QM BBP CPP

BUSINESS BLUE PRINT
QUALITY MANAGEMENT
POWER PLANT
GOLD STONE CEMENT LIMITED
SAP Implementation Partner
Version 1.1
Prepared By: Debasish Ghosh

Business Blue Print Material Management
Gold Stone Cement Limited August, 2019
Sign-off /Approval
Name of team members Organization/Business Unit Signature
SGN SOFTWARE PVT LTD 2019, All Rights Reserved. This document is proprietary to SGN Software Pvt. Ltd.
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by any means, nor may you modify or create derivative works based on the text of any file, or any part thereof for public, private or commercial
use, without prior written permission from Globalnest
EXECUTIVE SUMMURY
Goldstone Cements Limited is a public limited company.
Goldstone Cements Limited was incorporated on 26 December, 2007. The registered office of
the company is at VILL MUSIANG LAMARE (OLD), KHLIEHRIAT, KHLIEHRIAT, and Meghalaya.
BUISNESS BLUEPRINT OVERVIEW

This document summarizes the findings of the SGN consulting team and GSCL Team, with
respects to SAP processes to be implemented in GSCL.
Following activities were carried out during different phases of the project.
Business Process Mapping
GAP Analysis
The information was gathered through above activities carried out during different phases of
projects i.e. reviews of business processes, business procedures, documentation and relevant
reports
The purpose of Business Blueprint document is to prepare to move forward with the
implementation of GSCL's SAP S4 HANA system. At the conclusion of the blueprint, SGN
consultants will determine the SAP functionality required to run the GSCL business.
The Blueprint and its associated appendices present a summarized perspective of all functional
business processes that will be implemented. As such, the Blueprint document will serve from
this point forward the dual role of both official project scope as well as system acceptance
criteria.
The body of this document describes the organizational structure, Master Data, and S4 HANA
functional process flows to be implemented at GSCL. Generally, requirements that can be met
using standard S4 HANA functionality through routine configuration tasks are not explicitly
documented. However, certain key requirements are explicitly identified and summarized to
highlight their importance to GSCL and to document the approach proposed to meet the
requirement.
One section of the document summarizes identified gaps. The project team has discussed this
list with agreement on the approach going forward. Acceptable approaches may require:

Additional programming or technical effort.
Recognition and acceptance of procedural changes ("Workarounds") using standard S4 HANA

Additional resource commitment.
Simply the recognition and acceptance of a limitation – meaning, the recognition and
acceptance of a product gap, arising due to the non-availability of the feature in the SAP
software.
Other section of the document summarizes Value SAP Q&A on Organization Structure, Master
Data and
Business Processes. These were used as per Value SAP Methodology to discuss the GSCL
requirements in detail.
The Blueprint reiterates the S4 HANA organizational structures that have been identified and
will serve as the basis for the initial configuration activities. No significant configuration and
customization choices have been identified that will prevent the future implementation of
additional capabilities within the S4 HANA environment. The Logistics Information Systems is
being configured with reference to the Journey Cycle. Accordingly the transaction data is
stored, updated and retrieved by the system on the basis of monthly Calendar defined for a
specific financial year. In future if the business process changes and GSCL chooses to follow the
Calendar Year concept in place of Calendar, the system stores, updates and retrieves the data
on the basis of the Calendar Year. The information gathered and documented in the Blueprint is
sufficient for the team to go forward into the Realization phase. However, it is critical that both
the SGN and GSCL team agree on the scope of the project as presented in this document.
Acceptance by both teams is required to move the project into the next phase.

Contents
EXECUTIVE SUMMURY.................................................................................................................................3
BUISNESS BLUEPRINT OVERVIEW................................................................................................................3
1.Existing Materials Quality checking..........................................................................................................5
1.1 RAW MATERIAL :................................................................................................................................5
1.2 IN-PROCESS MATERIAL :.....................................................................................................................5
2.Explanations of Functions and Events.......................................................................................................5
3.Organizational Considerations..................................................................................................................6
4.Process Flow Diagram...............................................................................................................................6
Diagram 1 – Quality Inspection for Incoming materials...........................................................................6
Diagram 2 – Quality Inspection for In-process materials.........................................................................7
5.Changes to Existing Organization Processes.............................................................................................8
6.Description of Improvements...................................................................................................................8
7.Solution in SAP.........................................................................................................................................9
8.Description of Functional Deficits...........................................................................................................12
9.Integration Considerations.....................................................................................................................12
1.Existing Materials Quality checking
1.1 RAW MATERIAL :

All incoming raw materials quality is checked. Name of the materials and their quality checking
parameter are described below.
Raw Coal-Moisture and ash analysis. Sample is collected shift wise
Raw water-Quality analysis
Soft water-Quality analysis, sample is collected Season wise
Moslate-Quality analysis, sample is collected Season wise, QC done before GRN.
1.2 IN-PROCESS MATERIAL :

