SAP PP, QM, PM

As Is
for PS (Shirur Plant)
JAPFA STRIDE

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 Approvals
Version 1.1
Sr.No. Role Name Date Signature

1 Japfa IT Team Mr. Prashant Desai

Mr. Rahul Zanzad

2 Japfa Core
Business Team

3 Japfa HOD

4 Japfa Project Mr. Mukesh Singh

Manager

5 Primus Project Mr. Anand Kulkarni

Manager

6 Primus Delivery Mr. Nupur Shete

Manager

7 Primus Mr. Atul Kulkarni

Functional Team
Mr. Shubham More

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AS IS:
Quality Management:-
 Inward Inspection for Day Old Chick, vaccine, medicine, feed in business – Not available in
SAP.
 Bookkeeping is done manually during each stage to maintain records of each stage in
business.
 In-process inspection (daily monitoring) done in actual business process
 In-process inspection (Inspection type 03) in SAP is not available
 Final inspection is done visually in the actual business process
 Final inspection (Inspection type 04) in SAP not available
 No Scope for QM module.(Inward, In process and Final inspection)

Production Planning & Manufacturing:-

 Based on past sales figures and plant capacity (Flock) production plan is finalized by manual
planning.
 No planning and No MRP Run in the existing SAP environment.
 Chick growing period for 6 months including Brooding and Growing Phase.
 Brooding Phase - 0 to 04 week (Parent Bird Maintain)
 Growing Phase -05 to 24 weeks (Parent Bird Maintain)(16 to 24 -Prelaying)
 It includes vaccination, medication, feed consumption, mortality
 Restrictions to Consume ROH from storage locations.
 At a time of confirmation there is a manual control for storage locations
 After 6 months i.e. after Brudeeing and Growing stage Laying phase starts (7 to 18 months)
 Laying Phase - 25 to 64 weeks (Approx.) (Parent Bird Maintain)
 Laying Phase – 25 to 64 weeks -Production Phase -We get Eggs. Approx.178 Quantity (170-
180)
 Laying Phase – After 64 weeks parent bird sale
 Presently there is one single order for bird for first six month on monthly basis
 Production order creates for female birds only.
 Consumption 261 MVT & By Product 531 MVT done with transaction code CO11N and 101
MVT with transaction code MIGO
 Shade-wise operation mentioned in routing. Operation-wise confirmation functionality is
used
 No any revenue generation during the first 6 months. At the time of confirmation, expenses
go to Asset GL.
 Manual expenses booking done in FI for 6-month expenses in SAP for amortization
 After 6 months following two types of orders are available in SAP (monthly creation of
production orders)
1. Birds (For 64 weeks)
2. Hatching eggs (after 25 weeks)
Future Business Requirement: we need to make a combined order for both of them
BOM, Routing master data need to be updated accordingly

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  Presently both birds and hatching eggs have different BOM in SAP.
 In production there is no process of scrapbooking at the time of confirmation
 After 25 weeks Eggs are Transferred to Hatchery on daily basis
 In SAP BOM, routing and Work Centres are maintained
 In Work Centre activity type is not maintained
 Routing maintained with multiple operations(shade wise) but in the future, we need a single
operation and single Work Centre.
 Confirmation is done for each Hatching egg and live bird production order.
 261 MVT and 531 MVT done with transaction code CO11N while 101 MVT goods receipt
done with transaction code MIGO against Order.
 Validation at transaction code MIGO for MVT 101:- (261-531=101)for female birds
 Various customized reports available in SAP
 Batch has been given through transaction code MIGO at the time of Goods Receipt with 101
MVT by manually
 1 Flock is considered as batch,and for MVT 101 and MVT 261 batch is same for first 6 months
 Bookkeeping is done manually during each stage to maintain records of each stage in
business.
 Weekly weight is captured of live bird
 Custom reports used -
1. Daily growing report -ZPS_GROW
2. Daily laying report-ZPS_LAYING

Plant Maintenance:-
 Plant maintenance activity divided based on a daily, weekly, monthly, quarterly, half-yearly,
and yearly basis in business
 In SAP No Plant Maintenance cycle was performed
 In SAP required PM master data equipment, task list, and functional location not maintained
 Minimum stock level and safety stock level maintained for each required spare based on
business cycle execution
 Minimum Stock level, Inventory level not maintained in SAP.
 Reports need to be developed based on business requirements in SAP.
 Workflow /mail communication required for notification generation in PM

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JAPHA PS Business Flow:-

Sales purchase to JAPFA Hatchery (PH) Plant

Requirement-

Production Planning and Manufacturing:

1. Check the feasibility of MRP Run

2. Check the feasibility of auto amortization

3. Need to maintain single operation and single work centre in routing in SAP

4. Single production order for the first 6 months for the bird instead of month wise production orders

5. Check feasibility for combined production orders of bird and hatching eggs(Laying Stage)

6. Production order confirmation entries need to be done in FIORI.

7. Monthly age report of DOC

8. Body weight should be weighed through N-Pick and report is generates through SAP

Existing plant details:-

Z program list:-

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