ps bhel new plant bbp

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•• ECC 6.0 Roll Out ProjectECC 6.0 Roll Out Pro ject

•• BBP PhaseBBP Phase

•• Module :- PSModule :- PS

Date Title Consultant BPO16.02.2010 BBP_PS Murali Mohan Muraleedharan

PS_01 Date of print: 7/24/2013Page: 1 of 19

BHEL SAP



Table of Contents

I.Executive Summary:.......................................................................................................3

II.ESD Organizational Structure........................................................................................4

III.Organizational Elements:..............................................................................................4

IV.Master Data..................................................................................................................4

V.Business Processes:.....................................................................................................8

VI.SAP Solution:..............................................................................................................10

VII.Process Flow:............................................................................................................14


S.No Activity Description



I. Executive Summary:

The Electronics Division (EDN) of BHEL was formed in 1976, mainly to establish a strong base in

the areas of power and industrial electronics and supplement the company’s pioneering efforts inpower generation, transmission, industry and transportation sectors.

Making a modest beginning in 1976, the unit has registered continuous

and impressive growth, which is amply reflected in the fact that a large number

of power plants in the country today, are equipped with products and systems

made by BHEL-EDN. As reported by the ARC Survey for the year 2005, BHEL is

holding over 65 per cent of the Market share of DCS Supplies to Power Industry in India

(including hardware, software and services).

Technical collaborations with international leaders as well as BHEL-ElectronicsDivision’s relentless efforts and unwavering commitment to in-house solutions

have contributed to its rapid growth and suc cess. Despite stiff competition posed by the

world leaders and domestic private manufacturers, the unit has successfully maintained its growth

rate and become a major force to reckon with in power and industrial electronics.

Electronics Division has also been making pioneering efforts in Renewable Energy Sector by

commissioning Large-size Grid-Interactive as well as Stand-Alone Solar Power Plants, thus lighting

the lives of people living in remote parts of the country. The unit has also been making humble

contribution to Indian Space Programmes by fabricating Space Grade Solar Panels and Space

Quality Batteries for ISRO.

In recognition of its commitment to the quality systems and pro cedures, the unit

has been certified for ISO 9001 since July 1993. To fulfill its role of a responsible corporate citizen,

envisaging protection and conservation of the environment and ensuring that it’s products and

systems are also environment-friendly, BHEL has framed a Corporate Environment Management

Policy. Accordingly, the Electronics Division has become the first Electronics Industry in Bangalore

to get ISO 14001 Environment Management System certification and OHSAS 18001 certification. The

Electronics Division has established itself in the field of IT applications, using the state-of-art

technology systems, for communication, computing, networking and security requirement of the

organization in achieving its business goal. In this pursuit, the unit has been certified to ISO/IEC

27001:2005 Information Security Management System from STQC, Ministry of Communication

and Information Technology, Government of India.

BHEL has also joined United Nations' “Global Compact” and has committed tosupport the set of core values enshrined in its ten principles in the area of

Human Rights, Labour s, Environment and Anti-Corruption.

Electronics Division of BHEL is using SAP ECC 6.0 version in all product

groups in EDN. Different plants for different product groups have been

created in SAP. The Project oriented department involved in execution of




the project Other departments are purchasing capital goods directly and

for this they can procure from out side if it is not available in plant.

Feasibility is done for the project before execution and once it is ok then

the orders are generated.

Presently projects are operating from EDN and BHEL wants to operate

from the ESD as well

II. ESD Organizational Structure

The New Plant should be capable of working on its own for the Businesstransaction. All the excise and accounting should be created for the plantaccount. Delivery of the FG should be from the new plant. All the Businessprocess of ESQP should be replicated to the New Plant.

III. Organizational Elements:

The Project System has no organizational structures of its own, incorporate it into the existing structure by making assignments to theorganizational units in Accounting and Logistics. It is this which enablesthe Project System to present data clearly and in many different ways.

Project system will use all modules Organizational elements likeFI/CO,MM,PP,PM

Company code:

Controlling Area

Business Area

Profit center

Cost center

Plant

IV. Master Data

Project Definition

WBS elements




Network

Network activities

Activity elements

Milestones Material/BOM

To be able to carry out a project in its entirety, the project goals must be

precisely described and the project activities to be carried out must be

structured. A clearly and unambiguously structured project is the basis for its

planning, monitoring, control and success.

