PTS Module NirmITee (MAHAGENCO SAP–ERP)
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PTS Module NirmITee (MAHAGENCO SAPERP) Introduction ERP E: Enterprise R: Resource P: Planning SAP S: System A: Applications P: Products ..in data Processing 3 Vision Implement an integrated ERP system that brings IT culture,
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01
PTS Module
NirmITee
(MAHAGENCO SAP–ERP)<br>
NirmITee
(MAHAGENCO SAP–ERP)<br>
02
Introduction ERP
E: Enterprise
R: Resource
P: Planning
SAP
S: System
A: Applications
P: Products
……………………..in data Processing<br>
E: Enterprise
R: Resource
P: Planning
SAP
S: System
A: Applications
P: Products
……………………..in data Processing<br>
03
3 Vision Implement an integrated ERP system that brings IT culture, automates & integrates business processes, embeds transaction processing controls and provides appropriate reports to facilitate decision making and smooth functioning of MSPGCL operations Objectives Project NirmITee’s Vision & Objectives<br>
04
4 01/06/2010 Journey So Far Workshops for Validations with Subject Matter Experts for the current business process Core Team SAP Training JULY 2004 Project Kick off
Module Leads On boarded
AS IS Process Listing Started Project Preparation phase Completed
Business Blueprint Phase Commenced
Detailed Process Study and Validations SAP Org Structure Finalized
Preparation of Global Template Commenced BBP Validation by Business Process Owners BBP Validation by L&T InfoTech Experts, KPMG and SAP Business Blueprint Ready
Realization Phase Commenced Power user training & User Acceptance Testing<br>
Module Leads On boarded
AS IS Process Listing Started Project Preparation phase Completed
Business Blueprint Phase Commenced
Detailed Process Study and Validations SAP Org Structure Finalized
Preparation of Global Template Commenced BBP Validation by Business Process Owners BBP Validation by L&T InfoTech Experts, KPMG and SAP Business Blueprint Ready
Realization Phase Commenced Power user training & User Acceptance Testing<br>
05
5 NirmITee Core Team<br>
06
6 NirmITee Core Team<br>
07
7 Current Process Study Approach Process Area – Business Scenario Process Input Reports Process Output Process Flow Output Document Plan Execute Monitor Process Trigger Pain Area Control Roles Process Complexity Process Integration Legacy Systems Data Management<br>
08
8 AS IS - TO BE Transformation Process Based Approach<br>
09
9 TO BE Process Benefits Consolidation of Purchasing Requirements leading to efficient Procurement
Improved maintenance practices leading to better Availability factor
Tracking of Rework efforts in Maintenance Activities
Optimum utilization of working capital with decrease in interest
Controlling of non sequential supply by linking material to activity
Reduction in stationery expenditure across all departments Less efforts in tracking of Coal Company wise Materialization and Easy matching of Missing and Unconnected wagons
Reduction in Procurement Cycle Time
Reduction in cycle time for filling a vacancy and Payroll Process
Better Employee succession planning by maintaining skill matrix
On-Time Fulfilment of Legal & Statutory reporting requirement e.g. MERC, CEA etc
Simulation of requirement planning of Fuel for different scenarios
Snapshot of the project integrated with multiple contractor’s schedule Cost Reduction Effort Reduction<br>
Improved maintenance practices leading to better Availability factor
Tracking of Rework efforts in Maintenance Activities
Optimum utilization of working capital with decrease in interest
Controlling of non sequential supply by linking material to activity
Reduction in stationery expenditure across all departments Less efforts in tracking of Coal Company wise Materialization and Easy matching of Missing and Unconnected wagons
Reduction in Procurement Cycle Time
Reduction in cycle time for filling a vacancy and Payroll Process
Better Employee succession planning by maintaining skill matrix
On-Time Fulfilment of Legal & Statutory reporting requirement e.g. MERC, CEA etc
Simulation of requirement planning of Fuel for different scenarios
Snapshot of the project integrated with multiple contractor’s schedule Cost Reduction Effort Reduction<br>
10
10 TO BE Process Benefits contd.. Effective Preventive Maintenance planning leading to Asset life optimization
Availability of unit wise profitability
Better employee satisfaction level due to transparency
Effective root cause analysis to eliminate repetitive failures
