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Sample Business Blueprint Document for Textile Industry

1.0                 Introduction

 

The Purpose of the Business Blueprint, which is the main deliverable of Business Blueprint Phase of SAP Implementation, is to serve as strategic Master plan for Sales and Distribution module for XYZ Garments Industries Ltd, Bangalore, India. This Blueprint has been developed by discussing all inputs gathered from the core team by scheduling meetings and demos. This document shows the business requirements in detail, and serves as the basis for organization, configuration and development activities for PP Module. I hope it helps to New Consultant to understand the basic Process in Textile Industry. how Process is mapped and blue Printed.

SAP Methodology used – ASAP, Version ECC 6.0

Organization units

1.1                     Plant:

In sales, plant refers to a physical organization unit from where goods are manufactured.

Plant Description Location
1000 XYZ Garment Bangalore

1.2                      Bill of Material:

The Bill of Material will be created for Semi finish and finish material at plant level. BOM will have defined components, quantities, unit of measure and process byproducts for a predefined base quantity of BOM header material. BOM will have an effective date that is required during creation and further usage. Any material should have single BOM and identified by its unique number.  BOM will be used to maintain different component details at plant level for a material.

The definition of the quantity structure of an XYZ material (product) enables you to define grid and category-dependent specifications. These specifications can also be cost-relevant.

 

For the definition of the bills of material of XYZ materials, the following costing-relevant functions are available:

  • If you use XYZ materials in the BOM as components whose grid values are different than those of the finished product, determine for each grid value of the finished product which grid value of the component material should be available for production and in which quantity.
  • If you use XYZ materials in the BOM as components whose grid values are identical to those of the finished product, specify for each component material a standard input quantity. If necessary, enter variances from the standard input quantity for each grid value of the finished product or enter the input quantity zero.
  • Depending on the produced category of the finished product, you can usually specify (for all grid values) whether or not certain components should take part in the BOM explosion.
  • Transaction code for BOM Create/Change/Display- CS01/ CS02/ CS03.

1.3                     Work Center:

Machine, labour, group of machines or group of labour can be defined as work centre. Work centre will be used in costing, scheduling and capacity planning.

Scheduling: operation times and formulae will be entered in work centre. So that operation duration can be calculated.

Capacity: the available capacity and formulae for calculating capacity requirements are entered in work centre.

Defaults-                             Routing

Costing Date-                     Cost centre

Scheduling and capacity –  Lead time Scheduling and capacity

Production operations are managed with work center by defining the work center in routing in each plant. Work center category, type of work center capacity, work center capacity formula, total hours available and factory calendar are to be defined.

Machines where set of operations are performed, has to be identified as work center. Similar types of machines are to be clubbed as one machine to get better control and capacity loading analysis in SAP.  Work centre has six views to enter the work centre data.

In the initial entry screen plant, work center name and work center categories are to be entered.

Inputs to Work Center

Work center views Relevant fields
Basic data Person responsible, usage and standard value key
Default Control key, unit of measure for standard values
Capacity Capacity category, Set up formula, processing formula
Capacity header Capacity planner group, factory calendar, unit of measure, start time, end time, length of breaks, capacity utilization, number of individual capacities, relevant to finite scheduling and allowed overload
Scheduling Capacity category, set formula, processing formula, dimension and unit measure of work
Costing Cost center, activity type and formalae
Technical System created

Transaction code for managing work centers in SAP

Transaction description Transaction Code Remarks
Creating Work Center CR01 Authorized user can create a work center
Change Work Center CR02 Authorized user can change the work center
Display Work Center CR03 This is only for display. No changes are allowed here.

1.4            Routing

Routing will be created for Semi finish and finish material at plant level having defined set of operations and work center. Processing time, set up time and labor details will be maintained for the operation. Costing will be done at operation level in production cycle.

 

Any material can have multiple routings with defined work centers and operation details. Routing will be selected at the time of MRP run based on the lot size. Lot size should be predefined for the proper selection of routing in the routing header. Routing will have a Group and Group counter. Group will be the same for alternative routing. Group counter identifies the Alternative routing with different number.

 

Control Key in operation:

Control key provides control in operation which trigger scheduling, ‘capacity requirement’, ‘automatic goods receipt’, costing and ‘confirmation required’ as per business process requirement for each operation. Each control key is used with operation, work center and operation details to make control data for scheduling, capacity and costing. Only one operation will be defined for ‘Auto Goods Receipt’ and ‘milestone confirmation’ in the production order.

Material routing data details based on material and plant.

Routing Data

  1. Operation Details
  2. Work Center Details
  3. Quality Inspection Details

Inputs to Material routing

Routing Relevant Fields
Initial input screen Material, plant
Routing header view Routing usage, status, range of lot size, unit of measure
Sequence overview Range of Lot size
Operation overview Work center, plant, control key, base quantity, operational unit, breaks, set up time, machine time, unit of machine and details of external processing if the operation is defined for external processing.
Material component allocation New allocation, operation no, sequence
PRT view PRT link, material, plant, quantity and control key
Inspection characteristic view Characteristic, sampling procedure, catalog, tolerance key

Managing material routing in SAP

Creating Routing CA01 Authorized user can create a Routing
Change Routing CA02 Authorized user can change the Routing
Display Routing CA03 This is only for display. No changes are allowed here.

1.5    Business Process:

At XYZ  garment will be produced using numerous operations using yarn e.g. Nylon XX.

The various processes are Knitting, Dyeing, Cutting, Stitching, & Garment finishing.

The sequence of operation is same more or less, sometimes dyeing operation may takes place after Knitting or after stitching.

Apart from these main operations washing, ironing etc. may takes place, as decided material code will not be created for these sub process however as per sequence these processes will be treated as operation in the main processes routing.

Knitting –> Dyeing –> Cutting –> Stitching –> (Washing & Ironing Process In between) –> Garment finishing.

1.6                        ORDER PLANNING AND PROCESS – Make To Stock Scenario

  • Production orders contain all the information you need for the production process, for example quantity, basic date, information about BOM and routing. The production orders in XYZ contain XYZ-specific data (grid values and categories) to meet the requirements of the apparel and footwear industry.

 

  • Create a production order for an XYZ material in the SAP standard application. In a production order for an AFS material you can maintain the quantity to be produced at SKU level. Here you can find information from both the XYZ BOM.

 

  • Once the production order is created all the rid values are copied in to the production order from the Bill of material. In our case grid are color & size.

 

  • If wants to create the color wise production orders, then we have to manually delete the other colors grid kipping which color is required.

 

  • Once the order is created. Material availability check is carried out & then order can be released.

 

  • Subsequent Goods issue, Confirmation & Goods receipt can then be takes place to produce the required SKU’s stock during the Order Confirmation. This will consume the raw material stock & update the SFG, FG stock automatically in the one transaction only.

1.7                Production order type

Order type is one of the main controls which is having following items

  1. Manual and automatic selection of BOM and routing.
  2. Task list type as routing.
  3. Reservation or purchase requisition selection.
  4. Costing
  5. Material availability check for materials.

Plant wise production order types will allow user to track respective production orders with different numbers. Costing will make use of the production order type.

1.8                MRP Controller.

The person responsible for a group of materials in MRP in a plant or company.

Material that takes part in material requirements planning must be assigned to an MRP controller.

MRP Controller Description
NY01 Nylon Garment – SFG
NY02 Nylon Garment – FG

 

1.9                 Production Scheduling Profile.

specify that in a production or process order particular operations in a business are carried out in parallel.

MRP Controller Description
NY01 Nylon Garment – SFG
NY02 Nylon Garment – FG

 

1.10                  Production order Number Range

Each Order Type will have a unique number range assignment to identify specific plant with order number.

Suggested mapping of Order types (4 Digit)- Customized

Order Type Description Number range
ZNY1 Nylon Garment – SFG
ZNY2 Nylon Garment – FG

1.11    Process Overview Table for Production Planning.

Process step Business condition Business role T. code Expected results
Creating a BOM Master record This is for to define the raw component required to manufacture finish product & its assignment as per grid values. You create a BOM master record when you start a production of any new product. CS01 The BOM master record has been created and the order can now be created.
Change  BOM  Master record This helps to make changes in BOM master data. Any required changes can be maintained in master data. CS02 The BOM master record can be changed as per requirement
To display BOM  Master record This helps to view data associated to Bill of material. All information on BOM reviewed at any point of time. CS03 The BOM master record can be displayed as per requirement.
Creating a Work Centre Master record This is for to defines the machine / labor as a work centre to determine capacity,  scheduling, Costing, etc. You create a Work Centre master record when a new machine is introduced. CR01 Work centre are created & can be used in routing.
Change  Work Centre  Master record This helps to make changes in Work Centre master data. All information on Work Centre reviewed at any point of time. CR02 Work centers can be changed as per requirement
To display Work Centre  Master record This helps to view data associated to Work Centre. All information on Work Center reviewed at any point of time. CR03 Work centers can be displayed as per requirement
Creating a Routing Master record A representation of how you process work on your floor. Typically, a routing is made up of a series of operations, also called routing steps. You create a Routing master record when a new operation sequence is defined for a finish or SFG product. CA01 Routing is created for FG or SFG product.
Change  Routing  Master record This helps to make changes in Routing master data. All information on Routing reviewed at any point of time. CA02 Routing can be changed as per requirement
To display Routing Master record This helps to view data associated to Routing. CA03 Routing can be displayed as per requirement

To Create Production order

 

Determines the production quantity to produce Grid wise. Here for Grid wise production order manual deletion of other grid is necessary. Various other functions are also carried out during order creation like reading of BOM, Routing, material availability check, releasing of order, etc. Production order of required color with different sizes is created CO01 Production order is created
To Change Production order

This helps to change details maintained in Order. This change is applicable to certain parameters under specific status of order

 

Order can be changed say for quantity, read PP master data, etc. CO02 We can change details regarding Order in subject.
To Display Production order

This helps to view details maintained in Order.

 

Order details can be viewed. CO03 We can view details regarding Production order.
Creating Order Confirmation This transaction is used to confirm the operation in routing as per the sequence maintained, as well as the goods issue for raw material assigned to this order can be done this is called back flush & also goods receipt of finish or SFG garment taken place as per the business requirement of XYZ This is for the confirmation of order, Goods Issue & auto goods receipt. Unless this we cannot post the FG or SFG in stock. CO11N Order Confirmation is saved along with goods movement posting for raw material & Finish or SFG materail.
Display Order Confirmation This helps to display only the confirmation done operation wise. We can view the Confirmed Order.. CO14 We can view the Confirmed Order.
Cancel Order Confirmation This helps to cancel or reverse incorrect confirmation may be due to wrong input or due to incorrect goods movement during back flush & auto GR. Cancel order confirmation Document. CO13 Here order confirmation as well goods movement is cancelled.

1.12    Reporting

Process step Business condition Business role T. code

Production Order  Summary Report

 

 

Provides an overview of production order in details.

This also helps to see the operation overview in order along with the Status.

This also helps to see the confirmed & delivered order.

With the this report user  can prepare a overview report

 

COOIS
Work centre List This provides the list of work Centers. List of Work Centers CR05
Multilevel BOM report This provides the level wise explosion Bill of Material BOM Level determination CS11,CS12, CS13
Automatic goods Movement  : Error Handling To see & rectify incorrect goods movement during Order Confirmation Incorrect goods movement can be correct using this transactions COGI

1.13    Gaps & Queries Discussion:

  1. Work Cards

A customised screen will be provided to print the information/instructions related to Order.

The format and logic for the same needs to be discussed by XYZ internally as any such format is not available & then will be finalised & shared with Oracle apps 11i -ERP, scoping of the screen and logic to decided after format receipt by Oracle apps 11i -ERP

  1. Packing Process

The format and logic for the same needs to be discussed by XYZ internally and finalized once the same is finalised internally by XYZ the same will be shared to Oracle apps 11i -ERP , scoping of the screen and logic to decided after format receipt by Oracle apps 11i –ERP.

I hope this sample Business Blue Print for Textile Industry helps the consultant to get introduction to SAP Implementation in Textile Industry.

Regards,

G.V.Shivakkumar

Please refer my previous blog related to SAP WM.

https://people.sap.com/shivakkumar.geethavenkatesan79

 

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2 Comments

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  1. shivakkumar Geetha venkatesan Post author

    Hi Debasis  SAP and Oracle 11i communicated through cic interface. Client used Oracle 11i used for order to cash application earlier and when they decided to implement pp using SAP. They decided to use SAP and Oracle and later in some point of time they decided to migrate to sap for OTC also..Advantage in the sense I mean in sap they will get all facilities..compared to oracle 11i.i think here I need not want to explain the already known facts..I mean the advantages of using SAP..

    In my point of view SAP ERP is more popular, Sap is on the top and will remain on the top in future because of its continuous research and development for improvement. like Sap S4 HANA ..etc..which helps the business more.

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