Department Name :

Department Head :

Scope of Work:

Number of Resources:
Number of ERP Users:
Number of Resources for Manual activ
Any other Remarks/Reports

Department Structure:
PPC
Sudhindra Kulkarni

1. The objective of the process is to plan and ensure that the products are
manufactured in a controlled manner as per the customer purchase order
and/or contract (accepted configuration).
2. To meet on-time and quality customer delivery rate fluctuation linked to
customer demand variation by taking into account demonstrated capacity
in planning activities.
3. Develop priority planning to satisfy demand at each level of the
production management system.
4. Ensuring the right level of resources.

15
15
2
High Level Business Unit Process Flow Chart
[The below steps are just for example purpose..Please delete
them and then add your department specific steps]

Pull 12 months forecast sales order

Planning flow chart. report from ERP.

Inputs from Inputs

Develop Rolling 12 months Master
CU/
Production Schedule (MPS). Customer
demand
APM

CU/ Forecasted
APM A Resource planning as per AxMP-01.2.
sales order
(Infrastructure, Capacity, Manpower).
DUH/ Cutting tool plan per Business
AxMP-05.5plan
and Budget
APM. plan

DUH/ Business plan

and Budget
APM. B Capacity Planning.
plan

ERP/ MPS, routings

and CT, LT
data. required.
Map MPS vs Capacity
(MPS level).
ME
Consider demonstrated capacity.
MPS, capacity
PPC plan
Verification of machines planned
vs capacity required.
MPS, capacity
PPC plan

Plan matching with

requirement? MPS, capacity
PPC plan

Yes

Trigger for prepone/

postponement.

PPC MPS
C

B
PPC MPS

PPC Material Planning. MPRs’

SCM
Check inventory coverage SCM
for tracker
rolling 12 months.

SCM tracker
SCM and action
tracker.
Raise MPR for which material is
not ordered/MPR not raised.
 Raise MPR for which material is
not ordered/MPR not raised.
SCM tracker
SCM and action
tracker.

Procurement of material asDelay

per
PPC “Purchasing” process. management
tracker

Monthly review of material

PPC
planning with SCM team.MPS

No
On track?
3 months
PPC production
Yes plan.

Escalate.
Adaptive actions as AxMP-05.2.

PPC LoB/MRP
Follow AxMP-05.2 “Delay
Management” process.

D 3 months
PPC production
plan.

A C D

3 months
PPC Confirm next 3 months Production production
plan. plan.

Confirm Material requirement

plan (MRP) availability.
3 months
PPC production
plan.
Map MRP vs Capacity.
Use demonstrated capacity.

Confirm cutting tool

3 months
PPC production
availability
plan.

3 months
PPC No production
Acceptable? plan.

Yes

3 months
PPC production
Load for maximum demonstrated
plan
capacity.
 Load for maximum demonstrated
capacity.

Monthly
PPC scheduling
plan.
Trigger overtime, tactical
outsourcing, production process
changes request, etc., as needed.
Route card
PPC and shop
order.

Follow applicable process

procedure. Manufacturin
Process owners g Status in
ERP.

Mfg. of parts,
E and QA
Prod. clearance on
r/c, parts.

Monthly scheduling Plan.

Shift wise plan to shop weekly.
Stage
Process owners clearances in
ERP.
Release of route card and shop
order, production documentation
Monthly
PPC as per plan. production
plan

APM Manufacturing/outsourcing asMonthly

per sales
plan. plan

Monthly sales
APM plan
Monitor and track daily.

Clearance and update of mfg.

Monthly sales
APM stages on R/c and ERP. plan

Update sales tracker and Sales and

production tracker on daily basis.
Delay
management
APM and PPC trackers,
capacity plan,
etc.
On track?

Products
Follow AxMP-05.2 “Dela
cleared from
QAmanagement” process.
QA on r/c and
ERP.