Effective budgetary control through system and Centralized payment is possible Uniformity in Procurement processes across power stations
Uniformity in Inventory processes across power stations
Asset capitalization and depreciation calculation
Standardized of Project Template across Mahagenco Process Improvement Process Standardization<br>
Availability of unit wise profitability
Better employee satisfaction level due to transparency
Effective root cause analysis to eliminate repetitive failures
Effective budgetary control through system and Centralized payment is possible Uniformity in Procurement processes across power stations
Uniformity in Inventory processes across power stations
Asset capitalization and depreciation calculation
Standardized of Project Template across Mahagenco Process Improvement Process Standardization<br>
11
11 TO BE Process Benefits contd.. Online Inventory Report and Automatic Reports on Non-Moving/Slow-Moving Items
Ease of reporting for fuel procurement and consumption
Availability of Budget consumed Vs. budget allocated
Easy Availability of schedule variances & cost variances and Availability of Project historical data
Availability of data and analysis on plant performance parameters
Effective vendor selection based on Quality Performance
Online Availability of data employee personal information
Availability of Breakdown preventive and corrective maintenance cost with Mean Time Between Failure and Mean Time To Repairs
Linkage of asset accounting with plant maintenance for capital purchases and Complete traceability of individual machine Location
Tracking of all types of waste Disposals Data Driven Management Information system<br>
Ease of reporting for fuel procurement and consumption
Availability of Budget consumed Vs. budget allocated
Easy Availability of schedule variances & cost variances and Availability of Project historical data
Availability of data and analysis on plant performance parameters
Effective vendor selection based on Quality Performance
Online Availability of data employee personal information
Availability of Breakdown preventive and corrective maintenance cost with Mean Time Between Failure and Mean Time To Repairs
Linkage of asset accounting with plant maintenance for capital purchases and Complete traceability of individual machine Location
Tracking of all types of waste Disposals Data Driven Management Information system<br>
12
SAP Modules Procure to Pay Process (PTP or Purchase)
Project Monitoring & Control (PM or Projects)
Enterprise Asset Management (EAM or Maintenance )
Plan to Supply (PTS or Operations)
Energy Data Management (EDM )
Human Capital Management (HR)
Order to Cash (OTC or Sales )
Finance & Costing ( FICO )<br>
Project Monitoring & Control (PM or Projects)
Enterprise Asset Management (EAM or Maintenance )
Plan to Supply (PTS or Operations)
Energy Data Management (EDM )
Human Capital Management (HR)
Order to Cash (OTC or Sales )
Finance & Costing ( FICO )<br>
13
13 Procure to Pay Process Flow User Section Procurement/ CPA / APS Competent Authority Stores Start End Finance Plant Maintenance Requirements Consumption Based Planning Purchase Requisitions
Material & or Service PR Release Strategy/Approvals Procurement Budget Check (auto) E-Tendering Interface / Manual Process Quotations Create Purchase Order / Contracts Create Imprest Cash Purchase Order PO Release Strategy / approvals Goods Receipt / Service Entry Goods Issue to User Inter-Plant Stock Transport Order Vendor Liability created in Accounts Payable Vendor Payments Key Movements Theft Cases Physical Inventory Verification
(For Section Stores and Major Stores) Gate Pass Quality Inspection Capital requirement All other Sections / Department requirements Internal Section Transfer Within Plant Invoice Posting FI Posting and Settlement CPA Consolidation (if Required) Admin Approval (if required) FI Posting and Settlement<br>
Material & or Service PR Release Strategy/Approvals Procurement Budget Check (auto) E-Tendering Interface / Manual Process Quotations Create Purchase Order / Contracts Create Imprest Cash Purchase Order PO Release Strategy / approvals Goods Receipt / Service Entry Goods Issue to User Inter-Plant Stock Transport Order Vendor Liability created in Accounts Payable Vendor Payments Key Movements Theft Cases Physical Inventory Verification
(For Section Stores and Major Stores) Gate Pass Quality Inspection Capital requirement All other Sections / Department requirements Internal Section Transfer Within Plant Invoice Posting FI Posting and Settlement CPA Consolidation (if Required) Admin Approval (if required) FI Posting and Settlement<br>
