Process Definition Document Plan To Make - (Production Execution)

Table of content
PROCESS DEFINITION DOCUMENT PLAN

TO MAKE –(PRODUCTION EXECUTION)
Bhupesh S Samel
IBM INDIA PVT. LTD.
Project UNIFY
1 Document Control Information............................................................................................3

1.1 Document Details.......................................................................................................... 3
1.2 Revision Log.................................................................................................................. 3
1.3 Distribution List............................................................................................................. 3
1.4 Scope of this Document.................................................................................................3
1.5 Process Owners and Users.............................................................................................4
2 Master Scenario................................................................................................................ 5
3 Process Coverage...............................................................................................................5
4 Best Practices.................................................................................................................... 5
5 Proposed Solution.............................................................................................................. 5
5.1 Master Data.................................................................................................................. 5
5.2 Process Flow Diagram & Description...............................................................................6
5.2.1 Production Execution Process............................................................................................6
5.2.1.1 Planned Order.......................................................................................................................... 6
5.2.1.2 Production Order Type.............................................................................................................. 6
5.2.1.3 Material Availability Check........................................................................................................ 7
5.2.1.4 Lot Size & Order Type selection.................................................................................................. 7
5.2.1.5 Generation Batch & Serial number at Production Order Release:..................................................7
5.2.1.6 Printed Circuit Board Assembly (PCBA) Process...........................................................................8
5.2.1.7 Box Build Assembly Process....................................................................................................... 8
5.2.1.8 IC Programming Process............................................................................................................ 8
5.2.1.9 Job Work Assembly Process....................................................................................................... 8
5.2.1.10 Re-balling process................................................................................................................... 8
5.2.1.11 PTH Assembly Process.............................................................................................................. 8
5.2.1.12 Packaging Process.................................................................................................................... 8
5.2.1.13 Rework Process........................................................................................................................ 9
5.2.1.14 Cable Harness Process.............................................................................................................. 9
5.2.2 Production Manufacturing Flow for DLM:.......................................................................9
5.2.2.1 Conversion of Planned order production order..........................................................................10
5.2.2.2 Release of production order.................................................................................................... 10
5.2.2.3 Kit Collection.......................................................................................................................... 10
5.2.2.4 Production Execution & In process Inspection...........................................................................10
5.2.2.5 Good Receipt for the Production Order....................................................................................12
5.2.2.6 Final Quality Analysis (FQA) (Quality Inspection after Production)...............................................12
5.2.2.7 Technical Completion of Production Order................................................................................12
5.2.3 Production Manufacturing Flow for B&F:......................................................................13
5.2.3.3 Material Requisition against production order...........................................................................14
5.2.4 Production Manufacturing Flow for New Tech:..............................................................15
5.2.4.3 Material Requisition against production order...........................................................................17
Process Definition Document Page 1 of 21

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5.3 Current Challenges faced.............................................................................................17
5.4 WRICEF Objects........................................................................................................... 18
5.5 Automation Plan......................................................................................................... 18
6 Gaps.............................................................................................................................. 19
7 Future Roadmap.............................................................................................................. 19
8 Sign-off........................................................................................................................... 20

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1 Document Control Information

1.1 Document Details
Customer Cyient Ltd

Name
Document
4.2_P2M_ Production Execution_V2.0
Name
Project Name
Project UNIFY
1.2 Revision Log
Revision Change Description Author E-mail Release

Number Date
1.0 Initial Bhupesh S. Samel bhusamel@in.ibm.com 03.07.2018
1.1 Changes incorporated raised during Bhupesh S. Samel bhusamel@in.ibm.com 09.07.2018
P2M PDD walkthrough
1.2 Updated Sec 5.4 WRICEF based on Bhupesh S. Samel bhusamel@in.ibm.com 18.07.2018
review points
1.3 Updated Sec 5.4 WRICEF based on Bhupesh S. Samel bhusamel@in.ibm.com 31.07.2018
review points held on 30 JUL 2018
2.0 Final Version Bhupesh S. Samel bhusamel@in.ibm.com 03.08.2018
1.3 Distribution List
Sr. Name E-mail

