P. 1
FICO Rollout Project

FICO Rollout Project

|Views: 1,654|Likes:
Published by Hasan Shadab

More info:

Published by: Hasan Shadab on Jul 07, 2011
Copyright:Attribution Non-commercial

Availability:

Read on Scribd mobile: iPhone, iPad and Android.
download as DOC, PDF, TXT or read online from Scribd
See more
See less

07/22/2013

pdf

text

original

Business Blueprint

For Quality Polymer SAP Rollout

By and

Project: Organization: Title: Doc Ref: Version:

SAP Roll Out Quality Polymer Business Blueprint 62417566.doc Final

Date of last change: 7/7/2011

This document marks the completion of the Business Blueprint phase of the SAP R/3 implementation for Quality Polymer. With this acceptance, the following document is confirmed and becomes the basis for the next phase (Realization) to proceed.

Name

Title

Signature

Date

Team for Quality Polymer Sdn. Bhd. :
Kuraish Hatim Veno Gober Chow Kwang Chai Janet Ling Ng Hong Chee Cheam Heng Lai Yaw Seng Heng Choo Kim Soon Team Leader, Sales and Distribution Team Leader, Material Management Team Leader, Purchasing Co-Team Leader, Production Planning Co-Team Leader, Production Planning Team Leader, Financial & Controlling Project Advisor Project Manager Team Leader, Technical

Ea Consulting Asia Pacific Sdn. Bhd. :
Wong Wei Ling Team Leader, Sales and Distribution, Financial & Controlling Project Manger Team Leader, Purchasing and Invoice Verification Ramesh Sunkarapalli Team Leader, Production Planning

Adeline Lee

Project: Organization: Title: Doc Ref: Version:

SAP Roll Out Quality Polymer Business Blueprint 62417566.doc Final

Date of last change: 7/7/2011

Table of Contents
Table of Contents...................................................................................................................3 Table of Exhibits....................................................................................................................6 1 Executive Summary.............................................................................................................1 2 Quality Polymer Rollout Project Overview.........................................................................2 2.1 Project Organization ....................................................................................................2 2.2 Project Scope ..............................................................................................................3 2.3 Project Timeline ...........................................................................................................3 3 Organization Structure........................................................................................................5 3.1 Financials ....................................................................................................................5 3.1.1 Financials Organization Structure.....................................................................5 3.1.1.1 Credit Control Area.............................................................................5 3.1.1.2 Cost Center Hierarchy........................................................................6 3.1.1.3 Profit Center Hierarchy.......................................................................7 3.2 Logistics........................................................................................................................8 3.2.1 Sales Organization Structure............................................................................8 3.2.1.1 Sales Area..........................................................................................8 3.2.1.2 Shipping Point....................................................................................9 3.2.2 Purchasing Organization Structure....................................................................10 3.2.3 Inventory Management Organization Structure.................................................11 3.2.3.1 Storage Locations for Quality Polymer................................................11 4 Master Data ..........................................................................................................................13 4.1 Financials ....................................................................................................................13 4.1.1 Order Type........................................................................................................13 4.2 Logistics........................................................................................................................13 4.2.1 Customers and Vendors....................................................................................13 4.2.2 Material Types...................................................................................................13 4.2.3 Material Types, Material Groups and Number Ranges......................................14 4.2.4 Material Valuation and Account Determination..................................................14 4.2.5 Product Hierarchy.............................................................................................14 4.2.6 Batch Management...........................................................................................14 4.2.7 Shelf Life Expiration Date (SLED) and Classification for Batch Specification....15 4.2.8 Bill of Materials (BOM)......................................................................................15 4.2.8.1 Material BOM......................................................................................15 4.2.8.2 Alternate BOM....................................................................................15 4.2.9 Master Recipe...................................................................................................16 4.2.10 Recipe Group..................................................................................................16 4.2.11 Resources (Work Centers)..............................................................................16 4.2.11.1 Processing Unit: ..............................................................................16 4.2.11.2 Labor: .............................................................................................16 4.2.12 Production Versions........................................................................................16 5 To-Be Business Scenarios..................................................................................................18 3

...................................................Canning Balance............................ Functional Requirements.............25 5......................................3 BS298 Blocking of Tote tanks used for temporary storage.20 5.......3 Inventory Management..........................................1 Conversion strategy........................................................................................1 BS130 Sales from Stock (Tanker)................................30 9....20 5....................................4.........................25 5..........................1 System Environment.............................3.......2..................................................................................................................1 BS215 Procurement for Stock – Raw Material...........................................................2 BS297 Stock Adjustment during Tanker Exit.. List of Reports.........................2 BS130 Sales from Stock (Tote Tank)...............................3 BS352 Production Planning – Pilot Production for New Materials..Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566................................. Functional Requirements...2 User Exits................21 5.............................................doc Final Date of last change: 7/7/2011 5..................................................................................................................................................................................................................4...............1 Test data ..............4 BS 353 Production Planning ..29 7 Conversion Approach...............................................5 BS347 Production Planning ................30 9.................................................33 A...........................................................................................1 BS329 Planning by Production....................................................32 Appendices.....................................................31 11 Testing Approach.......4.........2 Conversion Data Preparation..........................31 10 Training..............................................................................................1 BS273 Creation of Material Master for Quality Polymer...................2 Purchasing and Invoice Verification..............33 B.................................................................................................................................................................................................................................1 Interfaces..................................4..........................33 4 ......................... To-Be Business Scenario Master List.......6 Controlling............................2 BS331 Production Planning ............................................................22 5..................................................6 BS348 Production Planning – Assorted Materials..........................................................................................................................................................................................................27 5..1 Sales and Distribution ...........................................................................29 7...1...........................................3................................................................................................5 Financial Accounting.....18 5............3 Actual Conversion ....22 5..................................................................................................32 11....23 5.......................... To-Be Business Scenario Master List.......................7 BS351 Production Planning – Common Semi Finished Material........................27 5.......4....................................................................................33 A........2..........32 11..Reprocess Formula.......3..........2 BS233 Vendor Consignment of IBC tote.....................................21 5.....................................................................................................Make to Stock..4......................18 5........................4 Production Planning...1..................27 5...............................................................1.......29 8 Authorizations......................................2 Testers (Users) for UAT.................................23 5.2 Transport Strategies...........33 B.........................28 6 Interfaces and Enhancements.................................23 5.......30 9 System Landscape...................................................................19 5..............................29 6...........................................................................1..........29 6.....................................................29 7...29 7...................................................22 5.....................33 C..24 5....33 Appendices.......................................................................................4........................................................................................................................

...............33 5 ............................................................. List of Forms............................................................................................33 E.................................................................................................................................. List of Conversion Objects................................33 D.......... List of Reports.... List of Forms...................Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566......................33 D........doc Final Date of last change: 7/7/2011 C..................... List of Conversion Objects.............................................................................33 E..............................................................