Take adaptive actions as

per AxMP-05.2
Forecast,
Agreement
APM F with G
customers on
part numbers
 F Forecast, G
Agreement
APM with
customers on
part numbers

Line impacting
delivery dates?
Buffer stock
PPC and APM monitoring
tracker, LoB.

SCM and ERP FG inventory

Route Card Management

Inputs from Credit to stores.
Inputs

Monthly
PPC Monitoring
production of stock levels
plan
monthly basis as agreed w
customer.

As per contract?
Route card
PPC and shop
order release.

Present Buffer stock status

Route card MRM.
and shop
order,
material

Routecard Management
Route card
signed and
QA and stores Route card and shop order released and
stamped,
handover to stores. material.
R/C holding responsibility – Stores.

PPC Issue of material by stores.Production

plan.S/o.
Endorse traceability details on R/c,
Stamp and sign on r/c and s/o.

Inspection of material by QA.

Route card,
finished/
Endorse traceability details on r/c, s/o.
Prod. semi-finished
Stamp and sign on r/c and s/o.
product.
 Move material cleared by QA to card
Route
production WIP area. signed and
stamped,
Prod. R/C holding responsibility – Prod.
finished/
semi-finished
product.

Movement of material to work centers

based on scheduling plan.
R/C holding responsibility – Prod.

SCPO, parts,
In-process inspection as per theroute
defined
card
signed and
routings by QA inspectors.
SCM and QA
R/C holding responsibility –stamped
QA. for
previous
operations.

Move to subsequent operations after

each stage clearance.
R/C holding responsibility – Prod.
Processed
parts from
suppliers, DC,
SCM CoC, QA
documentati
A on, Invoice,
etc.

A
GRN
clearance,
route card
QA signed and
stamped for
Movement of material to suppliers after
RI, parts.
100% machining completion as per
routing.
R/C holding responsibility – Stores.

Route card,
Prod. parts.
Receipt of parts from suppliers. Raise
GRN, move and handover the original r/c
to receiving inspection.
Inspect and clear parts. FG parts
R/C holding responsibility –credited
QA. to
stores,
QA transactions
in ERP, r/c
signed and
stamped.
Move to subsequent operation if
applicable.
R/C holding responsibility – Prod.

Final inspection and credit parts to stores

along with necessary documentation
including accepted tags.
R/C holding responsibility – QA.

Preserve route card as per AxMP-010.5

“Record management” procedure.
R/C holding responsibility – QA.
 Basic Req.

Outputs / Control
Process Steps Resp. / Sup Documents method
12 months Monthly sales
PPC Engineer forecast
plan review
report.

PPC Master Monthly sales

Engineer/AP Production
per AxMP-01.2. M Schedule. plan review
ty, Manpower).
r AxMP-05.5 Resource Monthly sales
HODs’ planning. plan review

PPC/
Capacity plan Monthly sales
plan review
Planning. APM

MPS mapped
PPC Engineer with capacity Monthly sales
requirement plan review
apacity required. report.
level).
nstrated capacity.
MPS mapped
with capacity Monthly sales
PPC Engineer requirement plan review
report.
machines planned
y required. MPS mapped
with capacity
requirement Monthly sales
PPC Engineer report. plan review
Action list if
No any.
PPC
Engineer/SC Action Monthly sales
tracker plan review
M

gger for prepone/

postponement.
Monthly
PPC Engineer Material
LoB planning
/SCM review

Monthly
PPC Engineer Material
MPRs’. planning
/ME review

Monthly
SCM/
SCM tracker. Material
planning
ME review

Monthly
PPC/ SCM tracker Material
and action planning
tracker.
SCM review

Monthly
PPC/ SCM tracker Material
and action planning
tracker.
SCM review
 Delay
PPC and SCM management
tracker, SCM Sales review
tracker.

PPC/ Delay
management Sales review
meetings
SCM tracker.

PPC/ 3 months
Sales review
production meetings
APM plan.

