A STUDY ON ENTERPRISE RESOURCE PLANNING (ERP) By M.

MOULISHANKAR
Register No:

10MBA1042 Of

VIT UNIVERSITY CHENNAI

PROJECT REPORT Submitted to the FACULTY OF MANAGEMENT STUDIES In partial fulfilment of the requirement For the award of the degree Of MASTER OF BUSINESS ADMINISTRATION VIT UNIVERSITY VIT BUSINESS SCHOOL CHENNAI MAY&JUNE - 2011

BONAFIDE ISSUED BY THE COLLEGE

BONAFIDE ISSUED BY THE COMPANY

ACKNOWLEDGEMENT

If words are considered as symbols of approval of acknowledgement, then let the words play the heralding role of expressing my gratitude to all those who have helped me directly (or) indirectly in this project.

First of all thank our God Almighty for successful completion of this project. I owe my sincere thanks to Mr.Sanjeet Pandey, Senior Executive and Mr.Rajiv Kumar Malhotra , Delivery Manager for permitting me to do this project.

I also wish to convey my sincere thanks to my project Manager Mr.Mukesh Sharma , for his encouragement and guidance for the completion of this project. I would like to thank my project guide Mr. Mukesh Hirwani, for the immense support during the project.

I would like to thank all the staff of management studies for their good co-operation in clarifying various concepts. Last but not the least I am very much indebted to my family and friends for their warm encouragement and moral support in conducting this project work

TABLE OF CONTENTS:

S.No 1 2 3 4 5 6 7 8 9 10 11 12

Title Company Profile Introduction Learning Objective Area of ERP Tools used in ERP Platform to develop ERP Inventory Management Purchase Order Workflow of the process Production & Planning process Quality process Learning Outcome

Pg.No 6 9 9 10 10 11 11 14 15 17 19 20

Wipro Companies: Wipro Consumer Care & Lighting: Wipro Consumer Care and Lighting (WCCLG), a business unit of Wipro Limited, started with vegetable oil production in 1947 and has since come a long way and established a profitable presence in the branded retail market. With a vast plethora of products spanning soaps, baby care products, health and wellness, Wipro's products have touched the lives of millions of consumers across India and global markets. It is also a leader in institutional lighting in specified segments like software, pharma and retail.

Wipro Consumer Care and Lighting has been one of the fastest growing FMCG companies, both organically and through acquisitions. Some of the Wipro products are

Wipro Baby Soft WBS Saffron & Milk of Almond soap WBS Tulsi and Almond Oil Soap WBS Powder Wipro Bulbs Wipro Laptop WBS Baby Oil WBS Diapers Wipro Baby soft Nappies Wipro Baby soft Feeding bottles and accessories

Wipro Infrastructure Engineering Wipro Infrastructure Engineering, a division of Wipro Limited, delivers precision-engineered, world-class hydraulic cylinders, components and solutions, and truck hydraulic components to OEMs globally in the infrastructure and related industries. It represents the Kayaba, Kawasaki, Sun Hydraulics and Teijin Seiki range of hydraulic products in India. With state-of-the-art manufacturing facilities and extensive product

development and testing facilities, Wipro Infrastructure Engineering has emerged as a leader in the hydraulic cylinders and truck tipping systems market in India. WiproEcoEnergy Wipro EcoEnergy, the renewable energy services arm of Wipro, is a one-stop shop for all the renewable and alternative needs of your organization. Our scope of work provides the entire range of sustainable and energy efficient solutions such as, Customized clean-energy solutions for institutional clients Energy Efficiency (reduce) and Renewable Energy (replace) Consulting, implementation and managed services We work on the industrial scale; our technologies are proven, have direct customer relevance, and are commercially viable. We are technology agnostic because we work on best technologies and recommend the same based on your unique environment. Wipro EcoEnergy provides clean and sustainable energy solutions for all kinds of spaces, from factories to institutions and from offices to homes.