..3...................3: ASAP Implementation Methodology....................................................Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.......................................9 Figure 3...12 Figure 4..........................2......1.............18: Sample of a BOM.............13 Figure 4............2.........14 Figure 4................................10 Figure 3...............2.................................8 Figure 3......................................3 Figure 2............15: Material Types............................................................19: NPM System Landscape & Additional Server for Quality Polymer Rollout 31 6 ...........2.............................................1................6 Figure 3........................14: Material Types........................................17: Batch Number Assignment.........10: Mapping of Purchasing Organization Structure..........................................16: Additional Product Hierarchy for Quality Polymer..............................................................1: Rollout Project Organization.....4: Timeline for Quality Polymer Rollout .............................14 Figure 4......2.....................2...doc Final Date of last change: 7/7/2011 Table of Exhibits Figure 2........................6: Mapping of Cost Center Hierarchy.......2.............1................5 Figure 3........................11 Figure 3.........................................2.......................5: Mapping of Credit Control Area.....3...........................1............13 Figure 4....... Material Groups and Number Ranges.......7: Mapping of Profit Center Hierarchy...............................................2: Scope of Quality Polymer Rollout.9: Mapping of Shipping Point..11: Mapping of Inventory Management Organization Structure...........2...........1......1.......2.............2 Figure 2.......................................13: Order Types...................................................3 Figure 2.2........4 Figure 3...................................15 Figure 9...........7 Figure 3..................................................................................14 Figure 4.........8: Mapping of Sales Area....12: Storage Locations for Quality Polymer.

This plant will also be the production plant for all of Quality Polymer productions. There will be other storage locations identified for other logical mapping. continuing the trend to consolidate credit limit per customer buying from more than one company. into design decisions in the SAP R/3 system. which will also be structured to the companies. As with all SAP R/3 company codes in NPM. Finally. which will act as a base for the remaining phases. thus. Quality Polymer will have one Sales Organization and Distribution Channel to handle its sales processing. in order to ensure a timely. a subsidiary of Quality Polymer.doc Final Page 1 of 33 Date of last change: 7/7/2011 1 Executive Summary This report contains the conceptual design of the SAP R/3 system for Quality Polymer. Company code for Desa Baiduri. The main purpose of this report is to describe and freeze the scope of implementation. For the logistics structure under the company code. Quality Polymer will share the same credit control area. As this is a rollout implementation from Nippon Paint SAP R/3 system. Quality Polymer will adopt most of the relevant business scenarios and business processes from Nippon Paint Malaysia (hereafter also referred to as “NPM”). it is important to note that the conceptual design detailed in this document is to streamline expectations and clarify the scope. A single Purchasing Organization is also identified to handle the procurement for the whole company. Costs incurred by departments and sub-departments can be viewed in a cost center hierarchy. will also be introduced for this rollout implementation. . Quality Polymer will fall under the NPM umbrella of controlling area. one plant with multiple storage locations is used to monitor the inventory of the company. The report will highlight all the adopted business scenarios from Nippon Paint Malaysia and focus on the additional business scenarios and business processes. These can be matched against the revenue generated by Profit centers. fully using the company code that has already been setup during Project Cheetah Implementation. Four different storage locations are used to house the four raw materials tanks and another twelve storage locations are used to map to the twelve storage tanks for the finished goods. The Business Blueprint document maps and translates the ‘To-be’ business requirements of Quality Polymer. which were gathered during the business workshops.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. effective and successful implementation.

identified key users from Quality Polymer and ea Consultants under the supervision of the internal project managers.Ms Lin (PU) Azreen (QP) Wong Wei Ling (ea) PP PP Ng Hong Chee (TLProcess) . Choo Kim Soon and the external project manager Adeline Lee. In addition.doc Final Page 2 of 33 Date of last change: 7/7/2011 2 Quality Polymer Rollout Project Overview 2.Zawiah (PU) Janet Ling (TL-Master Data) Lum (QP) Ramesh SV(ea) Figure 2. Yaw Seng Heng as the Project Advisor on the best business processes to adopt from NPM. which is headed by the MD of Quality Polymer.1 Project Organization The Rollout Project is under the responsibility of the Steering Committee.Project Manager Co.1. Lee Buck Siang. Daily project activities were undertaken by the project team members from the combination of core Project Cheetah Team Leaders from each module.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. Project Team Organisation Structure Project Sponsor Project Sponsor Mr Lee Buck Siang Mr Lee Buck Siang Quality Review Quality Review Alfred Chong Alfred Chong Project Manager Project Manager Adeline Lee (ea) Adeline Lee (ea) Project Advisor Project Advisor Yaw Seng Heng Yaw Seng Heng Steering Committee Steering Committee Mr Lee Buck Siang (MD) Mr Lee Buck Siang (MD) Mr Yaw Seng Heng (GM) Mr Yaw Seng Heng (GM) Mr Leong Wai Khoon Mr Leong Wai Khoon Ms Wong Siew Ying Ms Wong Siew Ying Adeline Lee (ea) Adeline Lee (ea) Alfred Chong (ea) Alfred Chong (ea) Choo Kim Soon Choo Kim Soon Co. Alfred Chong provides quality review and overall project direction with Mr.Zawiah (PU) Chow KC (TL-PUR) Norhafizah (QP) Adeline Lee (ea) SD SD Kuraish Hatim (TL) .1: Rollout Project Organization 2 .Jesmine (PU) Charlotte Chong (QP) Wong Wei Ling (ea) MM/PUR MM/PUR Veno Gober (TL-MM) .Mdm Song (PU) . ea Consulting Manager.Project Manager Choo Kim Soon Choo Kim Soon BASIS/ABAP BASIS/ABAP Choo Kim Soon (TL) Lee Kian Ann Damodaran FICO FICO Cheam Heng Lai (TL) .

which maps the business requirements into SAP and defines the approaches to be used in activities like conversion. all modules will be rolled out to Quality Polymer. ASAP is broken into five stages as shown in the diagram below: ASAP Methodologies A results-based roadmap to support the core components of an SAP implementation Figure 2. with the exception of Warehouse Management. Stage 2 – Business Blueprint The purpose of this stage is to document the Business Blueprint. The table below denotes the modules that will be implemented for the two companies.doc Final Page 3 of 33 Date of last change: 7/7/2011 2.2 Project Scope As this is a rollout system from NPM.3.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.Project Preparation The purpose of this stage is to perform initial project planning and preparation activities for the follow-up phases. being a subsidiary of Quality Polymer will only be implemented with the Financial and Management Accounting Module.3: ASAP Implementation Methodology Stage 1 .2. Existing NPM SAP Module Quality Polymer Financial Accounting (FI) Yes Management Accounting (CO) Yes Sales and Distribution (SD) Yes Purchasing (MM-PUR) Yes Invoice Verification (MM-IV) Yes Inventory Management (MM-IM) Yes Warehouse Management (MM-WM) Production Planning (PP) Yes Figure 2.3 Project Timeline The implementation approach for the rollout project is based on the Accelerated SAP (ASAP) implementation methodology. 3 . identifying the project team members and developing a detailed project plan. Major activities include preparing the project infrastructure. Desa Baiduri.2: Scope of Quality Polymer Rollout Desa Baiduri Yes Yes - 2.

develop and test interfaces. Stage 3 – Realization The purpose of this stage is to configure all of the business requirements based on the Business Blueprint conceptual design. A support team for power users must be formed for the initial critical days of going live as well as to support end users for a long-term period. and preparation for end user training is established. Activities in this phase include end-user training. Stage 5 – Go-Live and Support The purpose of this stage is move from a pre-production environment to a live production operation environment. The Business Blueprint is an important component of ASAP as it specifies the conceptual design on which the rest of the implementation is based.doc Final Page 4 of 33 Date of last change: 7/7/2011 training and testing under the Realization phase.4: Timeline for Quality Polymer Rollout 4 . user acceptance tests are conducted. and actual conversion of “live” data. It is the result of requirement gathering workshops and prototyping efforts. Stage 4 .3. The objectives are to configure the system.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. “cut-over” activities and formation of an internal help desk to support the organization after going “live”. system management. The Rollout Project commenced on 8th October 2003 and is a three-month project implementation. The integration of the logistics modules and the financial modules demand an aggressive timeline as depicted in the diagram below. Project Timeline Project Management ASAP Phase Project Preparation Oct Nov Dec Jan Weeks 1 3 9 3 Go Live Business Blueprint Realization Final Preparation Go Live & Support Note: 15 weeks project with certain weeks overlapping 2 15 Total 5th January 2003 Figure 2. conversion programs.Final Preparation The purpose of this stage is to prepare for going live. enhancements and reports as well as conduct overall integration test. System authorizations are also created.

