tobe pp08 prt process final v1.1
TRANSCRIPT
SAP-TO BE ProcessNAWPP008
PRT Process PRODUCTION PLANNING
Ver1.107.10.2006
STATEMENT OF CONFIDENTIALITY / DISCLAIMER
This document is the property of Caritor, Inc. No part of this document shall be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise without prior written permission from Caritor, Inc.
Table of Contents
Table of Contents
1 PRT Process..........................................................................................................................................31.1 AS IS Process............................................................................................................................................31.2 Core to Be Process....................................................................................................................................61.3 Changes to Existing Organization...........................................................................................................111.4 Description of Improvements and Key Metrics........................................................................................111.5 Notes on Further Improvements..............................................................................................................111.6 Functional Deficit and Method to Remove That......................................................................................111.7 Interface Requirement.............................................................................................................................111.8 System Configuration Considerations.....................................................................................................111.9 File Conversion Considerations...............................................................................................................111.10 Any reports required related to current business process.......................................................................111.11 Any document/output would be printed for this business process...........................................................111.12 Authorization Considerations...................................................................................................................111.13 End User Training Requirements............................................................................................................121.14 Process Flow Chart.................................................................................................................................13
2 SAP Standard Reports....................................................................................................................... 15
3 Custom Developments......................................................................................................................... 18
Caritor Confidential Page ii
naw SAP-TO BE Process
1 PRT Process
TO-BE Document
For SAP R/3 Implementation at New Allenberry works.
Date: 07.10.2006
Sr. No of TO BE document NAWPP008
Ref. Sr. No. Of AS-IS document Tool Crib Process
Name of Business Process: Production Resource Tools Process
Module: Production Planning Sub module: PRT Process
Version no of document: 1.1 Date: 07.10.2006
Version Management This Document is subject to change control. Every change of the document has to Undergo change control procedure and has to be registered in the following table
Version Change Prepared By Date
1.0 Pradeep Kumar Verma 22.08.2006
1.1 Changes in existing organization , functional deficit, file conversion has been updated.
Ananth Raj 07.10.2006
1.1 AS IS Process
Tool Crib Process
Inventories are being checked for many of the PRTs
Beside direct consumption items (Raw Materials), all those materials (tooling etc) which come to NAW belong to one or the other product.
Operational requirement are such that to plan production of a product one needs to have , beside availability of raw materials , details like availability of various other tools required to manufacture that product.
These may be Cutters, special tools, Jigs, Fixtures, Gauges / Instruments, Work Instructions or any other specific item.
Caritor Confidential Page 3
naw SAP-TO BE Process
NAW wants that while planning for a product; all the details regarding availability of PRTs for that particular product is retrievable from System by the PPC user on one click of the button.
‘F’ Tool room Activities
Basically Tool Room’s job is to manufacture/ repair Tools, Gauges, Fixtures and Jigs required by Production. The complete activity is defined in the Activity Chart.
Caritor Confidential Page 4
naw SAP-TO BE Process
Caritor Confidential Page 5
naw SAP-TO BE Process
1.2 Core to Be Process
PRT Process:Introduction of PRT:
Unlike machines and fixed assets, production resources and tools (PRTs) are movable (not stationary) operating resources that are required to perform an activity and can be used repeatedly. For example, PRTs include documents, engineering drawings, jigs and fixtures, and measurement instruments. NAW is using jigs,Guages, fixture and small cutting tools which will be maintained as PRT in SAP system .We can assign production resources/tools to internal and external activities and can use the assignment to determine:
· Quantity,· Operating time, or· Dates
of the PRTs required to carry out the activity.There are several categories of production resources and tools in the SAP system. The category determines the characteristics and business functions that a PRT can have. Production resources/tools can be created with the following categories.
Material PRT has its own material master record with the view “PRT”. A material PRT can either be purchased or produced. It can also be stocked and both value and quantity can be tracked.
Miscellaneous PRT has its own PRT master record and can neither be procured nor kept in stock.
Document PRT has its own document info record, (for example engineering drawings or NC programs). These PRTs can be managed using the SAP document management.