Wipro GE Medical Systems Limited Wipro GE Medical Systems Limited is focused on delivering advanced solutions for significant challenges faced by healthcare organizations today. Wipro GE Healthcare, a joint venture between Wipro and GE, is part of GE Healthcare South Asia and caters to customer and patient needs with a commitment to uncompromising quality. We successfully manage a continuum of clinical information across the entire enterprise and our highly energized team provides superior customer and patient satisfaction, maximizing customer productivity with Six Sigma quality and uncompromising integrity. Wipro BPO: In tune with the Wipro philosophy of growing leaders, the culture and environment at Wipro BPO is one that promotes self-development in perpetuity.There are

career opportunities available to suit each and every individual - opportunities exist across diverse business and service lines ranging from Banking & Capital Markets, Insurance, Travel & Hospitality, Retail & Consumer Products, Energy and Utility, Technology, Manufacturing, Telecom & Healthcare sectors. We have built deep expertise in Processes like Finance & Accounting, Procurement, Marketing, Legal, HR Services, Tech Support, Customer Services and Analytics. At Wipro BPO, you will get a in-depth understanding about the best way to service the customer requirements by leveraging Quality, Innovation, a self-sustaining Process Framework, IT expertise and Domain knowledge.

Company Profile: Wipro IT Business, a division of Wipro Limited (NYSE:WIT), is amongst the largest global IT services, BPO and Product Engineering companies. In addition to the IT business, Wipro also has leadership position in niche market segments of consumer products and lighting solutions. The company has been listed since 1945 and started its technology business in 1980. Today, Wipro generates USD 6 billion (India GAAP figure 2009-10) of annual revenues. Its equity shares are listed in India on the Mumbai Stock Exchange and the National Stock Exchange; as well as on the New York Stock Exchange in the US. Wipro makes an ideal partner for organizations looking at transformational IT solutions because of its core capabilities, great human resources, commitment to quality and the global infrastructure to deliver a wide range of technology and business consulting solutions and services, 24/7. Wipro enables business results by being a transformation catalyst. It offers integrated portfolio of services to its clients in the areas of Consulting, System Integration and Outsourcing for key-industry verticals.

Leadership at Wipro: building trust: With more than 100,000 associates from over 70 nationalities and 72 plus global delivery centres in over 55 countries, Wipros services span financial services, retail, transportation, manufacturing, healthcare services, energy and utilities, technology & telecom

Wipros unwavering focus has been on business transformation with matchless innovation in service delivery and business models. More than 800 active clients that include governments, educational institutes, utility services, and over 150 Global Fortune 500 enterprises have benefited from this approach.

Innovation at Wipro: delivering enhanced business performance Wipro is at the forefront of technological and business co-innovation with 136 patents and invention disclosures. With enhanced business performance at the core of its deliveries due to its strong R&D and Innovation focus. One of the worlds largest third party R&D services provider, Wipro caters to product engineering requirements in multiple domains. Most of the technology that you come across in daily life - airplanes, automobile navigation systems, cell phones, computing servers, drug delivery devices, microwaves, printers, refrigerators, set top boxes, TVs - will find a Wipro component in them. Our service portfolio includes product strategy and architecture, application and embedded software, electronic and mechanical hardware, system testing, compliance and certification and product sustenance and support.

World over, businesses are transforming constantly, in order to get better and better. Wipro provides the right insight, technology and support to help businesses transform, making business functions simpler, faster and better. In other words, Wipro transforms businesses that help transform lives.

Completing the circle of transformation: A long history celebrates Wipros journey as one of the most trusted global brands. This trust extends to a series of products, services and solutions that cover diverse businesses - from consumer care to cutting-edge information technology innovations. Over the

years, along with our business, our identity has undergone a transformation, adapting to the changing global dynamics. Heres a snapshot of our journey till date.

Beginning Started off in 1945 as a vegetable oil manufacturer in Amalner, the Indian heartland of the state of Maharashtra. The company was called Western India Products Limited. Rise Diversified operations into hydraulics and information technology. Starts making moves in the global market and Azim Premji selects the name Wipro, derived from Western India Products. Consolidation In the 1990s Wipro built a reputation across domains for a series of products and services including consumer care (Wipro Shikakai, Wipro Baby Soft), branded hydraulic cylinders, products (Wipro branded PCs, laptops, peripherals), In all these endeavors, the Wipro identity has been a powerful motivator in driving transformation in line with the worlds needs. A consensus has been built around our brand that is reflected in the definition of our identity.

Converging trends for the next step in technology evolution:

The Communication industry has gone through a revolution. On one side there are traditional pressures on reducing Cost to Serve while on the other hand, there is a great emphasis on revenue and growth. Emphasis of Communication Service Providers has changed from technology infrastructure to innovative value added services.