Lob reflecting
3 months
PPC/ production Sales review
plan meetings
populated
with material
availability.

. SCM
AxMP-05.2.
Lob reflecting
3 months
production Sales review
PPC plan meetings
.2 “Delay populated
with material
process. availability.

Cutting tool
Prod/ plan
incorporated Sales review
into monthly meetings
plan/LoB.
SCM

Agreed 3
months
production
PPC and APM plan Sales review
published, meetings
Action
tracker, if
applicable.

Agreed 3
months
production
plan Sales review
PPC published, meetings
Action
tracker, if
applicable.

Relevant
requests such
PPC/ as Sales review
outsourcing, meetings
ECRs’,
overtime, etc.
SCM
Concerned Relevant Sales review
Process records meetings
owners applicable.

Sales and
PPC/ Monthly Production
scheduling
review
plan.
Prod. meetings
 Route card Sales and
and shop Production
PPC orders
review
released for meetings
manufacture.

Route cards
Prod and Sales and
updated for
SCM/ Production
manufacturin review
g stages, meetings
products.
QA

PPC/ Sales and

Sales tracker Production
updated,
Prod, QA and Action list. review
SCM meetings

Route cards
updated for
manufacturin Sales and
g stages, Production
Prod and QA products, review
stage meetings
clearances in
ERP.

Sales and
Sales tracker Production
PPC updated, review
Action list. meetings

Sales and
Sales tracker Production
PPC updated, review
Action list. meetings

Delay
management Sales review
PPC meetings
tracker.
Concerned Delay Sales review
process management meetings
owners tracker.

Sales tracker, Sales review

PPC/ meetings
Delay
Process management Shop
owners tracker. Alert Meeting
PPC-F13

PPC/ Sales tracker,

Sales review
meetings
Delay
Process management
owners tracker.
Sales tracker
QA/ updated,

Delay
Follow AxMP-05.2 “Delay management
Sales review
management” process. tracker
meetings
updated.
PPC Products
credited to
stores with
Take adaptive actions as documents.
per AxMP-05.2

Buffer stock Sales review

G PPC monitoring
meetings
tracker.
 G
APM/ Buffer stock Sales review
monitoring meetings
tracker, LoB.

PPC
Line impacting
delivery dates? Buffer stock
APM/ monitoring Sales review
tracker, meetings
Recovery
plan, LoB.
PPC

Recovery Bufferasstock Sales review

PPC plan (LoB) per
status. meetings
AxMP-05.3 “Delay
Management” process.

CreditProcess
to stores. Outputs / Control
Steps Resp. / Sup Documents method

Hard copy of
Route card
and shop Sales review
Monitoring of stock levels
PPCon order and meetings.
monthly basis as agreed with released in
customer. ERP.

Material
released,
route card
As per contract? and shop
order Production
Stores updated with review
traceability meetings.
requirements
, signed and
Recovery planstamped
(LoB). on
r/c andplan
Include in 3 months s/o.
to build buffer stock.

Material
released,
Present Buffer stock status in route card
MRM. and shop
order Production
QA updated with review
traceability meetings.
requirements
, signed and
stamped on
r/c and s/o.

Physical
movement of Production
Prod. material to review
WIP area in meetings.
production.

Route card
updates,
clearances in Production
ERP and
Prod. review
physical
movement of meetings.
parts to work
centers.

Route card
updates,
clearances in Production
QA ERP, stamped review
meetings.
and signed
on r/c.
 Route card
updates,
clearances in
Production
ERP and
Prod. review
physical
movement of meetings.
parts to work
centers.

Route card
updates,
clearances in
ERP and
Stores and Sales review
Logistics/SCM physical
movement of meetings.
parts to
suppliers, DC
and SCPO.

Receipt of
finished parts
as per routing
from
Stores and suppliers, Sales review
QA GRN, ERP meetings.
clearances,
receiving
inspection
reports.