14
Process Integration in SAP – Project Monitoring & Control Planning (P&P + Civil) Project Procurement ( P&P ) Project Site Office Project Accounts EPC
Contractor Initiate Project Create Contract Create Purchase Order based on BBU Set Budget for Main Package Integrate MSP
Schedule in SAP and Simulate Release Project Create Base line Version Prepare Erection Activities schedule in MSP Create Project Structure Receive Materials & Quality check Complete Closing pre requisite Payment to Vendor Handover to
O &M Confirm Activities Start End Assign Material to Erection activities Create Service Entry sheet & Approval Prepare L1 BBU Approval of L1 BBU Prepare Billing Break Up (Material & Service)<br>
Contractor Initiate Project Create Contract Create Purchase Order based on BBU Set Budget for Main Package Integrate MSP
Schedule in SAP and Simulate Release Project Create Base line Version Prepare Erection Activities schedule in MSP Create Project Structure Receive Materials & Quality check Complete Closing pre requisite Payment to Vendor Handover to
O &M Confirm Activities Start End Assign Material to Erection activities Create Service Entry sheet & Approval Prepare L1 BBU Approval of L1 BBU Prepare Billing Break Up (Material & Service)<br>
15
Enterprise Asset Management Process Flow Maintenance Planning Dept. ( MPD ) Quality ( FQAD ) Maintenance Finance & Accounts Procurement & Stores Breakdown/Preventive/Corrective/Predictive/Calibration/Overhaul (OH) Start End Master DATA:
Equipment Master / Measurement Points /
Bill of Material / Location /strategy /Task list / Planning Maintenance Order Maintenance Execution
Time Confirmation & Material /Service Posting Technical Completion Business Completion AOH \ COH Project Planning and Monitoring Asset Capitalization for Capital Equipments Budget Check Create Purchase Requisition Justification / Budgetary Approvals Procurement Cycle with Budgetary Control Accounts Payable Work Inspection/ Result Recording yes No External service Requirement Notification WCM Approval
Permits Material available ?<br>
Equipment Master / Measurement Points /
Bill of Material / Location /strategy /Task list / Planning Maintenance Order Maintenance Execution
Time Confirmation & Material /Service Posting Technical Completion Business Completion AOH \ COH Project Planning and Monitoring Asset Capitalization for Capital Equipments Budget Check Create Purchase Requisition Justification / Budgetary Approvals Procurement Cycle with Budgetary Control Accounts Payable Work Inspection/ Result Recording yes No External service Requirement Notification WCM Approval
Permits Material available ?<br>
16
Plan to Supply Process Flow Procurement & stores Head Office POG Operations Finance and Accounts Start Annual Generation Planning – Unit wise Annual Requirement of Materials for Production Aggregate Generation and Requirement Plan Monthly Demand planning for Generation and Material Requirement Define Bill of Materials Work Centers, Routing of Power Daily Power Generation Daily Consumption of Materials and Enter Activity Details Event Recording Inventory Management Product Costing Accounting Entries Report Generation End Carry out Procurement Activities<br>
17
Order To Cash Process Flow Human Resources Coal Office RCD All Power Stations Start Create Order for FAC and PLF incentive End Create Service Order for Deputation / Training Service Create Billing Document Create Service Order for Oil Testing/ Sampling Create Billing Document Create Billing Document Consolidated Energy Details Create Sales Order for Energy Billing Confirm Sent out Energy Units Create Sales Order for Scrap Material Confirm Quantity Create Billing Document Thermal Power Stations Create Sales Order for Mill Reject/Sale of Ash Confirm Quantity Create Billing Document Finance and Accounts<br>
18
Posting to Finalization and Plan to Control- Structure<br>
19
Accounts Receivable Accounts Payable Budgeting & Finance Cash and Bank Management Asset Management General Ledger Period End Activities Inter Unit Trns
GL Posting
Profit center planning
GL based reporting Annual Budgeting
Project Funding
WC Mgmt. Billing
Receipts
Special GL Trns
Period End closing O&M Budgeting
Procurement process
Invoice posting
Special GL Trns
Vendor Payments
Period End Closing Bank Posting
Cash Posting
Bank Reconciliation Capital Budgeting
Asset procurement
Invoice posting
Sale / transfer /
Scraping
Period End process Recurring Entries
Automatic Clearing
Accrual Entries
Open Item Valuation
