Dear SAP experts, I need a soft copy of step by step phase implimentation in pp.My mail id is ikhlaqcharga@gmail.com. Thanks and Regards
Solution
Step 1: SAP PP Overview Presentation to the Client.
The very first step during an implementation is the presentation of SAP to the client team.The consulting team is expected to provide an overview of SAP and explain this is a simple manner.
Step2: Decide the organizational Structure for SAP PP - Plants and Storage Locations :
Deciding facilities as Plants-
The role of a consultant is to decide the manufacturing plants which must be identified separately in SAP as Plants.
The place where activities related to warehousing or manufacturing take place are referred to as Plants.
At a plant level, the material is valuated, and the inventory is also stored.
Deciding Storage Locations @ a Plant-
Once the individual decides on the plants he is also required to decide the storage locations where the materials will be inventoried or stored in the system.
Illustration -
Company Code=Dew Steels Pvt Limited
Plant 1= 0001
SLOC1= RAW= 0001
SLOC2= FGI=0002
SLOC3= SHOP= 0003
SLOC4= SCRAP= 0004
Plant 2= 0002
SLOC1= RAW= 0001
SLOC2= FGI=0002
SLOC3= SHOP= 0003
SLOC4= SCRAP= 0004
SLOC5= REWORK = 0005
Step3 : Understanding the Manufacturing or Logistical Business Processes :
The following points and questions need to be answered:
- Production Strategy– Begin with finding whether the Production process is Made-to-Order or Made-to-Stock and if there are few products manufactured Made to order and few products manufacture made to stock.
- ManufacturingLocations and Supply Chain- Understand themanufacturing facilities and warehousing facilities in the company &their geographical locations. This will help you understand the supply chain of the company.
- Products Manufactured–The individual is required to prepare a list of theProducts manufactured in different plants.
- Manufacturing Facility– The individual should first understand the Production process and the different Machines the product must go through before it is manufactured.The person should make a note of theoperations or Machine where the production has to be booked and/or costing needs to be booked.
MRP and Planning Strategies– The individual should tabulate the Planning strategiesand MRP Methods forevery component which is a part of the BOM
Preparations for Made-to-stock - If the production is made-to-stock understandthe existing forecasting methods and the forecasting rules. The individual should ideally know if the forecasting is for a product or for a group of products which belong to a family.
Design of BOM– The individual should understand the raw materials which are to be consumed in production and decide on the components should become a part of the Bill of Materials.
Design ofRouting/Recipes-Similarly right before designing the Routing, it is imperative to involve thecosting team to decidetheoperations which will eventually become a part of the Routing/Recipes.
Study of Legacy System- Studying the existing Legacy system and the different activities which record on their computers and the different activities they perform to the external the computers {if any}. Understanding the Legacy system will help the individual understand how their current systems can be duplicated, eradicated or even optimized inSAP.
Shop Floor Recordings– one must understand the shop floor as well as the product confirmations processes at each and every operation along with finding out how the products are received in stock and if there have been any quality inspections being carried out on the output.
Quality Inspectionsto be carried out– One must be aware of the quality inspections methods which are being used and the product passing as well as the rejecting activities. The individual must find out how important is the quality of the product for the company and incase there is a requirement for implementing SAP Quality Management.
Asking the management–whether the product has been reworked upon and what is the scrapping process. The individual should make a note incase the scrapped or reworked materials have been sold in the market or have been re-used in production.
Step4 : Document the Business Processes in a Blueprint Document:
A Blueprint is a document which primarily records all the current processes and the to-be processes for all of these existing processes.
Listed below are the processes which can become a part of your Blueprint - This is only an example:
- Raw Material Procurement
- Raw Material Staging to the shop floor for Production
- Master Data creation - BOM,
- Master Data creation - Work center
- Master Data creation - Routing/Recipe
- Material Requirement Planning for the Raw Materials
- Material Requirement Planning for the assemblies/subassemblies
- Production order creation and Release
- Shop Floor Execution
- Production order Goods Receipt
- Quality Inspections in Production
- Product Costing and Order settlement
- Technical developments like interfaces, reports, Module Pools, user exits and LSMW
- Gaps Analysis
Creation of Functional specifications for the ABAP developments:
The consultants are required to create the functional specifications for the Technical ABAP developments. All such documents are referred to as a descriptive document which would explain in detail the logic which should be utilzed for developing the ABAP technical object. This document comprises of the tables and the fields as well as the link between these to help the ABAP'er in designing or developing the same.