ERP
transactions Production
and
Prod. movement of review
meetings.
parts for
processing.

Credit of
finished parts
as per
routing, GRN, Sales review
QA ERP meetings.
clearances,
inspection
reports.

Records
QA Audits.
maintained.
 MRP & MPS
Capacity planning
WIP report
S. No. Steps in detail Process Person Responsible

1 We are having orders from Inter unit (ASM1-- Sales Order APM
>ASM2, ASM -->API, AAI-->ASM, ASYM-->ASM). Creation
Eventhogh all orders are in Navigen , we need to
enter the data in each unit again manual

2 MRP done in Manual MRP Process Pratap

3 Master Production Schedule and SIOP MPS Pratap

4 Capacity Planniing in not in place in ERP Capacity Planning Pratap

5 Cycle Time Comparsion witn respect to Estimation Cycle time Planners

-Standard time and Actual Monitoring Monitoring

6 Commitments to customer (Simulation Planning) PO Confirmation Pratap

7 Material Planning Material Coverage Pratap

8 Delay Triggering Customer Pratap

Commitment

9 Scheduling to Production Production Plan Pratap

10 Shop order release is manual Shop order Pratap

11 Rejection should be capture from operation wise Quality Deviation Devanand

12 Whenver rework generared-Rework order not Quality Deviation Pratap

generated

13 Updation to Sales order Customer APM

Commitment

14 WIP Valuation is not system generated and it is Inventory Valuation Pratap

done by manual
15 Physical Location and System location is Inventory Control Pratap
different/Assembly location to be created

