Vedanta Alumina Ltd.

SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

Page 1 of 1
Version No – 1.2

SAP R/3 IMPLEMENTATION BUSINESS BLUEPRINT Production Planning

Prepared by Aniruddha Mukherjee

Checked by Vishal Rathore

Reviewed By

Approved By

Date

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Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

Page 2 of 2
Version No – 1.2

TABLE OF CONTENTS
OBJECTIVE OF BUSINESS BLUEPRINT PHASE.........................................................................................................................................................................................3

SCOPE OF BPBP DOCUMENT ..................................................................................................................................................................................................................6 PRODUCTION PLANNING IN SAP - OBJECTIVE ...............................................................................................................................................................................7 SECTION I .......................................................................................................................................................................................................................................................8 SECTION II....................................................................................................................................................................................................................................................12 ORGANIZATION STRUCTURE ..............................................................................................................................................................................................................12 OTHER MAJOR CONFIGURATION ......................................................................................................................................................................................................17 SECTION III ..................................................................................................................................................................................................................................................21 SECTION IV ..................................................................................................................................................................................................................................................78
SPECIAL ORGANIZATIONAL CONSIDERATIONS:.................................................................................................................................................................................80

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Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

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Version No – 1.2

OBJECTIVE OF BUSINESS BLUEPRINT PHASE: This document is the outcome of the As-Is study, Discussion at Training and during the To-Be process and business process requirement analysis for the Vedanta Alumina Limited. Based on this As-Is coupled with inputs from the core team members during To-Be discussion, we arrived at the Business Processes, which are to be incorporated in the Business Blue Print. The aim of this document is to map the best business processes related to the Production Planning module in SAP ECC 5.0. This document is to be studied by core team members & process owners from Vedanta Alumina Limited. The preparation of this document is an essential precursor for prototyping and testing. The development work will start once process owner’s approval for this Blue Print is obtained followed by a corporate presentation to the senior management team, Vedanta Alumina Limited. This document will be used for configuring Production Planning module in SAP implementation. Document is based on discussions/presentations between representatives of VAL & PWC. In other words it contains 1. SAP Organization Model in context of existing business scenario and future requirements/issues as envisaged by VAL. 2. Mapping of business processes/issues brought forward by PwC & VAL, with SAP functionality. 3. Gaps & issues emerged during the discussion between VAL & PwC. 4. Business Process Flows mapped in SAP as per the scope defined.

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Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

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Version No – 1.2

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

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

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2 CONFIDENTIAL PDF created with pdfFactory trial version www.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 5 of 5 Version No – 1.Vedanta Alumina Ltd. SAP ECC 5.pdffactory.com .

com . SECTION IV: Appendix-Process ( SAP) Flow Diagrams. and Gaps identified for business processes as per SAP.2 SCOPE OF BPBP DOCUMENT The objective of this Blue Print presented to the Project Sponsor is to document the following: a) Business Requirements of VAL that need to be translated into SAP. SAP Gaps as identified by PwC Team with respect to the present scope of implementation and Business Requirements of VAL.Vedanta Alumina Ltd. SAP ECC 5. factory visit & discussions between PwC SAP consultants and VAL core team members have prepared this. As-Is and / To-Be Business processes. b) c) In order to bring the clarity and better understanding. CONFIDENTIAL PDF created with pdfFactory trial version www. SAP consultants team members on the basis of As-Is document.pdffactory. the document has been divided in five sections: SECTION I: Scope of SAP Production Planning and Control module for the project. SECTION II: Organization structure.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 6 of 6 Version No – 1. Details of SAP New Business Process description supported by Process Flow diagram with respect to Different SAP process indicating the desired “To be Processes” / Business Blue Print. SECTION III: Master Data Management.

Costing.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 7 of 7 Version No – 1. EIS. Important Tasks within Process Order Processing.pdffactory. The module also provides better handling of all business transaction. An Example of PO Processing. Special Topics of Production.Objective To provide a Production Planning. Sales & Distribution and Quality Management in order to achieve superior operational efficiency. statutory compliance. and MIS for better decision-making management Control. execution. Confirming and Settling Process Orders. CONFIDENTIAL PDF created with pdfFactory trial version www.com . control and record maintenance system fully integrated with Finance. Shop Floor Control in the R/3 System.2 Production Planning in SAP . cost reduction and profitability. This is achieved through the following components: • • • • • • • Integration into Process Planning and Control. SAP ECC 5. Creating a Process Order.Vedanta Alumina Ltd. Materials Management.

4 MPS 1.Vedanta Alumina Ltd.2 SECTION I Scope of Production Planning Module in VAL PARTICULARS Master 1.2 Demand Management 1.2.pdffactory.1 General Master Records 1.1.2.1.2.2.3 Resource 1.1.1. SAP ECC 5.4 Recipe 1.5 Batch Production Planning and Procurement Planning 1.4 MRP Alumina Power X X X X X X X X 1.2 X X X (MM) CONFIDENTIAL PDF created with pdfFactory trial version www.2 Material BOM 1.3 Long-Term Planning 1.2.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 8 of 8 Version No – 1.1 Sales and Operations Planning 1.com .1.1 Material Master 1.

2 Repetitive Manufacturing 1.1.3 Process Manufacturing 1.1.2 Forecast 2.1 Market-Oriented Planning 2.2 Batch Search Strategy 1.Vedanta Alumina Ltd.3 Control Cycle 1.4 Inventory Management 1.2 PARTICULARS 1.3 Demand Management 2.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 9 of 9 Version No – 1.1 Discrete Production 1.4 KANBAN 1.4 Serial Numbers Business 2.1. SAP ECC 5.1.3.1.1.1 Batch 1.3.1 Production Planning and Procurement Planning 2.3.1.3.com .5 Master Production Scheduling 2.1 Sales and Operations Planning 2.4 Long-Term Planning 2.pdffactory.4.4.4.1.1.6 Material Requirements Planning Alumina Power X X X X X (MM) CONFIDENTIAL PDF created with pdfFactory trial version www.1.1.3 Production 1.1.1.4.

Vedanta Alumina Ltd.1.2 Material Requirements Planning 2.3.1.3 Consumption-Driven Planning 2.3 Evaluations: Logistics Information System 2.2 Material Requirements Planning 2.2.1.1.1.2 Sales Order Oriented Planning 2.3 Capacity Requirements Planning 2.2 PARTICULARS 2.3.4 Process Order Execution 2.1 Forecast 2.2.1.com .1 Process Order Creation 2.6 Evaluations: Logistics Information System 2.pdffactory.2.2.1 Process Manufacturing 2.7 2.1.1.1.7 Replenishment Stock Transfer with Reservation MM X X MM X X X X X X X X X X X X CONFIDENTIAL PDF created with pdfFactory trial version www.2 Evaluations: Logistics Information System Alumina X X Power 2.3.2.2.1.1. SAP ECC 5.1 Master Production Scheduling 2.2.1.2.2.3 Evaluations: Logistics Information System Production 2.2.1.2.1.1.1.1.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 10 of 10 Version No – 1.2 Material Staging 2.5 Evaluation and Mass Processing 2.

3.4.5 Stock Transfers / Trans.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 11 of 11 Version No – 1.1.1 Characteristics 3.1 Classification System 3. SAP ECC 5.1 Goods Movements 2.1.1.4.4. Postings 2.1.2 Physical Inventory & Cycle Counting 2.1.1.2.8 2.3 Alumina Replenishment Stock Transfer with Direct Transfer Posting X MM X X X X MM X (MM) X X X X Power X Inventory Management 2.com .4.1 Reservation 2.2 PARTICULARS 2.1.3.1 Physical Inventory Cross-Application Components 3.2 Classes 3.pdffactory.2.4 Goods Receipt 2.1.6 Goods Issue 2.4.Vedanta Alumina Ltd.3 Classification X X X X X X X X CONFIDENTIAL PDF created with pdfFactory trial version www.