The credit limit will be checked during the creation of sales order and delivery order. The system will block any sales order or delivery order that fails the credit check.1 Financials Organization Structure 3.1. Therefore Quality Polymer will adopt the criteria for credit check from NPM.doc Final Page 5 of 33 Date of last change: 7/7/2011 3 Organization Structure 3.5: Mapping of Credit Control Area 5 . Financial Organization Structure Client 300 Production Credit Control Area 1000 Nippon Paint Company Code 7000 Quality Polymer 7100 Desa Baiduri Sales Organisation 7000 Quality Polymer Figure 3. Quality Polymer belongs to the same credit control area as NPM.1 Credit Control Area A credit control area is an organizational unit for specifying and controlling customer credit limits.1. The credit limit assigned to a customer is valid across all company codes in the credit control area.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.1.1. Approval by the Credit Representative is required before the sales document can be further processed.1 Financials 3.

doc Final Page 6 of 33 Date of last change: 7/7/2011 3.1.2 Cost Center Hierarchy The standard hierarchy and coding structure of the cost centers for Quality Polymer and Desa Baiduri are as follows: Cost Center Hierarchy NPGROUP Nippon Paint Group 70000000 Quality Polymer 70100000 Pasir Gudang 71000000 Desa Baiduri 71100000 Pasir Gudang 71101000 Gen Adm in 71102000 Sales 70101000 Production 70103000 Technical 70106000 FG W /hse 70109000 Safety & Health 70111000 Purchasing 70113000 IT 70199000 Dum y m 70102000 QC 70101300 Em ulsion 70101500 RawMaterials 70101600 Maint&W ater Treatm ent 70101700 Factory Office 70104000 Sales & Marketing 70108000 Managem ent 70110000 Finance & Audit 70112000 HR &Gen Adm in 70112100 Hum Resources an 70112200 General Adm in 1000 Controlling Area Figure 3.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.1.1.6: Mapping of Cost Center Hierarchy 6 .

3 Profit Center Hierarchy The standard hierarchy and coding structure of the profit centers for Quality Polymer and Desa Baiduri are as follows: Profit Center Hierarchy NPGROUP Nippon Paint Group 70000000 Quality Polymer 71000000 Desa Baiduri 70100000 Pasir Gudang 71100000 Pasir Gudang 1000 Controlling Area Figure 3.1.1.1.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.doc Final Page 7 of 33 Date of last change: 7/7/2011 3.7: Mapping of Profit Center Hierarchy 7 .

2.2.doc Final Page 8 of 33 Date of last change: 7/7/2011 3.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.1 Sales Organization Structure 3.1 Sales Area The sales area and assignment of the sales organization to the company code for Quality Polymer is as shown below.2 Logistics 3.8: Mapping of Sales Area 8 . Sales Organization Structure– Sales Area Company Code 7000 Quality Polymer Sales Organisation 7000 Quality Polymer Distribution Channel 7A Pasir Gudang Division 01 General Sales Area Sales Office 7001 Pasir Gudang Figure 3.1.2.

1.9: Mapping of Shipping Point 9 .doc Final Page 9 of 33 Date of last change: 7/7/2011 3.2 Shipping Point The shipping point is required for delivery processing. The figure below shows the assignment of the shipping point to the plant.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.2.2. Sales Organization Structure– Plant & Shipping Point Company Code 7000 Quality Polymer Sales Organization 7000 Quality Polymer Distribution Channel 7A Pasir Gudang Plant 7001 Pasir Gudang Shipping Point 7001 Pasir Gudang Figure 3.

doc Final Page 10 of 33 Date of last change: 7/7/2011 3.2.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.2.2 Purchasing Organization Structure The Purchasing Organization Structure for Quality Polymer is as follows: Purchasing Organization Structure 7000 Quality Polymer Company Code Purchasing Organisation 7000 Quality Polymer Purchasing Group 100 Raw material purchases 300 Non-stock and services items purchases 400 Trading items 301 Other item purchases Plant 7001 Quality Polymer Figure 3.10: Mapping of Purchasing Organization Structure 10 .

2. water treatment materials and indirect materials 11 .doc Final Page 11 of 33 Date of last change: 7/7/2011 3.3.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.3 Inventory Management Organization Structure The Inventory Management Organization Structure for Quality Polymer is as follows: Inventory Management Organization Structure Company code 7000 Quality Polymer Plant 7001 Quality Polymer 3000 Finished goods 3701 FG tank1 3702 FG tank2 370 3 FG tank 3 370 4 FG tank 4 370 5 FG tank 5 3706 FG tank6 370 7 FG tank 7 3708 FG tank8 3709 FG tank9 3710 FG tank 10 371 1 FG tank 11 371 2 FG tank 12 Storage Locations 1000 Raw m aterial 1101 Monom er tank 1 1102 Monom er tank 2 110 3 m onom er tank 3 1104 Monom er tank 4 2200 EM Plant 240 0 Maintenance M isc W H 400 0 W aste 500 0 Technical Dept 510 0 M arketing Misc Figure 3.2. Stores filter bags.2.1 Storage Locations for Quality Polymer The details of Storage Locations for Quality Polymer are as follows: Storage Location 1000 1101 1102 1103 1104 2200 2400 Location Description Raw Material Warehouse Monomer tank 1 Monomer tank 2 Monomer tank 3 Monomer tank 4 EM Plant Maintenance Misc Type of Storage It stores raw materials such as additives. catalyst and Surfactant Stores monomer Stores monomer Stores monomer Stores monomer Represents Quality Polymer Production area that stores raw materials before it goes into production. parts.11: Mapping of Inventory Management Organization Structure 3. boiler materials.

Figure 3.doc Final Page 12 of 33 Date of last change: 7/7/2011 Storage Location 3000 3701 3702 3703 3704 3705 3706 3707 3708 3709 3710 3711 3712 4000 5000 5100 Location Description Finished Goods Type of Storage Serves as a temporary storage location and stores finished goods. FG tank 1 Represents Storage Tank 1 FG tank 2 Represents Storage Tank 2 FG tank 3 Represents Storage Tank 3 FG tank 4 Represents Storage Tank 4 FG tank 5 Represents Storage Tank 5 FG tank 6 Represents Storage Tank 6 FG tank 7 Represents Storage Tank 7 FG tank 8 Represents Storage Tank 8 FG tank 9 Represents Storage Tank 9 FG tank 10 Represents Storage Tank 10 FG tank 11 Represents Storage Tank 11 GF tank 12 Represents Storage Tank 12 Waste Stores disposed product ie.2. calendars etc.12: Storage Locations for Quality Polymer 12 . Sludge etc. uniforms.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. Technical Dept Stores materials from QC Lab Marketing Misc Stores T-shirts.