16 Green Tag, Yellow tag and Red tag should generate Quality Control Devanand
from system.

17 Data integration with Scheduler is not smooth. Integration Amit

18 Access control is not there in ERP Inventory Control Pratap

19 Inventory Status Inventory Control Pratap

20 Duplication of work Productivity Pratap

21 Delivery challan Reversal Vendor Jagadeesh

Management

22 System Flow and Physical flow not matching ERP Integration Maria

23 Shelf life order should trigger with Consumption Purchase Order Vinod
and expiry date

24 Split Routecard Shop order Pratap

25 Acces Control for Inventory Location Inventory All

management

26 Re-Structuring of BOM and routing BOM and Routing All

27 Cycle time Validation Routing PPC,ME

28 Item Codes-Non Standard Item Master PPC,ME

29 FAI and DFAI Control/Delta FAI to be happen Change All

automated management

30 Delta FAI trigger with change details to CFT Change All

management
31 PO date change-Approval to all Purchase Order All

32 SO Closure automatic Shop order PPC

33 RM and BOI Mapping with respect to Demand and Reporting PPC

Production Plan

34 Customer Coverage mapping/Demand and Stock Reporting PPC

details to be covered at one page

35 COC in manual Productivity Vivek

36 DFAI SO should go 1st before Production SO Change CFT

management

37 Plan Vs Actual report Reporting PPC

38 Daily plan for deburring,API, Assembly,Special Scheduling PPC

Process etc../Daily mail for Deburr,QA to CFT

39 Bulk-RM Sizes should be there in system Masterdata PPC

40 End bits should not be taken for RM Ordering MPS PPC

41 Double Inventory avoiided Inventory Control CFT

42 Requirement to be plotted against RM BOI SLI Inventory Control CFT

43 Operation wise Posting issue-Stage wise control Production CFT

confirmation

44 SO cannot release without mastering to data Sales order control CFT

45 FIFO at RM, WIP, FG etc.. Inventory Control CFT

46 Seralization to be happen automated (SO, DC, FG, Lot Control PPC

Shipment)
47 Open SCPO to be happen Purchase Order PPC

48 Rework Process (Rework Order , Rework PO) Rework Handling PPC

automated

49 Assembly SO not be launched unless child parts are SO Control PPC

not there

50 Customer PO number to be updated on DC, Regulatory PPC

Assembly RC

51 RM data before GRN to be available Inventory Control PPC

52 Identification of Class 1 Part in Routecard Traceability PPC

53 Identification of Premium or AOG part in RC Traceability PPC

54 Auto lot number updation Traceability PPC

55 FG,CP, Spare part identification in RC Traceability PPC

56 No inventory credit without input material Inventory Control PPC

consumption

57 Bulk RM Sizes in System (Balance size also) Inventory Control PPC

58 Auto updation on demand changes in firm zone Customer APM

Commitment

59 Sales tracker in system Customer CFT

Commitment

60 Scrap disposition in system (Inventory to be Inventory Control Stores

removed from System)

61 Auto trigger on the status where it increases more Delay management CFT
than L/T /Trigger for deviation in
Production,Vendor,Deburr,QA

62 Realtime data capturing for Production actuals Production Control Production

63 Auto priority for NCR Closure NC Management Quality

64 SO aging with Status/location of Shop order WIP Control PPC

(Balance qty)

65 Auto GRN updation in SO (Split the SO as per Shop order control PPC
Heatnumber) for indentified qty (Ex: 50pcs launch-
SO has to split automatically based on heatnumber
in system
66 Consume RM based on Heatnumber available in RC Inventory Control Stored

67 Daily FG,SMFG-Auto mail generation Reporting CFT

68 ECR creation to be done Change CFT

management

69 OTIF Trend Reporting CFT

70 Secondary Constraints (Availability-Occupied) Scheduling PPC

71 FAI Scheduled hours-Actual Hours (Project Plan Vs Production Control PPC

Actual)

72 Turnback details at workcenter ( Deburr, QA) Production Control CFT

73 Scrap/Rework ratio -Historical data Production Control PPC

74 Batch size for Production Lot MPS PPC

75 SO Launch with Scrap/rework ratio MPS PPC

76 Capacity calculation with historical OEE and MPS PPC

Standard OEE

77 Partial Output decision making MPS PPC

78 Child part standard cost to be updated WIP Control Finance/APM

automatically
79 Throughput time for each part Customer PPC
Commitment

80 RM and BOI Procurement leadtime Procurement SCM

81 Part-Machine Matrix to be controlled (Routing to be Scheduling PPC

correct)

82 Set-up time and Quality inspection time in Scheduling PPC

production Plan

83 PM Schedule should be there in plan Scheduling PPC

84 FG Build plan logic (Absolute or based on Demand MPS PPC

or changes based on scenario)

85 Identification of Outsourced Orders SO Control PPC

Type of Activity: Type of Data Pain Points, if any
Manual /
ERP System
Manual Inter Unit Order Inter unit order need to be enter manually-It need to be
updated by System (Ex: Night batch, Import Data mode
etc…)

Manual Demand, Stock, Current System doesn't support MRP. System should run
WIP,PO,PR MRP automatically (Family, Customer, Part level etc..)

Manual Demand, Stock, MPS is manual and it need to be done automated for
WIP,PO,PR 18months. SIOP not in place and it should generate
Considering RM, Capacity in Plance

Manual Routing, BOM, MPS, Capacity planning is manual . It need to be brought

through system (Capacity Planning includes-Machine ,
Manpower, Workcenterload, Vendor Load etc..)
Manual Routing No Real time Comparion for Estimation Vs Standard Vs
Actual-It Impacting Capacity Planning and Customer
commitments

Manual PO Whenever PO Comes, we can not able to commit the

shipment date to customer

Manual PO, Inventory Material Planning, PR Creation , PO Creation is manual. It

need to changes based on demand varies. It should cover
deterministic Planning and Consumption based Planning .

Manual PO,SO, WIP Whenver there is a delay in Material, production etc..

Triggering will not be there in system to make contigency
plan.

Manual WIP, Production Pllan Production Plan and Actual should be through system and
realtime.