Storage.2000.4000) and four plants (Non-Virtual) will be created which may be as follows: PRODUCTION PLANT 1000 2000 3000 DESCRIPTION VAL Alumina Plant VAL Power Plant VAL Smelter Plant CONFIDENTIAL PDF created with pdfFactory trial version www. As per discussion with Finance & Materials. there will be only four Company Code (1000. Costing. Purchasing.Vedanta Alumina Ltd. A plant has its own material master data. Work scheduling. Production resources/tools.3000. Quality management. Sales.2 Section II Organization Structure Plants The plant is an operating area or branch within a company. You can maintain data at plant level for the following views on a material master record in particular: MRP. views in bold would be used in case of Vedanta Alumina Ltd. The plant is assigned to a single company code. SAP ECC 5.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 12 of 12 Version No – 1. Forecasting.com . Among this.pdffactory.

Alumina Plant (1000) STORAGE LOCATIONS To – Be submitted by MM DESCRIPTION CONFIDENTIAL PDF created with pdfFactory trial version www. All data referring to a particular storage location is stored at storage location level. The logical and physical storage locations will be configured to track the inventory in the shop floor.com . The configuration of the storage locations will be done according to the physical or the logical movement of materials in the shop floor. Several storage locations can be assigned to a plant. The detailed discussion on storage locations will come in the plant specific documentation.pdffactory.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 13 of 13 Version No – 1.2 Storage Locations Storage location is an organizational unit allowing the differentiation of material stocks within a plant. This applies mainly to storage location stocks. SAP ECC 5. Proposed Storage Locations for plant relevant for PP.Vedanta Alumina Ltd.

SAP ECC 5.Vedanta Alumina Ltd.2 Power Plant (2000) STORAGE LOCATIONS To – Be submitted by MM DESCRIPTION CONFIDENTIAL PDF created with pdfFactory trial version www.pdffactory.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 14 of 14 Version No – 1.com .

pdffactory.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 15 of 15 Version No – 1. Note: The Resource of caustic may not used on day-to-day basis. Alumina as Hydrate is Obtained.2 Main Resources in Alumina Plant RESOURCES Calcinations Unit Hydrate Unit Process Caustic Unit DESCRIPTION Hydrate is Calcined into Alumina.com . CONFIDENTIAL PDF created with pdfFactory trial version www.Vedanta Alumina Ltd. PwC ‘s Suggestion is to manage WIP through a generalist approach. SAP ECC 5. Unit where Process Caustic may be captured as WIP. It may be used at the end of the month to capture WIP for Caustic and that too would be used if any other work around is not found at realization and integration testing phase.

0 IMPLEMENTATION Production Planning Business Process Blueprint Page 16 of 16 Version No – 1. CONFIDENTIAL PDF created with pdfFactory trial version www.pdffactory.2 Main Resources in Power Plant RESOURCES Power DESCRIPTION Resource for power Plant.Vedanta Alumina Ltd.com . SAP ECC 5.

Periods and the Fiscal Year will be from April – March. The Factory calendar will be named as Al and PO for Process and Power plants respectively. The Factory calendar will be named as Al and PO for Process and Power plants respectively. One plant may have more than one MRP group.com . Material Groups The functional grouping of the materials for reporting and analysis.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 17 of 17 Version No – 1. Holiday Calendar Every Plant will be having a holiday calendar with details of the holidays as public and other holidays. either as fixed or a moving day in a year. SAP ECC 5.Vedanta Alumina Ltd. and then MRP group can be created. power (raw materials for process plant) etc. CONFIDENTIAL PDF created with pdfFactory trial version www. The number of MRP group to be finalized in the Realization phase. Material type assignment has to done on one to one basis.pdffactory. Periods and the Fiscal Year will be from April – March. MRP Group If we are going for different process order types for Alumina (finished materials).2 Other Major Configuration Factory Calendar Every Plant will be having a factory calendar with details of the working days and the holiday schedule. It can be used to restrict the scope of analysis and searching specifically material master record via search help.

Vedanta Alumina Ltd. We would use Lot-for-Lot Order Quantity in general (EX). For these type of material MRP type PD would be used in general. Lot-sizing Procedure Using this system should calculate the Order quantity for planned order. SAP ECC 5. It is consumed from material planning. MRP Controllers It specifies the group or the number of the controller responsible for Material requirement planning in your organization (Plant or Company). Relevant information related to Re-order point and safety stock would be provided in the material master record.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 18 of 18 Version No – 1.2 MRP Type For material those would be planned on the basis of manufacturing requirement would be planned through Classical MRP.pdffactory. which is relevant for material requirement planning. should be assigned to a MRP controller CONFIDENTIAL PDF created with pdfFactory trial version www. Based on this requirement planned Order would be generated in the system for finished product. The material.com . Raw Materials would be planned through consumption based planning.

0 IMPLEMENTATION Production Planning Business Process Blueprint Page 19 of 19 Version No – 1. SAP ECC 5.Vedanta Alumina Ltd. Note: The Order type of caustic may not used on day-to-day basis.2 Order Types for Alumina Plant ORDER TYPE AL HY NAOH DESCRIPTION Order Type for Alumina. Order Type for Caustic. PwC ‘s Suggestion is to manage WIP through a generalist approach. Order Types for Power Plant ORDER TYPE POW DESCRIPTION Order Type for Power. CONFIDENTIAL PDF created with pdfFactory trial version www. It may be used at the end of the month to capture WIP for Caustic and that too would be used if any other work around is not found in realization phase or integration testing phase.pdffactory. Order Type for Hydrate.com .

They are fixed or constant in nature. CONFIDENTIAL PDF created with pdfFactory trial version www. certain Masters are required to be maintained prior to carry out the Transactions and Reports. Report Analysis. This master is listed below with explanation text.pdffactory. These processes are: • • • • • • • • • Finished Product Planning.Vedanta Alumina Ltd.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 20 of 20 Version No – 1. Consumables Planning.2 To-Be Processes Production Planning Processes The Business Blue Print is divided into various sections as defined by the different processes as discussed during to-be and Expectation from SAP. Cost Analysis. Production Scheduling.com . To carry out these processes. Goods Movement. These Masters are created before Go-Live through Mass data upload process. SAP ECC 5. Order Execution. Capacity Evaluation. Raw Materials Planning. The system would access these master data while the user will be carrying out transaction on day-to-day basis. So from user point of view also it mandatory to understand the relevant or organization specific master data in detail so that actual business process is replicated into the system in terms of data and hence phenomenal purity.

2 Material Classification Fully system supported Material Classification can be done with the standard material classification system in SAP (Class Type 001). No. Here.2 Section III Sl. This will allow better search.Vedanta Alumina Ltd.com .1 Batch Management Fully system supported The manufacturing mode of VAL is a typical case of process manufacturing scenario. N 1.pdffactory. N CONFIDENTIAL PDF created with pdfFactory trial version www. batch tracking is not possible physically. SAP ECC 5. Process Name Process PlantLogistics General Data Mode Process Description/remarks Gap (Y/N) Remarks 1. So production in SAP as well as in reality won’t be captured through batches.0 1.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 21 of 21 Version No – 1.

