tobe pp05 shopfloorexecution

7/26/2019 TOBE PP05 ShopFloorExecution

1/17

SAP-TO BE Process

NAWPP005Shop Floor Control

PRODUCTION PLANNING

er!"0

!#"0$"%00&

STATEMENT OF CONFIDENTIALITY / DISCLAIMER

This document is the property of Critor! Inc" No prt of this document sh## $e

reproduced! stored in retrie%# system! or trnsmitted $y ny mens! e#ectronic!

mechnic#! photocopyin&! recordin&! or other'ise 'ithout prior 'ritten permission from

Critor! Inc"

n'(


2/17

Table of Contents

T')le o* Contents

! Shop Floor Control"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""#

1.1 AS IS Process............................................................................................................................................3

1.2 Core to Be Process....................................................................................................................................5

1.3 Changes to Existing Organization...........................................................................................................1

1.! "escri#tion of I$#ro%e$ents an& 'e( )etrics........................................................................................1

1.5 *otes on +,rther I$#ro%e$ents..............................................................................................................1

1.- +,nctional "eficit an& )etho& to e$o%e That.......................................................................................1

1./ Interface e0,ire$ent.............................................................................................................................1

1. S(ste$ Config,ration Consi&erations.....................................................................................................1

1. +ile Con%ersion Consi&erations...............................................................................................................1

1.1 An( re#orts re0,ire& relate& to c,rrent b,siness #rocess.......................................................................11.11 An( &oc,$ento,t#,t 4o,l& be #rinte& for this b,siness #rocess...........................................................1

1.12 A,thorization Consi&erations...................................................................................................................11

1.13 En& ser Training e0,ire$ents.............................................................................................................11

1.1! Process +lo4 Chart.................................................................................................................................12

% SAP St'n+'r+ Reports""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""!,

# Csto. De/elop.ents"""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""""!

C'r1tor Con*1+ent1'l P'2e 11


3/17

n'

(SAP6TO BE Process

! Shop Floor Control

TO-BE Doc.ent

For SAP R3# I.ple.ent't1on 't Ne( Allen)err4 (ors"

"ate7 13..2-

Sr. *o of TO BE &oc,$ent *A8PP5

ef. Sr. *o. Of AS6IS &oc,$ent Pro&,ction Exec,tion

*a$e of B,siness Process7 Sho# +loor Control

)o&,le7 Pro&,ction Planning S,b $o&,le7 Sho# +loor Control

9ersion no of &oc,$ent7 1. "ate7 13..2-

9ersion )anage$ent This "oc,$ent is s,b:ect to change control. E%er( change of the &oc,$ent has to n&ergo changecontrol #roce&,re an& has to be registere& in the follo4ing table

ers1on Ch'n2e Prep're+ B4 D'te

!"0 An'nth R'6 !#"0$"%00&

!"! AS IS Process

Production Execution

Production Execution

Creation of Production Order

In NAW no production order concept is adopted presently.

The product wise daily plan is released to Production by PPC for each machine in every

production line.

The Daily Production Plan is generally within the months plan.

The release of Daily plan is Production Order for the Production Department.

C'r1tor Con*1+ent1'l P'2e #


4/17

n'

(SAP6TO BE Process

Material Staging

Raw materials are moved to respective machines in trolleys or trays by PPC.

After the operation is performed the material is moved to Paring !ay waiting for movement

to ne"t machine for ne"t operation in the other Production #ine.

There are different Paring !ays for different operations

Production Confirmation

Production is confirmed after all the operations by putting paint mar on the product .

Goods receipt from Production

$inal products% after final inspection% are handed over to $inished &oods 'tores by PPC on

Production Credit 'lip made manually.

atc!es for manufactured Products

(eat treatment code is punched on products depicting year% month% )* and charge number.

C'r1tor Con*1+ent1'l P'2e ,


5/17

n'

(SAP6TO BE Process

!"% Core to Be Process

Pro+ct1on or+er De*1n1nt1on7

A #ro&,ction or&er &efines 4hich $aterial is to be #ro&,ce&; at 4hich location; at 4hat ti$e; 4hich

operatioand how much wor is re+uired. ,t also defines which !O-% Routing is to be used .

The wor processes within a company are e"ecuted using orders.