Equipment PRT has its own equipment master record and has the full equipment functionality. This category is particularly useful for those production resources or tools which are maintained by self or serviced at regular intervals. With the equipment category, we can furnish proof of service or usage values for the production resource/tool.
In NAW we are using only MATERIAL PRT .
Structure of PRT:
Structure is having Basic data and Default values, which are detailed below:
Basic data:
Basic data contains general information about the PRT (Production resource or tool). Important basic data includes the task list usage and the requirement record indicator.
Default Values:
Caritor Confidential Page 6
naw SAP-TO BE Process
This is the next data of PRT contains the default values. These values are proposed while allocating the production resource to an activity.
Control Key: It specifies how the PRT is to be handled after it is allocated to an activity (for example, whether it is scheduled).
Standard text key is used to store texts that are required often. (e.g. a text describing how to work with the PRT). In NAW we will not use standard text for PRT’s
Quantity formula: The system uses formulas for quantity and usage value to calculate the required quantity of the PRT and its usage value. In NAW we will use SAP Standard Formulae SAPF01 to calculate the quantity of PRT used.
The offset determines when a PRT should be available; that is, offset to the start or finish of an activity. It also determines when the PRT is no longer required. We are not using offset in NAW .
To create a production resource/ tool as a material, create a material master in which One maintain the Production resources/tools view. The PRT data are plant specific.
MENU PATH: LogisticsMaterials Management Material Master Material Create (general) immediately
The initial screen for creating a material appears.
Caritor Confidential Page 7
BASIC DATA DEFAULT VALUES
Control Key Standard text Quantity formula Offset
PRT Structure
naw SAP-TO BE Process
Enter the relevant data on the initial screen
To create a material PRT we must enter a material type which allows us to maintain the Production resources/tools view. One such material type is FHMI.
Choose Continue.
1. The Select Views dialog box appears.
Select the Prod. Resources/Tools view and choose Continue.
2. The Organizational Levels dialog box appears.
Enter the plant to which the production resource/tool is assigned and choose Enter.
3. Maintain the basic data and the default values for task list allocation
If we have allocated a PRT to an activity, we can no longer change the base unit of measure and the unit of issue in the master record.
4. Save the material, now material PRT will be created. NAW will be using following number ranges, serial No. and Material Type for different kind of Materials.
Material No Range Serial No Batch PRT Material Type
Jigs and Fixtures External Internal Applicable Yes FHMI
Gauges External Internal Applicable Yes FHMI
Cutters External NA Applicable Yes FHMI
Cutting Tools Internal NA Applicable Yes FMHI
Checking PRT Availability:
In production order to do availability check for PRT’s we will start the overall check manually, which will be done as given below.
Function Availability PRT in the order header or on the activity overview in the Production Order.
The system checks the availability of all PRTs in the production order. If there is a material shortage, the network is given the material shortage status. If a PRT is unavailable, this is also
Caritor Confidential Page 8
naw SAP-TO BE Process
recorded in an error or warning log. For storage and issue of tools refer the Flow chart and also tool crib process is covered in MM process. Refer MM To Be MM008.
Caritor Confidential Page 9
naw SAP-TO BE Process
Caritor Confidential Page 10
naw SAP-TO BE Process
1.3 Changes to Existing Organization
PRT stocks will be available online and availability check for these PRTs at order level will be done.
1.4 Description of Improvements and Key Metrics
PRT availability check will be transparent and will be available online.
PRT can be blocked for particular operation.
Total usage of the PRT will be available which describes for which material this PRT has been used and for which order and what quantity has been produced.
1.5 Notes on Further Improvements
NIL
1.6 Functional Deficit and Method to Remove That
Stock of the PRTs should be continuously monitored in the system.
1.7 Interface Requirement
There are no interface requirements as no data is to be transferred from legacy system to SAP system.
1.8 System Configuration Considerations
Specific setting is required for order type dependent parameter and Specific setting is required for PRT quantity calculation.
1.9 File Conversion Considerations
Usage of the PRT can be downloaded from SAP system to excel and print out can be taken if required.