Vedanta Alumina Ltd. Classification Creation/change of Class and Characteristics Fully system supported Example: length. Class is an assembly of characteristics that can be attributed to a N product (or to several similar products). etc.2 Sl. N CONFIDENTIAL PDF created with pdfFactory trial version www. weight..4 MRP Profile Fully system supported If the order types are more than one. It can also be defined as a grouping of similar products according to common characteristics Example – Pump class.com . automatic selection of order type during manual order creation).0 IMPLEMENTATION Production Planning Business Process Blueprint Page 22 of 22 Version No – 1. Boiler class etc. profiles will help in maintaining some controlling data.3 1.e.pdffactory. SAP ECC 5. No. (i. Process Name Mode Process Description/remarks Gap (Y/N) Remarks Characteristic is a property that describes and differentiates objects. colour. 1.

Make to stock and Gross Requirement planning.7 Based on this system checks the availability.Vedanta Alumina Ltd. No. We use E for produced goods.2 Sl. 1.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 23 of 23 Version No – 1.5 Procurement Type This would help the system to identify the procurement type for the N particular material.com . N Any other availability check to be introduced can be considered at Realization stage. N 1.pdffactory. Availability Check Fully system supported CONFIDENTIAL PDF created with pdfFactory trial version www. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 1. F for external procurement and X for both type of procurement..e. This is used for accumulating the total requirement on daily basis. In Vedanta we would use checking rule 01 for all semi-finished and finished product.6 Strategy Group Fully system supported For Material Produced In-House we need to maintain Strategy 11 for semi-finished product i. SAP ECC 5.

Vedanta Alumina Ltd. Basic Data 2.com . MRP 2.2 Change Material Master Change values of settings as necessary in the material master can N be done anytime.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 24 of 24 Version No – 1. For example: for raw material there won’t be any Work Scheduling View. No. Views such as Basic data 1.pdffactory. N 2.1 Maintain Material Master Fully system supported Material master for Finished and Semi finished goods. MRP 3.1 Create Material Master Fully system supported Fully system supported Create relevant views for each material and give the values of respective fields.1.0 Process PlantProduct Data Management 2. CONFIDENTIAL PDF created with pdfFactory trial version www.1.2 Sl. SAP ECC 5. MRP 1. MRP 4 and work scheduling (as and when required basis). Material Classifications may be used. but frequent change is not recommended. N 2. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 2.

In case of Process manufacturing scenario. View settings without changing.2. as necessary. this can be done along with recipe itself. 2. N CONFIDENTIAL PDF created with pdfFactory trial version www. In case of Process manufacturing scenario.2. This purely for read only purpose.2 Maintain Bills of Material Fully system supported Create and change. Standard BOM will be created and saved in the system.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 25 of 25 Version No – 1. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 2. master data for Bills of Material. SAP ECC 5. this can be done along with recipe itself.pdffactory.1.1 Create Bills of Material Fully system supported Fully system supported Create BOMs for all materials produced in-house. No. N 2. this can be done along with recipe itself.Vedanta Alumina Ltd.2 Change Bills of Material Change values of settings as necessary.com .3 Display Material Master. N 2.2 Sl. In case of N Process manufacturing scenario.

com .2. Processing Unit capacity categories may be used for a Resource. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 2. SAP ECC 5. This would capture logical N place of operation under a plant and at the same time collect the costing data generated out of activity consumption. CONFIDENTIAL PDF created with pdfFactory trial version www.1 Create Resource Fully system supported Create Resource for all processing facilities in the plant with capacity categories of Processing Unit. This is purely Read Only view for BOM.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 26 of 26 Version No – 1. However data N related to Resource category and Capacity category may be changed at the time of realization depending on the simulation test result.3. No.pdffactory. master data for Resource. N 2. 2. Every resource is assigned to a cost centre.3 Maintain Resource Fully system supported Create and change.3 Display Bills of Material View settings without changing.Vedanta Alumina Ltd. as necessary. All Resource shall be attached to a Cost Centre.2 Sl.

com . if required. It can be used to change any existing field value apart from resource category and capacity category. The entire standard recipe will be created in the system for all the plants and material combination. Gap (Y/N) Remarks 2.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 27 of 27 Version No – 1. SAP ECC 5. Any extra capacity category can be introduced by using the functionality. This is used for viewing the master N data in Read only mode.2 Sl. as necessary.3. 2.4 Recipe Fully system supported Create and change. separate control key can be created at time of realization phase.Vedanta Alumina Ltd.pdffactory. However.3 Display Resource Fully system supported View settings without changing. Control Key PI01 can be used up N while creating the Recipe. No. master data for Recipe.2 Change Resource Fully system supported N 2. CONFIDENTIAL PDF created with pdfFactory trial version www. Process Name Mode Process Description/remarks This process would enable the user to capture any enhanced functionality in future.3.

CONFIDENTIAL PDF created with pdfFactory trial version www.4.Vedanta Alumina Ltd.com . This is not under the Purview of current scope of the project. internal relations. and PI05 may be used depending on the business processes integrated along with the operations. Fully system supported View settings without changing and in Read Only mode.4.2 Sl.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 28 of 28 Version No – 1. Gap (Y/N) Remarks 2.1 Create Recipe. The respective operations.4.2 Change Recipe Fully system supported Change values of settings as necessary. Any change in the process can be mapped in future through this transaction.pdffactory. their phases. No. N 2. material assignments are to be mentioned .3 Display Recipe.The standard values for operations can also be mapped through this functionality. N 2. SAP ECC 5.4.4 In-Process Inspection Fully system supported Recipe will have In-Process Inspection Characteristics (Managed N by the QM module). Process Name Mode Process Description/remarks Create Recipe for all materials produced in-house. Fully system supported N 2. Control keys like PI01.

Process Name Mode supported Process Description/remarks of the project.2 Sl.com . Here in Vedanta only one production version would be created.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 29 of 29 Version No – 1. alternative BOM etc can be captured through this. CONFIDENTIAL PDF created with pdfFactory trial version www. If New BOM is to be attached keeping the existing one in the system N with the same recipe. 2.5. 2. It can be locked or Unlocked on as and when required basis. So in case of recipe it is mandatory to maintain Production version.pdffactory. SAP ECC 5. Multiple production versions are only used N when more than one production line is there. one production version is generated and the previous one is locked in changed mode. N Multiple production versions might be there for a material. Functionalities related to Lot size.5 Production Version Fully system supported It’s a combination of BOM and Recipe.5. Gap (Y/N) Remarks 2.2 Change Production version Fully system supported Data related to production version can be changed at anytime. No.1 Create Production version Fully system supported At the time of recipe creation system prompts to maintain Production version.Vedanta Alumina Ltd.

3.Vedanta Alumina Ltd.2 Sl.5.Production Planning.3 Display production version Fully system supported This is for displaying purpose – read only mode. or a number of planned independent requirements schedule lines. No.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 30 of 30 Version No – 1. Planned independent requirements are used to perform Demand Management functions.com .pdffactory. N Process Plant. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 2. The Production Strategy would be “ Make to stock”. A planned independent requirement contains one planned quantity and one date. Demand Management Fully system supported N CONFIDENTIAL PDF created with pdfFactory trial version www. one planned quantity split over time according to dates. SAP ECC 5. “Gross Requirement Planning” will be used. that is.0 Process PlantProduction Planning (PP-PI) Planning cycle will start from demand management.

1 View Demand Fully system supported Demand on monthly scale can be viewed from planned independent requirement.2 Change PIR Fully system supported If any change is required in PIR. change would be directly taken into account in the stock/requirement list.Vedanta Alumina Ltd.pdffactory. this process can be used . For affecting the N CONFIDENTIAL PDF created with pdfFactory trial version www. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 3.com .1 Create PIR Fully system supported Create demand for standard finished product in the system based on the Rough-cut Planning idea. 3. No. 3.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 31 of 31 Version No – 1. Down time of five days can be taken into account in PIR so that time for opportunity based maintenance or annual maintenance (Shut down type) can be taken in To account in production planning in advance.1.2 Sl.1. It is not driven by N sales. this should not be more than the maximum production capacity since production is totally based on Utilization of Full Plant capacity.If MRP elements are not already converted. SAP ECC 5. which will be considered at the time MRP run. The Requirement for finished product is N fed into the system. For Vedanta.