Manual SO,RC Whenever Planned order converted to Production order,

SO and RC has to be printed automatically and it should
consider RM heatnumber and FIFO in Stores
Manual SO,RC,Inventory Currently any rejection is not reflecting at next stage.

Manual SO,RC,Inventory Whenver rework generated-Rework order not created and

it is not linked to main SO

Manual SO Based on production actual, updation to sales order should

happen automatically.

Manual WIP System does not calculate the WIP valuation automatically.
And it also doesn't tell about planned cost and actual cost
at WIP
ERP System WIP Parts physically credited to store and system tells at WIP
and Vice versa.

Manual Quality Based on the acceptence, all quality tags should come
from system and not manual-currently manual

Manual Demand, Stock, Data integration with other scheduler to be smooth and
WIP,PO,PR easy data transfer in both way.

ERP System There is no access control in ERP based on function wise.

(any one can release PO, SO,RC, QA Clearance etc…)

ERP System Stock, WIP Planner not getting realtime WIP which is impacting the
decision making

ERP System PO, DC , Invoice There are many duplication of work in ERP.(GRN Creation
for Interunit DC, PO etc..)

ERP System DC We create the DC for "X" vendor and send the parts to "X"
vendor subcontracting. But "X" denies the parts due to his
load etc… In this we cannot reverse the DC and send it to
another vendor

ERP System Flow of Information Parts physically goes to store , but shows in WIP and Vice
Versa

ERP System MRP,PO The material which are having Shelflife,PR should generate
based on Expiry date and Min Max Stock

ERP System Shop order,Routing Whenever we need to create SO to be split because of

various reason-system should support based on stage we
need to split

ERP System Access Control Currently anybody can move inventory from any location
to any location

ERP System BOM, Routing Current BOM and Routing is not operation wise -stage
wise. Which is impacting the inventory control and WIP
Control

ERP System SO,Routing, Master System should record the average actual cycle time /month
wise and populate the same in routing file

ERP System Item Card Current item codes have duplication( Same material
-procuring at 3 different codes) causing inventory variation

ERP System Item Whenever the MO revised, system should trigger DFAI
Card,BOM,Routing automatically in System and to be printed on SO. DFAI SO
should prioritize in Planning. DFAI SO list with change
details to be avaialble in System
ERP System Item Whenver Delta FAI production order generated, alert mail
Card,BOM,Routing should go to CFT.
ERP System PO Whenever SCM revised PO date(Deviation to PR date),
change content should go to Indenter.

ERP System SO Order When SO Released qty credited to FG Stock, SO has to

close automatically

ERP System Demand, Stock, We need a report for the visibilty for coverage of Parts
WIP,PO,PR against demand and Production

ERP System Demand, Stock, We need a report for the visibilty for Status of Demand
WIP,PO,PR (FG Stock, WIP, RM Coverage etc..)

ERP System Sales Order, GRN, RC COC is manual process. We need automated.

ERP System Configuration data Whenever part has revised, Revised parts Production order
should process 1st and then subsequent production order

ERP System Scheduling, Production Plan Vs Actual report to be generated and automail should
Actual go from system.

ERP System Scheduling, Production Auto generated plan to deburring, QA, vendor and Stores
Actual for their function

ERP System GRN Whenver we have bulk material in system,Size of bulk

sheet should be there in system

ERP System Stock, WIP End bits identified for disposal should not be taken for RM
Ordering

ERP System Stock, WIP Double inventory should not get generated for any
production order.

ERP System Projection Projection of RM to be made available against each item

ERP System Production actual Production confirmation should happen against operation
wise

ERP System Sales Order, Production Series production Order should not release before
order mastering the data

ERP System Stock Inventory Should consume based on FIFO at all levels

ERP System Master data Serialized parts-Seriolization should happen automatically

and it should be appear at all stages
ERP System Subcontracting Order Open SCPO should happen against the part.