We at Wipro have leveraged our two decades of experience in this segment to help achieve your business objectives. We not only understand the network technology but also have deep rooted competence on driving IT transformation and operational efficiencies. On the technology side, Wipro has the unique distinction of being unilaterally strong on the Network, Devices, IT and Service Platform. On business operations, years of management of L2C and T2R operations puts us in the forefront for transformation, optimization and re-engineering with committed business benefits

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Various Phases inside the company: There are many processes where the project flows inside the company. The project has to flow in all the phases then only it should completed. And there will be many managers and supervisor inside the company to test and supervise functions of various phases in the company. The important phases that are essential for the project are

Project planning, feasibility study: Establishes a high-level view of the intended project and determines its

goals.

Systems analysis, requirements definition: Defines project goals into defined functions and operation of the intended application. Analyses end-user information needs.

Systems design: Describes desired features and operations in detail, including screen layouts, business rules, process diagrams, pseudo code and other documentation.

Implementation: The real code is written here.

Integration and testing: Brings all the pieces together into a special testing environment, then checks for errors, bugs and interoperability.

Acceptance, installation, deployment: The final stage of initial development, where the software is put into production and runs actual business.

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Maintenance: What happens during the rest of the software's life: changes, correction, additions, moves to a different computing platform and more. This, the least glamorous and perhaps most important step of all, goes on seemingly forever.

Designations inside the company for the project: Project Delivery Manager

Project Portfolio Manager

Project Manager

Project Lead

Project Analyst

Project Engineer

Problems facing in the development of the project:

Improper communication between managers Understanding between developers and testers was not efficient. Less resource in which it cannot be delivered in time. No proper planning in which if planning is not good other phases will be affected.

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Team work is quite important.

Introduction: Enterprise Resource Planning (ERP) has been widely implemented application software all the industries these days. Most of the manufacturing companies try to adopt ERP to employ the best practices. This ERP system have fundamentally changed the work of IT organizations. ERP is better to implement in phase wise, not just installing the system at a time all functional modules. If companies do the implementation part phase by phase, then the firm will get great benefits from the software. There are lot of objectives that most of the companies plan to achieve with the help of ERP implementation. To achieve the potential growth rate Increase the return on investment Availability of the relevant information on regular basis Better decision support system Scalability of the business operations Repeatable Processes Lower Training Costs Reduced Inventory Costs Improved Business Visibility Increased Profits

Learning Objective: The main learning objective is to understand all the details about the ERP software package. It means why the company needs the ERP software and how they are customize the software according to their needs and how they are developing the ERP packages

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for a company and what kind of process involved in the developing the ERP and what kind of tools and languages used to develop ERP.

Area of ERP: There are many areas and departments in organization which use ERP for their works. Different departments use the ERP software for different purposes they need not be used for the same purposes. The areas which use ERP software are Financial Management Supply Chain Management Manufacturing Project Accounting Customer Relationship Management Workspace Collaboration Service Management Human Resource Management Database Log Electronic Banking

Tools used in ERP: The tool which is used to develop ERP software is Microsoft Dynamics. Microsoft Dynamics AX 2009 is a comprehensive business management solution for midsized and larger organizations that works like and with familiar Microsoft software to help you improve productivity. Microsoft Dynamics AX is built to make it easy to do business across locations and countries by consolidating and standardizing processes, providing visibility across your organization, and helping simplify compliance.

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Built on a proven foundation of advanced technology, Microsoft Dynamics AX helps customers seize global business opportunities with support for high transaction rates and hundreds or thousands of users across multiple sites. It also includes support for local languages, currencies, and legal requirements for more than 36 countries.

