Blue Print PP

Phosphorus India Ltd
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PROJECT MANAGER
Mr.
MODULE EXPERTS
FICO : Mr. Gokul
MM :
PP : Mr. Y. M. Reddy
SD : Mr. Krishna Mohan
PROJECT CO-ORDINATOR VERTICAL LEAD
MR.SRINIVASA REDDY MR.MILIND RAHANGDALE
FI-CO MM SD PP HR
Mr. Mortin
Mrs. Meenakshi Mr. Arvind Mr. GiriPrasad Mr. N.Gulhane Mr. Suresh
Mr. Venu Mr. Madhav Mr. G. Ravikumar Miss. Sangeeta
Mr. Jawar Miss. Bindi Priya
Mr. Srikanth
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TABLE OF CONTENTS
1. INTRODUCTION
2. PURPOSE
3. SCOPE
4. BUSINESS BENEFITS
a) GENERAL
b) PP-RELATED
5. ORGANIZATION
o GENERAL EXPLANATION
o NAMING CONVENTION
o DEFINITION OF ORGANIZATIONAL UNITS
I. CLIENT
II. COMPANY CODE
III. PLANT
IV. STORAGE LOCATION
6. BUSSINESS PROCESS OVERVIEW OF PIL

7. CROSS-APPLICATION/CENTRAL ORGANIZATIONAL UNITS
a) CALENDAR
b) UNITS OF MEASUREMENT
8. MATERIAL GROUPING - FINISHED PRODUCT AND SEMI-FINISHED
PRODUCTS
a) PRODUCT LIST
B) Material Types
9. BOM
9.1 BOM TYPES
o MULTIPLE BOM
o VARIANT BOM
o BOM USAGE
o GROUP BOM
o BOM GROUP
9.2 ITEM CATEGORY
a) RECURSIVE BOM
b) CO PRODUCTS / BY PRODUCTS
c) ALT ITEM CATEGORY GROUP
9.3 ESSENTIAL PRODUCTION SCRAP
9.4 GENERAL DATA FOR BOM
a) REQUIREMENTS / EXPECTATIONS
b) GENERAL EXPLANATIONS
c) NAMING / NUMBERING CONVENTIONS
d) DESCRIPTIONS OF IMPROVEMENTS
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e) DESCRIPTION OF FUNCTIONAL DEFECTS

f) APPROACHES TO COVERING FUNCTINAL DEFECTS
g) AUTHORIZATION & USER ROLES
10. MASTER DATA
a) PRODUCTION PLANNING
b) MATERIAL REQUIREMENT PLANNING
c) PRODUCTION CONTROL
d) CAPACITY PLANNING & SCHEDULING
11. WORK CENTER

A) PERSON RESPONSIBLE FOR THE WORK CENTER
B) CAPACITY
C) SHIFT AND SHIFT SEQUENCE
d) WORK CENTERS IN PIL
12. ROUTING
INTRODUCTION
13. PRODUCTION PLANNING
SALES & OPERATIONS PLANNING
DEMAND MANAGEMENT
14. MATERIAL REQUIREMENT PLANNING- MRP
a) MRP CONTROLLER
b) PRODUCTION PLANNING AND PROCUREMENT PLANNING
15. PLANNED ORDERS PROCESSING
16. SHOP FLOOR CONTROL
a) PRODUCTION ORDER CREATION
b) PRODUCTION ORDER RELASE
c) PRODUCTION ORDER CONFRMATION
d) PRINTOUT OF PRODUCTION ORDER
e) REPORT
17. REPETITIVE MANUFACTURING

18. REPORTS
19. ANNEXURE I
20. ANNEXURE II
21. GAPS
a) IDENTIFICATION OF GAPS
b) ADDRESSING OF GAPS
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23. Introduction
Phosphorus India Ltd is a corporate giant in the Agrochemical and Industrial Chemicals
sector in India and has major presence
• The Specialty Chemicals (Insecticide, Fungicides, herbicides, fumigants and
rodenticides)
• Caustic Chlorine
• White Phosphorus
• Industrial Chemicals
• Captive Power Generation of 48.5 MW
The group has major products in the Insecticide, Herbicide, Vidicide, Fumigant, and Industrial
Gases. Apart from this, the group also has manufacturing facilities in UK, USA, China and
Argentina.
Phosphorus India Limited today, has the widest range of generic agrochemical and other
chemical intermediates. Over and above, good markets in India, these agrochemicals are
exported to more than 100 countries in the world.
24. PURPOSE
The purpose of the Business Blueprint is to document the detailed System and
Business Process Requirements, and to implement the SAP R/3 System. This document
summarizes the proposed decisions associated with implementation as they relate to the
configuration of SAP.
25. SCOPE
The Implementation Scope includes the following SAP R/3 Sub-Modules in Production
Planning:
7.1 MASTER DATA
• Material master
• Bill of material
• Work center
• Routing
7.2 PRODUCTION PLANNING
• Sales & Operations Planning
• Demand management
7.3 MATERIAL REQUIREMENT PLANNING
7.4 CAPACITY PLANNING & SCHEDULING
7.5 PRODUCTION CONTROL

• Order
• Control
• Goods movement
• Confirmation
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26. KEY BUSINESS BENEFITS

The SAP System will provide the following Key Business Benefits:
a) General
• SAP will provide Access to Real-Time, On-Line Information with timely processing.
• SAP will offer stronger, more robust Reporting Tools.
• SAP’s Integrated Database eliminates the need for data replication and stand-alone
systems, decreasing the chance for human errors. This will reduce non-value-added work
while improving overall data integrity and give broader information access.
• SAP is “Packaged” Software, which is readily scalable. As such, the SAP software will
serve as a facilitator of future growth.
b) PP-Related
• Entire Production Planning and Control process will be captured for the first time in a
computerized SAP R/3 system.
• Part numbers for semi-finished product defined, so that stock valuation at various WIP
stages can be done through SAP.
• Material requirement planning will be performed through a much accurate MRP run
process in SAP. Material will be planned from the raw materials till the finished product
stage.
• For the Material Type Production resources, consumables and tools, consumption based
planning will be undertaken.
• Planned Scrap outcome of the production process will be accounted through the SAP
system automatically and back-flushed to Scrap store.
• Capacity planning, Production scheduling with the PIL Shift sequence will be performed
through SAP.
• Product Costing to be obtained through SAP.
• Standard SAP reports will be generated for all production processes.
• All the Work Centers in PP are assigned to Cost center. All the production costs will
automatically get accumulated in the cost centers.
• All the PP master data will be loaded on to the system resulting in generation of the
planned costs of the production processes. Actual production can be confirmed in the
system, which will generate the actual costs. Variance in the planned and actual costs can
be identified and the desired improvements can be effected in order to improve and further
control the production process. This is only possible through the integration of the various
modules.
27. ORGANIZATION
SAP an organizational structure consists of the following units: -
The client is the top level of the organizational level. Several company codes can be assigned
to one client. In turn, several plants can be assigned to a company code, and several storage
locations assigned to a plant.
Plants must always be consecutively numbered for all company codes. Consequently, plants
assigned to different company codes cannot have the same number. However, the numbers of
storage locations can be repeated, as long as they are assigned to different plants.
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• Plant: An organizational unit serving to subdivide an enterprise according to

production, procurement, maintenance, and material planning aspects. It is a
place where either material is produced or goods and services provided.
• Storage location: An organizational unit allowing differentiation between
the various stocks of a material in a plant.
7.1 CORPORATE STRUCTURE
Phosphorus India Ltd Group of companies comprises of two

Companies
• Company code 1: Phosphorus India Ltd Unit-1 (PIL1)
• Company code 2: Phosphorus India Ltd Unit-2 (PIL2)
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We will go for SAP Implementation in PIL01 Company.
PIL
Group
of
Comp.
PIL
PIL Unit-2
Unit-1 Ankleshw
Vapi ar
ISOPROT
Freon URON TCAC ZNP Plant ALP Plant
CPP Plant Plant Plant with Plant
2 Prod.
Line
RMS FGS Con. Scrap RMS FGS Con. Scrap

Store Store Store Store
Semi-Finish Semi-Finish
Storage Storage
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Plants:
1. PIL Unit-1 Located At Vapi
Plant Name Products SAP Nomenclature

a. CPP Plant CPP (Chloropyriphos) CPPP
CPP Plant
CPP
Chloropyripho
b. Freon Plant Freon-22 FREP
Freon-12
Freon Plant
Prod. Line for Prod. Line for

Freon-22 Freon-12

c. ISO Plant Isoproturon ISOP
ISOP Plant
ISOPROTURON
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Storage Locations:
1. PIL Unit-1 Located At Vapi
Sl. No Plant Description Nomenclature in sap

01 CPPP Raw Material storage S110
02 Spare parts storage S120
03 Finished Products storage S130
04 Scrap storage S140
05 FREP Raw Material storage S210
09 ISOP Raw Material storage S310
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28. Business Process Overview of PIL Group
Forecast/
Demand
Planning
Production Procurement
PIL PIL
Unit-1 Unit-2
Depot-1 Depot-3
Sales Sales & Distribution
Finance
Invoicing
Collection
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29. CROSS-APPLICATION/CENTRAL
ORGANIZATIONAL UNITS
a) General Explanation
An organizational unit serving subdivides an enterprise according to production, procurement,
maintenance, and material planning aspects. It is a place where either material is produced or
goods and services provided.
All data that is valid for a particular plant, as well as for the storage locations belonging to it, is
stored at plant level. This includes, for example, MRP data and forecast data.
b) Naming Convention
It is being proposed that the following number of plants will be created
CPP Plant Code- CPPP
FREON Plant Code- FREP
ISOPROTURON Plant Code- ISOP
c) Definition of Organizational Unit
An organizational unit serving subdivides an enterprise according to production, procurement,
maintenance, and material planning aspects. It is a place where either material is produced or
goods and services provided.
d) Assignment of Organizational Units
All data that is valid for a particular company code, as well as for the plants and storage locations
assigned to it, is stored at company code level. This includes, for example, accounting data and
costing data if valuation is at company code level.
e) Changes to existing Organization
It had been proposed that 3 plants be created (CPPP, FREP, and ISOP) and assigned to the
company code PIL1. Various storage locations for finished goods, raw material, Semi-finish,
Scrap, and Consumables will be created and assigned to each plant.
1. CALENDAR
Requirements/Expectations
Factory calendar needs to be maintained in the system. In this the working days are to be defined
and the holidays. This information is used in various modules. Country wise calendars are already
maintained in the system.
The Factory Calendar needs to be updated each year based on the decided holidays. The Factory
Calendar acts as the basis for Capacity Planning as it defines the working days in a year. In SAP
there are two types of holidays. Holidays are to be created and then assigned to the factory
calendar.
2. UNITS OF MEASUREMENT
Requirements/Expectations
Units of measure are required to facilitate the procurement and management of various items in
multiple order units.
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General Explanations
The unit of measure is utilized to describe the unit in which items are procured or stored. There are
over 220 different units of measure provided by SAP.
System Configuration Considerations
Units of measure to be used must be entered in the Purchase Requisition and Purchase Order in
SAP.
Special Considerations: Units of measure that are being used will be configured in
SAP if they do not exist
30. MATERIAL GROUPING - FINISHED

