TOBE PP08 PRT Process Final v1.1

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


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.



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:



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.


BASIC DATA DEFAULT VALUES

Control Key Standard text Quantity formula Offset

PRT Structure


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



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.



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.



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



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



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



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


MRP Controller


List: Confirmations

Profile (Standard)

Production Order


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





System Status

List: Documented Goods Movement

Profile (Standard)

Production Order


MRP Controller


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





Material

Person in charge

Selection profile status



3 Custom Developments

Print Requirements


Development Requirements


1.0 PRT Loan Slip


TOBE PP08 PRT Process Final v1.1

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