Development Materials Material record is created for costing simulation purpose. 4. The loose finished goods will also be identified by this material type.2. consumables and cooling towers.1. Returnable Packaging Packaging materials such as tote tanks. Packaging Material Packaging materials such as tote tanks. Figure 4.13: Order Types Range From 710000 720000 730000 740000 760000 770000 External To 719999 729999 739999 749999 769999 779999 External 4.1 Order Type Internal orders are used to collect. This material is managed at quantity basis only. Waste Materials Materials used to track waste generated. Indirect Material Materials that are not part of trade.1 Customers and Vendors Quality Polymer will adopt both the customer and vendor account groups and partner functions from NPM.1. Semi-Finished Product Semi-finished goods produced in-house or through subcontractor.2. monitor and settle costs. and mainly classified as consumable material for used in production such as Boiler materials.2 Material Types For Quality Polymer Rollout.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.2. The order types to be used by Quality Polymer are as follows: Order Type 7EMP 7VEC 7FOK 7MKT 7RPC 7QP1 7DIS Name Staff Expenses Motor Vehicle Expenses Forklift Maintenance Marketing & Promotion/Project Expenses Repacking Order Quality Polymer Ad-Hoc Order Quality Polymer Discount Figure 4. Pipeline Material Materials such as water that flow into the production process directly. due to the NPM design that has been up. 4.doc Final Page 13 of 33 Date of last change: 7/7/2011 4 Master Data 4. This material type will not allow quantity or value updates. and it is used to produce finished goods. drums and pails. Trading Goods Materials purchased externally and sell to customer. Finished Goods Final product from production and pack in various packaging sizes. the following material types will be adopted from NPM: Material Type ROH HALB FERT HAWA ZIND Material Description Raw Material Types of Material Raw material used to produce finished goods.1 Financials Quality Polymer will adopt the chart of accounts and account groups from NPM. Water treatment chemicals.14: Material Types LEIH VERP PIPE ZDM ZWTM 13 .2 Logistics 4.

batch management will be used to differentiate material with heterogeneous yield. For Quality Polymer Rollout.2.2. Batch records will be created upon goods receipt as per purchase order and upon release of process orders for materials produced inhouse 14 .16: Additional Product Hierarchy for Quality Polymer 4.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. result qualities or varying constituents.2. 4. Material Groups and Number Ranges Materials with the same attributes can be assigned to a material group for analysis and search purposes. Material Groups and Number Ranges 4.3 Material Types. a number is assigned to uniquely identify it.2.17: Batch Number Assignment All batches will have internally assigned numbering. Each material is assigned a material number to represent a material master record created in SAP system.2.2.6 Batch Management Similar to NPM. Below is the new product hierarchy relevant for Quality Polymer Rollout: Material Type ROH ROH ROH ROH Product Hierarchy 200021010200000005 First Level Second Level Third Level 20002 2000210102 Vinyl Acetate Copolymer Latex Copolymer 200021010400000006 20002 2000210104 Homo Polymer Latex Others – Latex 200041030000000012 20004 2000410300 Catalyst Additive Water Based Additive 2000810700 20008 Monomer Monomer Figure 4.4 Material Valuation and Account Determination Quality Polymer will adopt Material Valuation and Account Determination from NPM.15: Material Types. It is mainly used for analysis and pricing.5 Product Hierarchy Product Hierarchy is used to group materials by combining different features. the following material groups and number ranges have been identified: Material Type Raw Material (ROH) Packaging Material (VERP) Indirect Materials (ZIND) Material Group Material Description Number Range ROH008 Monomer M001 – M999 VERP005 Tote PT0000000 – PT9999999 VERP006 IBC PI0000000 – PI9999999 ZIND009 Boiler Materials IM521 – IM530 ZIND010 Consumables IM531 – IM540 ZIND011 Cooling Towers IM541 – IM550 Figure 4. The following number ranges will be assigned for Quality Polymer: Types of Material Batch Number Assignment Assorted Material yymmddQA01 – QA99 Semi-Finished Product (HALB) & Finished yymmddQ100 – Q999 Goods (FERT) Trading Goods (HAWA) Free format(10 Digits) Raw Material (ROH) 000Q100000 – 000Q999999 (10 Digits) Internal Number(10 digits) Packaging Material (VERP) Figure 4.2.doc Final Page 14 of 33 Date of last change: 7/7/2011 4. In order to monitor a batch.

Level 2 and below will consist of semifinished and raw materials to manufacture the semi-finished product of the next higher level. A BOM specifies the proportion or the actual quantities of the lower level components to be used in the final product.2. 15 .2. For Quality Polymer.8 Bill of Materials (BOM) The Bill of material (BOM) can de defined as a formally structured list of components that make up a finished product or semi finished product. Differences between alternative BOMs are very minimal.8. The product is represented by a number of alternative BOMs.8.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.2. Example of a BOM to manufacture product L012BC1 (current material naming convention): L012BC1 Level 0 L012 BC1 Level 1 M001 SR7000 Level 2 M002 M003 Level 3 Figure 4.doc Final Page 15 of 33 Date of last change: 7/7/2011 4. Together with the production date. 4. up to three (Level 0-2) levels of BOM will be identified (Currently only one material has 4 Levels of BOM).2 Alternate BOM A finished or semi-finished material can be produced from alternative combinations of materials depending on the quantity to be produced (lot size).1 Material BOM The components of a material BOM are defined as components that are used during the production process. the following types of BOM will be created: 4. Generally for Quality Polymer.2. Level 1 will consist of the loose semi-finished material and packaging material.7 Shelf Life Expiration Date (SLED) and Classification for Batch Specification SLED and Classification is also adopted in Quality Polymer Rollout.18: Sample of a BOM Level 0 will be for the finished product with a specific packing size. 4. The highest level of the BOM is defined as level zero. SLED will provide Quality Polymer with the material expiration date while the classification will store all the Quality Inspection Specification for any particular batch.2.

Processing units are linked to cost centers and activity types. Resources can be categorized as either processing units or labor.11.2.11 Resources (Work Centers) Resources are production facilities and persons involved in a production process that have different capacities.2. the operation Premixing can have the following phases: • • Prepare raw materials Mix raw material homogenously. An operation is subdivided into phases. The resulting data is used for process order settlement. For Quality Polymer.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.2. For Quality Polymer. Production cost will then be calculated by multiplying actual processing time with the rate.2.10 Recipe Group A Recipe Group is a 6-character field. the numbering for the Recipe Group will be internally assigned as follows : Type of Group Recipe Group 4. Labor resources contain data that can be used by production planning (capacities) and by personnel administration (employee).9 Master Recipe A master recipe is used for the manufacturing of a semi-finished product or finished product. A production version determines which alternative BOM is used together with a chosen master recipe to produce a semi-finished product or a finished product.2: Mapping of Recipe Group For Quality Polymer. one cost center will be defined for each and every work center. For example.1 Processing Unit: Processing units are resources used in production.11. which can be assigned internally or externally. The Recipe Group can combine several masters with following criteria: • • Different production processes for the same material.2.2. 4.12 Production Versions Production versions are used in situations where one material can be produced by several production processes. 4. Like two different materials may have the same production process Internal Number Range 50000 .2. Each operation is carried out at a primary resource. Monomer Mixing Tank(MMT) and Reactor are examples of processing units. For example.599999 Figure4. Process worker and drumming hands are examples of labor resource used in Quality Polymer’s environment. 4. They are subdivided into categories to specify their suitability for certain purposes or their use in certain processes. 4. A master recipe consists of a header and several operations.2 Labor: Labor resources are people in the production process who have different levels of capacity assigned to them. 16 .5.doc Final Page 16 of 33 Date of last change: 7/7/2011 4. Similar production processes for different materials. The rate will be pre-defined for labor and machine activities. Each phase has one or more process instructions. the production process can be different if a similar material is produced for two different lot sizes.