ERP System Production order, Rework Production order and Rework Purchase order
Purchase order should happen automatically

ERP System Production Order Assembly order should not be launched unless we have
child parts in stock

ERP System Production order, Customer PO number to be appear on Delivery challan and
Purchase order assembly order.

ERP System Purchase Order Transit Inventory details should be there in system (ASN to
be updated in system)

Manual Production Order card Production order card should have visibility that part is
Class-1 Part.

Manual Production Order card Whenever we have launched as AOG or Premium, System
should trigger in System and also Routecard as critical

ERP System Production order, Lot number to update auto for all parts
Purchase order

ERP System Production Order card There should be identification for FG,CP, Spare routecard.

ERP System Production order, No Inventory credit without input material consumption.
Purchase order However there should be provision for Positive re call.

ERP System Stock Whenver partial bulk material is partially used, mandatory
field to update the balance size also.

ERP System Sales Order Whenever demand updates in firm zone, there should be
alert communication to CFT

ERP System Sales Order, Production Sales tracker to be reviewed through System
order,

ERP System Stock Whenver any part declared as scrap and physical
disposition of scrap made (Scrap sales), Inventory to be
removed from system.

ERP System Production Order Whenevr any production order delayed at any stage more
than planned, there should be trigger in System for
delayed stage

ERP System Production Order Realtime update of Production actual

ERP System NC Data Based customer due date, auto priority should set for NC
Closure

ERP System WIP Data Production order aging data with status of parts.

ERP System GRN Details Auto updation of SO Launching based on heatnumber

available

ERP System GRN Details Consume RM based on heatnumber availbale in RC

ERP System FG,SMFG Auto reporting daily production credit to store/FG

ERP System Master data ECR to be filled throgh system and monitored via system

ERP System Sales order Actual OTIF and Projected OTIF to be get from system

ERP System Secondary Constraints Based on Scheduling-availability of Seconday constraints

(Fixture /Vacuum bed etc) and its load level

ERP System Production Actual Planned Vs Actual usage of Machine hours for FAI

ERP System NC Data Turnback at each workcenter to be monitored

ERP System NC Data Historical data of Scrap ratio / Rework ratio of parts

ERP System Production Order/Sales Production should plan based on batch size of Production
Order

ERP System Production Order/Sales Production should plan based on Scrap/Rework ratio
Order,NC Data

ERP System BOM, Routing,MPS Capacity to be calculated based on actual OEE and
Standard OEE

ERP System Production order Partial inventory should not be made for workcenter

ERP System Sales Order BD has to maintain standard cost of Child parts and its
actual cost to be monitired
ERP System BOM,Routing Standard and actual through put time each time should be
made in System.

ERP System Master data Varaiable leadtime wrt Vendor and part should be
available

ERP System Routing,Production Machine scheduling should happen based on available

routing and machine matrix (Resource group)

ERP System Routing,Production Set-up time and Inspection time should be consider in
scheduling

ERP System Routing,Production Machine scheduling should consider PM Plan also

ERP System Routing,Production MPS should run based on fgbuild plan of various situation
(Absolute number, Based on demand, etc…)

ERP System Production Order Outsourced orders to be identified by stores team, so that
RM can be sent against these orders to vendor.
SAP Team comments Remarks

Need more information.

SAP Standard

SAP Standard

SAP Standard

SAP Standard During confirmation user to enter actual

time taken.

Other Module SD

SAP Standard

Need more information.

SAP Standard

SAP Standard

SAP Standard

SAP Standard

SAP Standard Once the production order is completed the

stock will be posted to SO inventory is it is
MTO process.

SAP Standard
SAP Standard

Need more information.

SAP Standard

SAP Standard

SAP Standard

SAP Standard Do not compare your Legacy sytem with

SAP. Work on process.

SAP Standard

SAP Standard This is your LEGACY issue.

SAP Standard Unless stock is disposed MRP will not

generate new PR. Or you have move to a
quarantine Storage location.