No.
1 Core Team Members :
Sadananda Sadananda.Thimmaiah@cyient.com;
Nagendra M Nagendra.Mysore@cyient.com;
Kannan M V Kannan.Mandayam@cyient.com;
Rameshbabu Partha Rameshbabu.Partha@cyient.com
2 Business Process Owner:
Suchitra Royroth Suchitra.Royroth@cyient.com;
Ram Mudaliar Ram.Mudaliar@cyient.com
3 Project Manager
Ramakrishna Potluri Ramakrishnav.Potluri@cyient.com
4 IBM Project Team
Rakesh Tripathy Rakesh_Tripathy@in.ibm.com

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1.4 Scope of this Document
This document covers the Production execution as per business process transaction for all Cyient Manufacturing
Plants. They are as follows:
Plant Description
1100 Cyient DLM - Unit-1 DTA
1101 REPL - Unit-1 EHTP
1102 Cyient DLM : Unit-2 DTA
1103 Cyient DLM - Unit-2 EHTP
1104 Bangalore STPI Unit
1107 Bangalore DTA
7500 B& F (USA)
7600 NewTech (USA)
1.5 Process Owners and Users

This is for use of the entire Cyient Manufacturing Plants

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2 Master Scenario
Master Scenario Production Execution Processes for Cyient Manufacturing Plants
3 Process Coverage
Process Coverage Engineer to Order Project Assembly
Make to Order Production
Rework Processing
4 Best Practices
Best Practices Master data should be maintained in advance to enable auto-determination of relevant master data
in transactions. SAP Best practice to adopt standard discrete manufacturing processes for
Engineering to make kind of processes and scenarios relevant for Cyient
5 Proposed Solution
Proposed Solution The below is Proposed Solution with 1. Master Data 2. Process flow diagrams & description 3.
WRICEF objects included in the solution and Automation plan if any.
5.1 Master Data
This document is to list down the various operations that are required in SAP for CYIENT to implement Production
execution business processes.
Master data required for Production Execution:

 Material Master
 Work Centers
 Bill of Materials
 Routing
 Production Version
 Batch Management
Prerequisites for Production Execution:

1) Availability of above required master data in the system
2) standard cost estimation run for Semi Finished / Finished Material
Type of Manufacturing:
 Proto Type :
It is Engineering to Produce .Hence this is driven by Project System in SAP
 Mass Production:
Design is provided. Mass Production done based on the sales order given by customer. Hence this is
Make to Order manufacturing
 Job Work :
Customer provides all the raw materials .Only conversion charges are billed.
There is no Make to Stock kind of production scenario applicable for Cyient Manufacturing plants.

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Cyient DLM manufactures Electronic Manufacturing Services and Mechanical Manufacturing Services.
Cyient DLM manufacturing plant supports multiple industries including aerospace, defence, medical technology,
consumer products, transport and heavy equipment
 Electronic Manufacturing Service produce:

 PC board Assemblies
 Complex wire and cable harness
 Product assemblies (Box Build)
Utilizing both surface mount technology (SMT) and plated through hole boards (PTH), Cyient DLM equipped
to handle an array of mixed technology products.
Our various methods of soldering are: • Wave soldering • Convection reflow • Vapour phase reflow • Robotic
soldering • Selective soldering
 Mechanical Manufacturing:
Cyient DLM manufactures high-precision machining and castings, creating complex mechanical
components and assemblies.
 CNC milling and turning

 Jig boring
 Precision grinding/polishing
 Advanced metrology labs
 3D printing (metal and plastic)
 EDM (wire and plunge)
5.2 Process Flow Diagram & Description
5.2.1 Production Execution Process

5.2.1.1 Planned Order
In Cyient Business Procedure, For Semi finished and finished goods would have planned order based on output
of Material requirement and it will have requirements quantities and dates, as well as administrative data are
listed
Note: As per Cyient manufacturing process, Planned Manufacturing of regular product process orders converted
with reference to planned order which is generated from MRP.
5.2.1.2 Production Order Type