Q2….doc Final Page 17 of 33 Date of last change: 7/7/2011 For one semi-finished product or finished product.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. there can be several production versions with various validity periods and lot-size ranges... Production versions are used together with alternative BOMs. The Numbering of Production Versions is Q1. The different ways of production are defined as production versions.Q9. 17 .

Once the sales order is free from the credit limit block or the credit limit block has been released by the Credit Representative. When the sales order is saved. The availability check will allow the Sales Administrator to verify if the requested delivery date can be met or a new delivery date is to be proposed. After the process order has been released. Before the tanker is filled up with the loose FERT from the storage tank. the tanker must be weighed to obtain the Berat Tanpa Muatan (BTM). If the customer does not pass the credit limit. the tanker 18 .1 BS130 Sales from Stock (Tanker) When a customer confirms a sale with Quality Polymer. goods movement is allowed for the process order.1 Sales and Distribution In addition to new business scenarios that are specific only to Quality Polymer.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. SAP will perform an availability check for the loose FERT. different criteria can be set for credit limit check. The Sales Administrator will create a sales order based on the customer purchase order. No further processing of the sales order is possible until the approval is executed. SAP performs a check on the customer’s credit limit. After the tanker has been filled up. Quality Polymer will also adopt the following Sales and Distribution business scenarios from NPM: • • • • • • • • • • • • • • BS103 Maintenance of Customer Master BS104 Maintenance of Customer Partner Function BS105 Maintenance of Customer Info Record BS106 Maintenance of Pricing Structure BS122 Sales from Stock BS125 Trading Sales BS126 Cash Sales BS128 Credit Note Processing BS129 Debit Note Processing BS141 Goods Return from Customer BS142 Replacement of Goods / Exchange of Goods BS143 Development Material Sample Processing BS147 Handling of Returnable Packaging BS149 Charge Back to Transporter 5. the Sales Administrator informs the Production Department to create a process order for filling up the tanker with the loose FERT. a block will be imposed on the sales order.doc Final Page 18 of 33 Date of last change: 7/7/2011 5 To-Be Business Scenarios 5. Depending on the customer’s credit status.1. the Sales Administrator needs to create the sales order in SAP.

an accounting document is also recorded immediately in the customer accounts receivable. The Gate Pass will also be created. sales orders that have been approved might not be subject to checking during delivery order. No further processing of the sales order is possible until the approval is executed. the Sales Administrator cannot use the material number from the purchase order but have to select the appropriate material number based on the unit of measure in the purchase order. if the customer does not pass the credit limit. When the billing document is generated in SAP. In addition to the material requested. The delivery order is printed after the Sales Administrator post goods issue for the delivery order. However. This is to safeguard the change of customer’s credit limit status from the time of sales order to the delivery order. After the process order has been confirmed. As in sales order processing. the Sales Administrator runs the delivery due list and creates delivery orders for all the sales orders that are due for delivery. a block will be imposed on the sales order. If the customer does not pass the credit limit. depending on additional credit limit settings. the Sales Administrator will also have to enter an additional line item for returnable packaging If the purchase order is from NPM. the Sales Administrator needs to create the sales order in SAP. Another round of credit limit check is done for each delivery order. depending on additional credit limit settings. Alternatively. 5. The Sales Administrator will only generate billing documents to the customer once the transporter has returned a copy of the delivery order to Quality Polymer. a goods receipt is done for the process order and the Production Department will inform the Sales Administrator the confirmed quantity. The Sales Administrator creates the delivery order based on the confirmed quantity. Another round of credit limit check is done for each delivery order. The Sales Administrator will create a sales order based on the customer purchase order. it is possible to create the delivery order immediately for urgent delivery. SAP will perform availability check for all items in the sales order. a block will be imposed on the delivery order. This is to safeguard the change of customer’s credit limit status from the time of sales order to the delivery order. When the sales order is saved. different criteria can be set for credit limit check. The availability check will allow the Sales Administrator to verify if the requested delivery date can be met or a new delivery date is to be proposed. if the 19 . However.doc Final Page 19 of 33 Date of last change: 7/7/2011 will be weighed again to obtain the Berat Dengan Muatan (BDM). the Finance Department will clear the invoice against incoming payment received.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. With this posting. As in sales order processing. No further processing of the delivery order is possible until the Credit Representative has released the credit limit block. A printout of the Gate Pass is given to the transporter for security clearance before leaving the premises of Quality Polymer. When the sales order is free from the credit limit block or the credit limit block has been released by the Credit Representative. sales orders that have been approved might not be subject to checking during delivery order. Goods are issued as per the quantity difference between the BTM and BDM.2 BS130 Sales from Stock (Tote Tank) When a customer confirms a sale with Quality Polymer.1. Depending on the customer’s credit status. SAP performs a check on the customer’s credit limit.

When the billing document is generated in SAP. After picking is done. an accounting document is also recorded immediately in the customer accounts receivable.2.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. the Warehouse Personnel will update the delivery order with the confirmed quantity and post goods issue. No further processing of the delivery order is possible until the Credit Representative has released the credit limit block. 5. The Gate Pass will also be created. This Purchase Order will be subjected to three levels of approval.Indirect Material BS213 Procurement for Direct Consumption .000 > RM5. a block will be imposed on the delivery order. the Finance Department will clear the invoice against incoming payment received. Level 1 2.000 20 . a Purchase Order will be created in the SAP system.non stock items BS230 One-time Purchase Order BS250 Expedite Purchase Order/Late Delivery BS260 Vendor Evaluation 5. Level 2 < RM5. raw materials. The levels of approval is dependent on the Purchase Order amount as below: 1.2 Purchasing and Invoice Verification In addition to new business scenarios that are specific only to Quality Polymer. the following Purchasing and Invoice Verification business scenarios will also be adopted from NPM: • • • • • • • • • • • BS201 Maintenance of Consumption-Based Planning (CBP) BS203 Creation of Purchasing Info Record BS204 Changing of existing Purchasing Info Record BS209 Creating of new Vendor Master for Quality Polymer BS206 Changing of existing Vendor Master BS211 Procurement for Stock – Trading BS212 Procurement for Stock . also known as the Release Strategy in the SAP system. The Sales Administrator will only generate billing documents to the customer once the transporter has returned a copy of the delivery order to Quality Polymer. Please refer to BS147 Handling of Returnable Packaging for the return of the tote tank from the customer to Quality Polymer.000 – RM500. The Warehouse Personnel generates a list of delivery orders that are due for picking and prints the picking list. A printout of the Gate Pass is given to the transporter for security clearance before leaving the premises of Quality Polymer.1 BS215 Procurement for Stock – Raw Material When Quality Polymer determines a requirement to purchase items ie. With this posting.doc Final Page 20 of 33 Date of last change: 7/7/2011 customer does not pass the credit limit.