N Basic idea is full utilization of plant capacity.1.1. For affecting the existing planned Order. N 3.com .2 Sl. Process Name Mode supported Process Description/remarks taken into account in the stock/requirement list. which is not based on sale requirement.3 Display PIR Fully system supported View the Planned independent requirement in display mode.4 Production Strategy Fully system supported Make to stock production-planning strategy will be used for the Process plant. Gap (Y/N) Remarks 3. 3. No.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 32 of 32 Version No – 1.5 Staggered period Split Fully system supported The requirement of PIR can be split further into smaller periods (Ex.1. CONFIDENTIAL PDF created with pdfFactory trial version www. Months into weeks or weeks into days). SAP ECC 5. This has been decided pertaining to actual philosophy of production. MRP has to be run once again. Requirement type LSF and/ BSE can be used to meet such requirement. Hence Planned Orders can be N split automatically for smaller periods.Vedanta Alumina Ltd.pdffactory. On the basis of the same PIR can be generated further. We can use our own period splitting key to split the requirement into smaller periods.

it is used to procure or produce the requirement quantities on time both for internal purposes and for sales and distribution.1.6 Reorganization of PIR Fully system supported N 4.Vedanta Alumina Ltd.com . CONFIDENTIAL PDF created with pdfFactory trial version www. you can delete planned independent requirements for which there are no sales orders in the database.pdffactory. Gap (Y/N) Remarks 3. MRP tries to strike the best balance possible between • • Optimising the service level and Minimizing costs and capital lockup. the automatic creation of procurement proposals for purchasing and production. No. You can delete the planned independent requirements history. in particular.2 Sl. In doing so. SAP ECC 5. Process Name Mode Process Description/remarks With the reorganization function.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 33 of 33 Version No – 1. that is. This process involves the monitoring of stocks and.0 Material Requirement Planning The main function of material requirements planning is to guarantee material availability.

No. existing Stock ( if any). planned order and Production Orders ( N if not delivered) would be displayed along with ATP .com . Process Name Mode Process Description/remarks Gap (Y/N) Remarks 4.3 View Stock/Requirement list Fully system supported View Stock /requirements list to check stock position in terms of MRP elements.safety stock( if any ) . SAP ECC 5. All the PIR.pdffactory.1 Run MRP on material Fully system supported Activate Materials Planning for all materials at Plant to derive Gross requirements.Vedanta Alumina Ltd.2 Sl. You can use total planning for a single plant or you can use the scope of planning to control whether the total planning run is executed on a multi-plant level 4.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 34 of 34 Version No – 1. 4. This transfers the demand created by the PIR N for dependent planning for the BOM items. User will be able to see the most CONFIDENTIAL PDF created with pdfFactory trial version www.2 Total Planning Fully system supported Total planning covers the planning of all the materials that are relevant for requirements planning and includes the BOM explosion for materials with a bill of material.

6 Planned Order Fully system supported Proposal to manufacture after MRP execution is generated troughplanned order. CONFIDENTIAL PDF created with pdfFactory trial version www.pdffactory. It can be viewed from stock/ Requirement list.. No.Vedanta Alumina Ltd.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 35 of 35 Version No – 1.e.com . 4.5 MRP List Fully system supported Functionality relevant to MRP i.4 Stock overview Fully system supported View Stock overview as and when required. System enables the user to check stock available for the stock items at various areas of the organization. N 4. Gap (Y/N) Remarks 4.2 Sl. all MRP elements can be viewed from time to time. Process Name Mode Process Description/remarks updated information related to Material Requirement. It will show the conditions of Stock or Requirement at time of last MRP run. Planned Orders are converted to process order before the start of N process in the shop floor. SAP ECC 5.

SAP ECC 5.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 36 of 36 Version No – 1. They N enable the planning of resources. You can adjust the analyses for each user according to the planning level. CONFIDENTIAL PDF created with pdfFactory trial version www.1 Process Order Fully system supported Process orders are used for the production of materials or for rendering of services in a specific quantity on a specific date. Available capacities and capacity requirements can be selected according to various criteria and cumulated using any period split you choose.2 Sl. 5. To manufacture products in the shop floor as per the Recipe and Bill of Material (Material BOM) N 6. The component "Capacity Planning" is available in the N System for this purpose.0 Process PlantProcess Execution N 6.pdffactory.1 Capacity Evaluation Fully system supported Company can use capacity evaluations to analyse capacity loads in your company. No.Vedanta Alumina Ltd. control of process order management. 5.0 Process Name Process PlantCapacity Planning Mode Process Description/remarks Gap (Y/N) Remarks The economic use of resources is an objective for many areas of a company. and specify the rules for account assignment and order settlement. planning horizon and the area of responsibility.com .

Process Name Mode Process Description/remarks Actual confirmation to shop floor to go ahead with manufacturing. It is generally done before the commencement of manufacturing.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 37 of 37 Version No – 1. System would display missing part list (if any). For Vedanta forward scheduling is recommended as scheduling type. Process Order is created from stock/Requirement list.2 Sl. Gap (Y/N) Remarks 6.Vedanta Alumina Ltd. No. The quantity to be produced under such a process Order has to be mentioned clearly. This can be obtained from Planned order. 6. Logically these materials have to be available in system before the commencement of process. The N scheduling of process order that has to be followed really for shop floor happens at this phase and system schedules the process order. But system allows creation of process Order separately. The Materials have to be issued to the Process Orders Or will have to be back flushed.pdffactory. Other wise for any offline requirement Process Order can also be created manually.3 Check Material Availability Fully system supported Process order consumes materials (Semi-finished / Raw). SAP ECC 5.2 Create/ Change Process Order Fully system supported Creating a process order is not a stand-alone process. For Vedanta System will N CONFIDENTIAL PDF created with pdfFactory trial version www.com .

6. Gap (Y/N) Remarks 6. SAP ECC 5.e.pdffactory. 6.4 Release Production Order Fully system supported Process Order Release is carried out on verge of production initiation. you can also cancel three CONFIDENTIAL PDF created with pdfFactory trial version www. N either partial or final. time taken.Vedanta Alumina Ltd. if you entered three confirmations for a phase. Also actual yield.com . In Vedanta this release procedure should be manual i.6 Confirmation cancellation Partially system supported It is possible to cancel data previously confirmed. But decision-making should be at the level of user whether the Process Order could be processed after such missing part. Every completion P confirmation entered in the system can be cancelled. N user has to release the Process Order every time Production is initiated against a new Process Order.5 Confirm Production Order Fully system supported This is for Confirming actual completion of production for an order. No. Thus.2 Sl.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 38 of 38 Version No – 1. scrap. Process Name Mode Process Description/remarks configured in such a way that system should raise warning if the material is not available. and goods movements will be confirmed..

N 6. SAP ECC 5. For Vedanta Red Mud Can be taken as by Product /Waste. this functionality will be used. This will ensure the total consumption for production. For any return of goods issue. No. 6. After Goods receive store will be updated in inventory. Process Name Mode Process Description/remarks confirmations and all confirmations automatically created by them. movement type 262 will be used.7 Issue Materials & Components Fully system supported For Posting goods issued for Production. Unplanned materials can also be issued for a process order.9 Receive Produced Materials Fully system supported Goods Receipt for produced goods is captured through this functionality. Movement type used for this process is 261.pdffactory. Standard SAP movement type is 531. Generally 101 is standard SAP movement type through N CONFIDENTIAL PDF created with pdfFactory trial version www.Vedanta Alumina Ltd.com .0 IMPLEMENTATION Production Planning Business Process Blueprint Page 39 of 39 Version No – 1.2 Sl. Gap (Y/N) Remarks 6.8 By-product receipt Fully system supported Any by-product should also be taken as a component (-ve qty) into the BOM of in-house produced materials and that by-product will be receipt into the stock at the time of confirmation.