Production orders against specific business with production stage has been created for Cyient as below:

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Required
Production Stage Order Type Description Execution
Order type
Assembly Order Assembly Order
AS01 Production Order
Box Build Assembly BX01 Box Build Assembly Order Production Order
IC programming Order IC01 IC programming Order Production Order
Job Work Assembly Order Job Work Assembly Order

JB01 Production Order
BGA re-balling BG01 BGA re-balling order Production order
PTH Assembly Order PMS1 PTH Assembly Order Production Order
Packaging Order PK01 Packaging Order Production Order
Rework Prod. Order - Stock Rework Prod. Order - Stock

Manufac. Item RW01 Manufac. Item Production Order
Cable Harness Order CH01 Cable Harness Order Production Order
All Master data key data structure is defined in KDS (Key data structure) Document-UNIFY_KDS_PP & QM
5.2.1.3 Material Availability Check

Material availability is checked to ensure that all the material components are available on requirement dates.
Material availability will be checked at the time of creation and releasing the order. The checking scope is
defined through checking group which needs to be defined in material master. After the availability check we
can view a missing part list if any component is not available. Missing part always shows the result of the last
check.
5.2.1.4 Lot Size & Order Type selection

In material master, Lot size with minimum or maximum lot size will be maintained requirement for the FG and
the associated Semi finished, Intermediate, Pre-processed Goods. Suitable order types will be automatically
picked up while converting planned orders to process order. This will be done by maintaining the production
scheduling profile for each material for which process order is created. In production scheduling profile, we
maintain the required order type for the material. This is to ensure that incorrect manual entry is avoided
5.2.1.5 Generation Batch & Serial number at Production Order Release:

In Cyient manufacturing of product, new Batch number will be follow the logic within 10 digit in SAP and while
release the process order by Production department the system will generate the batch number based on the
batch number logic.
And also Production person will update the information of the existing customer specific serial numbers in
customized text field in production order tab (provided Customer specific serial numbers are harmonized and
not exceeding more than 12)
Based on the following logic, while release the production order by Production personal, the system will
generate the automatic batch number and serial numbers.
Batch No and serial no logic for CYIENT plant will be identified after discussion.

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5.2.1.6 Printed Circuit Board Assembly (PCBA) Process

In Cyient manufacturing business scenario for PCB Assembly is populating the board with electronic
components forms a printed circuit assembly (PCA), also known as a printed circuit board assembly-PCBA.
Note: Production order will be creating with reference to material and specific order type AS01
5.2.1.7 Box Build Assembly Process
In Cyient manufacturing business scenario for Box Build is assembling the many sub-assemblies with mechanical
components, screw driver, wirings and plastic materials etc to make desired Finished product.
Note: Production order will be creating with reference to material and specific order type BX01
5.2.1.8 IC Programming Process

In Cyient manufacturing business scenario, Raw ICs are programmed either in house or using subcontracting
process. In house IC programming process is captured using this process.
Note: Production order will be creating with reference to material and specific order type IC01
5.2.1.9 Job Work Assembly Process
In Cyient manufacturing business scenario, if customer is supplying the job work to Cyient by providing 100% all
raw /packaging materials then this process is captured by Job work Assembly Process.
Note: Production order will be creating with reference to material and specific order type JB01
5.2.1.10 Re-balling process
In Cyient manufacturing business scenario, BGAs are re-balled either in house or using subcontracting process.
In house Re-balling process is captured using this process
Note: Production order will be creating with reference to material and specific order type BG01
5.2.1.11 PTH Assembly Process

In Cyient manufacturing business scenario, if manufacturing is done using Plated Through Hole Technology
refers to the mounting scheme used for electronic components that involves the use of pins of the components
that are inserted into holes drilled in PCBs & soldered to pads on the opposite side while through-hole mounting
provides strong mechanical bonds when compared to surface-mount technology techniques.
Note: Production order will be creating with reference to material and specific order type PMS1
5.2.1.12 Packaging Process
In Cyient, this kind of process used for packing Printed Circuit Boards.
Note: Production order will be creating with reference to material and specific order type PK01
5.2.1.13 Rework Process