Depending on the type of project and the emphasis in project monitoring,

Structure the project in the Project System using the structures work

breakdown structure (WBS) and/or networks. Structures for example WBS

and networks allow size and reuse structures and sequences of events in the

projects.

Each project starts with the definition and classification of the structures

required for processing and the incorporation of these into the existing

enterprise structure.

Once the decision is taken from the top management to go-head for any

project, the project planner will carry out detailing of the project structure. This

includes Work breakdown structure (henceforth referred as “WBS”), Work

breakdown structure elements (WBSE), Network and Network activities.

Milestones and material component planning will be done in WBS/Activity, as

required.

The Steps involved in creating the project structure are described below:

1. Project Management will start preparing the project structure. Project

builder, a tool in SAP Project system, will be primarily used for creating

the project structure.




2. Project coding mask has to be Maintain in the Customization for a

particular profile, In Each Coding we will define the no of levels the work

has to be broken down.

Project Coding Mask- ES/0001-XX-XX-XX

3. Project Definition will be created; the coding used will remain

your Project Number.

4. Choose Suitable “Project Profile”. All the default values like Controlling

area, company code, Plant, planning profiles, Budget Profiles and other

important project parameter, which are customized, will get defaulted on

the screen through these profiles.( Most of the defaulted values can be

changed in the project during project creation, before saving it for the first

time).

5. Once the project definition is created, the Work break down structure is

prepared. A hierarchy of Work breakdown elements (WBSE) will be created. The

structure will primarily have One WBS at 1st Level. The actual costs will be

captured against the lower level of WBS elements. These WBS elements will be

planning elements as well as Account assigned elements so that planning and

actual cost can be posted on those WBS Elements. The top level WBS element

will be a ”billing” element where all the total budget, plans, actual costs and

revenue can be collected covering the entire project.

1. Department is having the Start date and End date of the Project and based on

forward scheduling the system given the end date of the project.

2. The Individual object such as WBS elements, Network, Network activities, Activity elements, milestones and Material components if any

can be selected from template area and dropped on the project definition on

the project builder. It is recommended to first create the Work break down

structure for the project. Later the Project WBS should be expanded to the

required level by selecting the network and network activity. Project structure

can also contain WBS without any activities and network.




3. Network is nothing but flow of activities, so the Network will hold group of

Activities. Network is required for planning, analyzing, controlling and monitoring

schedules, dates and resources at the Activity Level. Activities are to be

maintained for each Network. Relationships are to be maintained for eachActivity, depending on the requirement user can consider Finish- Finish (FF),

Start- Start (SS), Start- Finish (SF) & Finish -Start (FS) Relationships.

• The Project oriented department involved in execution of the project aremainly Make to order projects.

• Feasibility is done for the project before execution and once it is ok thenthe orders are in place.

• Presently already these projects are operating from EDN Plant and BHEL

wish to operate the same projects from another plant too i.e. ESD.

Customer Expectations:

BHEL wants to monitor the progress of ESD plant Projects through PS.

BHEL also want to follow the process of Project Execution and Maintenance

Details of Process TO BE mapped in SAP:




V. Business Processes:

Sl.No

BHEL ESD BUSINESSPROCESS

SAP Sub ProcessMODULE

1. Registering Sales Inquiry Sales Inquiry Creation

Monitoring of status of Inquiry

Monitoring of Due date forsubmission through Inquiry List

PS

2. Quotation for Projectorder

Creation of Quotation withreference to Inquiry.