1.10 Any reports required related to current business process
Usage of the PRT is available as a standard SAP report.
1.11 Any document/output would be printed for this business process
PRT usage report can be printed if required.
1.12 Authorization Considerations
All authorization consideration will be transactional related which is elaborated in 1.13.
Caritor Confidential Page 11
naw SAP-TO BE Process
Business Roles Number of Users
Business Manager 1
Operations Manager 1
Master Production Scheduler / MRP Controller 1
Planning Engineers Nil
Shop floor supervisor Nil
1.13 End User Training Requirements
Business User Segments Number of Users Type of Transaction Geographical Location
Business Manager 1 Display, Reports
Operations Manager 1 Display, Change, Reports
Master Production Scheduler / MRP Controller
1 Display, Change, Reports
Planning Engineers Nil Create, Change, Display
Shop floor supervisor Nil Display
Caritor Confidential Page 12
naw SAP-TO BE Process
1.14 Process Flow Chart
MPS/MRP
Planned Orders
Production Orders
(Created Status)
Production
Orders (Released
status)
Customer Orders
Demand
Plan
Mat. Availabilit
y
N Y Missing Parts List
SL stock, open PO/Pur.Ord, Lead times, lot sizes.
Figure 1: Production Order Creation
Caritor Confidential Page 13
naw SAP-TO BE Process
List of Released
Production Orders (Pull
List)
Production Orders
261
Stores
Figure 2: Goods Issue to Production Order
Sign-off (Approval) for this document:
Name of Team members: Organization / Bus. Unit Signature
Mr A.Sen NAW
Mr N.M. Ogra NAW
Mr S.M.Sharma NAW
Pradeep Kumar Verma (Consultant PP) Caritor
Caritor Confidential Page 14
naw SAP-TO BE Process
2 SAP Standard Reports
SAP Standard Reports
Sl No: Report Description Selection Criteria Output
01 Stock Overview (MMBE) Material, Plant & Storage location Stock Status at each storage location
02 Material List (MM60) Material, Plant, Material Type & Material Group
Material Master Details
03 Missing Parts Information List (CO24)
Plant from “Selection from Reservations” & MRP Controller from “Selection from Order” with Profile for Material View
Shortage List
04 Production Order Information System (COOIS)
List: Item
Header
Profile (Standard)
Material
Production Order
Production Order Type
MRP Controller
Selection status Profile or System Status
List: Item
Profile (Standard)
Material
Production Order
Production Order Type
MRP Controller
Selection status Profile or System Status
List: Confirmations
Profile (Standard)
Production Order
Production Order Type
MRP Controller
Selection status Profile or
List of Orders based on Selection Criteria
List of Orders based on Selection Criteria, with material components
List of Orders based on Selection Criteria, with confirmation details
List of Orders based on Selection Criteria, with Goods Issue & Receipt details
Caritor Confidential Page 15
naw SAP-TO BE Process
SAP Standard Reports
Sl No: Report Description Selection Criteria Output
System Status
List: Documented Goods Movement
Profile (Standard)
Production Order
Production Order Type
MRP Controller
Selection status Profile or System Status
05 PRT Where used in Task List (CA70)
Production resources/Tools
Material
Plant
Time Key Date
Task List Type From
Status form
Usage from
Plant
Planner Group from
Material From Material number
PRT Where used list with all details .
06 PRT Usages in order
( CF11)
Production resources/Tools Material
Plant
Order Selection
Plant
Production Scheduler
MRP controller group
Order type
Schedule start date
Scheduled delivery date
Order
It will give PRT usages counter
Caritor Confidential Page 16
naw SAP-TO BE Process
SAP Standard Reports
Sl No: Report Description Selection Criteria Output
Material
Person in charge
Selection profile status
Caritor Confidential Page 17
naw SAP-TO BE Process
3 Custom Developments
Print Requirements
Sl No: Report Description Selection Criteria Output
Development Requirements
Sl No: Report Description Selection Criteria Output
1.0 PRT Loan Slip
Caritor Confidential Page 18