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In Cyient, rework process is carried out if
1) Non-conformance observed during manufacturing or
2) Product is returned by Customer due to defect and requires correction.
(Note: Sales Return is covered as part in PDD 2.1_O2C_Domestic Sales_V1.0 and Quality in Sales return in
PDD 8.1_QM_Quality Processing_V1.0)
Note: Production order will be creating with reference to material and specific order type RW01
5.2.1.14 Cable Harness Process
In Cyient manufacturing business scenario, Cables are procured from vendors and performs processes like
cutting, stripping, soldering, Crimping and housing and sells to the customer.
Note: Production order will be creating with reference to material and specific order type CH01
5.2.2 Production Manufacturing Flow for DLM:
Production Planning & Execution

Sales Dept
Sales Order /
Customer Forcaste / Customer Packing/
Creation Sales Dispatch
Invoice
System
Project
Project WBS Mass

Creation Creation
Proto
Production
Planner
Pl. Order
MRP Run
Creation
-- Material Shortage
-- Work Center Load
-- Labor Availability.
Production
Scheduler
Production
Production
Check the Scheduling/
Order Yes
Constraints Capacity
Creation
Levelling OK
Procuremen
WareHouse
COC
Purchase
Store Good
Order
t/
Receipt PO No
Creation
Vendor
CSMS
Production
Execution
Production
Production
Order Op. wise Production
KIT Issue Order
Confirmation/ Goods Receipt
OK Release
Label IQC
Pick List
Quality
Quality Ok / Blocked Ok / Not

Inspection Not OK FQA
Not OK Stock Quality OK
Not OK
Notifications
Non Standard SAP

Non SAP Steps
Standard SAP Process Steps Interface
(Manual Business
Process Steps (Developments/ (SAP to NON-SAP)
Process Step)
WRICEF)
5.2.2.1 Conversion of Planned order production order
As per Cyient manufacturing process, Planned Manufacturing of regular product process orders converted with
reference to planned order which is generated from MRP. Planned orders have pegged requirements either
from Order Reservation from Network order (in case of Proto Type) or Sales Order (in case of Mass Production)

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5.2.2.2 Release of production order
Production Scheduler before releasing the Production order check following parameters:
 Material availability
 Capacity Load
 Labour Availability
Before release, check in the system, Material availability check and prompt for missing materials list for the
production order if any. Then Production scheduler will take final call for releasing the order.
Similarly, Production scheduler will perform capacity availability for the order. In DLM Mysore location, for 2
plants DTA and EHTP, production lines are shared resources. Hence we will create work centers in DTA plant
only and will be shared by EHTP plant. Also we will have in SAP the list work centers actually in use. This will give
realistic picture and real time capacity load.
And also Production person will update the information of the existing customer specific serial numbers in
customized text field in production order tab (provided Customer specific serial numbers are harmonized and
not exceeding more than 12)
5.2.2.3 Kit Collection
Based on the reservation generated after release of the production order, pick list is printed and handed over to
warehouse person who will in turn prepare kit as per list and do the label printing for dispensed materials and
finally kit will be given to production supply area (PSA)
In PSA, the customer serial numbers generated in the process order will be pasted on each printed circuit board
before starting heating process. Hence additional manual entry in the logbook for customer serial number can
be avoided.
5.2.2.4 Production Execution & In process Inspection
During Shop Floor execution, Operator will log in to SAP system with his log in id and scan Production order,
work center, Date and time.