Project Quotation against theSales Inquiry for the execution of the Project

PS

3. Sales Order ByMarketing Department.

Issuance of initial Sales Order withreference to quotation – PS to be

subsequently issued

PS

4. Creation Of Project Project structure for Make TOrder Projects

PS

5. Issuance Of BOM’s andPR from Projects

Issuance of BOMs , PRs andProduction orders from Projectsystems

Creation of Material componentfor WBS

PS

6. Monitoring Of activities

In the Projects meansdeliverables or BOM’s

Monitoring of activities in Project

systems:

Engineering activities

Material Procurement

Manufacturing / testing

Shipping and Billing

PS




7. Sales Order delivery WBS element / Material elementto be delivered

PS

8. Delivery relatedbilling.

Outbound delivery from SD PS

9. PGI from Projectsystem

PGI for shop items (Movement281)

Statistical GR for PR items fromproject systems to enable billingof PR items

PS

10. Picking and Packing.Picking based onnative SAP

transactions. Packinginvolves native SAPtransaction of generating handlingunit and furtherprocess based on‘developments’

Picking and packing in projectsystems

Generation of packing list from

project systems

PS

11. Short shipment fromPROJECT SYSTEMS

Creating short-shipmentmaterial as a separate activityat relevant deliverable WBSlevel

Creation of separate Sales

order (short-shipment type)

PS

12. Third Party Materialto Shop duringexecution

Changes to Sales order (PS) andconsequential changes of Projectsystems for changing a 3 rd partymaterial into shop material

PS




VI. SAP Solution:

No.BUSINESS PROESSS

STEPS /BPP NUMBER

INPUT DATA / SPECIALINFORMATION

TRCODE

OUTPUT RESULT Improvement

1 Project – Create

Provide the Project: ES/1234 and selectthe Profile according tothe requirement andWBS: ES/1234-SH1

CJ20N Project Creation

2 WBS – CreatePROJECT DEF: ES/1234PROJECT PROFILE:ES CJ91

WBS Active WBS Created - ES

3 Network – CreateProject : ES/1234

Network Type : PS04 CJ20N

Valid Until:01.01.2010

Network Created :4000635

4 Create Project CostPlan

Project : ES/1234

And do the cost plan inPPB

CJ20N

Valid Until:01.01.2010

Project ES/1234 Costed – Material + ActivityCosting

5 Create ProjectRevenue Plan

Project : ES/1234WBS - ES/1234-SH1-76

VA01




and do the revenueplanning in PPB

Valid Until:

01.01.2012

Project ES/1234Revenue Plan

Completed BY CreatingSale Order : 12345

6

Project Budgeting –Copy Revenue andCost Plan to BHELBudget Version(Original) – Version11

Project : ES/1234Source : Version 0

Target : Version 11CJ9FS

Execute Revenue and Costplan transferred toBudget Version for

reporting purpose.

7 Budget Planning Project : ES/1234

CJ30

Execute CJ3B Transaction

Copy 100 % of planned cost asBudget. BudgetDocument0100000003posted.

8 Supplement Budget

Project : ES/1234WBS: ES/1234-SH1-76-01Amount : 50,000 INR

CJ36

Execute CJ3B Transaction

Supplement BudgetPosted :100000005document posted.

9Create Project Sale

Order

WBS - ES/1234-SH1-76VA01

Project Sale Order

Created

10Create ProjectPurchaseRequisition.

Project : ES/1234Network Order :12345

CJ20NProject PurchaseRequisition Created: 1234567

11 Material Transfer Project’s/1234 CN33 Material




Network:ES/1234/SH1-0001Materail:E1000

Transferred

12Create ProjectPurchase Order

Project : ES/1234Network Order :4000635 ME21N

Project PurchaseOrder Created :1234567

13

Create GoodsReceipt

Project PurchaseOrder : 1234567

MIGO Material DocumentCreated : 1234567

14

Perform Order

Related/ DeliveryRelated Billing –Project Billing

Sale Order Number:

31001535Invoices Doc Type:ZPBL

VF01Billing DocumentCreated : 2345678

15Display Line ItemActual Report

Project : ES/1234CJI3

Line item ActualReport Displayed

16

Display Cost Report- Plan BasedHierarchical Report :Plan/Actual/Commitment/Rem.Plan/Assigned

Project : ES/1234S_ALR

_87013533

Report Displayedwith correct values

17

Display Cost Report- Plan BasedHierarchical Report :Actual/Commitment/

Total/Plan in COArea Currency

Project : ES/1234S_ALR

_8701

3542


18

Display Project

Structure InformationSystem Report

Project : ES/1234Select Project Cost andProject Revenue andAccruals

CN41


19 Perform – Actual Project : ES/1234 CJ44 Report Executed




OverheadCalculation onProject –

with correct values

20

Perform - ResultAnalysis ( IndivProcessing)

Project : ES/1234KKA2

Results Analysis –Report Executedand resultsreviewed by user.