PRODUCT AND SEMI-FINISHED PRODUCTS
The following material grouping has been defined for the finished and semi-finished products at
Phosphorus India Ltd UNIT-1 in the SAP. The Material Grouping is for the Reporting purpose.
a) Product List:
Company Name: PIL1 Company Name: PIL2
• Finish Products: • Finish Products:
7.1 CPP a. TCAC
7.2 Freon-22 b. ZNP
7.3 Freon-12 c. ALP
7.4 ISOPROTURON • By-Products
• Semi-Finish Product: • 30% HCL
1. PNC (Sub Contracting) • Co-Products:
2. HTCP mass • 90% Na2SO3
3. NaTCP Salt • 24% Phosphoric Acid
4. CPP Organic Layer
• Trading Materials
o EDC (ROH Material type)
o Xylene (ROH Material type)
o Methanol
o White Phosphorus
• By-Products
• 30% HCL
• 90% Ammonium Sulphate
• CPN in CPPP Plant
• Effluent
• Co-Products:
• Freon-11
Note: Initially we will not consider Co-Products. After successful completion of

SAP, these Products will be added.
CPP Product has 4 variants like ethyl CPP 97%, Ethyl CPP 98%, Methyl CPP
97% and Methyl CPP 98%. First We will go for CPP and then after successful
completion of this, we will use variant configuration or Variant BOM
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b) MATERIALS Types
Sr. No. Material Type Description
1 ROH Raw Materials
2 HALB Semi Finished Products
3 FERT Finished Products
4 ERSA Spare parts
5 HAWA Trading Goods
6 VERP Packing Material
7 LEIH Returnable Transport Packing
8 PIPE Pipeline Material
9 FHMI Production resources / Tools
10 NLAG Non–Stock Materials
31. Bill of Materials

A formally structured list of the components that make up a product Or assembly. The list
contains the object number of each component, together with the quantity and unit of measure.
We can create the following BOM in the SAP system:
a. Material BOMs
b. Equipment BOMs
c. Functional location BOMs
d. Document structures
e. Order BOM
a) Material BOM Types
1. Multiple BOM
One product can be manufactured from alternative combinations of materials depending on the
quantity to be produced (lot size). The product is represented by a number of alternative BOMs
(alternatives). The differences between the alternative BOMs are only small. Usually the only
difference is in the quantity of individual components. A multiple BOM groups together several
BOMs that describe one object (for example, a product) with different combinations of materials for
different processing methods
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2. Variant BOM
The term "variant" refers to changes to the basic model of a product. These changes occur when
components are left out or added.
If you are producing several similar products that have a lot of common parts, you can describe
these products using a variant BOM. This is the case, for example, if you replace one material
component with another to make a different product. Variants can also differ by containing different
quantities of a component. You create the new BOM as a variant of an existing BOM.
Variant BOM
In M/s Phosphorus India Ltd variant BOM can be created in case of ethyl CPP
97%, methyl CPP 97, Ethyl CPP 98% and methyl CPP 97% as the final products
vary with only change in 2 Raw Materials.
But initially we will go for one Product CPP. Later on after successful
implementation we will go for variant BOM
b) BOM USAGE
BOM Usage defines the area where a BOM can be used like Production, Engineering/Design, Plant
maintenance, Spares, Costing relevance, sales.
Different BOMs will be maintained for different areas. In the standard system for Production, you can
create a BOM for all material types. You cannot create BOM for Material Type HIBE (Operating
Supplies). Operating supplies are procured externally and are required for producing other products.
c) Group BOM
A BOM that is not assigned to any plant is a group BOM. It is valid across the entire company. A group
BOM is not exploded in material requirements planning and in the production order. Group BOMs are
mainly created in the design phase and then later assigned to one or more plants for production.
d) BOM Group
A collection of bills of material that lets you describes a product or a number of similar products. BOM
group comprises of: -
• All the variants of a variant BOM

• All the alternatives of a multiple BOM
e) Use Of BOM in PP
The data stored in bills of material serves as a basis for production planning activities such as:
• A material requirements planning (MRP) department explodes bills of material on a certain

date to calculate cost-effective order quantities for materials.
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• A work-scheduling department uses bills of material as a basis for operation planning and
production control.
• A production order management department uses bills of material to plan the provision of
materials.
The data stored in bills of material is also used in other activities in a company such as:
• Sales orders
As an aid to data entry. You can also create and maintain a BOM specifically for a sales order
(variant configuration).
• Reservation and goods issue
As an aid to data entry
• Product costing
To calculate the costs of materials required for a specific product
INTEGRATION
Material Management (MM): Reservation and goods issue
Finance and Controlling (FI/CO): Product costing: To calculate the costs of

materials required for a specific product
Item category
Categorization of the items in a BOM according to set criteria, such as whether they refer to an object
(for example, material master or document info record) or whether they are kept in stock. This
categorization allows you to process data that is relevant to the individual items in a BOM. The item
category is used to control field selection, default values for BOM maintenance, triggering of specific
system activities, and so on.
The standard R/3 System contains the following item categories:
• Item Categories for Material Items: You can use the following item categories for
material items:
• Stock Items
• Non-Stock Items
• Variable-Size Items
• PM Structure Elements
• Intra Materials
• Document Items
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• Class Items
• Text Items
9 Stock item
This item category is used to manage material data that allows an item to be kept in stock.
9 Document item
This item category is used to manage document data that allows you to process original application
data (for example, graphics created with a graphics program).
9 Class item (for configurable BOMs)
In configurable material BOMs, you can enter a class as a placeholder for selectable items. The class
can contain either materials or documents.
When you assign characteristic values while configuring the BOM, the system replaces the node with
an object that has the same values as those assigned to the characteristic of the configuration. This
makes BOMs with a larger number of variants easier to maintain, as you do not have to enter all items
manually and assign a selection condition to them.
Class items can be relevant to MRP.
a) Recursive BOM
When a header material is a component in a BOM, it is Recursive BOM.
b) CO Products / BY products
A product that is automatically produced when main product is manufactured having considerable
value is Co Product and negligible value is BY Product.
Co product can be considered as a finished or semi finished but this is not the case for a By Product.
In Current situation, only Bi-Product terminology is being used. As per SAP procedure we have
divided these products into Bi-Products and Co-Products, which are mention in above Product
list.
ESSENTIAL PRODUCTION SCRAP

The essential scrap generated in the production process will be included as by-products in the Bill of
material. The same will be back flushed to the scrap storage location when the order is confirmed. For
inclusion in the bill of material, part numbers have been defined for the different types of scrap
generated in production for both the plants.
GENERAL DATA FOR BOM

¾ Requirements/Expectations
To define a uniform BOM applicable to both Production, Costing and inventory management
functionality of the organization. The same BOM will be used in various functionality's of Production say
for example,
BOM explosion during Production planning MRP run.
BOM explosion during production confirmation while back flushing.
¾ General Explanations
BOMs are used in their different forms in various situations where a finished product is assembled
from several component parts or materials In the case of BOM, simple BOM, variant BOM, and
multiple BOM will be used as applicable.
Multi-level BOMs will be created for various products manufactured in plants CPPP, FREP, ISOP.
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The first level will contain all the finished products, which are dispatched to the customer and then
the second level and so on.
The last level down the line will have raw materials procured from outside for the purpose of
manufacturing finished or semi-finished components.
¾ Naming/Numbering Conventions
Each BOM for a finished product will have the finished product code as the header.
¾ Description of Improvements
Creation of consistent and uniform master data, for example bill of material, and activities across
the organization for the purpose of Costing, Production and Inventory Management purpose.
Putting the same data say for example the methods of production, time required for production etc
for each and every material at one place.
¾ Description of Functional Deficits

In some cases both Variant and multiple BOM are required for production. For example certain
product will be a variant BOM with reference to a BOM which represent the most standard BOM of
that product.
As in SAP it is not possible to have both variant and multiple BOM for the same header material it
is required to decide which functionality (Variant/ Multiple) is required to greater extent and then
accordingly choose one of them and manage without other functionality.
¾ Approaches to covering Functional Deficits

To make up for the limitation mentioned above it will be required to decide which is a more suitable
and required functionality to decide on the BOM type to be created.
¾ Authorization and User Roles

The functions of BOM creation, Change, Deletion will be available only with the designated
person/group of person within each plant. Similarly display mode will be available for end-users
working on the functionality.
BOM Structure for Phosphorus India Ltd, Vapi (PIL1)
Finish and Semi F Products CPP Freon-22 Freon-12 ISO PNC
Base Qty 1900 100 100 1500 2500

Operation Loss 2% 5% 4% 1.50% 1%
Selling Cost Rs./- 400 520 600
Purchase
U/M Cost
Sr.
Raw Material
No Rs.
1 Chloroform Organic
kg 25 145 --
2 CTC (Carbon Tetra Organic
Chloride) kg 30 -- 130
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3 Inorganic
Anhydrous HF Acid
kg 60 33 28
4 Chlorine Inorganic
kg 18 0.5 0.5
5 Acid
H2SO4 Sulfuric Acid
kg 22 0.04 0.04 2400 3000
6 Soda Ash Inorganic
kg 10 25 25
7 48%NaOH Inorganic
kg 15 2100 0.012 0.002
8 TCAC Organic
kg 60 1900
9A C N Organic
kg 75 600
10 CuCl Catalyst
kg 90 9
11 Rani Catalyst Catalyst
kg 4
12 DETC Organic
kg 80 1100
13 HNO3 Nitric Acid Inorganic
kg 25 1800
14 Cumin Organic
kg 60 3500
15 Hydrogen Gas
kg 20 90
16 EDC Solvent
kg 25 5000
17 PCU Organic
kg 70 1250
18 Xylene Solvent
kg 55 300
19 Urea Inorganic
Kg 25 550
20 DMA Organic
kg 60 450
21 Packing
HDPE Drum 210 lit
Nos. 400 22.5
22 Jute Bag Packing
Nos. 70 30
23 13.6 lit Cylinder for Packing
Export Nos. 300 10 8
24 MS liner Drum 210 Packing
Lit Nos. 1500 77
25 Carbon Inorganic
Kg 200 0.5
26 Power Utility
KW hr 5.5 3800 450 450 15000
27 Steam Utility
kg 0.66 13700 410 410 15000
28 Water Utility
Kg 0.007 11400 300 300 4000
BOM Structure for Variant CPP.
Finish Products CPP Ethyl Ethyl Methyl Methyl