The technical objects for which the Functional Specifications are created are:
a) Reports
b) Interfaces
c) Module Pool
d) Data Conversion Objects
e) User-Exits
Data Load and Planning
TheConsulting team, should ideally list down all the Master data objects and how the data is required to be collected in every module.
Creation of the Data Collection Templates:
The consultant is required to design the Master data, for SAP Production Planning and Control, as well as decide the fields for which values have to be collected from the users for creating the corresponding master data in SAP. For instance: incase of "BOM", the consultant plans on generating aBOM and then entering the value for the following fields -
Selection Data:Plant, Start date of validity ,Header Material,BOM Usage.
Item Data: Item category, UOM, Component, Component Scrap , MaterialCode, Qty, Whether Recursive Indicator, whether a co-products.
Header Data: BOM Alternate text, Base quantity.
Educating the Data Collectors on the Data Collection Templates:
The consultants ideally are required to educate the users or the super users regarding the Master data template which they will be utilizing for the collection of Master Data.The individual also should educate the users on the values which he expects for the fields. You may default certain values for few fields and the you should also educate the data collectors regarding this. The template should be very clear and should encompass the definitions and particulars about each and every field as listed below:
Excel Row 1-Field Descriptions
Excel Row 2-SAP Field Names
Excel Row 3-Definitions and points to note
All Row below- Data for Collection
Development of a ABAP program for uploading the data in the collected format:
In SAP, an Upload program or an LSMW should be created for uploading the data in the same collection format as decided.
Configurations and Testing’s
The user is expected to configure the SAP Production Planning system, once the Blueprint is ready.The methods listed below are all involved as per the sequence of occurrence:
1)GoldenClient Configuration –The golden client is a client where onlyconfiguration are performed for all the modulesby only particular consultants.
2) Transfer (useSCC1 - Transaction code to transfer) configurations to theDevelopment Clientwhere the user would be carrying out the initial Unit test on his Module.
3) Carry outUnit test in the Development Client.All the consultants from the modules would create a list of transaction codes or activities for testing in SAP Development client for testing that the modules function in SAP.
4) Carry out aString test in the development client. A String test is referred to as a small integration test which is performed between the modulesfor testing the SAP integration and flow of information between them, and this has not been marked as the Integration test.
5) TheFunctional team tests the Technical objectswhich have been developedby theABAP Consultantsin the development client. This activity works in parallel with the unit test, string test. A Functional testing document is prepared for recording each test on the object.ABAP fixes all the issues recorded.
6) Once the Objects have been transferred to QA Client and the Configurations have been transported to the QA Client, the implementing teamperforms out an InternalIntegration test for the SAP Modules and SAP Technical objectswhich have been arranged in the sequence of occurrence.
Cutover Process and Golive
Definition:
A Cutover in SAP refers to the roll over from the existing legacy system to the new SAP system. A good cutover process or cutover plan is very critical for ensuring that the roll over is smooth or fine or for making sure that this movement to SAP. Cutover entails the following:
- Preparing the production client. This is known as the final Go live Client.
- In SAP Production Client, loading of all the Master Data.
- Identifying the cutover Schedules. Clearing these Dates to all and each in the organization.
- Promoting SAP in the organization and creating an Awareness of SAP.
- User must ensure that he has a Black out period which would act as an window for changing his systems to SAP and get it working in real time.
- Making a note of all the open documents which have to be entered inSAP such as the open purchase orders, open Sales orders, open production/process orders, on hand inventory etc. In this "Black Out Window", all these open documents and stock have to be uploaded in SAP.
- Ensuring that all the configuration and development transports have been transferred to theProduction Client.
- User you would be going live with SAP on a real time basis, post the black-out period.
The cutover process forSAP PP is listed below :
a) Uploading all the Assemblies/Subassemblies Stocksas SAPinventory using the 561 Movement type. User can move it to Quality Inspection stocks, in case there are few stocks are in quality. Likewise, if they are in blocked stock one can also upload in blocked stock in SAP.
b) The user can assume that whatever which was in production post the blackout is finished and is in stock, thus the user can create inventory for all of these expected receipts from these production orders and once the SAP Go lives after the Black-out period user can avoid recording the SAP transactions for the production orders which were already assumed to be finished and were already brought in to inventory.
Post Go live
Initially, the consulting team generally provides support for the organization for a period of45-60 days and records all the issues and solves them as per the priority of theissue.The organization at this stage has eventually started using SAP for the designed scenarios and processes. At this stage they require all the helping hand which can be received from the super users and the consultants.
This is the most critical stage and decides the success of the project.