Need more information.

SAP Standard

SAP Standard

Need more information.

SAP Standard Master Data discipline

Need more information.

Need more information.

Other Module MM

SAP Standard Possible in Planning. SO will be closed upon

goods delivery.

SAP Standard

SAP Standard

WRICEF COC Form to be developed.

Need more information.

SAP Standard Standard report. To be run with various

input parameters by MRP controllers.

SAP Standard

SAP Standard Material Number.

SAP Standard

SAP Standard

SAP Standard

SAP Standard

Need more information.

SAP Standard

SAP Standard
SAP Standard Not Possible in case of External processing.
If it is Material subcon You may create
manually.

SAP Standard Rework of production order is standard. For

Rework purchae order, reach out to
Materials management.

SAP Standard

Need more information.

Other Module MM

SAP Standard Master Data to be maintained

Need more information.

SAP Standard

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SAP Standard Contradictory to Sl no 49.

Need more information.

Need more information.

Other Module SD

SAP Standard

WRICEF There are reports to monitor. Mail triggering

may an enhancement.

SAP Standard
Need more information.

SAP Standard

WRICEF Enhancement.

SAP Standard

SAP Standard Standard report. To be run with various

input parameters by MRP controllers.

Need more information.

Need more information.

SAP Standard Capacity evaluation and levelling by planner.

Need more information.

Need more information.

Need more information.

SAP Standard Master data

SAP Standard Master data

Need more information.

Need more information.

Other Module FICO

SAP Standard

SAP Standard Master Data

SAP Standard

SAP Standard

SAP Standard Capacity evaluation and levelling by planner.

SAP Standard

Other Module MM
 Remedy

Inter Plant transfers

MRP Run

MPS Run

Capacity planning to be done

- Proper cycle times &
Routings

Capacity planning to be done

- Proper cycle times &
Routings

MPS Run

MRP Run

MRP Run-Exception report

Prod data maintainance

Operation wise Confirmation

- SCRAP Data

Rework order Process

WIP Valuation -Stage wise

 To be checked during
configuration -Process flow

Access control to be defined

WIP Reporting

Inter unit transfers

Subcon process definition

To be checked during
configuration -Process flow

Automatic reorder Point

Planning

Access control to be defined

Detailed BOM- No milestone

confirmations

Cycle time Validation

Standard Item codes to be

created -No duplications

Flowdown of Engg. Change

Mgt.-to RC & SO

Flowdown of Engg. Change

Mgt. to CFT
 PO Exception report

Automatic TECO

Material Coverage Report-

(Wrt Cust Demand & Prod.
Plan)

Flowdown of Engg. Change

Mgt.-to RC & SO &
prioritisation

Desc. of Bulk size against a

bulk material

Define stock levels for bulk

materials for consideration
for RM Ordering

No. duplication of
confirmations

Material Coverage Report-

(Wrt Cust Demand & Prod.
Plan)

Operation Wise confirmation

Classification FAI & PROD

orders

FIFO based Transactions

Based on launching -
Serialisation to be updated
 Blanket SCPO

Rework order Process

Type of part - Prod. Order

related

Type of part - Prod. Order

related

Operation wise Confirmation

Chk. Before confirmation

Desc. of Bulk size against a

bulk material

Operation wise Confirmation

Barcoding System configured

with SAP
 WIP Report

Based on RM Heat no. Prod.

Should be updated

Transaction

FG credit report

OTIF calculation from SAP

Capacity utilisation analysis

Scrap & Rework rates

Safety margin considering

Scrap ratios

Capacity planning

Costing
MPS based on FG build plan

Some Customization in
System OR Give SO of
different colour
 Requirements
1) Sales Order data - Firm & FCST (12 Mnths & 18 Mnths)
2) MPS & MRP
3) Capacity Planning
4) Shop Scheduling
5) WIP valuation
6) Transaction Control
No. of Machines 52 1 Serration