2 Sl. 6. Process Name Mode supported Process Description/remarks inventory..Vedanta Alumina Ltd. N The entire reservation list pending (if any) for the Process Order is deleted after this activity by the system itself. Gap (Y/N) Remarks 6. actual costs can be viewed after all issues and activities are completed in the process Order –change mode/display mode. Technical Closure (TECO) Once the process order is confirmed fully i. SAP ECC 5. it has to be declared Technically complete. No.11 Fully system supported CONFIDENTIAL PDF created with pdfFactory trial version www.pdffactory.10 View Cost Fully system supported The Planned vs. desired yield is confirmed in terms of Goods movement and activity confirmation is also done along with.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 40 of 40 Version No – 1.e.com . Generally 101 is standard SAP movement type through which goods receipt against production is captured.

N 7. 7. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 7. 7. SAP ECC 5. This enables the user to take decision related to business.1 Stock Overview Fully system supported It can be used to view Stocks for different material taking Plant and N storage location as additional selection criteria.Vedanta Alumina Ltd. N CONFIDENTIAL PDF created with pdfFactory trial version www.3 List of material Storage location assignment. Fully system supported Shows the exhaustive list for material.0 Reports Reports are generated in the SAP system based on the information fed on day-to-day basis.storage location assignment.pdffactory.2 Extend material views Fully system supported It shows the historical data related to material extension at different N point of time.com . No.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 41 of 41 Version No – 1.2 Sl.

N CONFIDENTIAL PDF created with pdfFactory trial version www. Currency Key etc. material group and created by. material type. SAP ECC 5.Vedanta Alumina Ltd.pdffactory. No.2 Sl. N 7. Fully system supported Shows the details assignment of cost centres to Resources.5 Material list with price and inventory values Fully system supported Gives the detail of standard price. N 7.4 Material List Shows Detail of a material on basis of selection criteria like plant. N 7. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 7.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 42 of 42 Version No – 1.6 Resource List Fully system supported Gives detail of resources. material.com .7 Cost Centre assignment. Per unit price.

2 Sl.Vedanta Alumina Ltd. N 7.com . N 7. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 7. N 7.11 Stock/Requirement list-collective display Fully System supported Gives the stock /requirement scenario for a MRP area or plant N CONFIDENTIAL PDF created with pdfFactory trial version www.8 Resources Capacity Shows the capacity records (Master) for different resources list wise.10 Where Used List Material Fully system supported Lists of material Used into different BOM.pdffactory. SAP ECC 5.9 Where used listResource Fully system supported Lists the different recipes where resources are used. No.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 43 of 43 Version No – 1.

pdffactory.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 44 of 44 Version No – 1.14 Stock/Requirement list Fully system supported Fully System supported Shows the detail scenario of stock or requirement scenario. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 7.13 Missing Part InfoSystem Fully System supported Gives the list of missing parts on plant.15 Collective Display of Planned Order. N 7. Material and different selection criteria for plant. Material and production version. N 7. SAP ECC 5. N 7.2 Sl. No. N CONFIDENTIAL PDF created with pdfFactory trial version www.12 Multi level Order Report Gives multilevel order report for Process Order with different information. Can display the planned orders collectively on the basis of MRP controller.Vedanta Alumina Ltd.com .

Vedanta Alumina Ltd. No. all MRP elements can be viewed from time to time.19 Process Order Individual list display. This is of static type. SAP ECC 5.pdffactory. Fully System supported Gives the detail of the information regarding process Order management –object wise.2 Sl. N CONFIDENTIAL PDF created with pdfFactory trial version www.17 MRP List –Collective Display Fully System supported Same as previous.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 45 of 45 Version No – 1. Process Name Mode Process Description/remarks Functionality relevant to MRP i.16 Fully System supported N 7. only it can be displayed MRP area wise.e. It will show the conditions of Stock or Requirement at time of last MRP run. N 7. Gap (Y/N) Remarks MRP List 7..18 Process Order Information System Fully System supported Gives the detail of the information regarding process Order management.com . N 7.

20 Resource analysis Gives plant wise analysis of resources. N 7.pdffactory. N 7. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 7. No.23 Process Order Analysis Fully System supported Shop floor analysis for Process Order.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 46 of 46 Version No – 1. N 7.com .2 Sl.22 Material Analysis Fully System supported Shop floor material analysis information. SAP ECC 5.21 Operation analysis Fully System supported Gives the shop floor information operation –wise.Vedanta Alumina Ltd. N CONFIDENTIAL PDF created with pdfFactory trial version www.

27 Capacity Planning Fully System supported Process Order Level. 7.2 Sl.pdffactory. plant and Process Order Level.26 Capacity Planning Fully System supported Resource Load Analysis. No. SAP ECC 5. N 7.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 47 of 47 Version No – 1.25 Exception analysis Fully System supported N Exception analysis at material. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 7.com . N CONFIDENTIAL PDF created with pdfFactory trial version www.Vedanta Alumina Ltd.24 Product Cost Analysis Shop floor Product cost analysis. N 7.

CONFIDENTIAL PDF created with pdfFactory trial version www.pdffactory. 7.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 48 of 48 Version No – 1.com . N 7.29 Fully System supported N Enhanced capacity evaluation-resource wise.Vedanta Alumina Ltd.30 Order View Fully System supported Enhanced capacity evaluation-Order wise. N Resource View 7.31 Material Consumption Fully System supported N Material Consumption analysis. No.28 Capacity Planning Resource Overload Analysis. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 7. SAP ECC 5.2 Sl.

34 Result of Costing run. No. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 7.35 Price Vs.Process Order View. N CONFIDENTIAL PDF created with pdfFactory trial version www. N 7.Vedanta Alumina Ltd. N 7. Fully System supported Analyse or compare Material Cost Estimates. N 7.com . Fully System supported Analyse or compare material cost estimates.2 Sl.33 Material to be costed. Cost Estimate. SAP ECC 5. Fully System supported Display of material to be costed.pdffactory.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 49 of 49 Version No – 1.32 Capacity Planning Table Capacity Planning table.

0 IMPLEMENTATION Production Planning Business Process Blueprint Page 50 of 50 Version No – 1.40 Costed Multi level BOM Multi level BOM: Value /Amount/Status N 7. SAP ECC 5.41 Cost components Fully System supported Analyse cost component split for planned cost: cost component N 8. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 7. No.pdffactory.0 Power PlantLogistics General Data CONFIDENTIAL PDF created with pdfFactory trial version www.com .2 Sl.Vedanta Alumina Ltd.

com .3 Material Classification Fully system supported N Characteristic is a property that describes and differentiates objects. Classification Creation/change of Class and Characteristics Fully system supported Example: length. weight.pdffactory. So production in SAP as well as in reality won’t be captured through batches in case of power plant.2 Batch Management Fully system supported The manufacturing mode of VAL is a typical case of process manufacturing scenario. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 8. Material Classification can be done with the standard material classification system in SAP (Class Type 001). 8. Here. batch tracking is not possible N physically. Class is an assembly of characteristics that can be attributed to a N product (or to several similar products).4 CONFIDENTIAL PDF created with pdfFactory trial version www. colour. This will allow better search. etc. No.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 51 of 51 Version No – 1. neither it is required. It can also be defined as a grouping of similar products according to common characteristics Example – Pump class. Boiler class etc. SAP ECC 5.2 Sl.Vedanta Alumina Ltd. 8.