payment will be arranged by the Quality Polymer’s Finance Department to the Vendor. From the BL.2 BS233 Vendor Consignment of IBC tote This scenario refers to the management of IBC totes. Goods Receipt and the Vendor’s Invoice. Therefore it is important to record the vendor’s batch number during Goods Receipt as this will provide a cross reference between SAP batch number and the Vendor’s batch number. a Goods Receipt transaction will be performed in the system to denote the acceptance of goods into warehouse. Quality Polymer will fax a copy of the BL (Bill of Lading) to the IBC vendor. The IBC vendor will deliver to the Store in Quality Polymer and Goods Receipt can be performed in the system as non-valuated stock.3 Inventory Management In addition to new business scenarios that are specific only to Quality Polymer. which is one of the packaging materials used in Quality Polymer. Quality Polymer will then make payment to the IBC vendor. SAP generates an internal batch number.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. Upon shipping out the Finished Goods. 5. a hardcopy will be printed out and sent / faxed to the vendor.doc Final Page 21 of 33 Date of last change: 7/7/2011 3. When the vendor finally delivers the goods to Quality Polymer’s warehouse. When these IBC totes are being used up to pack Finished Goods. Level 3 > RM500. 5. a Transfer of Consignment Stock needs to be done by performing a Goods Issue transaction in the system valuated at the price charged by the IBC vendor. Otherwise. The invoice will be entered into a system. With this. whereby 3-way-matching of the quantity an amount will be done in the system by comparing the Purchase Order. Finance and the Warehouse. Vendors will usually delivers the goods with a copy of Delivery Order and Invoice attached. Variance Verification will need to be performed among the Quality Polymer’s Purchasing. For good that are batch managed. an accounting document will also be recorded in the system. If everything is found to be consistent.2. As and when there is a requirement from Production Department and there is a shortage of IBC totes. A Consignment Purchase Order will be created in the system. the Purchaser will communicate with the IBC vendor to order for an estimated quantity of IBC totes. 000 Upon approval of the Purchase Order. the IBC vendor will be able to determine the quantity of IBC totes that they will be invoicing Quality Polymer for. the following Inventory Management business scenarios will also be adopted from NPM: • • • • • BS271 Deletion of existing Material Master BS272 Development Material Master Maintenance BS275 Inventory Management of Storage Location BS276 Inventory Consumed for General Usage BS277 Vendor Return 21 .

With this. Purchasing and Sales view centrally created in NPM. 4.3. the Quality Polymer user will be informed of the Material Master number and other details via email or fax. they will need to fill up a ‘Material Master Creation form. for the Finished goods (FERT) and Semi-finished goods (HALB) only. The Basic and Classification views of a Material Master will then be created by the NPM Technical. In order to reflect that these tote tanks are unavailable for usage. the Quality Polymer user will have to perform a Goods Movement in the system to mark them as ‘blocked’. which will be sent via email or fax to the NPM’s Technical Department. whereby the StockFinished Goods Accounts will be debited and the Stock Adjustment-Finished Goods Accounts will be credited accordingly. 2. Upon successful creation of the Material Master.3. Likewise.3 BS298 Blocking of Tote tanks used for temporary storage This scenario will take care of Tote tanks that are sometimes used for temporary storage. information on that Material will be sent back again to NPM so that the Material Master creation can be completed by having the Accounting.1 BS273 Creation of Material Master for Quality Polymer When Quality Polymer has a requirement to create a new Material Master in the system. Finally. the Standard Costing will be run in the system to obtain the value of the FERT and HALB concerned.2 BS297 Stock Adjustment during Tanker Exit This scenario takes place when the weight of a tanker that is about to leave Quality Polymer is found to be different from what was available in the storage tank as indicated in SAP. the difference will be adjusted by performing a Goods Movement 702 for Goods Issue out of the warehouse in the system. 22 . whereby the Stock Adjustment-Finished Accounts will be debited and the StockFinished Goods Accounts will be credited for the difference in amount accordingly.doc Final Page 22 of 33 Date of last change: 7/7/2011 • • • • • • BS278 Inventory Disposal BS280 Waste Treatment Processing BS282 Physical Stock Take BS290 Warehouse Housekeeping . Now. If more stock has been detected. if less stock has been detected upon tanker exit. 2. 5. the Quality Polymer user can proceed by extending the Material Master Production’s views (MRP 1. the Quality Polymer user is able to set up the BOM and Recipe (applicable to Finished and Semi-finished goods only). the difference will be adjusted by performing a Goods Movement 701 for Goods Receipt into the warehouse in the system. Forecasting and Work Schedule). Next.SLED Stock BS295 Write Off Stock Processing BS296 Inventory Disposal due to Operation Spillage During Loading 5. 3.3.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. Therefore. 5. adjustment has to be made by performing as follows: 1.

for each material to SAP. If the new delivery date of the raw material affects the customer promised date. The approved demand forecast will result in the production plan. MRP plans for all the materials in the plant. the Buyer has to reschedule the delivery date and inform the Production Planner.1 BS329 Planning by Production This Business Scenario caters for planning to be performed by the Production Department. that is. Production Department will check the feasibility of the production plan based on available capacity. The Buyer converts the planned order to a purchase requisition that can be converted to a purchase order at a later date. The system calculates the net requirement for all the materials based on the available quantity. one planned quantity split over time according to dates. the figures transferred to demand management will form the basis for production. Subsequently a monthly/weekly schedule is prepared. If there are any issues in capacity or demand.Make to Stock This business scenario caters for the make to stock (MTS) production planning for all the Finished goods/Semi-finished goods of Quality Polymer.4 Production Planning 5. After the production plan is finalized. The requirements will trigger planning of production for the next 12 months. The Production Department is responsible for forecasting all the finished materials with specific details. planned orders are created for both external procurement and internal production. 5. 5. or a number of planned independent requirements schedule lines. A monthly production plan is created for every material for the next 12 months. This forecast period can be flexible based on management decision.4. the requirement for each material is created for each finished material as “Planned Independent Requirements”. Market survey and past sales information will be used to forecast demand for each material for the purpose of planning the company’s future sales targets for the next 12 months. The Production Department can split this requirement into weekly or daily time buckets. During the MRP run. A “planned independent requirement “ contains one planned quantity and one date. For Make To Stock Production Planning.2 BS331 Production Planning . 23 . based on the selections in material master. there may be further fine-tuning of the plan. The raw material shortages from planned orders are found in the “Raw Material Shortage Report”. the Production Planner has to inform the Order Processing Department for necessary actions. If the vendor cannot meet the delivery date. The Raw Material Shortage Report has to be reviewed by the Purchasing Department for follow up with the vendor. In Demand Management. The Buyer issues the purchase order to the vendor and follows up with the vendor for delivery dates.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.doc Final Page 23 of 33 Date of last change: 7/7/2011 Therefore. the data is transferred to Demand Management by the Production Department manually. the user will be able to see that these tote tanks are blocked for usage upon executing a Stock Overview in the system.4.