Rectification of Errors
Reports
Period Close OTC – Order to Cash – Regulatory and Commercial Cell
EAM- Enterprise Asset Management – Plant Maintenance
PTP- Procure to Pay – Procurement and Stores
FMP – Fuel Management Process – Fuel Management Cell and Coal Office
RTR – Recruit to Retire – Human Resource Management
PMC – Project Monitoring and control – Projects & Planning
PTS – Plan to Supply - Operations Posting to Finalization – Process Chart OTC EAM PTP FMP RTR PMC PTS<br>
GL Posting
Profit center planning
GL based reporting Annual Budgeting
Project Funding
WC Mgmt. Billing
Receipts
Special GL Trns
Period End closing O&M Budgeting
Procurement process
Invoice posting
Special GL Trns
Vendor Payments
Period End Closing Bank Posting
Cash Posting
Bank Reconciliation Capital Budgeting
Asset procurement
Invoice posting
Sale / transfer /
Scraping
Period End process Recurring Entries
Automatic Clearing
Accrual Entries
Open Item Valuation
Rectification of Errors
Reports
Period Close OTC – Order to Cash – Regulatory and Commercial Cell
EAM- Enterprise Asset Management – Plant Maintenance
PTP- Procure to Pay – Procurement and Stores
FMP – Fuel Management Process – Fuel Management Cell and Coal Office
RTR – Recruit to Retire – Human Resource Management
PMC – Project Monitoring and control – Projects & Planning
PTS – Plan to Supply - Operations Posting to Finalization – Process Chart OTC EAM PTP FMP RTR PMC PTS<br>
20
Product Costing Overhead Cost Management Profit Centre Accounting Standard Hierarchy Master Data
Budgeting / Planning
Actual Postings
Period End Activities Standard Hierarchy Master Data
Budgeting / Planning
Actual Postings
Period End Activities Generation of Product Cost Reports OTC – Order to Cash – Regulatory and Commercial Cell
EAM- Enterprise Asset Management – Plant Maintenance
PTP- Procure to Pay – Procurement and Stores
FMP – Fuel Management Process – Fuel Management Cell and Coal Office
RTR – Recruit to Retire – Human Resource Management
PMC – Project Monitoring and control – Projects & Planning
PTS – Plan to Supply – Operations
PTF – Posting to Finalization - Finance Plan to Control – Process Chart OTC EAM PTP FMP RTR PMC PTS PTF<br>
Budgeting / Planning
Actual Postings
Period End Activities Standard Hierarchy Master Data
Budgeting / Planning
Actual Postings
Period End Activities Generation of Product Cost Reports OTC – Order to Cash – Regulatory and Commercial Cell
EAM- Enterprise Asset Management – Plant Maintenance
PTP- Procure to Pay – Procurement and Stores
FMP – Fuel Management Process – Fuel Management Cell and Coal Office
RTR – Recruit to Retire – Human Resource Management
PMC – Project Monitoring and control – Projects & Planning
PTS – Plan to Supply – Operations
PTF – Posting to Finalization - Finance Plan to Control – Process Chart OTC EAM PTP FMP RTR PMC PTS PTF<br>
21
Environment, Health & Safety Process Flow MSDS Mgmt. Accident Incident Mgmt. Occupational Health Compliance Mgmt. Maintain Hazardous material Specification Measure Environmental parameters Assign EHS specification to Material Master Maintain MSDS for Hazardous Material Separate Inventory Mgmt. for Hazardous Material Start Notification to Maintenance Conduct RCA & Safety Measures Closure of accident Report Generation & Submission End Planning & Scheduling medical check-up Conduct actual Medical Check-up Diagnosis, Vaccination , Consultation Registration of Accident/Incident Receipt of Hazardous Material Evaluate the Results Person specific data for Employee’ medical treatment Maintain Medical record & History Corrective actions Final Submission of report Report Generation<br>
22
Fuel Management Process Flow Coal Office & Head Office Finance Stores & CHP Operations & POG Requirement Calculation Start End Chemist Aggregate Annual Requirement Calculation Creation of Contracts and Supporting Contracts Approval of Contracts Advance Payment to Vendors (for Coal) Monthly Linkages Create PR on monthly basis Prepare PO based on PR Approval of PO Record FOIS Details on Receipt Unloading of Goods Inspection of Goods (Coal & FO) Check Grade Slippage Capture Actual Unloading Results & Compare with FOIS Identify Missing, Un Connected, & Sick Wagons Create GR for Goods Receipt and capture Transit loss Lodge Claims Check Rake Diversion Reconciliation of Rake Diversions Execute Transaction if any material Conversion Goods Issue & Record Consumption against Generation Post Invoice Processing of Payment<br>
23