Creation of Production order refers to

*hat is to be produced

*hen production has to tae place

*hat are all the components needed to produced and consumed for the specified

+uantity *hat are the PRTs re+uired to complete the order

Pro+ct1on Or+er cre't1on h's to *ollo( the proce+re7

A routing is selected/ its operations and se+uences are transferred to the Production

order. The !ill of -aterials is e"ploded and the items in the !ill of -aterial are transferred to

the Production order. Availability chec of components in stoc .

Availability chec for Production resource tools.

Reservations are generated for !ill of -aterial items held in stoc.

As the -RP is run the Planned order would be generated as per the P,Rs0plannedindependent re+uirements1.

$inished products will be received in the stoc by confirming the final operation in the

routing The planned costs for the order are generated.

Production Order can be created with reference to a material and a planned order. ,n

case of creation of Production orders through planned order% the system will allow forindividual% partial or collective conversions of planned orders.

When ' Pro+ct1on or+er 1s cre'te+8 the s4ste. cop1es /'r1os .'ster +'t' onto 1tsel*7

"outing# The system checs for the routing and copies the routing of the material

ill of Material# The system checs for the !O-s% which fall within the validity

date.*henever production order is created by conversion of a planned order% the!O- that is used for planning by the system will automatically get copied into order.,n case this needs to be changed 0where the norms for planning and e"ecution isdifferent1 this has to be manually changed by the user.

!efore releasing the Production order and starting production% the system has an

option to chec whether all the material components assigned to a Production order

C'r1tor Con*1+ent1'l P'2e 5


6/17

n'

(SAP6TO BE Process

are available on the calculated re+uirements dates. These availability checs can betriggered either automatically or manually and can be carried out at plant or atstorage location level.

,f any components are not available in the stocs% system will create a missing partslist and an error message will be issued to the users.

Pro+ct1on or+er con*1r.'t1on7

After creation and releasing a production order% the user confirmation

process has to be performed.. As a part of Production Order confirmation% the system shall allow for

updating the production control related information vi2.% +uantity ofproduction% activity data 0actual $i"ed time% actual 3ariable time% start 4 endtime% dates for individual operations within each production order .'ystem

will calculate the activities based on the confirmation +uantity and thenorms. This calculated figures for each of the activities will be displayed onthe confirmation screen and will be changed only if re+uired.

As mentioned earlier% creation of Production order results in creation of

materials reservations. ,f the material consumed is less than the planned+uantity% it is important that the open reservations are closed. The openreservations are considered as 5Demand elements for which material hasto be provided. (ence it is important to close the material reservations thatare no more relevant..

*ith a confirmation we would be able to specify

The +uantity in an operation that was produced as yield% scrap and

the +uantity to be rewored

(ow much wor was actually done

*hich wor center was used for the operation

*ho carried out the operation

B'tch 9'n2e.ent7

During the production confirmation the material that are being activated with batch

management needs to be assighned with the batch number.This batch number will

be updated e+uivalent to the production order number.

,n )A* batches are assigned after heat treatment%in which a code with e"ternal

numbering will be used .

C'r1tor Con*1+ent1'l P'2e &


7/17

n'

(SAP6TO BE Process

There are fe4 #rocess that are being highl( reco$$en&e& as a #art ofStan&ar& 3


8/17

n'

(SAP6TO BE Process

Important fields to )e maintained for NAW#

Material Master9 !ac flush indicator has to be maintained 6:6Always !ac

flush

Wor* center9 control ey6

PP;:6need to be maintained for raw materials

PP;


9/17

n'

(SAP6TO BE Process

Process flo+ c!art #

)o

yes

C'r1tor Con*1+ent1'l P'2e $

Con%ersion of #lanne& or&er

into #ro&,ction or&er

Confir$ation of #ro&,ction

or&ers

A%ailabilit( chec>)issing #arts list

#rocessing

?,alilt( stoc>

nrestricte& stoc>

elease of #ro&,ction or&er

@oo&s $o%e$ent an&

Technical co$#letion of or&er.