21

Purchase IndentCreation, ShopManufacturingProductConsumption

Project : ES/0633Network Type : PS02Material : SUITE:CJF07 CJ20N

Purchase IndentCreation, ShopManufacturingProductConsumption –Completed.

22 Create Project withrunning sequencenumber

WBS: ES CJ20N




VII. Process Flow:


CUSTOMER

CUSTOMER ORDER

CUSTOMER ORDERTO BUSINESSORDER

RECEIPT OF INTERNALORDERS BY EDN

RECEIPT OF INTERNALORDERS BY ESD

COMMERCIAL

PMC

NETWORK

WBS

COMMERCIAL

PMC

CUSTOMER ORDERTO BUSINESS ORDER

PROJECTDEF

ACTIVITY

DELIEVERABLES FOREXECUTION

MRP

RUN

WBSRESERVATIONS

PR ORDERS DEL TOWBS STK

PLANNEDORDERDS

PROD ORDERS

GR

SALESDELIVERY

SALES ORDER

PROD EXECUTION

BILLING

PIR’S FOR PROC

GRPROC FROMMM

MAKE TO RDER ITEMS



By Using a sales order, all costs and revenues involved for an order item are

assigned collectively to the item.. You can change the proposal manually. The

requirements type is determined on the basis of the MRP group and the

strategy group in the material master record.

The bill of material transfer component makes it easier to assign material

components to network activities and make this information up-to-date.

Assign bill of material (BOM) items to a network activity manually by

exploding the BOM and then change the BOM,

Assign a very large number of components and can assign components

during the design phase and expect to have to make several changes tothe BOMs.

BOM transfer function to assign individual BOM items to network

activities, the system creates a logical link using a references point.

Unlike the manual assignment of single components, you can

automatically update subsequent BOM changes in the network activity.

If any changes happens in quantities or the material description in a BOM

automatically transfer these changes to the network as well as to the

corresponding purchase requisitions and reservations.

Items from several types of bills of material such as:

Material BOMs

Sales order BOMs

WBS BOMs

WBS BOMs are mainly used together with Production lots. They are bills of

Material that are valid only for a particular WBS element.

Note : If WBS BOMs using with the Project System, it is not necessary to create

production lots)

BOMs from external systems, select activities from all the networks in a project

you can also assign BOM items that do not have a reference point.




set this status, the WBS elements should be having created or released system status.

This TECO status allows

• Assigning networks to the WBS element.

• Post actual costs

• Transfer actual costs

You can cancel the technically completed status. In this case the system sets the

Released status.

Closed (CLSD) status is set for those work breakdown structure or WBS element that

has been completed from both a logistic and an accounting point of view. The Closed

status can be set if the project definition or the WBS element have either the Released

or the technically completed status. The CLSD status prohibits

• Assigning networks, production orders or CO orders to the WBS element.

• Posting actual costs to the WBS element

You can cancel the closed status. In this case the system sets the technically

completed status.





CUSTOMER

CUSTOMER ORDER

CUSTOMER ORDERTO BUSINESSORDER

RECEIPT OF INTERNALORDERS BY EDN

RECEIPT OF INTERNALORDERS BY ESD

COMMERCIALPMC

COMMERCIALPMC

CUSTOMER ORDERTO BUSINESS ORDER

PROJECTDEF

WBS

ACTIVITY

NETWORK

MRPRUN

MR’S wrt to

BOM

SALES ORDER

SALESDELIVERY

BILLING

SPARE ITEMS

Material BOM



PS_01 Date of print: 7/24/2013P 19 f 19

PROJECTDEF

WBS

NETWORK

ACTIVITY

ManualCreation of

PR’s

PO

STATISTICALGR

ORDERRELATED

BILLINGBILLING

THITD PARTY ITEMS

ps bhel new plant bbp

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