Quality Assurance and Control Process Flow Projects /Plant Maintenance Quality Projects / Procurement & stores Start End Fuel Management Maintain Inspection Plan for Materials and Services Receive Goods Execute Inspection & Record Results Usage Decisions Post to un-restricted Stock Prepare GR Note Unload Fuel Post to block Stock Create Notification Replacement / Repair Execute Inspection & Record Results Identify Grade / Quality Slippage Lodge Claims Receive Loading End Results Prepare GR Note Notification Creation for Services Execute Job Work Inspection and Notification Completion Initiate Rework Technical Completion Chemist / Quality yes No yes No<br>
24
Recruit to retire Process Flow Recruitment Personnel Administration Time Office Portal Services Start End Payroll Finance Applicants Administration New Hiring Vacancy Planning – Internal / direct / Promotion Seniority Maintenance Deputation / Transfer Promotion Performance Appraisal and Training Retirement / Resignation / Termination Budget Administration E Services for Employee Management Time Administration Shift Planning Leave Management Salary Processing E- Services
Claims/ Reimbursements/ Leave Encashment Payroll Posting to Accounting Third Party Payments Roster Management<br>
Claims/ Reimbursements/ Leave Encashment Payroll Posting to Accounting Third Party Payments Roster Management<br>
25
Users End Users (Role wise access)
Power Users
Help Desk
Core Team<br>
Power Users
Help Desk
Core Team<br>
26
Cost Estimate is run by Finance Section before MM period opening activity.
MM Period & its impact
Roles & Authorization
Organization Structure (Company Code, Plant, Storage Location)
PTS Master Data- MM, BOM, Rate Routing, Work Center, Production Version<br>
MM Period & its impact
Roles & Authorization
Organization Structure (Company Code, Plant, Storage Location)
PTS Master Data- MM, BOM, Rate Routing, Work Center, Production Version<br>
27
What if data entry is delayed Data entry should be done on time/Real Time
On 5th of every Month Previous month gets Closed at @10:00 AM, Once MM period is closed, we can’t post pending data.
We can open previous month by sending request mail to HO-Finance.
But if you follow discipline , we will not require to open previous month MM Period 27<br>
On 5th of every Month Previous month gets Closed at @10:00 AM, Once MM period is closed, we can’t post pending data.
We can open previous month by sending request mail to HO-Finance.
But if you follow discipline , we will not require to open previous month MM Period 27<br>
28
Organization Structure and Master Data<br>
29
Material master : A material master is used to define the properties of finished and semi finished products in SAP(e.g. Power1, crushed coal )
Bill of material : A bill of material describes the components that are required to makes a product (e.g. BOM of power will have coal , oil , dm water, soften water)
Work center : A work centre is a location where an operation or activity is carried out within a plant. (e.g. Boiler, turbine, generator of unit)
Routing : The routing describes the sequence of operations in production (eg. Machine , labor time)
Production version : The production version defines the various techniques that can be used to produce a material Organization Structure and Master Data<br>
Bill of material : A bill of material describes the components that are required to makes a product (e.g. BOM of power will have coal , oil , dm water, soften water)
Work center : A work centre is a location where an operation or activity is carried out within a plant. (e.g. Boiler, turbine, generator of unit)
Routing : The routing describes the sequence of operations in production (eg. Machine , labor time)
Production version : The production version defines the various techniques that can be used to produce a material Organization Structure and Master Data<br>
30
Important Tcodes
MD61,MD62,MD63
MFBF,MMBE,MB5B,MB51<br>
MD61,MD62,MD63
MFBF,MMBE,MB5B,MB51<br>
31
MFBF
Assembly Backflushing
Component Backflushing
Activity Backflushing<br>
Assembly Backflushing
Component Backflushing
Activity Backflushing<br>
32
Goods withdrawal /Consumption Booking
Movement Types 131,132,201,202,251,252<br>
Movement Types 131,132,201,202,251,252<br>
33
Reversal of Documents For Power Posting Correction
ZMBST
ZMF41
For Activity Posting Correction
MF12 34<br>
ZMBST
ZMF41
For Activity Posting Correction
MF12 34<br>
34
Measuring Points DAM
LIVE_STORAGE
PROB_GEN
RAINFALL
Water Discharge
IK11
IK12
IK13
IK34 35<br>
LIVE_STORAGE
PROB_GEN
RAINFALL
Water Discharge
IK11
IK12
IK13
IK34 35<br>
35
... Generation Next with IT Thank You<br>