Platform to develop ERP: The MorphX language is used to customize the ERP software package according to their client. The development environment in Axapta is called The MorphX Development Suite or just MorphX. MorphX is an integrated development environment which consists of the Application Object Tree, the X++ programming language and several tools which provide an overview of the application. MorphX was used to build Axaptas application modules. Axapta is far easier to customize than other ERP packages. Developing a modern user interface can be a time consuming process. In MorphX, the user interface, including both forms and reports, are by default almost entirely generated by the system. Inventory Management: The Inventory management is the active control program which allows the management of sales, purchase and payments. Inventory management software helps create invoices, purchase orders, receiving lists, and payment receipts and can print bar code labels. An inventory management software system configured to your warehouse, retail or product line will help to create revenue for your company. The Inventory Management will control operating costs and provide better understanding. The inventory management means managing the storage of goods for the future needs. The inventory management includes various processes like purchase, sales, storage, return etc. The inventory classification is classified into various departments. They are

Components Raw Materials Tools(Moulds) Bill of Purchase

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Consumables Packing Material Tool room items Health care items

Details about the inventory process: Inventory classification Inventories classification is used for both sale and purchase items. These inventories are classified based on the product families and lines within the organization. Item structure/Codification These item structure and codification are well defined for inventory items. Item structure of inventory items are comprised of alpha numeric numbers. Product Items/Variants Product items should be maintained in inventory. And it can be of different sizes and configurations. Inventory Valuation methods This inventory valuation method is used to compute value of inventory for different set of inventory items. Unit of measurement & Unit Conversion The different measurements & conversion are used within the organization for inventory items. Inventory stock levels Meter Pcs/No Tons Each Kgs

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These inventory stock levels are controlled through Min/Max Safety stock levels. Then only we can predict the demand and able to supply the goods when they needed. Inventory Transactions Some of the inventory transactions are Stock Receipt Stock Issue Job work transactions Stock transfers transactions

Receipt of materials from vendors Once the materials are received form the vendor the receipt should be checked and it has to be stored and informed to purchase department. Store department will receive the material with the receipt. Inventory update for accepted items Then the material has been checked and the receipt also will be checked. Then the stores approval authority will update the stock. Material Rejection Material rejection can happen because of two reasons. They are either the received material is damaged or the quality of the material is not good. Job work process The company can do the production of the goods either by themselves or they can do the production of goods outside by the outsourcing. Warehouse Structure Warehouse is the place where the company can store the good for future purpose. Once the goods are produced they sent the goods to the warehouse from there the suppliers can get their goods. Bar Coding Bar Coding is a series of parallel vertical lines (bars and space), that can be read by bar code scanners. It is used worldwide as

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part of product packages, as price tags, carton labels, on invoices even in credit card bills and when it is read by scanners Statistical Analysis The companies usually require MIS reports to improve the productivity.

Purchase Order: It is procurement of required raw materials, Packaging Material, Sub Assembly and other Non Inventory Materials. It automates the processes of identifying potential suppliers awarding purchase order to the supplier, and billing processes. Purchase module is tightly integrated with the inventory control and production planning modules.

The functionalities of ERP package are

Non-Returnable Gate Pass Non-Returnable Gate Pass Returnable Gate Pass Returnable Gate Pass

- Inbound - Outbound - Inbound - Outbound

Non- Returnable Gate Pass - Inbound: Is a follow-on activity to a purchase order involves goods receipts. It forms the basis for updating the financials and inventory records and can trigger warehouse management and quality management processes. When the process is initiated, its referred as ongoing. When the goods received by the customer, the process referred as completed.

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Non- Returnable Gate Pass - Outbound: Once the goods are issued to the vendor from the company is referred as outbound operation. When the process is initiated, it is referred as ongoing. When the person receives the orders, it is referred as completed.

Returnable Gate Pass Inbound: Once the goods received from the vendor and again have to be sent it to them. The outstanding goods have to be received from vendor and dispatched again to the party. When the process is initiated, it is referred as ongoing. When the party sends the order to the vendor, the process refers as received. Once the process is over, it is referred as completed.

Returnable Gate Pass Outbound: The issued goods are sent it back to the vendor from the company known as outbound operation. When the process is initiated, it is referred as ongoing. When the customer sends the order to the vendor, the process refers as received. Once the process is over, it is referred as completed.

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Manual Document for RGP Inbound: Auto-generated document.