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Next Transactional screen will appear which will give Display screen giving information about Operator name,
Production order, Plant, Material no with descriptions, operation and work center.
Let’s take example of Screen Printing, from one end PCB plate will enter the machine and customer specific
design will be printed on PCB plate and then come out at other end. Operator will take that PCB plate and scan
the serial no. which will appear on the screen above marked in ‘orange colour’.
Inprocess Inspection check will be done for the same. If ‘OK’ then press ‘OK’ button which will trigger
confirmation plate wise. After Ok line should become grey out.
If not ok then press ‘NOK’ button. Then system should pop up for additional window wherein we can write
reasons for not ok.
For a given production order, system should bring list of component allocated operation wise and after pressing
GI button. Goods issue to the production order to be executed in the background.
Any reversal of confirmation or any material document has to trigger externally using standard SAP transaction
In SAP, operation wise Inprocess Inspection is not activated.

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In Cyient Manufacturing Plant DLM, some of the operations are performed outside as well which can be
captured using subcontracting operations in the SAP.
Note: These proposed solutions may undergo change/ modification during development depending on
feasibility of program logic.
5.2.2.5 Good Receipt for the Production Order
At the end of operation, good receipt for the Semi-finished/ Finished material using standard SAP transaction
MIGO and material document will be generated.
5.2.2.6 Final Quality Analysis (FQA) (Quality Inspection after Production)
Prerequisite: for final quality Analysis for Finished material, is ’04; Inspection type activation in the F material
master and all relevant QM masters are in place.
QA personal will check Quality parameter, if quality parameter is fulfilled then stock will be moved ‘Quality stock
to ‘Unrestricted stock’. If quality parameter is not fulfilled the stock will be moved to rejection location with
stock type as ‘Blocked Stock’. After approval only Finish Good Transfer will happen to the respective bonded
warehouse and will be dispatched to the customer from there.
In addition, as per Cyient business scenario in Mysore Plant, during test failure product is kept in either in
‘Debug’ area which are not as per quality norms or in ‘MRB’ (Material Review Board) for which decision is kept
on ‘Hold’ which may get reverted after consulting with higher Management/ Customer. This process will try to
address through quality process with further discussion.
There will be 2 level BOM for FG (Un packed) and FG (packed). Hence there will be 2 production orders for FG
(unpacked) and FG (packed) respectively. FG(Unpacked) production order will be created using ‘AS01’ order
type. after good receipt will go to ‘PK01’ (Packaging Store) as ‘Quality Stock’ and FQA will release FG(Unpacked)
Then for FG(Packed), production order will have created using ‘PK01’. FG(Unpacked) and packaging material will
gets issued to production order. After good receipt, stock will go to ‘FG01’ location as ‘Quality stock and FQA will
release then FG (packed)
5.2.2.7 Technical Completion of Production Order
Technical completion is the completion of a production order from the production logistics point of view. This
function usually should use when want to complete execution of an order prematurely, or if the order was not
properly executed and you want to delete open requirements of the order (for example, reservations, and
capacity requirements). You can still make postings for the order after the technical completion. You can, for
example, post a material withdrawal or a confirmation if they were forgotten
For Cyient business, TECO process wants to be automated which is either possible using mass TECO transaction
or through development.
For Mechanical Maintenance Services:
Cyient Ltd acquired two manufacturing units in United States. B&F, located in Connecticut and New Tech, located
in Florida. These units manufacture the Job Orders based on Customer Orders.
5.2.3 Production Manufacturing Flow for B&F:

Cyient B&F manufacturing process:

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Based on Customer Blue Print, Cyient B&F procures the Raw materials as per customer blue print. Cyient B&F
manufacturing unit has a group of machines having operations for CNC Milling, CNC Lath, grinding etc., each
customer order executes on any of one of the machines based on requirement. There are a few departments
supports namely Quality in process inspection department, final inspection, Administration department, Packaging
and shipping department.
Cyient B&F does not manufacture make to Stock. It is engineering to produce. It manufactures based on customer
order and delivers. It does not keep any finished stock.
All the manufacturing operations are based on Work order specifications and Bill of Material based on Work
order. With reference to Cyient B&F Work Order process, manufacturing operations execution mentioned below
Production Planning & Execution-B & F

