SAP R/3 IMPLEMENTATION BUSINESS BLUEPRINT Production Planning

Prepared by Aniruddha Mukherjee

Checked by Vishal Rathore

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5. Closure of Mapping Phase and start of Piloting Phase of implementation.

A pictorial presentation of complete SAP implementation is depicted in the following page:

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SECTION I Scope of Production Planning Module in VAL

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PARTICULARS 2.1.1.7 2.1.2 Evaluations: Logistics Information System

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PARTICULARS 2.2.1.8 2.3

Alumina Replenishment Stock Transfer with Direct Transfer Posting X MM X X X X MM X (MM) X X X X

Inventory Management 2.3.1 Goods Movements

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Power Plant (2000) STORAGE LOCATIONS To Be submitted by MM DESCRIPTION

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Order Types for Alumina Plant

ORDER TYPE AL HY NAOH

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Fully system supported

Fully system supported

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Fully system supported

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