CONFIDENTIAL PDF created with pdfFactory trial version www.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 52 of 52 Version No – 1.pdffactory.2 Sl. F for external N procurement and X for both type of procurement. profiles will help in maintaining some controlling data. No.5 MRP Profile Fully system supported Fully system supported N 8. 8. Process Name Mode Process Description/remarks If the order types are more than one. (i.Vedanta Alumina Ltd. This is used for accumulating the total requirement on daily basis.e. We use E for produced goods. Gap (Y/N) Remarks 8.7 Availability Check Fully system supported Based on this system checks the availability.. SAP ECC 5. automatic selection of order type during manual order creation).6 Procurement Type This would help the system to identify the procurement type for the particular material. In Vedanta we would use checking rule 01 for all semi-finished and finished product. Any other availability check to be introduced can be considered at N Realization stage.com .

1.0 Process Name Product Data Management Mode Process Description/remarks Gap (Y/N) Remarks 9. MRP 2. but frequent change is not recommended.Vedanta Alumina Ltd.1 Create Material Master Fully system supported Fully system supported Create relevant views for each material and give the values of respective fields. SAP ECC 5. For example: For raw material there won’t be any Work Scheduling View. CONFIDENTIAL PDF created with pdfFactory trial version www. MRP 4 and work scheduling ( as and when required basis ). N 9.com .1. MRP 3. N 9. Basic Data 2.1 Maintain Material Master Fully system supported Material master for Finished and Semi finished goods.2 Change Material Master Change values of settings as necessary in the material master can N be done anytime.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 53 of 53 Version No – 1. No. 9.pdffactory. MRP 1.2 Sl. Material Classifications may be used. Views such as Basic data 1.

2 Maintain Bills of Material Fully system supported Create and change. View settings without changing. Standard BOM will be created and saved in the system.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 54 of 54 Version No – 1.1. master data for Bills of Material.Vedanta Alumina Ltd. N 9. SAP ECC 5.3 Display Material Master. this can be done along with recipe itself.2. In case of Process manufacturing scenario. N CONFIDENTIAL PDF created with pdfFactory trial version www. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 9. as necessary. No. In case of N Process manufacturing scenario. 9. N 9.com . this can be done along with recipe itself.2 Sl. this can be done along with recipe itself.2 Change Bills of Material Change values of settings as necessary. This purely for read only purpose.2.1 Create Bills of Material Fully system supported Fully system supported Create BOMs for all materials produced in-house.pdffactory. In case of Process manufacturing scenario.

This would capture logical place of operation under a plant and at the same time collect the costing data generated out of activity consumption. as necessary. However data N related to Resource category and Capacity category may be changed at the time of realization depending on the simulation test result.2. Any N CONFIDENTIAL PDF created with pdfFactory trial version www.com .0 IMPLEMENTATION Production Planning Business Process Blueprint Page 55 of 55 Version No – 1. master data for Resource. 9. Processing Unit capacity categories may be used for a Resource.3.2 Sl. SAP ECC 5. All Resource shall be attached to a Cost Centre. This is purely Read Only view for BOM.3. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 9.2 Change Resource Fully system supported This process would enable the user to capture any enhanced functionality in future.Vedanta Alumina Ltd.1 Create Resource Fully system supported N 9.3 Display Bills of Material View settings without changing. It can be used to change any existing field value apart from resource category and capacity category.3 Maintain Resource Fully system supported Create and change. No. Create Resource for all processing facilities in the plant with capacity categories of Processing Unit. N 9.pdffactory.

internal relations.3.1 Create Recipe. master data for Recipe.3 Display Resource Fully system supported View settings without changing.4. The entire standard recipe will be created in the system for all the plants and material combination. This is used for viewing the master N data in Read _only mode. SAP ECC 5.Vedanta Alumina Ltd. The respective operations.4 Maintain Recipe Fully system supported Create and change. No. Process Name Mode supported Process Description/remarks value apart from resource category and capacity category. as necessary. their phases.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 56 of 56 Version No – 1.The standard values for operations can also be mapped through this functionality. Gap (Y/N) Remarks 9. Any extra capacity category can be introduced by using the functionality. 9.com . PI01 can be used up while creating the Recipe. N 9.pdffactory. material assignments are to be mentioned .2 Sl. Fully system supported Create Recipe for all materials produced in-house. PI22 N CONFIDENTIAL PDF created with pdfFactory trial version www. Control keys like PI01.

N 9. SAP ECC 5.Vedanta Alumina Ltd. alternative BOM etc.4. So in case of recipe it is mandatory to maintain Production version. Process Name Mode Process Description/remarks and PI05 may be used depending on the business processes integrated along with the operations.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 57 of 57 Version No – 1. Gap (Y/N) Remarks 9. Multiple production version might be there for a material. It can be locked or Unlocked on as and when required basis.pdffactory. Fully system supported View settings without changing and in Read Only mode.2 Change Recipe Fully system supported Change values of settings as necessary. Functionalities related to Lot size. Any change in the process can be mapped in future through this transaction. N 9.2 Sl.3 Display Recipe.4.com . No.5 Production Version Fully system supported It’s a combination of BOM and Recipe. N CONFIDENTIAL PDF created with pdfFactory trial version www.

3 Display production version Fully system supported N CONFIDENTIAL PDF created with pdfFactory trial version www. SAP ECC 5. Multiple production versions are only used N when more than one production line is there. If New BOM is to be attached keeping the existing one in the system N with the same recipe .2 Sl.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 58 of 58 Version No – 1. 9. Here in Vedanta only one production version would be created.5. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 9. This is for displaying purpose – read only mode. No.com .pdffactory.Vedanta Alumina Ltd.1 Create Production version Fully system supported At the time of recipe creation system prompts to maintain Production version. 9.5.5.2 Change Production version Fully system supported Data related to production version can be changed at anytime. one production version is generated and the previous one is locked in changed mode.

This has been decided pertaining to actual philosophy of production. No. SAP ECC 5.0 Production Planning (PP-PI) Make to stock production-planning strategy will be used for the Process plant. in particular.2 Sl.Vedanta Alumina Ltd. This process involves the monitoring of stocks and. 10.Production Planning. it is used to procure or produce the requirement quantities on time both for internal purposes and for sales and distribution. CONFIDENTIAL PDF created with pdfFactory trial version www.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 59 of 59 Version No – 1.com . Basic idea is full utilization of plant capacity. which is not based on requirement. For Power plant this functionality is used if and only if long term planning is done. the automatic creation of procurement proposals for purchasing and production.pdffactory. Process Name Mode Process Description/remarks Gap (Y/N) Remarks Process Plant.0 Material Requirement Planning The main function of material requirements planning is to guarantee material availability. Requirement type LSF and/ N BSE can be used to meet such requirement. that is.1 Production Strategy Fully system supported 11. 10.

