Business Blueprint

Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

BUSINESS BLUEPRINT

PRODUCTION MODULE
ON SAP ERP

AT

JYOTHY LABORATORIES LIMITED

Submitted By

INTELLECT BIZWARE SERVICES PVT. LTD.

SCENARIO – PP.04
Shop Floor Control

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

CONTENTS
1. SHOP FLOOR CONTROL (BULK PRODUCTION, PACKING, BUNDLING) .......................................................................................................................... 3
1.1 SAP BEST PRACTICE ...................................................................................................................................................................................................................... 3
1.2 TO BE PROCESS FLOWCHART ........................................................................................................................................................................................................ 4
1.3 PROCESS BLUEPRINT ...................................................................................................................................................................................................................... 5
1.4 IMPLEMENTATION CONSIDERATIONS ........................................................................................................................................................................................... 12
1.5 PROCESS STEP MAPPING .............................................................................................................................................................................................................. 13

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

1. Shop Floor Control (Bulk Production, Packing, Bundling)

Detailed explanation of the various scenarios of the business process followed in the company

1.1 SAP Best Practice

SAP Best Practice is not available.

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

1.2 TO BE Process Flowchart

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

1.3 Process Blueprint

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)
1.01
Planned Order:
Production manager schedule production on daily
basis and is circulated to factory Procurement Team This transaction will be used to view planned order list
for Material Planning. which have been generated by MRP run against firmed
MIR is prepared by production team and sent to store production plan of finished goods.
department. Store department issue the material
against same. Issuance of material is done on daily Input Fields:
basis.
Stock is being transferred from store location to  Plant (R) :
production floor. And entry is done on the ERP
system Note:
Only year and day of month is printed as a batch 1. Planned order will contain basic information
number with PKD. like order type, material, quantity, start date, end
date, alternative BOM and attached master
recipe etc.
2. Planned order will have number series starting
with 1.

1.02
Daily production report is prepared. This is prepared Process Order: 1. Validation for
to record the daily production, no of batches, BOM
manpower utilization, and target and production Production manager will use this transaction to create 2. Validation For
variance as per shift. This is Created By shift in daily production plan against production plan. Costing
charge and approved by production in charge and
production manager. Input Fields:
 Planned order(R) :
Production and consumption entry is done into ERP  Process order type(R) :
system. This is done on the next day of production  Partial Conversion(R) :
done.

Page 5 of 14
 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)
Note:
1. Following order types will be available into
system to create process order.
 PI01 Bulk Production
 PI02 Packing
 PI03 Bundling
 PI04 Assembly

2. Planned order will be converted to process order

into mass.

3. Conversion of planned order to process order

will be done on daily basis. Multiple process
order can be created with reference to one
planned order.

4. Batch wise process order will be created where

traceability of production is done in batches. E.g.
NTP.

5. System will generate internal number for

process order. Number range will be at client
level (Plant Independent).

 PI01 - Bulk Production:-

1000000001-2000000000
 PI02 - Packing:
2000000001-3000000000
 PI03 - Bundling
3000000001-4000000000
 PI04 – Assembly
4000000000-4999999999

Page 6 of 14
 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)

6. Validation will be enhanced where user will not

be able to do any changes against predefined
BOM.
7. Alternative BOM selection will be done by user.
8. Resource will be changed in process order if
required.
9. Production floor for components will be assigned
automatically from BOM master but user can
change it, if required.

Page 7 of 14
 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)
1.03
Material Staging: Issue Slip Output
MIR is prepared by production team and sent to store Store manager will do this transaction to issue raw
department Store department issue the material materials/ packing materials against process order.
against same. Issuance of material is done on daily Transfer posting will be done from general store to
basis. production floor.

Process order number will be provided by production

Stock is being transferred from store location to
team.
production floor. And entry is done into ERP system
Input Field:
 Order Number (R) :
 Staging Quantity (R) :

Note :
1. System will propose FEFO (First Expiry First
Out) for raw materials. User can overwrite this.
2. Batch determination will be done in background.
3. An Output will be printed from system after
transfer posting.
4. This transaction will be done on the same day
when physical stock is getting transferred.

1.04

Release Process Order:

Release of process order will be done by production

team.

Page 8 of 14
 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)
Releasing of process order will ensure that material is
available at production floor and standard cost estimate
is available for finished goods or semi finished goods.

Input Field:

 Order Number (R)

Note:

1. If order will have any missing components then

system will not allow to release.
2. If standard cost estimate is not done for material
(FG/SFG) then system will block order for
releasing.
3. Production supervisor will be entered in process
order.

1.05
Process Order Confirmation : 1. DPR Fields
Transaction will be done to record actual production, 2. BOM
overheads and consumption against process order. Validation
It will be done by production team. 3. Auto Batch
Generation

Input Fields:

 Order Number (R) :

 Phase(R) :
 Yield(R) :
 Posting Date :

Note::
1. Production entry will be done into system on next

Page 9 of 14
 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)
day of production..
2. Shift wise confirmation will be done.
3. Production entry will be done at production floor
always.
4. Fields related to DPR will be incorporated to this
screen.
5. Change will not be allowed for BOM components.
Only quantity can be changed within tolerance
limit.
6. Scrap/by-product generation will be also
confirmed here.
7. Backdated Production entry will be allowed for
one working day.
8. Batch Number generation:

a) System will create batch number

automatically for finished goods as
following logic.

Year Month Plant Series

YY MM XXXX XX
16 10 1101 01

b) User will enter batch number for SFG.

9. Batch number will have following details.

 Manufacturing date
 Expiry date
 Next inspection date
 Manufacturing Month and Year
 Formulation

Page 10 of 14
 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Step TO BE Process
AS IS Process, Requirements & Expectations Gap / Comment
No. (R-Required, O-Optional)
1.07
Technical Completion :

This transaction will be done to close the order from

technical side. This will be done by production team

Technical completion is prerequisite to do costing

analysis for process order

Input Fields:

 Order Number (R) :

Note:
1. Transaction will be performed in mass at the
end of month.

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

1.4 Implementation Considerations

Prerequisites Bill of Material, Resource, Master Recipe, Production Version and Planned Order
Enhancements 1. Validation For BOM change in process order.
2. Validation For BOM change in Order confirmation
3. Batch Number
4. DPR Fields addition at confirmation screen.
Outputs Issue Slip

Reports Production Report

KPIs Process Cycle Time, Actual v/s Standard BOM, Costing Variance.

Users

Changes

Authorizations

Improvements

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

1.5 Process Step Mapping

(Fitness definition : S – Standard, C – Configuration, D – Development, M – Manual/3rd Party)

Transactio Fitness Processing

Ste Responsibility/
Activity n Code in Remarks system (SAP, Gap
p Authorization
SAP non-SAP etc.)
S/C/D/M
None

Planned Production SAP

1 COOISPI S -
Order Manager

None

Process COR7/CO Production SAP

2 S -
Order R8 Manager

None

Material SAP
3 MF60 S Store Manager
Staging

None
Release
COR2/CO Production SAP
Process 4 S
R5 Manager
Order

None

Production SAP
Confirmation 5 COR6N S
Manager

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 Business Blueprint
Process Owner : Mr. Sreekumar Consultant : Mr. Nudrat Maab Ahmad Process code:PP.04 Version : 1.0

Technically
Completion Production SAP None
6 COHVPI S
Manager

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