DM Water-Qc analysis is done
Crushing coal-Qc analysis is done
*Calibration is done as per BIS requirement.
2.Explanations of Functions and Events
The following will trigger quality inspection process:
Issues of Goods Receipt Notes (GRN)
Process Order Releases
Ad-hoc decision by management to inspect materials (e.g. to re-inspect certain materials)
3.Organizational Considerations
The following are the organizational elements required for production.
 Plant
4.Process Flow Diagram

Diagram 1 – Quality Inspection for Incoming materials
Diagram 2 – Quality Inspection for In-process materials
5.Changes to Existing Organization Processes
The inspection processes will be recorded in the SAP system with details of inspection.
Inspection record history will be maintained as a central repository in SAP.
6.Description of Improvements
The following improvements on quality inspection process will result from implementation of
SAP System:
Improved harmonisation and standardisation of quality inspection process activities across GSCL
Central repository of quality information records and histories. This will facilitate MIS report
generation and decision making (e.g. supply vendor selection).
Online real time transparency and visibility of quality information of inspected lots. This will
facilitate monitoring (including remote) of quality inspection activities.
Automatic generation of inspection lots by system based on quality master data information
specified. This will ensure that quality inspections proceed as scheduled/necessary.
Quality inspections results recording can trigger quality notifications (in cases of quality defects)
automatically to personnel pre-designated on SAP system to initiate appropriate corrective
actions.
In case of negative usage decision, SAP system has in-built controls to ensure that materials are
not subsequently used to increase stock of usable materials.
Increased efficiency of the quality inspection process as a result of minimal paper work.

7.Solution in SAP
The Quality Inspection component of SAP is used to determine whether raw materials, spares,
consumables, semi-finished goods and finished goods consistently meet defined quality
requirements. SAP system is used to perform quality inspection of a material or product, using
inspection specifications that have been predefined in the Inspection Plan (master data).
Although the inspection results only document the current quality of a material or product, this
information is also useful for quality control (for example, to optimize future processes).
Note: For materials other than raw material (Spares/consumables etc.) quality inspection will
be performed by the user department physically.
Quality inspection on SAP covers the following important functions:
Inspection Lot Creation:
Quality inspections are processed on the basis of Inspection Lots. An inspection lot is a request
to a plant to inspect a specific quantity of material or one or more pieces of equipment or
functional locations. An inspection lot is documented by an inspection lot record in the SAP
system. Details during inspection can be recorded against the inspection lot during results
recording in the form of long text (like truck and driver details of incoming material)
Inspection lots are created automatically or manually and are used to process different types of
inspections. Once an inspection lot has been created, materials can be inspected for quality,
inspection results and/or defects can be recorded, and inspection can be completed with a
usage decision.
Incoming inspection lots will automatically be created upon GRN of corresponding purchase
order. In-process inspection lots will automatically be created upon release of corresponding
process order.
Manual creation of inspection lot is possible in case of miscellaneous lots (lot origin 89). The
corresponding inspection types will need to be maintained in material master.
The following procedure will apply for manual creation of inspection lot:
Logistics>Quality management>Quality inspection>Inspection lot>Processing>Create

(Transaction Code: QA01)
Enter material
Enter plant
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or by any means, nor may you modify or create derivative works based on the text of any file, or any part thereof for public, private or
commercial use, without prior written permission from Globalnest

Enter origin
Results Recording:
Results Recording component is used to record and process results for inspection
characteristics. The inspection lot is the reference object in results recording.
The recorded inspection results document the quality of the inspected product, and provide the
basis for creating batch specifications and inspection certificates. The recorded result data can
also be used to make evaluations for quality control purposes.
The following procedure will apply to record results of inspection:
Logistics>Quality Management>Quality Inspection>Work list>Inspection>Change data

Enter the date range for inspection lot
Press F8 or click on execute
Select corresponding inspection lot and click on results recording
Defects Recording:
When an inspection lot is processed, inspection results can be recorded in the form of
characteristic values or defects. A defect is any property or attribute of a material, product or
process that does not meet the inspection characteristic specifications. Defects are recorded
with the help of predefined defect codes maintained in the inspection catalogs.
The need to record defects depends on the inspection material and the production process.
Defect records can serve as a valuable source of information for quality control in many
different production environments. Defect records can be analyzed and causes of defects
ascertained. Corrective and preventive actions may then be taken as appropriate. Defect
records allow improvement of quality and optimization of processes, while reducing costs and
increasing productivity.
Defect records can be created in the following ways:
The system can create defect records automatically during results recording.
Defect records can be created manually using the defects recording function.
Once a defect record has been created, it is saved in the system as a quality notification. A
quality notification is a system-supported problem message that can be used to process

different types of problems relating to poor-quality goods or services. Quality notifications are
processed in the Quality Notifications component. See ‘Business Blueprint Document, Quality
Notification’
The following procedure will apply to record defects:

Select corresponding inspection lot and click on create defect
Inspection Lot Completion
Upon completion of inspection and results recording, a decision is reached about the usage of
the inspected material. The usage decision specifies whether the materials inspected will be
accepted or rejected. With the Inspection Lot Completion component, controls are set for the
following:
Complete an inspection (inspection lot completion)
Make the usage decision for the inspection lot
Make the usage decision for every individual operation in an inspection lot
Perform stock postings for inspection lots created on the basis of goods movements (for
example, to unrestricted-use stock, blocked stock, scrap). In case of fuel scrap, scrapping
through the manual inspection lot will be done.
When a usage decision is made for an inspection lot, the following occur automatically in SAP:
A quality score is determined for the inspection lot
The quality level (inspection stages for the next inspection lot) is updated
The quality management information system is updated with statistical data
Automatic follow-up actions are triggered
The following procedure will apply to make a usage decision:



Select corresponding inspection lot and click on usage decision
There is another process in sap, which is called Source inspection. This method is using when
quality checking has done before GR. Source Inspection : Well, we need to understand the
concept and use of Source Inspection. The inspection lots created using this are not stock
relevant as the material is not inward thru GR at the point when these lots are triggered. Hence
the UD will not have a stock posting tab and if you want a stock posting tab then it becomes
normal inspection (01). Hope you understand the difference, also after results record & UD if
you decide not to have an inspection lot triggered @ GR then you need to update it in the Q-
Info record.
8.Description of Functional Deficits
 Quality certificate for Crushed Coal,Raw water,Dm water
9.Integration Considerations
Quality inspection will integrate with the following modules on SAP system:
Materials Management (MM) to manage materials and material stocks in the system and
process inspections for goods movements
Production Planning and Control (PP) to process inspections during production when production
orders or process orders are released
Plant Maintenance (PM) to process calibration inspections for equipment or functional locations
when maintenance orders are released
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BUSINESS BLUE PRINT

GOLD STONE CEMENT LIMITED

SAP Implementation Partner

Prepared By: Debasish Ghosh

Gold Stone Cement Limited August, 2019

Name of team members Organization/Business Unit Signature

Gold Stone Cement Limited August, 2019

BUISNESS BLUEPRINT OVERVIEW

Business Process Mapping

Gold Stone Cement Limited August, 2019

Recognition and acceptance of procedural changes ("Workarounds") using standard S4 HANA

Gold Stone Cement Limited August, 2019

BUISNESS BLUEPRINT OVERVIEW................................................................................................................3

1.Existing Materials Quality checking..........................................................................................................5

1.1 RAW MATERIAL :................................................................................................................................5

1.2 IN-PROCESS MATERIAL :.....................................................................................................................5

2.Explanations of Functions and Events.......................................................................................................5

4.Process Flow Diagram...............................................................................................................................6

Diagram 1 – Quality Inspection for Incoming materials...........................................................................6

Diagram 2 – Quality Inspection for In-process materials.........................................................................7

5.Changes to Existing Organization Processes.............................................................................................8

8.Description of Functional Deficits...........................................................................................................12

Gold Stone Cement Limited August, 2019

1.Existing Materials Quality checking

1.1 RAW MATERIAL :

Raw Coal-Moisture and ash analysis. Sample is collected shift wise

Raw water-Quality analysis

Soft water-Quality analysis, sample is collected Season wise

Moslate-Quality analysis, sample is collected Season wise, QC done before GRN.

1.2 IN-PROCESS MATERIAL :

Crushing coal-Qc analysis is done

*Calibration is done as per BIS requirement.

2.Explanations of Functions and Events

The following will trigger quality inspection process:

Issues of Goods Receipt Notes (GRN)

Process Order Releases

Ad-hoc decision by management to inspect materials (e.g. to re-inspect certain materials)

Gold Stone Cement Limited August, 2019

The following are the organizational elements required for production.

4.Process Flow Diagram

Gold Stone Cement Limited August, 2019

Diagram 2 – Quality Inspection for In-process materials

Gold Stone Cement Limited August, 2019

5.Changes to Existing Organization Processes

Inspection record history will be maintained as a central repository in SAP.

Gold Stone Cement Limited August, 2019

Quality inspection on SAP covers the following important functions:

Inspection Lot Creation:

Logistics>Quality management>Quality inspection>Inspection lot>Processing>Create

Gold Stone Cement Limited August, 2019

The following procedure will apply to record results of inspection:

Logistics>Quality Management>Quality Inspection>Work list>Inspection>Change data

Enter the date range for inspection lot

Press F8 or click on execute

Select corresponding inspection lot and click on results recording

Defect records can be created in the following ways:

Gold Stone Cement Limited August, 2019

The following procedure will apply to record defects:

Logistics>Quality Management>Quality Inspection>Work list>Inspection>Change data

Enter the date range for inspection lot

Press F8 or click on execute

Select corresponding inspection lot and click on create defect

Inspection Lot Completion