Sales Dept
Customer Sales Order Customer Packing/

Sales Dispatch
Invoice
System
Project
Project WBS
Creation Creation
Proto Type
Engg. Dept
Production
Planner
&
PP Masters Pl. Order

MRP Run
Creation Creation
-- Material Shortage
-- Work Center Load
Production
Scheduler
Production
Production
Order Yes
Creation
Levelling OK
Procuremen
WareHouse
COC
Purchase
Store Good
Order
t/
Receipt PO No
Creation
External op Vendor
Vendor
Production
Execution
Production
Production
KIT Issue Order In house op
OK Release
Label IQC
Pick List
Quality

Not OK
Notifications
Non Standard SAP

Non SAP Steps
(Manual Business
Process Step)
WRICEF)
As per Cyient manufacturing process, Planned Manufacturing of regular product process orders converted with
reference to planned order which is generated from MRP. Planned orders have pegged requirements from
Order Reservation from Network order (in case of Proto Type)
 Capacity Load

Project UNIFY
Before release, check in the system, Material availability check and Capacity load check prompt for missing
materials list or capacity load for the production order if any. Then Production scheduler will take final call for
releasing the order.
5.2.3.3 Material Requisition against production order
Based on Work order specifications, purchase requisitions are raised to the vendors. After receiving the raw
materials in the stock, it is inspected as per specification and later issued to the work order (production order)
Based on the work order different kinds of operations are performed like cutting, milling, bending, heat
treatment, black oxide, welding, and plating. Some of the operations are performed outside as well. Operation
wise confirmation is advisable. Operation wise confirmation will be done for cumulative hours (e.g. Labour
hours and Set up time total actual time will be booked on the production order and not person wise hours
punching)
Inprocess Inspection capturing can be mapped for operatiowise in the system.
For Cyient no by –product or Co-products are proposed
The confirmation quantity of the order header will get posted to stock as the last operation gets confirmed
to ‘Unrestricted stock’ .If quality parameter is not fulfilled the stock will be moved to rejection location with
stock type as ‘Blocked Stock’.
After approval only Finish Good Transfer will happen to the respective bonded warehouse and will be
dispatched to the customer from there.
Technical completion is the completion of a production order from the logistics point of view. This function
usually should use when want to complete execution of an order prematurely, or if the order was not properly
executed and you want to delete open requirements of the order (for example, reservations, and capacity
requirements). You can still make postings for the order after the technical completion. You can, for example,
post a material withdrawal or a confirmation if they were forgotten
5.2.4 Production Manufacturing Flow for New Tech:
Cyient New Tech Manufacturing process:

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Based on Customer Blue Print, New Tech buys the Raw materials as per customer blue print. New Tech
manufacturing unit has a group of machines having operations for CNC Milling, CNC Lath, Co2 laser, Saw Deburr
and Passivate. Each customer order executes on any of one of the machines based on requirement. There will be
an order which requires heat treatment, to be sourced outside contract. A few department supports namely
Quality inspection department, Administration department, Packaging shipping, programming and Tooling
department.
New Tech does not manufacture make to Stock. It manufactures based on customer order and delivers. It does
not keep any finished stock.
Cyient new tech need to know Raw material stock value, WIP stock value and finished goods value if there is any
leftover stock.
Here are the list of work center used in for Cyient New Tech for manufacturing activity.
1. Lath machine
2. Milling machine
3. CO2 Laser machine
4. Saw machine
5. Deburr machine
6. Passivate machine
Production Planning & Execution-NewTech

Sales Dept
Customer Sales Order Customer Packing/

Sales Dispatch
Invoice
System
Project
Mass production
Engg. Dept
Production
Planner
PP Masters
&
already Created Pl. Order

MRP Run
as per customer Creation
Design -- Material Shortage
-- Work Center Load
Production
Scheduler
Production
Production
Order Yes
Creation
Levelling OK
Procuremen
WareHouse
COC
Purchase
Store Good
Order
t/
Receipt PO No
Creation
Vendor
Production
Execution
Production
Production
KIT Issue Order
OK Release
Label IQC
Pick List
Quality