0 IMPLEMENTATION Production Planning Business Process Blueprint Page 60 of 60 Version No – 1. But for Refinery Classical MRP (Deterministic) –PP and consumption based (MM). For power plant planning would be done either through Consumption based planning or Long term Planning. 11. Process Name Mode Process Description/remarks In doing so. For power plant planning would be done either through Consumption based planning (MM) or Long term Planning.pdffactory. both can be used. both can be used. CONFIDENTIAL PDF created with pdfFactory trial version www. MRP tries to strike the best balance possible between • • Gap (Y/N) Remarks Optimising the service level and Minimizing costs and capital lockup.2 Sl. But for Refinery Classical MRP (Deterministic) –PP and consumption based (MM).Vedanta Alumina Ltd.2 Total Planning Fully system supported Total planning covers the planning of all the materials that are relevant for requirements planning and includes the BOM explosion for materials with a bill of material. No.1 Run MRP on material Fully system supported N 11.com . SAP ECC 5.

planned order and Production Orders ( if not delivered) would be displayed along with ATP .safety stock( if any ) . But for Refinery Classical MRP (Deterministic) –PP and consumption based (MM).pdffactory.2 Sl. For power plant planning would be done either through Consumption based planning ( MM ) or Long term Planning.3 View Stock/Requirement list Fully system supported View Stock /requirements list to check stock position in terms of MRP elements. But for Refinery Classical MRP (Deterministic) –PP and consumption based (MM). Process Name Mode Process Description/remarks You can use total planning for a single plant or you can use the scope of planning to control whether the total planning run is executed on a multi-plant level. CONFIDENTIAL PDF created with pdfFactory trial version www. SAP ECC 5.Vedanta Alumina Ltd. Gap (Y/N) Remarks 11. User will be able to see the most updated information related to Stock/Requirement list. All the PIR. No. both can be used. both can be used.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 61 of 61 Version No – 1. existing Stock ( if any). For power N plant planning would be done either through Consumption based planning (MM) or Long term Planning.com .

11. System enables the user to check stock available for the stock items at various areas of the organization.4 Stock overview N 11. No. It can be viewed from stock/ Requirement list..6 Planned Order Fully system supported Proposal to manufacture after MRP execution is generated troughplanned order.5 MRP List Fully system supported Functionality relevant to MRP i. Planned Orders are converted to process order before the start of N process in the shop floor. all MRP elements can be viewed from time to time. SAP ECC 5.Vedanta Alumina Ltd.pdffactory. But for Refinery Classical MRP (Deterministic) –PP and consumption based (MM).2 Sl. both can be used. But for Refinery Classical MRP (Deterministic) –PP and CONFIDENTIAL PDF created with pdfFactory trial version www.e.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 62 of 62 Version No – 1. It will show the conditions of Stock or Requirement at time of last MRP run.com . For power plant planning would be done either through Consumption based planning (MM) or Long term Planning. Process Name Mode Fully system supported Process Description/remarks View Stock overview as and when required. For power plant planning would be done either through Consumption based planning (MM) or Long term Planning. Gap (Y/N) Remarks 11.

pdffactory. No. You can adjust the analyses for each user according to the planning level. The component "Capacity Planning" is available in the N System for this purpose.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 63 of 63 Version No – 1. Available capacities and capacity requirements can be selected according to various criteria and cumulated using any period split you choose. both can be used. Gap (Y/N) Remarks 12. planning horizon and the area of responsibility.2 Sl.1 Capacity Evaluation Fully system supported Company can use capacity evaluations to analyse capacity loads in your company. To manufacture products in the shop floor as per the Recipe and Bill of Material (Material BOM) N 13.0 Process Execution N CONFIDENTIAL PDF created with pdfFactory trial version www.com . SAP ECC 5.0 Capacity Planning The economic use of resources is an objective for many areas of a company.Vedanta Alumina Ltd. 12. Process Name Mode Process Description/remarks consumption based (MM).

pdffactory. and specify the rules for account assignment and N order settlement.2 Sl.2 Create/ Change Process Order Fully system supported Creating a process order is not a stand-alone process.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 64 of 64 Version No – 1. No. The quantity to be produced under such a process Order has to be mentioned clearly.com . This can be obtained from Planned order. The scheduling of process order that has to be followed really for floor happens at this phase and system schedules the process order. N CONFIDENTIAL PDF created with pdfFactory trial version www. 13. SAP ECC 5. Actual confirmation to shop floor to go ahead with manufacturing.Vedanta Alumina Ltd. They enable the planning of resources. control of process order management. It is generally done before the commencement of manufacturing. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 13.1 Process Order Fully system supported Process orders are used for the production of materials or for rendering of services in a specific quantity on a specific date. Other wise for any offline requirement Process Order can also be created manually. For Vedanta forward scheduling is recommended as scheduling type.

SAP ECC 5.3 Check Material Availability Fully system supported N 13. N user has to release the Process Order every time Production is initiated against a new Process Order. Gap (Y/N) Remarks 13. 13. Also actual yield.4 Release Production Order Fully system supported Process Order Release is carried out on verge of production initiation.e. The Materials have to be issued to the Process Orders Or will have to be back flushed. time taken.Vedanta Alumina Ltd. For Vedanta System will configured in such a way that system should raise warning if the material is not available. But decision-making should be at the level of user whether the Process Order could be processed after such missing part. Process Name Mode Process Description/remarks Process order consumes materials (Semi-finished / Raw). No.5 Confirm Production Order Fully system supported This is for Confirming actual completion of production for an order.2 Sl. In Vedanta this release procedure should be manual i.com .pdffactory. scrap. Logically these materials have to be available in system before the commencement of process.. System would display missing part list (if any). N either partial or final.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 65 of 65 Version No – 1. CONFIDENTIAL PDF created with pdfFactory trial version www. and goods movements will be confirmed.

Unplanned materials can also be issued for a process order.pdffactory. N 13. Every completion confirmation entered in the system can be cancelled.6 Confirmation cancellation Partially system supported It is possible to cancel data previously confirmed.2 Sl. SAP ECC 5.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 66 of 66 Version No – 1.8 By-product receipt Fully system supported Any by-product should also be taken as a component (-ve qty) into the BOM of in-house produced materials and that by-product will be receipt into the stock at the time of confirmation. This will ensure the total consumption for production.7 Issue Materials & Components Fully system supported For Posting goods issued for Production. you can also cancel three confirmations and all confirmations automatically created by them. movement type 262 will be used. Thus. No. For any return of goods issue. Standard CONFIDENTIAL PDF created with pdfFactory trial version www. Movement type used for this process is 261. this functionality will be used. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 13. 13.com .Vedanta Alumina Ltd. if you P entered three confirmations for a phase.

pdffactory. desired yield is confirmed in terms of Goods movement and activity confirmation is also done along with. N The entire reservation list pending (if any) for the Process Order is deleted after this activity by the system itself.2 Sl. N 13.For reversal 532 may be used. Process Name Mode Process Description/remarks movement type is 531.e. actual costs can be viewed after all issues and activities are completed in the process Order –change mode/display mode.11 Technical Closure (TECO) Fully system supported Once the process order is confirmed fully i. 13. Gap (Y/N) Remarks 13. SAP ECC 5.10 View Cost Fully system supported The Planned vs. CONFIDENTIAL PDF created with pdfFactory trial version www.9 Receive Produced Materials Fully system supported Goods Receipt for produced goods is captured through this functionality. After Goods receive store will be updated in inventory. Standard movement type 101.. it has to be declared Technically complete.Vedanta Alumina Ltd. No. For reversal 102 may be used.com .0 IMPLEMENTATION Production Planning Business Process Blueprint Page 67 of 67 Version No – 1.

0 Reports Fully system supported Reports are generated in the SAP system based on the information fed on day-to-day basis.2 Extend material views Fully system supported It shows the historical data related to material extension at different N point of time.Vedanta Alumina Ltd.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 68 of 68 Version No – 1.2 Sl. This enables the user to take decision related to business.com .storage location assignment.pdffactory. 14. Fully system supported Shows the exhaustive list for material. N CONFIDENTIAL PDF created with pdfFactory trial version www.3 List of material Storage location assignment. SAP ECC 5. 14.0 Reports N 14. 14. No.1 Stock Overview Fully system supported It can be used to view Stocks for different material taking Plant and N storage location as additional selection criteria. Process Name Mode Process Description/remarks Gap (Y/N) Remarks 14.