The Production Planner needs to update the goods issue to the process order before confirming the process order. Capacity is checked at each work center. After all the materials are issued to the process order. goods movement is allowed for the process order. For backward scheduling. If materials are required from the warehouse. 5. If the raw materials are available. The following fields are specified on the initial screen during the process order creation: • Material no. the BOM has to be selected manually. This information will be used to calculate the actual production cost and variance during process order settlement in product costing. The user also checks the availability of raw materials. and now needs to be produced in an up scale quantity to verify the accuracy of the BOM and master recipe. If the user wants to use a different BOM. • • Production plant . the user has to specify the basic finish date of production. In forward scheduling.The semi finished or finished material. If sufficient capacity is not available. The Production Planner saves the process order and a process order number is generated. different process order types are defined for the Normal Order. Goods are issued as per the planned raw material quantity from the Production Storage Location to the process order. . The standard values used are machine hours and labor hours.doc Final Page 24 of 33 Date of last change: 7/7/2011 The Production Department creates the process orders or converts the planned orders based on the production plan. After the process order has been saved and released. for which the process order is to be created. a goods receipt is done for the process order and goods are transferred to the warehouse. 24 . Process order type . the user has to specify the basic start date of production. The quantity for this production type is generally less than 400 kg. Reprocessing. the process order can be released. The process instructions for each phase and operation are used to carry out each process step of the production. The user specifies the scheduled date of production for the semi finished and finished products.The plant in which the process orders needs to be executed or produced. After the goods are produced.3 BS352 Production Planning – Pilot Production for New Materials This business scenario caters to production planning of pilot production for new materials by Production Department.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.4. and whether the scheduling type is backward or forward scheduling. the Production Planner furnishes the material shifting requirement to warehouse to transfer materials to the Production Storage Location on the production floor. the actual usage of the resources for the process order is confirmed using the standard values and activity types defined in the master recipe of the product. the Production Department initiates production.The process order type distinguishes usage in Production. Pilot production is generally for new materials that has been tested in the lab. After production is completed. the Production Department reschedules the process order. Pilot Production and Development Item. The system chooses the first alternative BOM and default master recipe for the process order. For Quality Polymer.

After the goods are produced. Production Department runs desktop MRP for this material desktop. to the designated Production Storage Location.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. The canning balance is defined as the leftover loose material less than the standard packing size. Production Department creates the BOM and master recipe. 5.doc Final Page 25 of 33 Date of last change: 7/7/2011 Production Department of Quality Polymer receives requirement for small lot production. the actual usage of the resources for the process order is confirmed. the actual usage of the materials for the process order is confirmed 5. If the raw materials are available. Once the master data has been setup. Technical Department of NPM creates the material code for the material to be produced by Production Department of Quality Polymer in the system. 25 . The Production Department creates the process orders based on the production plan. Production Department uses this canning balance as a component in Process Order for the new demand. After the goods are produced. The system nets off the demand by the canning balance quantity. If the canning balance is available. the process order can be released.4. goods movement is allowed for the process order. Production Department receives the requirement for new demand in the form of sales forecast or sales order and checks if canning balance is available for this demand. based on the list. The Production Department initiates production after all the materials have been issued to the pilot reactor. an additional line is included for the canning balance as a component. a goods receipt is performed for the process order and goods are transferred to the warehouse. In the process order material list screen. After the process order has been saved and released.4. Warehouse will transfer all the materials. goods movement is allowed for the process order.5 BS347 Production Planning . The user specifies the scheduled date of production for the semi finished and finished products. generally less than 400kg.Canning Balance This business scenario caters for the consumption of canning balance in production.Reprocess Formula This business scenario caters for the following situations where the Technical Department evaluates the possibility of creating a reprocess formula to consume old stock: • • Re-use of slow moving stock Re-use of multiple batches of the same material returned by customer. When all the materials are issued to the process order. The user also checks the availability of raw materials. process order is created using a different process order type. the Production Department initiates production. After the process order has been saved and released.4 BS 353 Production Planning . and whether the scheduling type is backward or forward scheduling. Upon completion. The Production Department furnishes materials requirement list for the Process Order to Warehouse.

The alternative BOM is created together with a production version for “reprocessing”. If materials are required from the warehouse. Warehouse transfers goods to the Production Storage Location. The system proposes the first BOM by default. Goods are issued from the Production Storage Location to the process order. expired materials and the customer returned materials in the warehouse. The alternative BOM contains the returned material and other raw materials. the Production Planner furnishes the material staging requirement for warehouse to transfer materials to the Production Storage Location on the production floor. The user specifies the scheduled date of Production for the semi finished and finished products. Production Department creates alternative BOM for the reprocess material. The finish date in the process order are put far ahead in the future so that purchasing department should not procure the material for this process order. Production Department creates the process order based on the reprocess formula (alternate BOM). After all the materials are issued to the process order. If there is a requirement that can use the “reprocess” process order. 26 . goods movement is allowed for the process order. The user saves the process order without releasing it. and whether the scheduling type is backward or forward scheduling. Production Department will use the “reprocess” process order to meet the new demand. The user can manually change the components of the process order based on the requirement. the actual usage of the resources for the process order is confirmed. the Production Department initiates production. Upon completion.doc Final Page 26 of 33 Date of last change: 7/7/2011 Production Department reviews the stock report to identify slow moving materials. The old or returned stock is to be used before placing any new requirements. The Production Planner releases the process order. The alternative BOM may be used for all returned batches of the same material because there is not much difference in the components and quantity of the various batches.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. This triggers the requirement for Production Department to create Process Order with a different Order Type. Goods receipt is also done for the process order and goods are transferred to the warehouse. Production Department checks for new demand and also process orders with the process order type “reprocess”. After the process order has been saved and released. Warehouse checks the process order and identifies the old or returned stock to be used based on the process order type. The Production Department needs to create only one alternative BOM for all the batches. The user needs to manually select the “reprocess” production version to trigger the selection of the alternative BOM for reprocessing.

Once the process order has been saved and released.6 BS348 Production Planning – Assorted Materials Assorted materials are materials produced during production where the quality is not as per the required specification. Goods receipt is performed for the product and the stock is blocked.5 Financial Accounting • • • • • • • BS400 G/L Account Master Record BS401 Account Assignment Template BS403 Bank Master Data BS404 Treasury BS405 Petty Cash Processing BS406 Vendor Master for Creditors without PO BS407 Vendor Invoice with Credit Term (Non-Trade Related) 27 Quality Polymer will adopt the following Financial Accounting business scenarios from NPM: .4.9 5. The process order must be ‘Technically Completed’. After production is completed.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. Production Department needs to produce additional amount of common semi finished materials to facilitate production in terms of capacity utilization and meeting customer delivery dates. Production Department will confirm the process order till the operation where production was abandoned.8 5.7 BS351 Production Planning – Common Semi Finished Material A number of common semi finished materials are used in the production of finished materials.doc Final Page 27 of 33 Date of last change: 7/7/2011 5. the actual usage of the resources for the process order is confirmed. Upon completion. Production Department then creates the process order based on the production plan. goods movement is allowed for the process order. Production Department initiates production. 5. After all the materials are issued to the process order. Initially.4. This additional amount is known as “postponement”.4. After that. Production Department identifies common semi finished materials with low stock level by comparing available stock with the stock level predefined in the material master. Production Department reviews the stock report for semi-finished materials in the warehouse. 5. a goods receipt is done for the process order and goods are transferred to the warehouse.4.

doc Final Page 28 of 33 Date of last change: 7/7/2011 • • • • • • • • • • • • • BS408 Vendor Invoice with Cash Term (Non-Trade Related) BS409 Credit Note/Debit Note from Creditor (Non-Trade Related) BS410 Credit Note/Debit Note to Creditor (Non-Trade Related) BS411 Creation Of Customer Master for Staff BS421 Creation & Revision Of Customer Credit Account BS413 Credit Note/Debit Note from Debtor (Non-Trade Related) BS414 Credit Note/Debit Note to Debtor (Non-Trade Related) BS419 Advance Payment From Customer BS420 Advance Payment To Vendor BS415 Staff Loan BS416 Staff Advances BS417 Month-End Processing BS418 Year-End Processing 5.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.6 Controlling • • • • • • • • • • • • • • BS470 Cost Element Master Data BS471 Cost Center Master Data BS472 Cost Center Planning BS474 Cost Center Distribution BS485 Cost Center Planning .2nd Half Year Revise Budget BS475 Profit Center Master Data BS476 Profit Center Planning BS477 Internal Order for Vehicle Maintenance BS478 Internal Order for Marketing & Promotion BS480 Internal Order for Staff Expenses BS481 Standard Cost Estimate for Existing Product BS482 Standard Cost Simulation for New Product BS483 Settlement of Process Order BS484 Eventual Cost Calculation For Manufactured Material Quality Polymer will adopt the following Controlling business scenarios from NPM: 28 .