CPP CPP CPP CPP
97% 98% 97% 98%
Base Qty 1900 1900 1900 1900 1900
Operation
Loss 2% 3 3.5 3 3.5
Selling Rs. 400 450 500 480 520
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Cost /-
U/ Purchasi
M ng Cost
Sr Material
.N Raw group
o Material Rs.
1 TCAC Organic kg 60 1900 1900 1900 1900 1900
2 ACN Organic kg 75 600 600 600 600 600
3 CuCl Inorganic kg 90 9 9 9 9 9
4 DMTC Organic kg 85 1110 1110
5 DETC Organic kg 80 1100 1100 1100
6 48%NaOH Inorganic kg 15 2100 2100 2100 2100 2100
7 EDC Solvent kg 25 250 260 260 270 270
8 Methanol Solvent kg 40 300 300 300 300
9 Carbon Inorganic Kg 200 0.5 1 1 1
1 Inorganic
0 Catalyst-1 Kg 0.5 0.5
1 Inorganic
1 Catalyst-2 kg 0.5 0.5
1 MS liner Packing
2 Drum 210 No
Lit s 1500 77 77 77 77 77
1 Utility K
3 W
Power hr 5.5 3800 4600 4600 4600 4600
1 Utility
4 Steam kg 0.66 13700 14000 14000 14000 14000
1 Utility
5 Water Kg 0.007 11400 11400 11400 11400 11400
BOM Structure for Phosphorus India Ltd, Ankleshwar (PIL2)
Finish and Semi F Products TCAC ZNP ALP
Base Qty 4250 1030 350

Operation Loss 1% 0.5% 0.75%
Selling Cost Rs./- 60 950 650
Purchasing
U/M Cost
Sr
.N
o. Raw Material Rs.
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1 MCAA Organic kg 10 2975

2 Sulfur Inorganic kg 8 553
3 Ferric Chloride Catalyst kg 40 17
4 Chlorine Gas kg 26 5903
5 Pyridine Organic kg 30 23
6 48%NaOH Inorganic kg 15 2835
7 TCE Organic kg 20 8.5
8 Aluminum Powder Inorganic kg 36 -- 240
9 White Phosphorus Inorganic kg 36 312 125
White Crystalline
10 Wax Inorganic kg 50 -- 10
11 Palm Oil Inorganic kg 40 -- 2
Ammonium
12 Cabamate Inorganic kg 85 -- 73
13 Bittrine Inorganic kg 560 -- 0.2
14 Black Coal Powder Inorganic kg 10 -- 10
15 Filler ABC Inorganic kg 200 -- 3
16 Zinc Dust Fine Inorganic kg 76 600 --
17 Zinc Dust Coarse Inorganic kg 130 200 --
18 HDPE Drum 210 lit Packing Nos 400 17
19 Power Utility KW hr 5.5 10625 43.75 125
20 Steam Utility kg 0.66 9000 1500 1000
21 Water Utility Kg 0.007 8400 0 500
22 LPG Utility kg 21 25
Plant wise list Of Production Resource Tools.
Sr. PRTs U/M CPPP ISOP FREP TCAC ZNP ALP

No
1 Fork Lift Nos 1 1 1 1 2
2 Weighing Nos 2 2 4 1 2 2
Balance
3 Trolleys Nos 4 4 6 1 2 6
4 Lift Nos 1 1 1 1 1 2
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5 Samplers Nos 10 10 15 10 5 20
6 Manometer Nos 5 5 5
7 Temp Indicator Nos 40 50 15 25 15 40
8 Pressure Nos 5 4 5 2 1 2
Transmitter
9 Chlorine Kit Nos 1 1
10 Torch Nos 2 2 3 2 2 5
11 Empty Drums Nos 100 50 50 10 10
12 Shovels Nos 5 5 2 2 2
13 Crane Nos 2
32. WORK CENTER

Operations are carried out at a work center. In the R/3 System work centers are business objects that
can represent the following real work centers, for example:
• Machines, machine groups

• Production lines
• Assembly work centers
• Employees, groups of employees
Use
Together with bills of material, work centers belong to the most important master data in the R/3
production planning and control system. Work centers are used in task list operations and work orders.
Task lists are for example routings, maintenance task lists, inspection plans and standard networks.
Work orders are created for production, quality assurance, plant maintenance and for the Project
System as networks.
Data in work centers is used for
Scheduling: Operating times and formulas are entered in the work center, so that the duration of an
operation can be calculated.
Costing: Formulas are entered in the work center, so that the costs of an operation can be calculated.
A work center is also assigned to a cost center.
Capacity plans: The available capacity and formulas for calculating capacity requirements are entered
in the work center.
Processing of the work centers involves the maintenance of the following data:
Basic Data
Capacity data
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Scheduling data
Costing data
• The work centers represent the different processing centers or production line responsible
for the production of the finished product.
• The work center master data is divided into different screens like, basic data, capacity
overview, capacity header, scheduling, cost center, defaults etc. The different screens are
controlled by the work center category, whereas the capacity data is differentiated
according to the capacity category.
• The basic data view includes the description of the work center, the task list usage and the
standard value key. The usage describes the usability of the work center in routings or
other task lists.
• The standard value key supports the parameters, which represent the individual
operational segments like machining and labor etc.
• The capacity view contains all the data for the availability of the capacity and the different
formulas for the capacity requirement calculation.
• The scheduling view contains the scheduling data.
• The cost center view contains the costing data.
Naming/Numbering Conventions
Each work center/production line would be identified by their alphanumeric codes.
The first two letters denotes the location of the work center/production line (plant wise), the next
two letters will denote the type of the machine and number (like 1,2,3 …etc) will identify machine .
Special Organizational Considerations

All the work centers in PHOSPHORUS INDIA LIMITED are in 3 plants CPPP, FREP, and ISOP.
The work centers that will be created as production lines (work center category) are for FREON
PLANT and as individual machines for all other operations like REACTION, SCRUBBER etc
Each of these work centers will have capacity data, scheduling data and a cost center attached to
it.
Changes to the existing Organization

After implementation of SAP the plants have to adapt to the new work enter codes/production lines
codes as proposed to be used in the system, and capacity evaluation, production scheduling and
routing to be based on the defined work centers/lines.
Description of Important
Maintaining the work center master data is critical for routing and scheduling production. However,
this data can also be used for different analyses including capacity evaluation, rough-cut capacity
planning etc. Because of the central availability of the data, different business applications can
access this data and redundant data maintenance is avoided.
Authorization and User Roles
Authorization of Work center creation edition or deletion will be as per the authorization matrix in
Annexure.
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10.1 INTEGRATION
Human Resource (HR)
A Logistics work center can be assigned to either an organizational unit or a work center in the Human
Resource Management System (HRMS). Assignments to other HR-objects, for example employees or
qualifications, can be maintained via the HR work center.
Finance and Controlling (FI / CO)
Costing: Formulas are entered in the work center, so that the costs of an operation can be calculated.
A work center is also assigned to a production cost center and the production cost center has been
assigned to appropriate activity types. The prices for these activity quantities are calculated using the
activity prices.
10.2 CAPACITY
Capacity planning comprises the following partial components:
¾ Capacity evaluation
In the capacity evaluation, available capacity and capacity requirements are determined and
compared with each other in lists or graphics.
126
¾ Capacity leveling
The objectives of capacity leveling are:
• Optimal capacity commitment
• Selection of appropriate resources
In most applications, you can use two types of planning table (graphical and tabular
versions) to display the capacity situation and to carry out capacity leveling.
10.3 SHIFT AND SHIFT SEQUENCE

The available capacity of a shift is defined by the following data:
• Shift start, shift end, break times
• Capacity utilization rate
• Number of individual capacities
Shift start, shift end and break times can be manually maintained in capacity. You can however
also use shift
• Shift definition: In a shift definition you define the start, finish, break times, and validity period
of a shift.
• Shift sequence: In a shift sequence, you define how shifts follow another on a daily basis for
the duration of a Cycle. You use shift definitions to do this.
If you change the working times, you only have to change the shift definition, not the available
capacity in all the work centers affected. The system changes the available capacity automatically.
Changes to the shift sequence only serve as an aid to entering intervals in capacity, and do not
affect existing available capacity.
In the case of three shifts the shift timings are as follows:
Shift Start Shift End Break*
1st Shift 6:00a.m. 2:00 p.m 60 Min

2nd Shift 2:00 p.m. 10:00 p.m. 60 Min
3rd Shift 10:00 p.m. 6:00 a.m. 60 Min
For machines which are automatic no breaks are scheduled. 30 Min break time for lunch
10.4 WORK CENTERS IN CPP Plant
No. of (BCT
Work W.C.
Work in
Center Description Categor Activity Type
cente Hrs/bat
y
rs ch)
127
CPHT HTCP 8 40 Machine Set, Mach, Lab, Pow,

Stage- Reaction
1 CPDI CPN 2 8 Machine Set, Mach, Lab, Pow,
Distillation
CPHY Hydrolysis 3 12 Machine Set, Mach, Lab, Pow,
CPFI Filtration 2 8 Machine Set, Mach, Lab, Pow,
Machine Set, Mach, Lab, Pow,
CPPR Pressure 3 12 Machine Set, Mach, Lab, Pow,

Stage- Reaction
2 CPRE CPP Reaction 2 10 Machine Set, Mach, Lab, Pow,
CPWA CPP Washing 2 4 Machine Set, Mach, Lab, Pow,
CPLV Low Vacuum 1 6 Machine Set, Mach, Lab, Pow,

Distillation
CPHV High Vacuum 1 6 Machine Set, Mach, Lab, Pow,
Distillation
For Bi- CPHC HCL Scrubber 1 24 Hrs Machine Set, Mach, Lab, Pow,
Produ Runnin
ct g
CPMI CPP + MeOH 1 8 Machine Set, Mach, Lab, Pow,
Mixing
CPCR Crystallization 1 12 Machine Set, Mach, Lab, Pow,
Stage-
CPAN ANF Filtration 1 8 Machine Set, Mach, Lab, Pow,
3 for
97%
CPPD CPP Distillation 1 8 Machine Set, Mach, Lab, Pow,
and
98% CPMD MeOH 1 8 Machine Set, Mach, Lab, Pow,
CPP Distillation
10.5 WORK CENTERS IN ISOPROTURON Plant

No. BCT W.C
Work Of Category
Descriptio
Stages Cente Work Activity Type
n
rs Cente
r
128
Stage-1 This Stage is out sourced

PNC
Hydrogena
Stage- ISHD tion 2 12 Machine Set, Mach, Lab, Pow,
2(PCU Reactor
Section) PCU
ISPD 1 6 Machine Set, Mach, Lab, Pow,
Distillation
DCU
ISRE 3 20 Machine Set, Mach, Lab, Pow,
Formation
Organic
ISWA 2 8 Machine Set, Mach, Lab, Pow,
Washing
Dehydratio
ISDE 2 12 Machine Set, Mach, Lab, Pow,
n
DMA
ISDM 2 12 Machine Set, Mach, Lab, Pow,
Stage-3 Reaction
(ISOPRO Crystallizat
ISCR 2 12 Machine Set, Mach, Lab, Pow,
TURON) ion
Centrifugin
ISCN 3 13 Machine Set, Mach, Lab, Pow,
g
Vacuum
ISRV 1 6 Machine Set, Mach, Lab, Pow,
Drying
ISO
Screening
ISPC 1 6 Machine Set, Mach, Lab, Pow,
and
Bagging
Amm. Sul.
ISEV Evaporatio 1 8 Machine Set, Mach, Lab, Pow,
n
Bi-
Product Vacuum
ISVD 1 6 Machine Set, Mach, Lab, Pow,
Stage Drying
Amm. Sul.
ISAP 1 4 Labor Labor
Packing
10.6 WORK CENTERS IN FREON Plant

¾ Production Line-1 for Freon-22
129
¾ Production Line-2 for Freon-12
Work Description No.

Productio Center Of
W.C.
n Line Work Activity Type
Category
Cente
r
FRRT-1 Pressure Reactor for 2 Machine Machine,
Pressure Reaction Labor
FRFF-1 FFE-HCL Scrubber 2 Machine Machine,
Labor
FRCA-1 Caustic Scrubber for 2 Machine Machine,
removal of acidity. Labor
Productio
FRSU-1 H2SO4 Scrubber for 2 Machine Machine,
n Line for
removal of moisture Labor
Freon-22 Freon Gas Compressor Machine Machine,
FRCO-1 4
Labor
FRD1-1 Distillation unit-1 2 Machine Machine,
Labor
Labor
FRFL-1 Freon Gas Filling 4 Machine Machine,
Station Labor
FRRT-2 Pressure Reactor for 2 Machine Machine,
Pressure Reaction Labor
FRFF-2 FFE-HCL Scrubber 2 Machine Machine,
Labor
FRCA-2 Caustic Scrubber for 2 Machine Machine,
removal of acidity. Labor
Productio
FRSU-2 H2SO4 Scrubber for 2 Machine Machine,
n Line for
removal of moisture Labor
Freon-12 Freon Gas Compressor Machine Machine,
FRCO-2 4
Labor
Labor
Labor
FRFL-2 Freon Gas Filling 4 Machine Machine,
Station Labor
10.7 WORK CENTERS IN TCAC Plant

Work Batch Cycle
Stages Description Qty. in Nos.
Center Time (BCT
130
Name in Hrs)
DCAC React.
TCDC 6 70
Cum Dist.
HCL Scrubber
24 Hrs
TCHCL1 in DCAC 1
Running
Section
Sodium
Stage-1 TCNa Sulphite 2 12
Evaporator
Na2SO3 final
TCNaRVD Moisture 2 12
removal
TCAC TCAC Reactor 6 48
TCAC
TCDI 2 24
Stage-2 Distillation
HCL Scrubber
24 Hrs
TCHCL2 in TCAC 1
Running
Section
10.8 WORK CENTERS IN ZNPP Plant

Batch Cycle
Work Center
Description Qty. in Nos. Time (BCT in
Name
Hrs)
ZNRE Reactor. 2 6
ZNBL1 First Ball Mill 2 12
ZNSE Sieving machine 1 3
ZNBL2 Second Ball Mill 2 12
ZNPC Final Packing 1 2
131
10.9 WORK CENTERS IN ALPP Plant

Batch
Work
Qty. in Cycle Time
Center Description
Nos. (BCT in
Name
Hrs)
ALFP Firing Pots 3 0.5
ALFC Firing Chamber 2 2
ALAD Wax Addition 1 1
ALWM Wax Melter 1 1
ALCM Crushing Machine 2 1.5
ALJC Jaw Crusher 2 1.5
Ammonium Carbide
ALAC 2 1
addition Section
ALBL Blending Machine 2 1.5
ALTR Transferring Trolleys 8 1
ALSC Phosphene Gas Scrubber 1 24 Hrs running
10.10 List of Q.C. Equipment.

• Following list of QC equipments where the external services are required
for overhauling.
• HPLC. 2 Nos.
• Gas Chromatography. 2 Nos.
• Lab Weighing Balance. 4 Nos.
• Carl Fisher equipment. 4 Nos.
• Specific Gravity meter. 4 Nos.
• PH Meter. 3 Nos.
33. ROUTING
INTRODUCTION:
Routings enable you to plan the production of materials (products). Therefore, routings are
used as a template for production orders and run schedules as well as a basis for product
costing.
132
As the production scenario in CPP, ISOPROTURON Plant is of discrete

manufacturing; so normal routing is considered for the above plants.
Rate Routing
A routing for whose operations the production quantity and a fixed duration has been defined.
Thus the production rate is also defined.
Rate routing is considered for Freon Plant as it purely involves repetitive

manufacturing scenario.
A routing is assigned to a specific plant, which is defined in the routing header. However, you can
assign individual operations of a routing to a different plant, if one or several operations are to be
carried out in another plant. The plants specified in the individual operations and the one specified
in the routing header must belong to the same company code.
Naming/Numbering Conventions
Each routing will be maintained for the finished good, as the header material.
Changes to existing Organization

None at present
Benefits
Online and close monitoring of the production, scheduling, capacity requirement calculation and
costing will be done for which at present there is no system.
Description of Functional Deficits

Need to be able to use a standard routing for an entire class of items.
Approaches to covering Functional Deficits

Test system to see if functionality exists.
ROUTING – MATERIAL ASSIGNMENT
133
Notes on further Improvements

Online and close monitoring of the production, scheduling, capacity requirement calculation and
costing will be done for which at present there is no system.
Authorization and User Roles
Authorization of Routing creation edition or deletion will be as per the authorization matrix to be
defined.
Components are assigned to operations in routing from the Bill of Material of the Header material.
INTEGRATION
Material Management (MM)
Plan the usage of materials

Plan the external processing of operations
134
Finance and Controlling (FI / CO)
Prepare cost calculation according to routings
ROUTING (FLOW CHARTS) for CPP Plant

Stage-1 TCAC ACN CuCl
Water
HCL
Scrubber
HCL Gas System at
HTCP Reaction 25 Deg.C
CPN to
Scrap CPN Distillation 30% HCL Acid
48% NaOH
Hydrolysis
Water
ETP1
Filtration
NaTCP
Cake
135
48% NaOH NaTCP Cake Water

Stage-2
Pressure Reaction
Lime DETC for Ethyl CPP or DMTC for Methyl CPP

Effluent
CPP Reaction EDC
MEE Water
CPP Washing
LDO EDC Storage
Tank
EDC Distillation in LVD

Rec.EDC
under Vacuum
Rec.EDC
EDC Distillation in HVD
CPP 95% Drumming
Required Data For CPP Routing/Batch 1900kg CPP
Base Qty. in Kg 1900 Manpower Activity Type

Available in
Hr / Set up time Machine Labor Time Power in
Sr. No. Operation KW W.C./24hr in hr time in hr in hr KWH
1 HTCP Reaction 12 9 1 35 315 420
2 CPN Distillation 12 12 0.5 12 144 144
3 Hydrolysis 15 12 12 144 180

4 Filtration 30 48 8 384 240
5 Press. Reaction 15 12 12 144 180
6 CPP Reaction 15 12 10 120 150
7 CPP Washing 10 12 4 48 40
8 LVD 10 12 4 48 40
9 HVD 10 12 4 48 40
136
ROUTING (FLOW CHARTS) for ISOPROTURON Plant
3200kg 4kg Catalyst

PNC RaniNckel
90 Kg
Stage-2 PCU Section Hydrogen Hydrogenation
Separation
PCU Distillation
Semi Finish Product

2500 kg Distilled 99%
PCU
137
1250 kg 900 kg H2SO4 300 kg Xylene 550 kg Urea

Stage-3 PCU
DCU Reaction
50 kg 48% NaOH
De-Hydration Washing at room Temp
4000l lit 26 % Ammo.
Sulphate
450 kg DMA Reaction Evaporation

DMA 4000 kg Water
Crystallization Centrifuging Vacuum Drying
RVD Vacuum drying

By-Product 1200 kg 90%
Amm. Sulphate/Batch
Screening, Pulverizing and

Bagging
1500 kg ISOPROTURON
138
ROUTING (FLOW CHARTS) for FREON Plant
CHCL3 Or HF Chlorine Gas

CTC Acid
Pressure Reaction
SbCl5 Catalyst
HF- HCL Separation in Rec. HF Acid 75 kg/hr

Distillation Column
Bi-Product
30% HCL Acid 4500 kg/hr
FFE for HCL Scrubbing
Caustic Scrubber for

acidity removal 48% NaOH 20kg/hr
H2SO4 Scrubber for 98%H2SO4Acid 50 Kg/hr

Moisture removal
Gas Compression
Co-Product Freon-11
330 kg/hr during Distillation Unt-1
Freon-12 Production
Distillation Unt-2
Freon-22 or Freon-12 to
storage Tank (1660/1330
kg/hr)
Filling Station For Filling Station for Filling Station for Filling Station for
Tuner 74kg Cylinder 50kg Cylinder 13.6 kg cylinder
139
TCAC Plant: Process Flow Diagram (ROUTING)
Stage-1
MCAA Sulfer FeCl3 Chlorine
SO2 Gas
HCL
HCL Gas Scrubbing
DCAC Reaction + Distillation
BCT-70Hrs System
30%HCL
Na2SO3
8000lit/day
Chlorine
Na2SO3 Evaporation
Pyridine
Tanker loading
RVD
Stage-2 TCAC Reaction HCL Gas

HCL
Scrubbing Na2SO3
System
TCAC Distillation 30%HCL

4000lit/day
99%
Tanker loading
TCAC
140
ZNP Plant: Process Flow Diagram (ROUTING)
ZNF ZNC WP ZNF ZNC WP
Reactor - 1 (SS-316) Reactor - 2 (SS-316)

BCT-8 hrs. Capacity - 600 kgs BCT-8 hrs. Capacity - 600 kgs
Coarse Material
Supper Fine Ball Mill (SS-316) ,

BCT-5 hrs, Cap.-1500 kgs
Sieving Machine 100 mesh

Capacity- 300 kgs/hrs
ZNP Tech(80%)
Bulk Packing as per order i.e.

drum packing
ZNP
141
ALP Plant: Process Flow Diagram
Aluminum Powder White Phosphorus Water Circulation Water S

Fire C
R
Firing Pot for Reaction Firing Chamber
U
B
B
E
C Wax
Crystalline Wax melter Crude ALP R
Palm Oil Spiral Cutter for blending /

crushing
JAW CRUSHER -1 NH4COONH2 26% Phosphoric
NH4COONH2 JAW CRUSHER -2 acid
Bitrrine
Filler ABC
Black powder Blender -1
Phosphene Gas
Phosphine gas
Trolleys
Hopper
34. PRODUCTION PLANNING

As-Is: Presently Production Planning is being done manually. This again depends on the skill of
Production Manager. Some time all information regarding planning wouldn’t flow from top-level
management to the shop floor person. Because of this we loose important customers who requires
material in time. There are many loopholes in the existing system. Because of this transparency
between top management and middle management is not maintained.
While taking some important decisions Top management has to depend on the information’s given by
respective dept. This can lead to wrong step in business.
To-Be: The Production planning is the backbone of any growing organization. Organization needs to
streamline and consolidate company’s sales and production operations.
To avoid above problem SAP R/3 gives the solution in following ways.
142
Planning and Processing of Production Process

Sale and Operation Planning for Material or
Sale Forecast
Product Group using MC87
SD
DEMAND AMANGEMENT
Creation Planned Ind. Requirement
using MD61
Cust. Req. Sales

Material Requirement
Order
Planning MD02
Planned Order
Conversion of Planned Order to

Prod. Order/ Purchase Order
` Check Availability
Components Capacity
N Purchase N Shift Dates /

Purchase order Provide Addl.
Req.
Capacities
Y Y
Order
Settlement
Production Order
Goods Movement
Order Release Confirmation To FG Store
CO15/CO11N
143
Process Flow
1. Sales and Distribution take requirements as concrete customer requirements from the market.
2. In Demand Management, sales are planned in advance via a sales forecast.
The result is the independent requirement, that is, the requirement for the finished product,
tradable assemblies, trading goods and replacement parts. This result triggers material
requirements planning.
3. In order to cover these requirements, MRP calculates procurement quantities and dates as
well as plans the corresponding procurement elements. The procurement element in the
planning run is the planned order or, for external procurement, the purchase requisition. Both
procurement elements are internal planning elements that can be changed, rescheduled or
deleted at any time.
4. If a material is produced in-house, the system also calculates the dependent requirements,
that is, the quantity of components required to produce the finished product or the assembly,
by exploding the BOM. If a material shortage exists, planned orders are created at every BOM
level to cover requirements.
5. The system then converts these planned procurement elements into exact procurement
elements: production orders for in-house production and purchase orders for external
procurement.
6. The progress of the order for materials produced in-house is controlled by using the
production order. The production order contains its own scheduling procedures, capacity
planning and status management. Cost accounting is also carried out via the individual
production order.
7. Materials that are procured externally trigger the purchasing procedure. In this case, you
must have chosen suitable vendors or you must have drawn up outline agreements.
8. The quantities made available by production or by external procurement are placed in stock
and are managed by Inventory Management.
7.1 SALES & OPERATIONS PLANNING
Sales & Operations Planning (SOP) is a flexible forecasting and planning tool with which sales,
production, and other supply chain targets can be set on the basis of historical, existing, and estimated
future data. Rough-cut planning can also be carried out to determine the amounts of the capacities
and other resources required to meet these targets. SOP is particularly suitable for long- and medium-
term planning.
For planning purpose, the required sales plan can be gathered from various sources like Forecasting,
Sales Information Systems and Co-PA (Cost-Profitability analysis) or can be created manually.
Based on sales plan, the production plan is created and the requirements are then transferred to
demand management.
a) CPPP PLANT - CPP

The product group of the CPP Plant is identified as “CPP” with 100% production share.
144
If we use 4 Variants of CPP, then Product Group of the CPP Plant is

identified as “ CPP “ with sales share of 30% for ethyl CPP 97%, 40%
for ethyl CPP 98%, 15% for methyl CPP 97% and 15% for Methyl CPP
98%.
These variants will be used after successful implementation of SAP
for plane CPP without variants.
b) FREP PLANT – FREON GAS

The product group of the FREON PLANT is identified as “FREON” with a sales share
of 70% for FREON-22, 30% for FREON-12.
c) ISOP PLANT
The product group of the ISOP PLANT is identified as “ISOPROTURON” with 100%
production share.
INTEGRATION
Sales and Distribution (SD)
9 SOP constitutes the planning functionality of the LIS information systems.

9 SOP plans are passed on to Demand Management in the form of independent
requirements. In turn, this data is fed to Master Production Scheduling and
Material Requirements Planning.
Finance and Controlling (FI/CO)
9 An interface with Profitability Analysis (CO-PA) allows using CO-PA data as

the basis for sales planning in SOP.
9 SOP results are passed on to Profitability Analysis (CO-PA), Cost Center
Accounting and Activity-Based Costing.
7.2 DEMAND MANAGEMENT

The function of Demand Management is to determine requirement quantities and delivery dates
for finished products assemblies. Customer requirements are created in sales order
management.
• The demand program is created in the form of planned independent requirements.

Demand management uses planned independent requirements and customer
requirements. Customer requirements are created in sales order management.
• To create the demand program, define the planning strategy for a product.
Planning strategies represent the methods of planning for production and
manufacturing or procuring a product.
• Using these strategies, it can be decided whether production is triggered by sales
orders (make-to-order production), or it is triggered by Forecast (make-to-stock
production).
145
• Or, you may want both sales orders and stock orders in the demand program. If
the production time is relatively long in relation to the standard market delivery
time, you may want to produce the product or, at least, certain assemblies before
any sales orders exist. In this case, the sales quantities are preplanned (for
example, with the aid of the sales forecast).
Based on the Manufacturing scenario of respective Finish Products, following Planning Strategies are
listed for Finish product for PIL1 as well as PIL2. We will be looking for CPPP, ISOP, and FREP Plant
only.
Sr.No. Finish Plant Strategy Production

Products Process
1 TCAC 10 MTS Descrit Mfg.
TCAP Plant Batch
Management
2 95% CPP 40 MTS Descrit Mfg.
Batch
Management
3 97% ethyl
CPP
4 26 MTO Variant
98% ethyl CPPP Plant Configuration
CPP Descrit Mfg.
with
Batch
5 97% methyl Characteristics
Management
CPP 1) Group and 2)
Purity
6 98% methyl
CPP
7 Freon-22 11 MTS REM
FREP Plant
8 Freon-12 10 MTS REM
9 Isoproturon 20 MTO Descrit Mfg.

ISOP Plant Batch
Management
10 ZNP 52 MTS without Descrit Mfg
ZNPP Plant Final Assembly .Batch
Management
11 ALP 50 MTO without Descrit Mfg.
ALPP Plant final assembly Batch
Management
146
35. Material Requirement Planning

As-IS: In current situation requirement planning are done in very haphazard way. Some time some raw
materials or spares are procured 2-3 times which unnecessarily piling up stock of costly materials. So
inventory increases.
Some time Production person doesn’t get required material in time. This happens mostly in
consumable material which equally important for production. This results in production loss.
Monitoring stock is very difficult. This results in wrong reporting at the end of month or year.
To-Be: To capture above problem and give systematic solution, in SAP R/3 system MRP gives solution
in following ways.
a) MRP CONTROLLER
b) PRODUCTION PLANNING AND PROCUREMENT PLANNING
c) CAPACTY PLANNING
What is MRP: The main function of material requirements planning is to guarantee material
availability, that is, it is used to procure or produce the requirement quantities on time both for internal
purposes and for sales and distribution.
This process involves the monitoring of stocks and, in particular, the automatic creation of procurement
proposals for purchasing and production.
In doing so, MRP tries to strike the best balance possible between
- Optimizing the service level and

- Minimizing costs and capital lockup.
So, when MRP run is carried out using PD (normal planning) as MRP type, the PLANNED ORDERS
are generated according to the demand mgmt (Planned Independent requirements). The MRP
controller checks the scheduled dates of the planned orders and converts them into the production
orders.
Material requirements planning take current and future sales as its reference points. Depending on
planning strategy, actual requirements trigger the MRP calculation. In MRP the requirements include
sales orders, planned independent requirements, material reservations, the dependent requirements
created by exploding the BOM and so on.
In case of in-house production the system creates planned orders for planning of production quantities.
When planning is complete planned orders can be converted into production orders.
In case of external procurement the system creates either a planned order or directly creates a
purchase requisition or a schedule line for a pre-existing scheduling agreement for planning the
external purchase order quantity.
13.1 MRP Controller

General Explanation
147
MRP Controller is the person responsible for a group of components in Material Requirement Planning
in a plant or company. Material that takes part in MRP must be assigned to a MRP controller. The field
for MRP Controller is located in the MRP 1 view of the Material Master.
The MRP controller is responsible for all activities, for specifying the type, quantity and time of the
requirements and he must also calculate when and for what quantity an order proposal has to be
created to cover these requirements. He needs all the information on stocks, stock reservation and
stock on order to calculate quantities and he needs all the information on lead times and procurement
times to calculate dates. The MRP controller determines a suitable MRP and lot-sizing procedure by
material to determine procurement proposals.
The most common lot-sizing procedures are available in the system and can easily integrate user-
defined formulas.
Naming Convention
For MRP controlling, it is proposed that there be one MRP controller in each section within the 3 plants.
The proposed codes to be used in SAP are as below:
Section: Plant MRP Controller

CPPP 500
ISOP 600
FREP 700
Definition: The MRP controller is the person responsible for a group of materials in MRP in a plant or
company. A material that takes part in material requirement planning must be assigned to a MRP
Controller. Each of these areas will have a separate MRP controller. MRP to be run separately in the 3
areas independently.
13.2 MRP control parameters

Various control parameters are available for the total planning procedure and for single-item planning
and multi-level planning, which you can set in the initial screen of the planning run. You use these
parameters to determine how the planning run is to be executed and which results are to be produced.
The control parameters include:
• Planning run type
Choose whether all materials are to be planned or only those with MRP relevant changes.
Planning run types are as fallows
o Net changing planning– NTECH

o Net change planning in the planning horizon ---NETPL
Planning horizon is maintained for 100 days
148
• Creation indicator for procurement proposals for materials that are procured externally
Choose whether planned orders, purchase requisitions or schedule lines should be created for
materials that are procured externally.
• Creation indicator for MRP lists: Define whether MRP lists are to be created.
• Planning mode: Determine how the system is to deal with procurement proposals
(planned orders, purchase requisitions, scheduling agreement lines) from the last planning run,
which are not yet firmed, in the next planning run.
• Scheduling: Choose basic date calculation or lead time scheduling
13.3 MRP RUN AT Phosphorus India LIMITED:

At PIL, for regular products MRP will be run once a week, based on the requirement by the customers.
Based on this requirement for all the finished products and the Dependent requirements will get
generated using transaction code MD02. In case there are changes to this requirement then MRP to be
run on weekly basis. But for export orders, MRP will be only run based on the Sales orders, using the
transaction code- MD50.
For Regular Orders: MD02, Once a week

For Export Orders: MD50, only on receipt of sales orders.
13.4 MRP Out put
The following evaluations are available for analyzing the planning result:
• MRP list
• Stock/requirements list
• Planning result (corresponds to the MRP list with individual evaluation layout)
Planning situation (corresponds to the stock/requirements list with individual evaluation layout)
149
13.5 CONSUMPTION BASED PLANNING

Consumption based planning is based on consumption values and uses forecasts or statistical
procedures to determine future requirements. Consumption based planning is characterized by its
simplicity and is mainly used for low value items. Manual reorder point planning is a typical process in
consumption based planning.
Monthly Plant wise list Of Consumables and Spare parts.
Sr. Consumable U/M CPPP ISOP FREP TCAC ZNP ALP

No
1 Hand Gloves Nos 150 160 80 150 180 200
2 Nose Mask Nos 100 120 50 150 150 200
3 Safety Goggles Nos 40 50 40 50 60 100
4 Bucket Nos 15 10 2 5 10 15
5 Funnel Nos 10 15 1 15 5 15
6 Filter P. Cloth Nos 10
7 Sp.Filter Cloth Nos 50 15
8 1” Hose pipe Nos 50 80 50 10 50 40
9 Brooms Nos 150 120 100 120 80 200
10 PH Paper Nos 20 15 10 15 20 15
11 Log Sheets Books Nos 10 15 2 10 15 15
12 Pen Nos 40 30 30 40 50 40
13 Staplers Nos 2 1 1 1 1 1
14 Calculators Nos 1 1 1 1 1 1
15 Chlorine Detector Nos 6 5
Spare Parts Nos
1 1.5”/2”/3/6/4 HDPE Nos 120/100 120/10 120/10 120/100 120/1 120/1
Valves /50/80 0/50/8 0/50/80 /50/80 00/50/ 00/50/
0 80 80
2 1” Asbestos Nos 250 250 250 250 250 250
Gaskets
3 2” Asbestos Nos 150 150 150 150 150 150
Gaskets
4 4” Asbestos Nos 80 80 80 80 80 80
Gaskets
5 4”/2” /6”PP Nos 250/280 250/28 250/28 250/280 250/2 250/2
Gaskets /200 0/200 0/200 /200 80/20 80/20
0 0
6 1”/2”/3”/4”/6” MS Nos 100 100 100 100 100 100
Flanges each each each each each each
7 1”/2”/3”/4”/6” MS Nos 100 100 100 100 100 100
Flanges each each each each each each
8 ½” x 3” Nuts Bolts Kg 50 50 50 50 50 50
150
9 1”/4” Nuts bolts Kg 50 50 50 50 50 50

10 V-Belt Nos 10 10 10 10 10 10
13.6 Capacity Planning

The capacity planning mainly consists of two elements i.e.
¾ Capacity Evaluation
¾ Capacity Leveling
13.6.1 Capacity Evaluation
After the MRP run, the capacity requirements are created by the system. The load on the entire
bottleneck work centers can be seen in the system. The system will highlight the periods when
overload exists in each work center. In such a situation capacity needs to be leveled so that production
plan becomes final.
13.6.2 Capacity Leveling
In capacity leveling, all the orders, which require that particular work center, will be dispatched to the
committed schedule one after other as per the priority. After leveling, the load on work center will be
evened out for the planning bucket. The revised scenario and schedule will be immediately reflected in
the evaluation.
If the capacity leveling is carried out to such an extent, that it has to be reflected in the schedule of the
dependent materials, then MRP run can be carried out again. At this time the planned orders, which
have undergone changes to schedule (firmed orders) will not be again changed by the system. The
dependent materials will be planned as per the revised schedule.
36. PLANNED ORDER PROCESSING

• Manually
The MRP controller enters a planned order manually. He determines which material is to
be procured, the required quantity, the date required, and whether the material is to be
procured externally or internally.
• Automatically
During the planning run, the system automatically determines the materials to be procured
with the required quantity and the required date.
After the planned order is created either manually or automatically a planned order profile
is allocated and data is processed. The data would include: material, plant, order quantity
and basic order dates. This will trigger the processing of material components, schedule
the planned order, edit account assignment and process the source of supply.
The system will check component and capacity availability and if needed, capacity leveling
can be carried out. Saving the planned order creates a purchase requisition, planned load,
creates dependent requirements and allows the processing of the planned order.
151
In case these requirements are produced in-house, the system creates planned orders that in
turn can be converted to Production orders before actual production execution. Alternatively, if
the requirements are procured externally, these requirements are directly converted into
Purchase requisitions. It would also be possible to convert the planned orders to purchase
requisitions.
NUMBER RANGES FOR PLANNED ORDERS
Phosphorus India Ltd: 1000 to 9999
37. SHOP FLOOR CONTROL

15.1 PRODUCTION ORDER
Production orders are a fundamental part of Production Planning and Control. PP is fully
integrated in the Logistics component and has, among others, interfaces to
• Sales and Distribution

• Materials Management
• Controlling
¾ Production order specifies:

• What is to be produced
• When production is to take place
• Which capacity is to process the order
• How much production costs
• The work processes within a company are executed using orders.

• As soon as a planned order or a company-internal requirement is generated from previous
planning levels (material requirements planning) shop floor control takes over the
information available and adds the order-relevant data to it to guarantee complete order
processing.
• Production orders are used to control production within a company and also to control cost
accounting.
• The production scheduler confirms and releases the order to shop floor for actual
production. After production, operation wise confirmation of the order is carried out and
relevant goods are sent (GR) into the storage location.
15.2 PRODUCTION ORDER CREATION
This function supports the production of goods in-house using the production order or work
152
order concept. The different functions involved are:
1. Order creation
2. Order release
3. Inspection lot processing
4. Goods issues
5. Order confirmation
6. Goods receipt
7. Order settlement
¾ When a production order is created the following actions are carried out:
• A routing is selected, its operations and sequences are transferred to the order
• The bill of materials is exploded and the items in the bill of material are transferred to
the order
• Reservations are generated for bill of material items held in stock
• The planned costs for the order are generated
• The capacity requirements are generated for the work centers.
• Purchase requisitions are generated for non-stock items and externally-processed
operations.
PRODUCTION ORDER NUMBER RANGE
PLANT NUMBER RANGE
Phosphorus India Ltd 5000000 to 5999999
15.3 RELEASE OF PRODUCTION ORDER
Release of the production order is an important business function, which controls things like
the goods issue for the order, confirmation of the order progress etc. Here either individual
production operations or the order itself can be released.
The production order release function is to be exercised in each production order, in the
transaction menu of the order header, after the creation of the production order. This function
sets the "released" status in the order header
After the creation of the production order, the individual operations or the order header itself
can be released as per the release date specified in the material master scheduling margin
key.
153
15.4 ORDER CONFIRMATION
A confirmation documents the processing status of orders, operations, sub-operations and
individual capacities. It is an instrument for controlling orders.
With a confirmation you specify

o The quantity in an operation that was produced as yield, scrap and the quantity to be
reworked
o How much work was actually done
o Which work center was used for the operation
o Who carried out the operation
o Exact confirmation shortly after completion of an operation is essential for realistic
production planning and control.
The following business transactions can be executed via confirmations:
o Updating order data (for example, quantities, activities, dates, status)

o Back flushing of components
o Automatic goods receipt (for one operation per order max.)
o Capacity reduction in the work center
o Updating costs based on confirmed data
o Updating MRP-relevant excess or missing quantities in the order
o You can enter confirmations for An order- to be entered daily
o An operation- to be done before period closing for inventory valuation of WIP.

o A sub-operation
o An individual capacity in an operation
o An individual capacity in a sub-operation
o For scrap, rejection, reworks, operation confirmation will be done.
15.5 PRINTOUT OF PRODUCTION ORDER

This function controls the printing of the shop papers, such as the operation confirmation slips,
time tickets etc.
The printing of the different shop papers is controlled by the settings made in the control key
attached to the individual production operations.
INTEGRATION
Production orders is fully integrated in the Logistics (LO) component and has, among
others, interfaces to
o Sales and Distribution (SD)

o Materials Management (MM)
o Controlling (CO)
154
15.6 Batch management

Definition of batch
The quantity or partial quantity of a certain material or product that has been produced
according to the same recipe, and represents one homogenous, non- reproducible unit with
unique specifications.
Purpose of batch management
• Legal requirements (for example, the guidelines set out by GMP-Good Manufacturing
Practice) or regulations on hazardous material.
• Defect tracing, callback activities, and regression requirement.
• The need for differentiated quantity-and value-based Inventory Management (for
example, due to heterogeneous yield/result qualities or varying constituents in
Production.
• Differences in usage and the monitoring thereof in materials planning in SD and
Production.
• Production or procedural requirements (for example, settlement of material quantities
on the basis of different batch specifications
Features of batch management
• Batch Number Assignment
This function used to assign a batch with a number that uniquely identifies it.
• Batch Specification
This function used to describe each batch uniquely using characteristics and characteristic
values. It specifies the permitted value range in the allocated material master record.
• Batch Status Management
This function used to indicate whether a batch is usable or unusable. We can set this status
o Manually in the batch master record or at goods receipt

o Automatically in the usage decision in quality management
155
• Batch Determination
o With this function, we can use various criteria to search for batches that are in stock, for
example:-
o When posting goods issues
o When combining suitable material components for production orders and process orders
o When creating a delivery according to particular customer requirements
• Batch Where-Used List
o The batch record contains all quality-relevant planned and actual data for the production of
a batch and complies with the GMP guidelines (Good Manufacturing Practices) for the
pharmaceutical industry and food industry.
o The batch where-used list shows the path of the batch from its procurement to its delivery
to your customer.
15.7 CLASSIFICATION
The classification system allows you to use characteristics to describe all types of objects and to group
similar objects in classes – to classify objects
Characteristics
Characteristics describe the properties of objects. The values of a characteristic specify these
properties.
When you create or change a characteristic, you can define the following settings:
• Format For example, numeric format is for figures, and character format is for alphanumeric
characters.
• Units of measure for numeric values
• Templates for entering values
• Required entries for a characteristic (required characteristics)
• Whether intervals are allowed as values
• Language-dependent descriptions and texts for characteristics and characteristic values
• Display options for characteristics on the value assignment screen
• Allowed values
• Default values that are set automatically on the value assignment screen
Class : Classes allow to group objects together according to criteria that is.
• Create classes for certain object types for example, material, workplace, equipment.
• Use the class type to determine which object types can be classified in a class.
156
• Assign characteristics to class. These describe the objects classify in class. When assign a
characteristic to a class, it can adapt (overwrite) the characteristic.
Class type: The class type is a central concept in the classification system. The class
type determines how classes are processed, and how objects can be classified and retrieved in
these classes. Class types for a specific object type, such as materials. Then use classes of
this class type to classify objects of this object type. First create a class, and then enter a class
type for the class. Each class type is a closed system. There is no link between the different
class types.
38. Repetitive Manufacturing

In M/s Phosphorus India Limited Vapi, we have considered Repetitive manufacturing
for Freon Plant, as the process is continuous.
Purpose
This component can be used for production planning and control in a repetitive manufacturing
environment.
You can use repetitive manufacturing as either make-to-stock REM or make-to-order REM such as in
the automotive industry, for example.
The goals of repetitive manufacturing are the following:
• Creation and revision of production quantities on a period and quantity basis (reduction in
individual lot and order-specific processing).
• Reduction in the production control effort and simpler back flushing tools(with the option of
using the full scope of the PP functionality).
Implementation considerations
You can implement Repetitive Manufacturing if the following is true of your production process:
• You produce the same or similar products over a lengthy period of time.
• You do not manufacture in individually defined lots. Instead, a total quantity is produced over a
certain period at a certain rate per part-period.
• Your products always follow the same sequence through the machines and work centers in
production.
• Routings tend to be simple and do not vary much.
Integration
Within logistics, Demand Management precedes Repetitive Manufacturing:
o SD Sales Operations (receipt of sales orders)

o PP Demand Management (creation of planned independent requirements)
o PP MRP
157
The following Logistics components are also relevant:
o PP Work Centers
o PP Routings
o PP Bills of Materials
o If required, Line Design for mapping complex production lines
Features
• Master data
There is specific master data required for Repetitive Manufacturing. This includes the repetitive
manufacturing profile and the product cost collector.
• Planning table
Within the framework of repetitive manufacturing, planning and control is carried out on the basis of
time buckets. Starting from the existing requirements situation, you can plan production quantities
based on periods. The scheduling data for products and product groups is thus broken down into a
series of time buckets, the user being presented with period views for the purposes of checking and
revision.
• Sequencing
You can use Sequencing to carry out takt-based scheduling which determines the sequence in which
planned orders are produced on the production line. Sequencing simplifies the dispatching process,
especially for high order volumes, and enables you to display them in a graphic.
• Pull list
You can use the pull list to control in-house material flow, supplying production with materials. The pull
list checks the stock situation at the production line, calculates the missing parts for the components
and triggers replenishment for these missing parts.
• Back flushing
Production completion confirmations are simplified and are made with reference to the material being
produced. The completion confirmation usually includes the backflushing of components and the
posting of production costs.
• Cost Object Controlling
In repetitive manufacturing, you ususally detemine costs per material or per production version via a
product cost collector (product cost per period).
Master Data for Repetitive Manufacturing

The following master data is available:
158
• The repetitive manufacturing profile is set in Customizing for repetitive manufacturing and is
entered in the material master record. You must also authorize the material for repetitive
manufacturing in the material master record.
• You create the production version in the material master record.
• If you want to plan using a planning ID , you must define one and enter it in the material master
record.
• If you want to use a production line for planning purposes, you must create one and enter it in
the material master record.
• If you use repetitive manufacturing in conjunction with the component PP line Design, you can
represent the production line as a line hierarchy. This makes sense if you have complex
production lines, which you want to schedule using takts.
• If you want to plan capacity, you must create a routing and enter it in the production version.
• You create a product cost collector for creating production costs.
39. REPORTS
Following reports will be provided
1. DAILY / MONTHLY PRODUCTION REPORTS

2. Monthly WIP Report.
3. Batch wise SCRAP GENERATION REPORT
4. Work Center wise Report
5. Batch wise Quality Report
6. Monthly Product wise RM consumption norms
7. Operation wise important parameter per Batch
The following standard reports are to be used in the Production Planning module:
TRANSACTION CODE PURPOSE
MMSC This report allows a user to easily create, or view,

storage location views for a material.
CRO5 This report produces a list of all work centers.
CR06 This report produces a list of all cost center assignments.
CR07 This report produces a list of all work center capacity.
CA60 This report enables you to list changes to individual routing

fields in the sequence which they occurred.
MD73 In the "Total Requirements Display", you can check and, if
necessary, change the planning figures. With this evaluation
function you can list all the planned independent requirements
that exist for a particular material or a product group. From this
total requirements display, you can access more detailed
information or you can branch into the change mode.
159
MD04 In the stock/requirements list, the most up-to-date

development of stocks and requirements is displayed. The
layout of the list on the screen is the same as that of the MRP
list.
MD05 Once you have carried out the planning run for the material via
single-item or total planning and where you have also
specified that an MRP list is to be created, you can then
display one of the lists with the function individual display.
Proceed as follows:
Starting from the menu screen of material requirements
planning, select Evaluations -> MRP list ->Individual display.
The initial screen for the Individual Display of MRP List
appears.
Enter the material number and the plant and press ENTER.
The MRP List screen now appears with an overview of the
Individual Lines.
MD06 With the collective display, all planned orders which

correspond to the specified selection criteria are displayed; for
example, all planned orders of a certain MRP controller.
MS07 The results of long-term planning are simulative planned

orders at finished product level for the long-term planning
version of the demand program. Simulative dependent
requirements and receipts are created for the components.
Simulative capacity requirements are also created for
materials that are produced in-house. Separate MRP lists are
also created for long-term planning. In the long-term planning
menu, the stock/requirements list is also available as well as
the planning situation as an individual layout.
MD09 With the evaluation, "Pegged requirements", you can retrace

which requirements are the source of which order proposals
and which independent requirements (especially sales orders)
will be affected if an order proposal is cancelled or if its date or
quantity is changed.
With the function, "Pegged requirements", you can determine
which requirements and order proposals caused the current
stock/requirements situation. This information is particularly
useful when you have to find out which independent
requirements (especially sales orders) are endangered if
planned orders are cancelled or if they cannot be delivered on
time.
CO20 This report shows a list of production orders according to the
selection criteria entered. The material produced, the order
schedule dates, the status of the order, and more are shown
for each production order. From this list, the user can view the
components and operational information for each order. This
report is one that is standard delivered with the information
systems, and in standard it does not include any totals listing.
Using this report requires that certain info structures are active
to reflect current data.
160
CO24 This report shows a list of missing parts according to the

selection criteria. You can use the missing parts information
system to display the missing parts list for a selection of
materials, or for all materials. It is possible to restrict your
selection to a specific plant, MRP group or requirements data.
CO26 The Production Order Information System offers various list

types in reporting.
Their layout can be adapted to suit your requirements. The
information displayed in the production order information
system as well as the layout of the information is controlled via
an overall profile, which you can enter on the initial screen.
The overall profile contains several subordinated single
profiles. They contain information regarding selection criteria
and layout of lists.
Overall Profiles
MM60 Your company may have so many materials that you will not
always know whether a specific material already exists in the
material master. You can find this out with the help of the
materials list.
CM01 Cap. Planning Evaluation by Work Centers – Load
CM02 Cap. Planning Evaluation by Work Centers –Orders
CM05 This report list displays all work centers and capacities with
overload in the next 60 calendar days.
CM21 This is a report of capacity leveling evaluation-work center
view
MCP3 Report for Production order analysis
MCP7 Report for work center analysis
MCRE Material usage analysis report
MCRI Product cost analysis report
T-CODE Description
MMBE STOCK OVERVIEW
CS01 CRT BOM
BOM CS02 CHANGE BOM
CS03 DISPLAY BOM
CA01 CRT ROUTING
ROUTING CA02 CHANGE ROUTING
CA03 DISPLAY ROUTING
WORK CR01 CRT WORK CENTER
CENTER CR02 CHANGE WORK ENTER
161
CR03 DISPLAY WORK CENTER

CO40 CRT CONVERT PLANNED ORDER INTO PRD ORDER INDIVIDUAL
PRODUCTION CO01 MANUAL CRT. PRODUCTION ORDER
ORDER CO02 CHANGE PRODUCTION ORDER
MD02 RUN MRP-SINGLE ITEM MULTI LEVEL
MRP MD04 STOCK REQUIREMENT LIST
MD11 CRT. PLANNED ORDER
COGI GOODS MOVEMENT ERROR
MC87 CRT. ROUGH CUT PLANNING FOR MATERIAL
MC78 ACTIVE VERSION FOR MATERIAL
SOP MC88 CHANGE ROUGH CUT PLANNING FOR MATERIAL
MC74 TRANSFER MATERIAL TO DEMAND MANAGEMENT
MC35 ROUGH CUT PROFILE
MB5B STOCK FROM POSTING DATE
MB51 STOCK DOCCUMENT LIST
COOIS PRODUCTION ORDER INFORMATION SYSTEM
MIGO GOODS MOVEMENT
40. GAPS
17.1 IDENTIFICATION OF GAPS
The following gaps have been identified for PIL1
1. Daily Prod. Report /Month wise production report
Daily/Monthly Production Report
Plant
Company Code
Material
Date
Production Dispatch Issue to Other Dept.

Sr.No Product Opening To-Day in Cumu (B) To-Day in Cumu. To-Day in Cumu. (D) Closing
. Stock (A) Kg in Kg Kg (C) in Kg Kg in Kg Stock (E)
In Kg = A+B-C-
D
In kg
1 CPP
2 ISO
3 Freon-22
4 Freon-12
5 PNC
162
2. WIP Report for each Product at the end of Month
WIP Statement for CPP Plant
Plant Material Month
Date
Stage Operation W.C. Work B.No. Raw Materials charged to reactor
Group Centers TCAC A C N CuCl NaOH DETC EDC Cat-1 Carbon
CPHT1 # 23
CPHT2 # 22
CPHT3 # 21
CPHT4 # 20
HTCP
CPHT CPHT5
Reaction # 19
CPHT6 # 18
CPHT7 # 17
Stage-1
CPHT8 # 16
CPDI1 # 15
CPN
CPDI
Distillation CPDI2 # 14
CPHY1 # 13
Hydrolysis CPHY
CPHY2 # 12
CPFI1 # 11
Filtration CPFIL
CPFI2 # 10
CPPR1 #9
Pressure CPPR2
CPPR #8
Reaction
CPPR3 #7
CPP CPRE1 #6
CPRE
Reaction CPRE2 #5
CPWA1 #4
Stage-2 Washing CPWA
CPWA2 #3
Low
vacuum CPLV CPLV
Drying #2
High
Vacuum CPHV CPLHV
drying #1
Total Qty in Kg A B C D E F G H
163
3. Monthly Product wise RM consumption Norms Report
INPUT DATA
Production in kg X Date
OUTPUT DATA
Raw WIP Total of RM Receipt RM WIP Closin Consumpti
S Material Openi Openi opening Consumption Closin g Total on Norms
r ng ng stock in Tod Cumm. Tod Cumm. g in Kg Stock of S=M+N-O- . = S/X
. Stock Stock kg (M)= ay (N) in kg ay (O) in kg (P) in Kg Closin R
N (K) in kg K+L (Q) g
o (L) Stock
. Kg (R)
1 TCAC A
2 ACN B
3 CuCl C
4 NaOH D
5 DETC E
6 EDC F
7 Cat-1 G
8 Carbon H
OR
INPUT DATA
Date
OUTPUT DATA
Production in kg G
RM Receipt RM Consumption
Raw Closing
Opening Cumm. Consumption Con. Norms. =
Sr. Materi Today Cumm. (C) Stock in
Stock Receipt Today E=A+B-C-D
No. al
(A) in Kg (B) in kg
in kg Kg (D) E/X
1 TCAC
2 ACN
3 CuCl
4 NaOH
164
5 DETC
6 EDC
7 Cat-1
8 Carbon
4. Batch wise quality Report for each Product.
Plant Date from Date To
Material Purity Range from To
Material Batch No. Purity Color Clarity of Liquid

Ethyl CPP 97% #1 97.2% Pale Yellow Clear
#2 96.9% Dark Brown Slight Particle
#3 97% Brown Hazy
Methyl CPP 98% #1 98.1% P.Yellow Clear
#2 97.9% P.Yellow Hazy
#3 98.4% Yellow Clear
5. Machine wise Batch details report
Plant Date from Date To
Material Work Center
Work Descriptio B. Start End BCT Operation Quality Down

Center n No in Hrs Parameters Details Time
Name Date Time Date Time detail
Temp Pres.
s
#1 40
#5 39
CPHT HTCP #8 35
Reaction #10 41
6. How to MAP Important Operation wise Parameters like Temp and

other inspection Report?
7. Products, which have crossed 90% of the shelf life period, should
not be shown in stock list. Once the shelf life falls on 90%, it
should move into Blocked stock.
8. How to get the details about Plant wise effluent generation?
17.2 ADDRESSING OF GAPS

The above gaps would be addressed by user exits/enhancements.
165
ANNEXURE I
Shift Sequence for PIL1
SHIFT SEQUENCE
Shift Shift End Break Break Type Days/Week

Start
Shift I 6:00 AM 2:00 PM 60 MIN BRK1 6
Shift II 2:00 PM 10:00 PM 60 MIN BRK2 6
Shift III 10:00 PM 6:00 AM 60 MIN BRK3 6
BREAK DETAILS
Break Break Text Breaks Timings Duration Of Break

BRK1 Breakfast 08:00am to 08:15 am 15 Mins
Lunch 11:30 am to 12:00 pm 30 Mins
Tea 01:00 pm to 01:15 pm 15 Mins
BRK2 Breakfast 03:15 pm to 03:30 pm 15 Mins
Lunch 07:00 pm to 07:30 pm 30 Mins
BRK2 Breakfast 11:30 pm to 11:45 pm 15 Mins
Lunch 02:00 pm to 02:30 pm 30 Mins
ANNEXURE II
Work Center Formulae
The execution time of an operation is defined as the sum of the set-up time and the processing
time. This is expressed in the following formula.
F=SET+RUN*LOT/B
The meaning of the formula parameters and the origins of their values are given in the
table below.
Meaning Origin
B Base Quantity General Operation Value
LOT Lot Size General Operation Value
RUN Processing time for base Standard Value
Quantity
166
SET Set-up time Standard Value
Operation wise important Parameter
Plant CPP
1. HTCP Reaction
Work Work B.No. Staring End BCT ACN TCAC Temp. TCAC%
center center Qty. kg Qty. kg C
Group Date Time Date Time
CPHT1 #1
CPHT2 #2
CPHT3 #3
CPHT CPHT4 #4
CPHT5 #5
CPHT6 #6
CPHT7 #7
CPHT8 #8
2. CPN Distillation
Work Work B. Staring End B Rec. Temp. Vacuum CPN%

center center No. C CPN C
Date time date time
Group T
CPDI CPDI1 #1
CPDI2 #2
167
3. Hydrolysis
Work Work B. No. Start End BCT Water qty. 48% Temp. C Alkali%
center center time Time kg NaOH
Group qty
CPHY1 #1
CPHY
#2
CPHY2
#3
CPHY3
4. Filtration
Work Work B. No. Start End BCT LOD % Temp. C Alkali% in NaTCP CFML
center center time Time CFML Qty. in Gen.
Group Kg
CPFI CPFI1 #1
CPFI2 #2
5. Pressure Reaction
B. Efflu
Work Work No. Start End BCT NaTCP Water 48% Pre Temp. T4C ent
center center time Time Charged qty. kg NaOH s C P% Gen
Group qty erati
on
in
Kg
CPPR1 #1
CPPR
CPPR2 #2
CPPR3 #3
6. CPP Reaction
Work
Work B. Start End EDC DETC in Temp.
center BCT NaTCP%
center No. time Time in Kg kg C
Group
CPRE CPRE1 #1
CPRE2 #2
168
7. CPP Washing
Work Work B. No. Start End BCT Water CPP Org. Effluent
center center time Time charged received in Generation
Group Kg Kg in Kg
CPWA1 #1
CPWA
CPWA2 #2
8. LV Distillation
Work B. No. Start End BCT CPP EDC Temp. Vacuum

center time Time Org. Rec. in mm Hg
charged
in Kg
CPLV #1
9. HV Distillation
CPP Liquid Clarity

Work Start End EDC Vacuum
B. No. BCT Output Purity Color
center time Time Rec in mm Hg
in Kg
CPHV #1
ISOPROTURON
1. Hydrogenation
Hydro
PN gen
Down Down
C Charg
Work Staring End BCT Temp. PNC% time if time
Work B.N Cha ed
center in C in Hrs Reasons
center o. rged Qty.
Group Hr
Qty. kg
Tim Dat Tim kg
Date
e e e
#1
ISHD ISHD1
#2
ISHD2
2. PCU Distillation
169
Work Work B.No. Staring End BCT PCU Down

center center PCU% purity Temp. time if Down
Group % C in Hrs time
Date Time Dat Tim Reasons
e e
ISPD ISPD1 #1
3. DCU Formation
Work Work Staring End

center center B.No. BC Xylen PCU UREA H2SO Temp. PCU
Group Date Time Dat Tim T e In Kg In Kg 4 in C %
e e in Kg kg
#1
ISRE1
ISRE
#2
ISRE2
#3
ISRE3
4. DCU Washing
Work Work B.No Staring End BC

center center . T Soda Water Temp. C Down time
Group Ash in Adde Effluent if in Hrs Down
kg d Generatio time
n (Amm. Reasons
Sul.Soluti
on)
Dat Time Date Tim
e e
ISWA ISWA1 #1
ISWA2 #2
5. De-Hydration
Work Work B.No. Staring End BCT Down

center center Temp. c time if Down time
Group Dat Time Date Tim in Hrs Reasons
e e
ISDE ISDE1 #1
ISDE2 #2
170
6. DMA Reaction

center center DMA in Tem DM time if in Down
Group Dat Time Date Tim Kg p. C A% Hrs time
e e Reasons
ISDM ISDM1 #1
ISDM2 #2
7. Crystallization

center center Temp. C time if in Down time Reasons
Group Dat Time Date Tim Hrs
e e
ISCR ISCR1 #1
ISCR2 #2
8. Centrifuging
Work Work B.No Staring End BC Down

center center . T LOD % DCU% time if Down time Reasons
Group in Hrs
Dat Time Date Tim
e e
ISCN ISCN1 #1
9. Rotary Vacuum Drying
Work Work B.No Staring End BC Purty Down

center center . T LOD % % time if Down time Reasons
Group in Hrs
Dat Time Date Tim
e e
ISRV ISRV1 #1
171

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Phosphorus India Ltd

PROJECT CO-ORDINATOR VERTICAL LEAD

MR.SRINIVASA REDDY MR.MILIND RAHANGDALE

6. BUSSINESS PROCESS OVERVIEW OF PIL

e) DESCRIPTION OF FUNCTIONAL DEFECTS

11. WORK CENTER

17. REPETITIVE MANUFACTURING

7.4 CAPACITY PLANNING & SCHEDULING

7.5 PRODUCTION CONTROL

26. KEY BUSINESS BENEFITS

• Plant: An organizational unit serving to subdivide an enterprise according to

7.1 CORPORATE STRUCTURE

Phosphorus India Ltd Group of companies comprises of two

• Company code 1: Phosphorus India Ltd Unit-1 (PIL1)

• Company code 2: Phosphorus India Ltd Unit-2 (PIL2)

We will go for SAP Implementation in PIL01 Company.

RMS FGS Con. Scrap RMS FGS Con. Scrap

Plant Name Products SAP Nomenclature

Prod. Line for Prod. Line for

Plant Name Products SAP Nomenclature

Sl. No Plant Description Nomenclature in sap

28. Business Process Overview of PIL Group

Sales Sales & Distribution

30. MATERIAL GROUPING - FINISHED

Note: Initially we will not consider Co-Products. After successful completion of

31. Bill of Materials

a) Material BOM Types

• All the variants of a variant BOM

• A material requirements planning (MRP) department explodes bills of material on a certain

• Reservation and goods issue

As an aid to data entry

To calculate the costs of materials required for a specific product

Material Management (MM): Reservation and goods issue

Finance and Controlling (FI/CO): Product costing: To calculate the costs of

The standard R/3 System contains the following item categories:

ESSENTIAL PRODUCTION SCRAP

GENERAL DATA FOR BOM

¾ Description of Functional Deficits

¾ Approaches to covering Functional Deficits

¾ Authorization and User Roles

BOM Structure for Phosphorus India Ltd, Vapi (PIL1)

Finish and Semi F Products CPP Freon-22 Freon-12 ISO PNC

Base Qty 1900 100 100 1500 2500

BOM Structure for Variant CPP.

Finish Products CPP Ethyl Ethyl Methyl Methyl

BOM Structure for Phosphorus India Ltd, Ankleshwar (PIL2)

Finish and Semi F Products TCAC ZNP ALP

Base Qty 4250 1030 350

1 MCAA Organic kg 10 2975

Plant wise list Of Production Resource Tools.

Sr. PRTs U/M CPPP ISOP FREP TCAC ZNP ALP

7 Temp Indicator Nos 40 50 15 25 15 40

11 Empty Drums Nos 100 50 50 10 10

32. WORK CENTER

• Machines, machine groups

Special Organizational Considerations

Changes to the existing Organization

Human Resource (HR)

Finance and Controlling (FI / CO)

10.3 SHIFT AND SHIFT SEQUENCE

1st Shift 6:00a.m. 2:00 p.m 60 Min

10.4 WORK CENTERS IN CPP Plant

CPHT HTCP 8 40 Machine Set, Mach, Lab, Pow,

Plan the usage of materials

Prepare cost calculation according to routings