Recorded by: Recorded date: Document created: Task notes:

mhirw 5/19/2011 5/19/2011 Returnable Gate Pass - Inbound

Form name: RGP/NRGP...................................................................................21 Form name: RGP/NRGP...................................................................................23 Form name: Infolog.........................................................................................25 Form name: Infolog.........................................................................................26 Form name: Infolog.........................................................................................27

1. Click Area Page node: Accounts payable -> RGP/NRGP Master.

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Form name: RGP/NRGP

2. Create a new record in the RGP/NRGP form. Press Ctrl+N to create a new record

3. Change Account number from '' to '3002'. 4. Change Name from '' to 'Blue Wonder Lights'. 5. Change External Document No from '' to 'Doc13'. 6. Change External Document Date from '' to '5/19/2011'. 7. Save the record in the RGP/NRGP form. Press Ctrl+S to save the record

8. Create a line i.e., go to Line section and press Ctrl + N. 9. Create a line i.e., go to Line section and press Ctrl + N. 10. Change Item Type from '' to 'Item'. 11. Change Item number from '' to 'B-R6'. 12. Change Name from '' to 'Battery Penlight R6'.

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13. Change Quantity from '0.00' to '10.00'. 14. Change Qty Recv Outstanding from '0.00' to '10.00'. 15. Change Qty Sent Outstanding from '0.00' to '10.00'. 16. Save the record in the RGP/NRGP form. Press Ctrl+S to save the record

18. Change Item Type from '' to 'Sample'. 19. Change Item number from '' to 'B-R14'. 20. Change Name from '' to 'Battery Baby R14'. 21. Change Quantity from '0.00' to '20.00'. 22. Change Qty Recv Outstanding from '0.00' to '20.00'. 23. Change Qty Sent Outstanding from '0.00' to '20.00'. 24. Save the record in the RGP/NRGP form.

25. Make sure the selection is changed in table WI_RGPNRGPLine to: Item Item er Name Qua ntity Quant Quant Qty ity receiv ed Item B-R6 Batter y Penlig ht R6 10.0 0 0.00 0.00 ity Sent Recv Outstan ding 10.00 10.00 Qty Sent Quanti Outstan ding Recv/S ent 0.00 5/19/2 5/19/2 011 011 Sendi date Receiv ing date

Type numb

ty to be ng

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27. Click Area Page node: Accounts payable -> RGP/NRGP Master. Form name: RGP/NRGP

28. Make sure the selection is changed in table RGP/NRGP Master to: RGPN pe RGP/NR Date RGPT ype Vendor/ Custom er Accou nt numb er RGP 000030_2 34 5/19/20 11 Inbou nd Vendor 3002 Blue Wond er Lights Name Externa l Docume nt No Doc13 Externa l Docume nt Date 5/19/201 1 Ope n Stat us

RGPTy GP Id

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29. Change Quantity to be Recv/Sent from '0.00' to '5.00'. 30. Make sure the selection is changed in table WI_RGPNRGPLine to:

Item Type

Item numb er

Nam e

Quant ity

Quant ity receiv ed 0.00

Quant ity Sent

Qty Recv Outstan ding

Qty Sent Outstan ding

Quantit y to be Recv/S ent 0.00

Sendin g date

Receivi ng date

Sam ple

BR14

Batte ry Baby R14

20.00

0.00

20.00

20.00

5/19/20 11

5/19/20 11

31. Change Quantity to be Recv/Sent from '0.00' to '10.00'. 32. Click the Receive button.

33. Click Yes in the Receive form. Are you sure want to receive the inventory.

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Form name: Infolog

34. Change Quantity received from '10.00' to '5.00'. 35. Change Qty Recv Outstanding from '0.00' to '5.00'. 36. Change Quantity to be Recv/Sent from '0.00' to '5.00'. 37. Change Quantity to be Recv/Sent from '0.00' to '10.00'. 38. Click the Send button.

39. Click Yes in the Send form. Are you sure want to Send the inventory.

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Form name: Infolog

40. Change Quantity received from '10.00' to '5.00'. 41. Change Quantity Sent from '0.00' to '5.00'. 42. Change Qty Recv Outstanding from '0.00' to '5.00'. 43. Change Qty Sent Outstanding from '10.00' to '5.00'. 44. Change Quantity to be Recv/Sent from '0.00' to '5.00'. 45. Change Quantity to be Recv/Sent from '0.00' to '10.00'. 46. Click the Receive button.

47. Click Yes in the Receive form. Are you sure want to receive the inventory.

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Form name: Infolog

48. Change Quantity Sent from '0.00' to '5.00'. 49. Change Qty Sent Outstanding from '10.00' to '5.00'. 50. Change Quantity to be Recv/Sent from '0.00' to '5.00'. 51. Change Quantity to be Recv/Sent from '0.00' to '10.00'. 52. Click the Send button.