7 Cost Centre assignment.Vedanta Alumina Ltd. material.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 69 of 69 Version No – 1. No. N CONFIDENTIAL PDF created with pdfFactory trial version www. material group and created by. SAP ECC 5.5 Material list with price and inventory values Fully system supported Gives the detail of standard price. Fully system supported Shows the details assignment of cost centres to Resources.6 Resource List Fully system supported Gives detail of resources. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 14. material type.4 Material List Shows Detail of a material on basis of selection criteria like plant. N 14.pdffactory. Per unit price. N 14. Currency Key etc.2 Sl.com . N 14.

Vedanta Alumina Ltd. SAP ECC 5. Process Name Mode Fully system supported Process Description/remarks Gap (Y/N) Remarks 14. N 14. No.pdffactory.com .9 Where used listResource Fully system supported Lists the different recipes where resources are used.8 Resources Capacity Shows the capacity records ( Master) for different resources list wise.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 70 of 70 Version No – 1. N 14.11 Stock/Requirement list-collective display Fully System supported Gives the stock /requirement scenario for a MRP area or plant N CONFIDENTIAL PDF created with pdfFactory trial version www.10 Where Used List Material Fully system supported Lists of material Used into different BOM. N 14.2 Sl.

pdffactory.com . N 14.2 Sl. N 14.15 Collective Display of Planned Order. No. Can display the planned orders collectively on the basis of MRP controller.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 71 of 71 Version No – 1. Material and production version. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 14. N CONFIDENTIAL PDF created with pdfFactory trial version www.13 Missing Part InfoSystem Fully System supported Gives the list of missing parts on plant.12 Multi level Order Report Gives multilevel order report for Process Order with different information.Vedanta Alumina Ltd. SAP ECC 5. N 14. Material and different selection criteria for plant.14 Stock/Requirement list Fully system supported Fully System supported Shows the detail scenario of stock or requirement scenario.

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14.19

Process Order Individual list display.

Fully System supported

Gives the detail of the information regarding process Order management –object wise.

N

CONFIDENTIAL

PDF created with pdfFactory trial version www.pdffactory.com

Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

Page 73 of 73
Version No – 1.2

Sl. No.

Process Name

Mode Fully System supported

Process Description/remarks

Gap (Y/N)

Remarks

14.20

Resource analysis

Gives plant wise analysis of resources.

N

14.21

Operation analysis

Fully System supported

Gives the shop floor information operation –wise.

N

14.22

Material Analysis

Fully System supported

Shop floor material analysis information.

N

14.23

Process Order Analysis

Fully System supported

Shop floor analysis for Process Order.

N

CONFIDENTIAL

PDF created with pdfFactory trial version www.pdffactory.com

Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

Page 74 of 74
Version No – 1.2

Sl. No.

Process Name

Mode Fully System supported

Process Description/remarks

Gap (Y/N)

Remarks

14.24

Product Cost Analysis

Shop floor Product cost analysis.

N

14.25

Exception analysis

Fully System supported

N Exception analysis at material, plant and Process Order Level.

14.26

Capacity Planning

Fully System supported

Resource Load Analysis.

N

14.27

Capacity Planning

Fully System supported

Process Order Level.

N

CONFIDENTIAL

PDF created with pdfFactory trial version www.pdffactory.com

Vedanta Alumina Ltd.
SAP ECC 5.0 IMPLEMENTATION

Production Planning
Business Process Blueprint

Page 75 of 75
Version No – 1.2

Sl. No.

Process Name

Mode Fully System supported

Process Description/remarks

Gap (Y/N)

Remarks

14.28

Capacity Planning

Resource Overload Analysis.

N

Resource View 14.29

Fully System supported

N Enhanced capacity evaluation-resource wise.

14.30

Order View

Fully System supported

Enhanced capacity evaluation-Order wise.

N

14.31

Material Consumption

Fully System supported

N Material Consumption analysis.

CONFIDENTIAL

PDF created with pdfFactory trial version www.pdffactory.com

SAP ECC 5.35 Price Vs. No. Fully System supported Display of material to be costed.Vedanta Alumina Ltd. Fully System supported Analyse or compare material cost estimates. N 14.pdffactory.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 76 of 76 Version No – 1. N CONFIDENTIAL PDF created with pdfFactory trial version www. Cost Estimate.Process Order View.32 Capacity Planning Table Capacity Planning table. N 14. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 14. N 14.33 Display Material to be costed.2 Sl.34 Result of Costing run. Fully System supported Analyse or compare Material Cost Estimates.com .

Vedanta Alumina Ltd.com . SAP ECC 5.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 77 of 77 Version No – 1. No.pdffactory.41 Cost components Fully System supported Analyse cost component split for planned cost: cost component N CONFIDENTIAL PDF created with pdfFactory trial version www.2 Sl. Process Name Mode Fully System supported Process Description/remarks Gap (Y/N) Remarks 14.40 Costed Multi level BOM Multi level BOM: Value /Amount/Status N 14.

Accounting Document.pdffactory. Material Document and Controlling document Generated.com .2 SECTION IV Process Plant: (SAP Flow Diagram) Purchase Requisition Create Demand Integration with MM Convert Planned Order to Process Order/Process Order Creation Integration With PM Integration with MM Raise PIR Run MRP Planned Order Scheduling Capacity Availability Check Material Availability Check Ready For Delivery (SD Integration Usage Decision (QM Integration) Technical Completion of Order Goods Received Process Order Confirmation Goods Issue against Process Order.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 78 of 78 Version No – 1.Vedanta Alumina Ltd. Calculation of Planned cost at the time of saving Release Closing Integration With FI-CO and MM Integration with FI-CO CONFIDENTIAL PDF created with pdfFactory trial version www. SAP ECC 5.

com .Vedanta Alumina Ltd.2 Integration With PM Process Order Creation Scheduling Integration with MM Material Availability Check Capacity Availability Check Closing Technical Completion of Order Goods Received Process Order Confirmation Integration With FI-CO and MM Goods Issue against Process Accounting Document. Material Document and Controlling document Generated. SAP ECC 5.pdffactory. Calculation of Planned cost at the time of saving Release Integration with FI-CO CONFIDENTIAL PDF created with pdfFactory trial version www.0 IMPLEMENTATION Power Plant: Production Planning Business Process Blueprint Page 79 of 79 Version No – 1.

Reading of meters at the end of power plant may be taken into account. Neither it would be batch managed nor separate material code would be maintained for that.2 Special Organizational Considerations: • • • • • • • • • Different Grades of Bauxites and coal would be treated as single material. Red Mud should be treated as Waste. Process Order would be created for a month for refinery.Vedanta Alumina Ltd.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 80 of 80 Version No – 1. SAP ECC 5. There will be no In –Process Inspection. Confirmation of process Order of refinery will be done shift –wise/Daily basis.com . Demand for Alumina should be generated on monthly scale. CONFIDENTIAL PDF created with pdfFactory trial version www. In power plant consumption would be posted based on the actual Production. In Refinery only three Resources might be there.pdffactory. At the end of every month Process Order would be reconciled. It will be managed through Moving Average price.

-----. Hydrate won’t be sold.2 • • • • • • Only one saleable item is there – Alumina.Vedanta Alumina Ltd.com . SAP ECC 5.pdffactory. Process Order confirmation in power plant would be done on daily basis. • All the raw materials will be planned by consumption based planning and that will be taken care by MM. For power plant process order should be created on daily basis.0 IMPLEMENTATION Production Planning Business Process Blueprint Page 81 of 81 Version No – 1.End ------ CONFIDENTIAL PDF created with pdfFactory trial version www. For power plant DM water would be considered as activity and would be directly booked to cost centre on a certain frequency. Distribution rule of power & steam will be posted on daily basis per process order (manually). For power & steam one PO will be generated on daily basis. Plant shall have only one resource.

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