Not OK
Notifications
Non Standard SAP

Non SAP Steps
(Manual Business
Process Step)
WRICEF)

Project UNIFY
As per New Tech manufacturing process, Planned Manufacturing of regular product process orders converted
with reference to planned order which is generated from MRP. Planned orders have pegged requirements from
sales Order Reservation (in case of Mass Prod)
 Capacity Load
Before release, check in the system, Material availability check and Capacity load check prompt for missing
materials list or capacity load for the production order if any. Then Production scheduler will take final call for
releasing the order.
5.2.4.3 Material Requisition against production order
Based on Work order specifications, purchase requisitions are raised to the vendors. After receiving the raw
materials in the stock, it is inspected as per specification and later issued to the work order (production order)
Based on the work order different kinds of operations are performed like cutting, milling, bending, sawing,
welding, and plating. Some of the operations are performed outside as well. Operation wise confirmation is
advisable. Operation wise confirmation will be done for cumulative hours (e.g. Labour hours and Set up time
total actual time will be booked on the production order and not person wise hours punching)
Inprocess Inspection capturing can be mapped for operatiowise in the system.
For Cyient, by –product or Co-products are not applicable
The confirmation quantity of the order header will get posted to stock as the last operation gets confirmed

Project UNIFY
to ‘Unrestricted stock’ .If quality parameter is not fulfilled the stock will be moved to rejection location with
stock type as ‘Blocked Stock’.
After approval only Finish Good Transfer will happen to the respective bonded warehouse and will be
dispatched to the customer from there.
Technical completion is the completion of a production order from the logistics point of view. This function
usually should use when want to complete execution of an order prematurely, or if the order was not properly
executed and you want to delete open requirements of the order (for example, reservations, and capacity
requirements). You can still make postings for the order after the technical completion. You can, for example,
post a material withdrawal or a confirmation if they were forgotten
5.3 Current Challenges faced
 Need Provision to check the capacity of work centres

 Covered in Sec 5.2.2.2 (by covering realistic work center)
 Work order release should not be permitted if any components not available in production store.
 Covered in Sec 5.2.2.2 (using Material availability check)
 Raw material consumptions should be based FEFO / For FG and SFG consumptions should be based FIFO.
 Using batch determination functionality in GI and PGI respectively
 Provision required to record the excess consumptions for work order.
 Covered in Sec 5.2.2.4 Production Execution
 Provision required to update circuit reference for BOM items in BOM. Need to maintain in Z table
 Need to check BOM classification or Z-table
 Current Capacity load in SAP is not realistic
 Same as point 1, covered in Sec 5.2.2.2 (by covering realistic work center)
 At present, Goods issue in SAP is triggered when material is supplied to Production supplying Area (PSA).
Hence WIP stock in system does not matching the actual stock
 Covered in Sec 5.2.2.4 (Production Execution)
 As per Customer requirement, Plate level traceability of material consumption is not there is SAP.
 AT present CSMS processing in real time and SAP posting is asynchronous. Hence only planned activity is
getting posted and not actual.
 CSMS and SAP interface, Automatic data transfer from SAP to CSMS and CSMS to SAP. ( Inspection lot
details / Work order details (after releasing) / Production qty / consumption qty / activity timings)
5.4 WRICEF Objects
 Workflow – NA
 Report – NA
 Interface - NA
 Conversion - For Master data upload
 Enhancement & model pool

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1) Enhancement for Automatic Batch generation during Production order release
2) Enhancement to have custom Tab in Production Order Screen, to add customer specific serial
number range
3) Enhancement for Automatic generation of desired ranged of serial no. during production order
release
4) Enhancement to have custom field as ‘ Serial No’ on the Production order confirmation screen
5) To have model pool to enter operation wise / plate wise confirmation and in process check during
Production Execution for DLM Mysore
6) Enhance to have validation during feeder change process
 Forms
1) IQC barcode label