10/17

n'

(SAP6TO BE Process

!"# Ch'n2es to E;1st1n2 Or2'n1


11/17

n'

(SAP6TO BE Process

!"$ F1le Con/ers1on Cons1+er't1ons

*I=

!"!0 An4 reports re>1re+ rel'te+ to crrent )s1ness process

*I=

!"!! An4 +oc.ent3otpt (ol+ )e pr1nte+ *or th1s )s1ness process

*I=

!"!% Athor1


12/17

n'

(SAP6TO BE Process

!"!, Process Flo( Ch'rt

F12re !7 Pro+ct1on Or+er Cre't1on

C'r1tor Con*1+ent1'l P'2e !%


13/17

n'

(SAP6TO BE Process

F12re %7 Goo+s Isse to Pro+ct1on Or+er

S12n-o** ?Appro/'l@ *or th1s +oc.ent7

N'.e o* Te'. .e.)ers7 Or2'n1


14/17

n'

(SAP6TO BE Process

% SAP St'n+'r+ Reports

SAP St'n+'r+ Reports

Sl No7 Report Descr1pt1on Select1on Cr1ter1' Otpt

1 Stoc> O%er%ie4 ))BE )aterial; Plant D Storage location Stoc> Stat,s at each storagelocation

2 )aterial =ist ))- )aterial; Plant; )aterial T(#e D)aterial @ro,#

)aterial )aster "etails

3 )issing Parts Infor$ation =istCO2! Plant fro$ Selection fro$eser%ationsF D )P Controller fro$Selection fro$ Or&erF 4ith Profile for)aterial 9ie4

Shortage =ist

! Pro&,ction Or&er Infor$ationS(ste$ COOIS

L1st7 Ite.

Gea&er

Profile Stan&ar&

)aterial

Pro&,ction Or&er

Pro&,ction Or&er T(#e

)P Controller

Selection stat,s Profile or

S(ste$ Stat,s

L1st7 Ite.

Profile Stan&ar&

)aterial

Pro&,ction Or&er


)P Controller


S(ste$ Stat,s

L1st7 Con*1r.'t1ons

Profile Stan&ar&

Pro&,ction Or&er

=ist of Or&ers base& onSelection Criteria

=ist of Or&ers base& onSelection Criteria; 4ith $aterialco$#onents

=ist of Or&ers base& onSelection Criteria; 4ithconfir$ation &etails

=ist of Or&ers base& onSelection Criteria; 4ith @oo&sIss,e D ecei#t &etails

C'r1tor Con*1+ent1'l P'2e !,


15/17

n'

(SAP6TO BE Process




)P Controller


S(ste$ Stat,s

L1st7 Doc.ente+ Goo+s

9o/e.ent

Profile Stan&ar&

Pro&,ction Or&er


)P Controller


S(ste$ Stat,s

5 PT 8here ,se& in Tas> =ist CA/ Pro+ct1on resorces3Tools

)aterial

Plant

T1.e

'e( "ate

T's L1st

T(#e +ro$

Stat,s for$

sage fro$

Plant

Planner @ro,# fro$

9'ter1'l

+ro$ )aterial n,$ber

PT 8here ,se& list 4ith all&etails .

- PT sages in or&er Pro+ct1on resorces3Tools

)aterial

Plant

Or+er Select1on

Plant

It 4ill gi%e PT ,sages co,nter

C'r1tor Con*1+ent1'l P'2e !5


16/17

n'

(SAP6TO BE Process



Pro&,ction Sche&,ler

)P controller gro,#

Or&er t(#e

Sche&,le start &ate

Sche&,le& &eli%er( &ate

Or&er

)aterial

Person in charge

Selection #rofile stat,s

/ )CP/ 6 8or> Center Wor Center8 pl'nt8 per1o+ 8or> Center

)CP1 6 O#eration Oper't1on8 pl'nt8 per1o+ O#eration

)CP5 6 )aterial 9'ter1'l8 pl'nt8 per1o+ )aterial

1 )CP3 6 Pro&,ction Or&er Pro+ct1on Or+er8 pl'nt8 per1o+ Pro&,ction Or&er

11 )CE 6 )aterial Cons,$#tion 9'ter1'l Cons.pt1on8 pl'nt8

per1o+

)aterial Cons,$#tion

12 )CI 6 Pro&,ct Costs 9'ter1'l 8 pl'nt8 per1o+ Pro&,ct Costs

C'r1tor Con*1+ent1'l P'2e !&


17/17

n'

(SAP6TO BE Process

# Csto. De/elop.ents

Pr1nt Re>1re.ents


De/elop.ent Re>1re.ents


C'r1tor Con*1+ent1'l P'2e !

tobe pp05 shopfloorexecution

Documents