2 User Exits Numerous user exits were created during Project Cheetah.1. This exercise also serves as a training and confidence building for the users to familiarize themselves with SAP R/3. providing new pieces of information required in the new system and ensuring that existing information is up-to-date.1 Interfaces Two interfaces created for Project Cheetah will be introduced to Quality Polymer: 1. The sources of data must be cleaned to ensure that the correct information is later entered to SAP. Preparation for conversion is required during the implementation because it is important to start the new system with clean and relevant data that is not obsolete. These data will be classified as master or transaction files depending on the type of data converted. (A summary of these conversion data objects is found in the Appendix). the user will manually enter all conversion objects into the Production System.1.1 Conversion strategy Due to the low volume master data in Quality Polymer. 7 Conversion Approach Conversion will be carried out to ensure that Quality Polymer will have all the relevant information when the system goes live. master data will be converted before transaction data. 7. In general. Gate Pass Enhancements 6. The latter is performed immediately after the period closing of the legacy system and for the new SAP system to run live at the start of the 29 . This entails removal of duplicate records (like customer or vendor master records).doc Final Page 29 of 33 Date of last change: 7/7/2011 6 Interfaces and Enhancements 6.3 Actual Conversion Conversion of “live” data to SAP will occur during the Final Preparation phase. The approach used in data conversion will be as follows: • • • Define conversion strategy Identify and clean data for conversion Perform the actual conversion 7. with the exception of GL accounts and its open items. This responsibility rests solely on NPM team leaders and Quality Polymer end-users. All these user exits will be reviewed to cater for the rollout of Quality Polymer.2 Conversion Data Preparation Data to be converted is identified with object description and the total number of records is estimated.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. Sales Document Approval Transaction 2. the users input the data into the Quality System to verify the data integrity and accuracy. data consolidation. Prior to the manual entry to the Production System. 7.

The Team Leaders will work closely with Quality Polymer management to determine the different level of access that each user can have. Quality Polymer will adopt the Authorization Policy that is in placed for NPM. An additional server has been setup for the role of testing by consultants and team leaders. One way of minimizing transaction data to be converted is to ensure that all open items are settled before the conversion process. This authorization profiles will enable the users to have a control environment on their access level in terms of the different transaction codes and organization structure that each user can have access to.1 System Environment Current NPM system landscape consists of three physical servers. This server will be a copy of the Production Server Client 300. each housing a single client as illustrated below • • • Development Server – Client 140 Quality System Server – Client 300 Production Server – Client 300 For Quality Polymer rollout. 30 . 8 Authorizations New Authorization Profiles will be setup for all Quality Polymer users. The diagram below depicts the system landscape of existing NPM servers and the additional server for Quality Polymer rollout implementation. Prior to go-live date. all entered data must be verified in the production system to ensure completeness and consistency. Prototype will take place in the Additional Server while training and user acceptance test will be conducted in Quality System Server Client 300.doc Final Page 30 of 33 Date of last change: 7/7/2011 period (month). all configurations will be set in the Development Server.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. 9 System Landscape 9.

1. all configurations settings will still be done in Development Server Client 140. This approach aims to empower key users to take NPM team leader will review the training materials prepared during Project Cheetah. The consultants will manually transport it to the Quality Polymer Playground Server. The key users will be exposed to NPM live environment on their respective module. At the end of every week.19: NPM System Landscape & Additional Server for Quality Polymer Rollout 9. 31 . A training plan will be draft out to ensure that different key users will have allocated slot to sit with NPM users for some SAP hands-on transaction. 10 Training Team Leader will conduct training for Quality Polymer Key Users throughout the life cycle of the Rollout Implementation. a consolidated list of change request from each module will be submitted to the Basis consultant to move the configuration to the Quality System Server Client 300. all the modules weekly change request will be transported to the Production Server Client 300. As depict in Figure 9. Prior to system go-live for Quality Polymer.doc Final Page 31 of 33 Date of last change: 7/7/2011 Current NPM System Landscape Development Server (Client 140) Additional Server For QP Rollout Playground Quality System Server (Client 300) Production Server (Client 300) Transport Route Figure 9.1.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.2 Transport Strategies The transport strategy for Quality Polymer Rollout has to be monitored manually.1.. Team leaders will train end-users during the Realization Phase using training material that has been fine-tuned.

recording the results of these tests. Testing will cover identification of the following: • • Test data Users for UAT 11. User acceptance tests (UAT) will be conducted in Realization stage. all test results will be recorded and verified by the testers and team leaders. 11. Together with NPM team leaders. The detailed plan for UAT will be prepared during the Realization phase. Quality Polymer key users will be responsible to perform the entire testing with the guidance of ea consultants and NPM team leaders. Upon successful testing of the system. Normally there are two sets of important data to be tested. In testing.doc Final Page 32 of 33 Date of last change: 7/7/2011 11 Testing Approach Testing covers the activities related to both scenarios and transactional testing on the system to ensure that the configuration settings are right.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566.1 Test data • • Core Business Scenarios data . confirming that the testing works and note the exceptions and finally signoff the system indicating acceptance of the system. namely.2 Testers (Users) for UAT Users to perform the User Acceptance Test will be identified during the early part of the Realization phase. conducting tests and documentation of the testing performed.A number of Nippon Paint core scenarios per company will be identified for testing Core Business Process data – The core business processes not included in the business scenarios item 1 above will be tested. 32 . ea consultants will also plan for the UAT. a big consideration will be given to the integration between SAP modules. The selected users have the responsibility of testing the system. users are to sign-off that they are willing to accept the new set of configuration. During the UAT. Therefore the testing must be completed and signed off by the testers. The testing approach will include test planning.

2 E.4 A.4 D.3 C.2 A.5 List of Conversion Objects Sales and Distribution Purchasing and Invoice Verification Inventory and Warehouse Management Production Planning Financial and Controlling Accounting 33 .3 E.3 B. B.3 A. A.Project: Organization: Title: Doc Ref: Version: SAP Roll Out Quality Polymer Business Blueprint 62417566. D.4 C.1 A.5 List of Reports Sales and Distribution Purchasing and Invoice Verification Inventory and Warehouse Management Production Planning Financial and Controlling Accounting D.5 Functional Requirements Sales and Distribution Purchasing and Invoice Verification Inventory and Warehouse Management Production Planning Financial and Controlling Accounting B.2 B.1 B.4 B.1 D.doc Final Page 33 of 33 Date of last change: 7/7/2011 Appendices A. E.4 E.3 D.5 To-Be Business Scenario Master List Sales and Distribution Purchasing and Invoice Verification Inventory and Warehouse Management Production Planning Financial and Controlling Accounting C.2 C.5 List of Forms Sales and Distribution Purchasing and Invoice Verification Inventory and Warehouse Management Production Planning Financial and Controlling Accounting E.1 E.2 D.1 C. C.

You're Reading a Free Preview

Download
scribd
/*********** DO NOT ALTER ANYTHING BELOW THIS LINE ! ************/ var s_code=s.t();if(s_code)document.write(s_code)//-->