53. Click Yes in the Send form. Are you sure want to Send the inventory.

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Form name: Infolog

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Workflow of the process: The workflow is nothing but the step by step procedure involves in the particular process. It means the procedure or the continuous step to do one process. The workflow of the process takes place both inside and outside of the company. If the workflow outside the organization means the process of taking purchase order or sales order. The best example for the workflow process is purchase order inside the company. The workflow process inside the company is if the new employee requires laptop for his work then he needs to inform this to his senior officer. Then the senior officer has to check and decide whether he needs laptop for his work. If the senior officer decided that the new employee needs the laptop then the senior officer has to submit the purchase order details to the purchasing authority persons. If the purchasing authority persons satisfied with the purchase order details then they will approve it and they will send it to the finance department. If the purchasing authority persons are not satisfied with the purchase order details then they will send back the order details to senior officer then again he has to modify the order details and submit to the purchasing authority.

FLOWCHART FOR THE PURCHASE DEPARTMENT

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START

CREATE PURCHASE ORDER PURCHASE ORDER DETAILS SUBMIT

PURCHASING AUTHORITY

REJECT & REMARKS

A/R

ACCEPT & REMARKS

FINANCE DEPARTMENT

STOP

Production & planning Process:

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The process of production planning is central to the success of any manufacturing company. In general terms, the production planning process involves generating a plan to satisfy customers in a manner that results in a reasonable profit. The specifics of the production plan should vary company to company, and industry to industry. Sales and marketing staff input customer needs to production planning. These needs include requirements volume and timing, target service levels, target lead times, and prices. Production planning incorporates a multiplicity of production elements, ranging from the everyday activities of staff to the ability to realise accurate delivery times for the customer. With an effective production planning operation at its nucleus, any form of manufacturing process has the capability to exploit its full potential.

Steps involved in the Flowchart: Receipt of order

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The order received is given to planning to plan and execute production. The production activity is done by customer order received by other customer. Production Planning The companies have to plan their production and they should fix monthly target according to that they have to plan their production process. They have to consider the availability of stocks and production capacity constraints. Raw Materials The raw materials are the most important thing which is used for the production of goods. So the companies have to concentrate more on the raw materials. Receipt of material from vendors The materials are received from the supplier along with the receipt, store checks material against the purchase order. Quality Inspection The quality inspection should be done in all the companies then only the company can give the best quality of goods which the people needs. So they should implement strict rules for the quality inspection. Review production scheduling The production department makes the daily target based on the monthly schedule given by planning department. The production department takes necessary actions to complete production as per schedule. Production Execution

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The companies after finishing the production works they have to give the same to shop floor to start production operations.

Dispatch Once the goods are completely finished then the goods will be dispatched after all the checks, packing instructions and manual.

Quality Process:

Quality control is a process employed to ensure a certain level of quality in a product or service. The basic goal of quality control is to ensure that the products, services, or processes provided meet specific requirements and are dependable, satisfactory, and fiscally sound. Essentially, quality control involves the examination of a product, service, or process for certain minimum levels of quality. The goal of a quality control team is to identify products or services that do not meet a companys specified standards of quality.

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Quality Assurance is the systematic monitoring and evaluation of the various aspects of a project, service or facility to maximize the probability that minimum standards of quality are being attained by the production process. QA cannot absolutely guarantee the production of quality products.

Quality Management Process: Quality Management System The quality management system means it will efficiently checks the quality of the goods which is produced in the company. Material Receipt
If the received materials require Quality checks, then they are quarantined and sent for QC Inspection.

Draw Samples The companies have to check the number of samples based on the sampling procedure. Perform QA Testing The companies will check the different parameters which require different materials. The quality assurance performs all the tests on the samples. QA Disposition Then the quality assurance department after inspection gives disposition as Accepted or Deviation or Rejected based on the findings. Learning Outcome:

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The main thing which I have learnt is how to prepare the documentation for the various operations in a module. During our period I had prepared document for the Returnable Gate Pass-Inbound. And also I came know the strength and weakness of the documentation. It is the best guidance for the new users. Using that documentation a new person can understand the ERP process clearly. I came to know about the importance of the documentation. And also I have learnt about the importance of ERP package and needs of the ERP software package. I also understood how those ERP package is developed and customize for the particular companies according to their needs.

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