2) PCB serial no barcode printing
3) Pick list smart form with barcode
4) Component Issue(kitting) barcode labels
Note: The WRICEF Objects as mentioned above are indicative only. Final deliverables shall be governed
by the "Development Tracker Sheet" as per the priority agreed to and assigned.
5.5 Automation Plan
NA
6 Gaps
Gaps 1) Automatic Batch generation not happening in current SAP system during Production order
release
2) To have custom Tab in Production Order Screen, to add customer specific serial number
range
3) Automatic generation of desired ranged of serial no during production order release
4) Printing of serial number using barcode printing
5) To have custom field as ‘Serial No’ on the Production order confirmation screen
6) To have model pool to enter operation wise / plate wise confirmation and in process check
during Production Execution for DLM Mysore
7) To have feeder and slot wise validation during Feeder change process
8) To have IQC, kitting label, pick list with barcode format.
7 Future Roadmap
Future Roadmap None

Project UNIFY
8 Sign-off
The Document has been signed off by:
Name Designation Signature Date
Kannan M V
Process Owner
Rameshbabu Partha
Suchitra Royroth
Business Owner
Ram Mudaliar
Ramakrishna Potluri Project Manager

Process Definition Document Plan To Make - (Production Execution)

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Process Definition Document Plan To Make - (Production Execution)

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PROCESS DEFINITION DOCUMENT PLAN

1 Document Control Information............................................................................................3

Process Definition Document Page 1 of 21

Process Definition Document Page 2 of 21

1 Document Control Information

Customer Cyient Ltd

1.2 Revision Log

Revision Change Description Author E-mail Release

1.3 Distribution List

Sr. Name E-mail

Process Definition Document Page 3 of 21

1.5 Process Owners and Users

Process Definition Document Page 4 of 21

Master Scenario Production Execution Processes for Cyient Manufacturing Plants

5.1 Master Data

Master data required for Production Execution:

Prerequisites for Production Execution:

Process Definition Document Page 5 of 21

 Electronic Manufacturing Service produce:

 CNC milling and turning

5.2 Process Flow Diagram & Description

5.2.1 Production Execution Process

5.2.1.2 Production Order Type

Process Definition Document Page 6 of 21

IC programming Order IC01 IC programming Order Production Order

Job Work Assembly Order Job Work Assembly Order

BGA re-balling BG01 BGA re-balling order Production order

PTH Assembly Order PMS1 PTH Assembly Order Production Order

Packaging Order PK01 Packaging Order Production Order

Rework Prod. Order - Stock Rework Prod. Order - Stock

Cable Harness Order CH01 Cable Harness Order Production Order

5.2.1.3 Material Availability Check

5.2.1.4 Lot Size & Order Type selection

5.2.1.5 Generation Batch & Serial number at Production Order Release:

Process Definition Document Page 7 of 21

5.2.1.6 Printed Circuit Board Assembly (PCBA) Process

5.2.1.7 Box Build Assembly Process

5.2.1.8 IC Programming Process

5.2.1.9 Job Work Assembly Process

5.2.1.10 Re-balling process

5.2.1.11 PTH Assembly Process

5.2.1.12 Packaging Process

5.2.1.13 Rework Process

Process Definition Document Page 8 of 21

5.2.2 Production Manufacturing Flow for DLM:

Production Planning & Execution

Project WBS Mass

Quality Ok / Blocked Ok / Not

Non Standard SAP

5.2.2.1 Conversion of Planned order production order

Process Definition Document Page 9 of 21

5.2.2.2 Release of production order

5.2.2.3 Kit Collection

5.2.2.4 Production Execution & In process Inspection

Process Definition Document Page 10 of 21

In SAP, operation wise Inprocess Inspection is not activated.

Process Definition Document Page 11 of 21

5.2.2.5 Good Receipt for the Production Order

5.2.2.6 Final Quality Analysis (FQA) (Quality Inspection after Production)

5.2.2.7 Technical Completion of Production Order

For Mechanical Maintenance Services:

5.2.3 Production Manufacturing Flow for B&F: