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SAP

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

SAP Overview
SAP Background
SAP Integration & Data Structures

Overview of SAP Production Planning (PP)


Reporting in SAP
2

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SAP Background

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

What Does SAP Stand For?


Systems

Applications and
Products in Data Processing

(Or in German

Systemanalyse
Und

Programmentwicklung)
4

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Who Is SAP?
Founded in 1972, SAP is the recognized leader in providing
collaborative business solutions for all types of industries and for
every major market
Headquartered in Waldorf, Germany, SAP is the world's largest interenterprise software company, and the world's third-largest
independent software supplier overall
SAP ranks as the world's third-largest independent software provider
SAP invests almost 12% of its revenue on research and development
SAP is used by more than half of the worlds top 500 companies
Has industry-specific functionality for 19 + industries
46 country-specific versions covering 28 + languages

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

SAP Integration & Data Structure

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

SAP Integration
Flexible: Configuration of the SAP modules to suit business needs

Flexible

Real-time:
Updates information immediately in the system as the data is saved
Provides improved access to real-time, integrated information
Reduces operational costs

Real-time

Integrated
Audit
Trail

Online

Audit Trail: All transactions can be tracked to the person entering or


changing data by their SAP user ID
Online: Display information and reports as you need them
Integrated:
Provides an enterprise with a common business language and the ability to develop global
processes and data structures
Increases the coordination of departments
Business workflow orientation versus stand-alone applications
Real-time ripple effect of data through all business functions
Seamless integration of data between business functions (e.g., automatic financial postings based
on transactional processing in all modules)
One-time data entry ensuring data consistency and reliability

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Integrated SAP backbone


SAPs strength is built around an integrated data platform

Product 1

Benefits

Product Lines

Product 2

Real-time access
to information

Product 3
Product 4

Corporate
Mfg.
HR
Quality
Finance

Spares
North
Latin
Asia
America America

Mid Europe
East

Regions
8

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Consistency of
processes across
products and
regions
Reduction in cycle
time

Types of Data in SAP R/3

Organizational Data
- Validation, check tables (e.g., ABAP Tables,
Source Code Tables)

Master Data
- Static data (e.g., material, vendor, Cost Center,
G/L Account, etc.)

Transaction Data (Movement Data)


- Data created by business activities (e.g., requisitions,
Purchase Orders, G/L postings)
- Document Principle: 1 business transaction = 1 SAP
document
9

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SAP structure simplified

R/3 INSTANCE SHARED PROGRAMS


R/3 Code
Custom ABAPs
Language Files

10

R/3 CLIENT SHARED DATA


Customers
Suppliers
Materials
Products
CoA

COMPANY LEGAL ENTITY


Sales Organization
Purchasing Organization
Plant
Project
Controlling Area
Profit Center Hierarchy
Cost Center Hierarchy

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The Document Principle

Documents

11

Single version of the truth

Enterprise visibility

Summary to detail views

Complete auditability

11
2014 WIPRO |LTDConfidential
| WWW.WIPRO.COM | CONFIDENTIAL
Harman
International Industries
| December 22, 2014

How SAP Transaction Work

Data tables
are files that
contain codes
and other
information.

Master Data Records


Accessed
SAP Transaction
Performed
Purchase
Order

xxxx
xxxx
xxxx
xxxx
xxxx

xxxx
xxxx
xxxx
xxxx
xxxx

SAP Data
Tables
Accessed

Examples of
Documents:
Customer orders
Goods issue
Production
orders
Vendor invoices

SAP Document Created


whenever stock is moved
or money is received
12

xxxx
xxxx
xxxx
xxxx
xxxx

Data Created for


Reporting and Analyzing

12
2014 WIPRO |LTDConfidential
| WWW.WIPRO.COM | CONFIDENTIAL
Harman
International Industries
| December 22, 2014

Integrated SAP concept - Overview


Purchasing
Strategic
purchasing

Materials
Management

Production
Work
scheduling

Engineering

Raw materials

Vendor

Sales
Strategic
sales

Finished products

Operative
purchasing

MRP

Job
preparation

MRP

Operative
sales

Goods
receipt

Warehouse

Production

Warehouse

Shipping

Invoice
verification

Inventory
accounting

Inventory
accounting

Billing

Internal
accounting

GL
accounting

Accounts
payable
Assets
accounting

Customer

Accounts
receivable

Accounting
Overhead
cost management

13

Materials
Management

Controlling

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SAP components

Sales &
Distribution
Materials
Management
SD
Production
Planning
MM

PP

FI

AM
PS
WF

PM
HR

Quality
Management

Plant
Maintenance
Human Resources

14

Asset
Management

CO

SAP
R/3

QM

Financial
Accounting
Controlling

Project
Systems

IS

Workflow
Industry Solutions

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SAP Integrated concept


Purchasing
Strategic
purchasing

Materials
Management

Production
Work
scheduling

Engineering

Raw materials

Vendor

Sales
Strategic
sales

Finished products

Operative
purchasing

MRP

Job
preparation

MRP

Operative
sales

Goods
receipt

Warehouse

Production

Warehouse

Shipping

Invoice
verification

Inventory
accounting

Inventory
accounting

Billing

Internal
accounting

GL
accounting

Accounts
payable
Assets
accounting

Customer

Accounts
receivable

Accounting
Overhead
cost management

15

Materials
Management

Controlling

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Integration is Key - ex. Benefits of integrated


order to cash
Strategic Benefits
The SAP Universe

Heightened understanding of customer


needs and profitability
Improved brand performance information
and greater clarity of global/regional brand
profitability
Improved management decision-making
across businesses due to greater clarity and
timing of information
Improved organizational flexibility (e.g.
shared services, regional/global
management structures)

Tactical Benefits
Reduced sales expense through crossselling
Improved cash collection enabled by
reduction in cycle time
Reduced working capital due to lower
inventory levels
Improved order fulfillment accuracy
Reduced back office expense due to
streamlined inter-company processing and
standardized reporting
Reduced cost of ownership

16

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The Document Principle

Documents

17

Single version of the truth

Enterprise visibility

Summary to detail views

Complete auditability

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Order fulfillment the value of integration

Order
Management
Delivery/POD
Inventory
Materials
Mgt
Transportion
Execution

Sales Order
Shipping Point

The sales order controls the follow up


activities in logistics

Goods issue
Transfer

Proof Of
Delivery

Real time information is delivered to


warehouse and transportation
management regarding materials
and quantities that must be picked,
packed and shipped

1997

Deadline monitoring
Availability check
Creating deliveries

Transportation
Planning Point

Allows shipments to be consolidated


for execution for better efficiency
Enables splitting of orders for actual
fulfillment at the site where materials
are stored
Monitoring of the delivery of the sales
order throughout the process is enabled
with out of the box integration with
materials management
18

POD
95
PC

Loading

Shipping papers

Picking
Packing
Picking confirmation

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Order to Cash transformation the value of


integration

Incentive &
Commision
Mgt
Invoicing
Accounts
Receivable
Adjustment
Management

Profitability
Analysis

Order #2077
Delivery
Requirements

Stock

60PC

Sales Price 300 USD


Cost
100 USD

Once the delivery activities have taken


place and a goods issue or POD has
been posted, the financial accounts are
immediately (real-time) updated
Integration with the front end
quotation and order management
ensures accuracy and timeliness of
bill presentment

XYZ

Delivery

Billing
Due List

Quotation

Balance Sheet
XX
XX

Allows service personnel to quote


and issue bills for service
Links between sales, delivery, and
finance are preserved for future
analysis via drill-down or adjustments

19

19
2014 WIPRO |LTDConfidential
| WWW.WIPRO.COM | CONFIDENTIAL
Harman
International Industries
| December 22, 2014

Order

Updated

SAP R/3 Integration

SD

FI

Sales &
Distribution

Financial
Accounting

MM

CO

Materials
PP Mgmt.

CS

QM

Asset
Accounting

EC

Enterprise
Controlling

Integrated Solution PS
Project
Client / Server
System
WF
Open Systems Workflow

Quality
Management PM
Plant MaintenanceHR

Human
Resources

20

AA

R/3

Production
Planning

Customer
Service

Controlling

IS

Industry
Solutions

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PP Business Concepts

Sales
Cycle

Order Settlement

Goods Receipt
(inward stock movement)

Material Forecast (SOP)

Production
Cycle
7

BOMs

MRP
Routings

Order Processing
5

21

Demand Management

Completion Confirmation

Production
Order

Planned Order
BOMs

Production Order

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Routings

Purchasing
Cycle
4

Organizational Data
Is the foundation which must exist within SAP R/3 before any PP
business processes can be modeled or executed
Defines the companys organizational and physical entities

Plant
Storage Location
Company Code

22

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Organizational Data
What functionality does Organizational Data provide in Production
Planning?
Allows materials, equipment, and planning to be the unique responsibility
of an individual or group
Since many individuals or groups may use similar data types, the
Organizational Data allows them to select only that data which is their
responsibility
Using the key, these individuals or groups may display, process, or print
information en masse

23

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PP Production - Orders and Organisation


Structures

Company
Controlling Area
Sales Organization

Purchasing Organization

Company Codes
Valuation Area
Plants
Demand Management
Production Control
MRP
Inventory Management
Production Order
Storage Locations / Batches / Special Stock
24

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Production Planning

MRP Controller

Ship Goods
to Customer

Run MRP and Create


Production Order

Production Order

Warehouse

Skate Sharpener
Production
Production Quantity
1,000

Start Date
2003
Finish Date
2003
25

Components
25

Jan. 6,

Produce
Skate
Sharpener

Feb. 1,

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Receive
Goods to
Inventory

Forklift

PP - Data in Production

Master Data

Factory Calendar
Material Master
Work Centers
Bills of Materials
Routings
Production Resources and Tools
CAPP Formulas
Transaction Data

26

Production Orders
Completion Confirmations
CO Object (Cost Collector)
Goods Movements (Receipt/Issue)
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Master Data
Is static data which represents things (like account, cost center,
material, vendor and employee numbers) rather than events (which
would be transaction data)
Is a central repository built in layers with each SAP R/3 module adding
its specific data to information already created by other modules
Is input to SAP R/3 transactions

Production Scheduler
Work Center
Material Masters
Bill of Materials
Routing
27

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PP Bills of Material

HEADER
Status
Texts
Usage
...
ITEM

Co-product
Scrap
MRP data
Recursiveness
...
SUB-ITEM
- Quantities
- Installation point

28

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PP Integration of BOMs in the System

Master Data
Material
Documents
Bill of material
Routings
PR/T
Work centers
Roughcut profile
ECM
Std trigger pts
Cost centers

Materials Management
Purchasing
Warehouse

Sales and Distribution

BOM

Sales order (for


variant configuration)

Plant Maintenance
Maintenance plan
Maintenance order

Controlling
Product costing
Unit costing
Standard costing

29

Production
Material requirements planning
Planned orders
Production orders

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PP BOM Categories

Material
Master
Record

Material
BOM

Equipment
Master
Record

Equipment
BOM

Document
Information
Record

Document
BOM

Material

Equipment

Document

Document
30

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Transaction Data
Is dynamic data, meaning it is typically changed or created many
times in one day
Records a business activity or event

Product Costing
Order Type
Sales and Operation Planning (SOP)
Materials Requirements Planning (MRP)
Production Order

31

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PP Integration Points

MRP

Planned Order

Purchase Requisition

Sales Order

Production Order

Purchase Order

Sales Order
Processing

Goods Issue

Goods Receipt

Stock Inventory
Shipping

Completion
Confirmation
Goods Receipt
Order Settlement

SD
32

PP
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MM
Actual Cost Update
G/L Account Update

FI/CO

PP Inv. Management - Overview

Forecast
Stocks

Material Requirements
Planning

Demand

Requirement

Production
(Internal Procurement)

Purchasing
(External Procurement)
Invoice

Goods Receipt
Warehouse
Management
Goods
Issue

Invoice
Verification

Transfer
Posting

Accounting
Sales and Distribution
33

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PP Inv. Management - Goods Movement

Ad hoc.

Delivery

Goods
Receipt

Production

Inventory

Inventory
Transfer
Posting

Goods
Issue
ConsumptionSamples
34

Goods
Issue
Sales Order
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PP Inv. Management

Material
Document
------ -------- ----- --------- ------

Inventory Management
From
From
Warehouse Consignment

Reservation
------ -------- ----- --------- ------

Goods
Issue

Production
Order
------ -------- ----- --------- ------

To
Consumption
Cost Centre
Asset
Project
Sales Order

Scrap

Sampling
BOM
------ -------- ----- --------- -----35

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PP Inv. Management - Transfer Posting

Company Code

Company Code

1000

Plant
1000

Stor. Loc.
1000

36

Master

----- ------ ----------- - ----- -------- ------- ---------

----- ------ ----------- - ----- -------- ------- ---------

2000

Product
123

Plant
2000

Quality
Inspection

Unrestricted
Use

Consignment
Store

Stor. Loc.
1000

Stor. Loc.
2000

Stock Transfers

Master

Product
789

Transfer Postings

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PP Inv. Management - Stock Fields in the


Material Master
Plant: CSPL
Total =
Consignment in QI
Consignment Stock
In Transfer
Returns Stock
Blocked Stock
In Quality Inspection
Restricted Use Stock
Unrestricted Stock

37

Storage Location: FRPR Storage Location: Main


Total =
Total =
Consignment in QI
Consignment in QI
Consignment Stock
Consignment Stock
In Transfer
In Transfer
Returns Stock
Returns Stock
Blocked Stock
Blocked Stock
In Quality Inspection
In Quality Inspection
Restricted Use Stock
Restricted Use Stock
Unrestricted Stock
Unrestricted Stock
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|

Storage Location: WMST


Total =
Consignment in QI
Consignment Stock
In Transfer
Returns Stock
Blocked Stock
In Quality Inspection
Restricted Use Stock
Unrestricted Stock

PP Inv. Management - Stock Overview

Unrestricted
Quality
Material XYZ
Inspection
UOM pc Use

Open POs
Production
Orders
Reservations
WM Stock
Mat. Movements
Display Material

38

Reserved

Total

10,000

2,400

550

COMP1

10,000

2,400

550

PLANT1
STOR1
STOR2
STOR3

6,600
2,000
2,000
2,600

2,000
0
1,500
500

0
0

PLANT2
3,400
STOR1 400
STOR2
0
STOR3 3,000

400

550

200
200
0

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0
0

0
550
0

Production Planning (PP)


1. Demand Management

- Maintain customer forecast


- Evaluate raw material forecast

2. FG & RM Planning

- Run planning and evaluate results


- Convert planned orders into production orders and
purchase requisitions into purchase orders

3. Prod. Order Preparation

- Link production orders and sales orders


- Finish final scheduling of orders
- Print shop floor documents

Master data

4. Prod. Order Execution

Costing

39

5. PO Close-out & Reporting

- Control components supply


- print labels
- post components consumption and finished goods
receipts

- Control and confirm PO bookings (qty and value)


- Close and settle production order
- Reports : usage & production

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Planning Levels
Profitability Analysis

CO/PA

Feedback/Corrections

Revenue Plans
Sales Plans (Quantities)
OK?

Region 1

Region 2

Sales and Operations Planning


Sales Plan
Production Plan

SOP

Product Group

OK?

Master Planning
Demand Program
Adjusted Master Plan

MPS
Product 1

Product 2

OK?

Material Requirements Planning

Dependent Requirements
Master Plan
Assembly 1
Procurement Plan
OK?

40

Part 1

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MRP
Assembly 2
Part 2

PP S&OP - Planning

SOP provides a method for:


Sales planning
Production planning
Feasibility estimates
Q
U
A
N
T
I
T
Y
May
Sales plan

June
TIME

Production plan
Capacity estimate

41

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July

PP S&OP - Planning Cycle

CO

Transfer

COPA

Sales Plan

SD

Forecast
Manual

SIS

Forecast
Cons.
History

SOP

Synchronous to Sales
Stock Level = 0
Target Stock Level
Target Days Supply
Manual

Production Plan
DISAGGREGATION
of Product Group

MM

Manual

Demand Management

42

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PP - Independent - Functional Data Flow

SD
Processing

Reservations

Demand
Management

Dependent
Requirements

Independent
Requirements

Planned
Order

MRP

External Procurement
Scheduling
Agreement
Invoice
Verification

Warehouse

43

Capacity
Planning
Production
Order

Convert
Planned
Order

Order
Processing

Final
Costing

In-House
Production

Purchase
Requisition

Purchasing
Function
( PO)

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Warehouse

PP Production - Procurement Types

44

In-House Production

External Procurement

Production
Order
------------------------------ ------------------ -------------------------

Purchase
Requisition
------------------------------ ------------------ -------------------------

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PP Production - External Procurement


Environment

Payment

Invoice

Delivery

MRP

Invoice
Verification

Goods / Service
Receipt

Requirement

Purchase
History

Source
Determined

Source List

PO

PO
Created

Vendor
Selected

Quota Arrangement
Outline Agreement
Info Record

45

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PP Production Doc. Category, Order Category,


Order Type

Document Category

Orders
Inventory Accounting Documents
Financial Accounting Documents

Order Category

PP Production
PM Maintenance Order
CO Production Order
CO Results-Analysis Order

PS Network
CO Internal Order
CO Model Order

Order Type

Production Order (Internal Number Assignment)


Production Order (External Number Assignment)
Production Order (Specific Procedures)

46

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PP Production - Order Types: Client Specific


Parameters

Order Type
(PP01)

Order Category
Control Indicators
Open item management
CO partner update
Revenue postings
Classification

Retention periods
Retention period 1
Retention period 2
Default values
Settlement profile
Planning profile
Status profile
Reference order
Number range
Field selection
Status
47

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PP Production - Definitions in the Production


Order

What is Produced?

For what Dates?

What Quantities are to


be Produced?
For Whom is Production
Being Carried Out
(Cost Object)?
What Resources and
Methods are Used?
What Costs are Involved
in Production?
48

- Products
- Activities
- Planned Order Dates
- Basic Order Dates
- Scheduled Dates
- Confirmed Dates
- Release
- Start
- Finish
- Planned Order Quantity
- Production Order Quantity
- Material (Stock)
- Cost per Item
- Order
- Asset
- Material Usage
- Production Resources/tools
- Inspections
- Planned Costs
- Actual Costs

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PP Production - Maintain and Allocate Factory


Calendar

1.

Maintain Public
Holidays

Public Hol. 1
Definition

Public Hol. 2
Definition

2. Maintain Public
Holiday Calendar

Public Holiday Calendar


Definition
ID: 08
Public Hol.-1
...
Public Hol.-n

3. Maintain Factory
Calendar

Factory Calendar
Definition
ID: P5
Public Hol. Calendar ID 08
Plant Public Hol. Definition
Exceptions

4. Allocate Factory
Calendar
Plant PP01

49

...

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Public Hol. n
Definition

PP MRP - Materials Planning Procedures


Planning
Procedures

ConsumptionBased Planning

ForecastBased Planning

Deterministic
MRP

Reorder Point
Planning
Manual
Reorder Point
Automatic
Reorder Point

50

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PP MRP Consumption Based MRP and


Deterministic MRP Differences
Deterministic MRP
MRP Including BOM Explosion
Using the forecast for unplanned
additional requirements
Using the forecast for the
total requirements
MPS represents a separate planning run

Consumption-Based MRP
Manual reorder point planning
Automatic reorder point planning
Forecast-based planning

Reorder Point

Safety Stock

Start
Date

No Materials Planning
51

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Delivery
Date

PP Capacity Planning - Environment

A
Material

PM / PS

Production planning

Basic data

Planned orders
Production orders
Process orders
SOP orders

Plant maint.
Projects

Bill of material

10

20

Arbeitsplan
Routing
TskLstGrp
10

30

40

50

Scheduling

C1

Center 1

20
30

Capacity requirements

Calendar

Capacity evaluation / leveling


t

52

Available capacity

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PP Capacity Planning - Elements of Capacity


Planning

Available
Capacity
Capacity
Levelling

Scheduling

Capacity
Evaluation

53

Capacity
Requirements

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PP Repetitive Manufacturing Process

Intro to Repetitive Manufacturing


Intro to Repetitive Manufacturing in SAP
Setup Master Data
Planning
Repetitive
Manufacturing
with
Cost Collector

Backflushing

Capacity Planning
Cost Controlling

Reporting Tools (Evaluation)

54

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PP Overview of Repetitive Manufacturing

55

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PP Industry Examples of Repetitive


Manufacturing

Bare
Boards

Stencil
&
Paste
Process

Pick & Place


Machine

Chips,
Capacitors,
Resistors

56

Oven

Component
Reels

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Finished
Printed
Circuit
Boards

Repetitive Manufacturing with Cost Collector

MRP

Normal Planned Orders (Optional)

Create RS Planned Orders


(Background)

Planning Table
(Run Schedule)

Reduce RS Planned Orders


(Background)

Backflush
(GR, GI, AP)

Repetitive Manufacturing
with Cost Collector

57

Cost Collector

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PP Repetitive Manufacturing

Make-to-stock repetitive manufacturing

Demand
management
Production line

Production line

Make-to-order repetitive manufacturing


S.order

SD

Production line
58

Production line

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PP Planning in Repetitive Manufacturing

Production
line 1

Run schedule quantities


time
Planning periods

Production
line 2

Run schedule quantities


time
Planning periods

59

Period-based planning (planning periods)

Planned orders (run schedule quantities)


authorize production; production orders not
needed!

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PP Material Staging and Backflushing

BIOS

RAM

Processor

Board

Motherboard

Production line

60

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Reporting Point Backflushing

reporting
point
10

reporting
point
40

20

WIP

30

Production Line

Component A
Component B
Component C
61

61
2014 WIPRO |LTDConfidential
| WWW.WIPRO.COM | CONFIDENTIAL
Harman
International Industries
| December 22, 2014

Stock
Mat A

PP Repetitive vs. Discrete

Workcenters

Workcenters

Input
1

Product
A

Product
B

Output

62

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

PP Repetitive vs. Discrete

Discrete Manufacturing

Repetitive Manufacturing

- Same product produced over a lon


period of time
- Production in restricted production - Period-based planning
lots
- Steady flow through production
(simplified routings)
- Varying sequence of work centers
(complex routings)
- Semi-finished products often
directly processed without interim
- Semi-finished products often put
storage
into interim storage
- Components are staged at lines,
- Material staged with reference to
with no reference to production lo
production lot / order
- Reduced administrative effort (no
- Release procedure
releaseprocedure)
- Completion confirmation for
- Completion confirmation based on
individual operations or orders
periodsbackflushing
(
)
- Order-based cost controlling
- Period-based cost controlling
- Products change
frequently

63

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64

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65

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66

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67

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68

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69

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70

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72

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74

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Chart Title
6

0
Category 1

Category 2
Series 1

77

Category 3
Series 2

Series 3

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Category 4

Chart Title
Category 4

Category 3

Category 2

Category 1

2
Series 3

78

3
Series 2

4
Series 1

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

Sales

1st Qtr

79

2nd Qtr

3rd Qtr

4th Qtr

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

80

2014 WIPRO LTD | WWW.WIPRO.COM | CONFIDENTIAL

81

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82

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