Naw

SAP-TO BE Process
NAWPP007
Tool Room Process
PRODUCTION PLANNING

Ver1.0
18.09.2006

STATEMENT OF CONFIDENTIALITY / DISCLAIMER

This document is the property of Caritor, Inc. No part of this document shall be
reproduced, stored in a retrieval system, or transmitted by any means, electronic,
mechanical, photocopying, recording, or otherwise without prior written permission from
Caritor, Inc.

Table of Contents

Table of Contents
1

Tool Room Process.................................................................................................................................3

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13

AS IS Process............................................................................................................................................3
Core to Be Process....................................................................................................................................7
Changes to Existing Organization.............................................................................................................8
Description of Improvements and Key Metrics..........................................................................................8
Notes on Further Improvements................................................................................................................8
Functional Deficit and Method to Remove That.........................................................................................8
Interface Requirement...............................................................................................................................8
System Configuration Considerations.......................................................................................................8
File Conversion Considerations.................................................................................................................9
Any reports required related to current business process.........................................................................9
Any document/output would be printed for this business process.............................................................9
Authorization Considerations.....................................................................................................................9
End User Training Requirements...............................................................................................................9

SAP Standard Reports..........................................................................................................................11

Custom Developments.........................................................................................................................13

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1 Tool Room Process

TO-BE Document
For SAP R/3 Implementation at New Allenberry works.
Date: 18.09.2006
Sr. No of TO BE document

NAWPP007

Ref. Sr. No. Of AS-IS document

Tool room process

Name of Business Process: Tool Room Process

Module: Production Planning

Sub module:Tool room process

Version no of document: 1.0

Date: 18.09.2006

Version Management This Document is subject to change control. Every change of the document has to Undergo change
control procedure and has to be registered in the following table
Version

Change

1.0

Prepared By
Ananth Raj

Date
18.09.2006

1.1 AS IS Process
Tool room Activities
Basically Tool Rooms job is to manufacture/ repair Tools, Gauges, Fixtures and Jigs
required by Production.
The complete activity is defined in the Activity Chart.

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Receive Work Request / Tool Indent for repair

or manufacturing of Tools ,jigs ,fixtures

Enter Job Order details in register

Study feasibility for manufacturing all

parts in house

Not feasible
IF

Inform Purchase
Feasible

Arranging raw material for reqd tooling

IF

Not Available
Raise Indent

Purchase Process

Available
Material Procurement

Send memo to VD for Bar/Plate cutting

VD Process
Caritor

Update raw material Stock register

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Plan manufacturing of tool

Process material upto Pre H.T stage

Code punching and inspection

IF

NOT OK

Rej. Tools held back for sometime before

disposal

OK
Send for H.T

H.T .Process

Processing of final operation

Offer finish tool to QA for checking &

enter in register

Receive Inspection

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IF

NOT OK

SAP-TO BE Process

Rework if possible

OK
Rej. Mat. handed over to Stores
Prepare M.D.S and get approval
from QA

Stores Process

Handover the ok tooling/Gauges along with M.D.S to

Tool crib/Gauge Room

Tool Crib Process

At the end of every shift Daily production registered

in production register

1)Requirement of Tooling for new products is given by D&D.

2)Tool Crib informs requirement for tooling against the worn out ones as well as for
repairs of defective toolings.
3) Selection of vendor and price settlement is done by Tool Room in case of job work
or Non standard items. PO raised by Purchase. standard items are dealt by Purchase
dep't independently.
4) Priorities in Tool manufacture plan are decided in consultation with PPC.

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1.2 Core to Be Process

TOOL ROOM PROCESS
Tool Room will receive Work Request / Tool Indent for repair or manufacturing of
tooling either from tool crib or from D & D. Feasibility study for manufacturing in house
or subcontracting will be decided by tool room .Material availability will be checked
which is outside of SAP.

There are four activities which happen in tool room.

1. Manufacturing of new tooling In-House
2. Procurement of new tool through subcontracting
3. Direct procurement of tool.
4. Repair/Rework of tool.
1. In House production of tool
Material master with material type FHMI for the tool to be manufactured has to be
created before manufacturing.
Valuation of the material will be standard price.
Tool room will raise a production order with order type ZP01.
Before the release of production order operations has to be assigned and
components required has to be assigned.
Work center (pending from NAW) will be assigned for the operation which has
the activity type (not yet decided) for capturing the cost.
After assigning the operation, components the order will be released.
Tool room will confirm the production order.
After confirmation the tool is posted to quality stock and automatic inspection lot
will be created as inspection type 04- Final inspection for production will be
active.
After quality inspection if the tool is ok, it is posted to tool crib storage location, if
rework is to be done it is posted to tool crib storage location where tool rework
order will be created. If rejected it is posted to blocked stock where stores
person will clear it
2. Subcontracting of New tool
Material master with material type FHMI should be created for the new tool.
If tool room decides to get the tool manufactured through the vendor by giving
the material then the following process is followed.
Valuation of the material will be moving average price for subcontracted items.

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Tool room will raise a purchase requisition for the job work with item category L
(T- Code ME51N) which is then converted to purchase order by the MM person
and processed further.
When new tool is in warded through GR, it will be posted to quality stock where
inspection will be done. If the tool is ok,or it is accepted on deviation then it will
be posted to tool room storage location for usage, if the tool not ok it will be
directly posted to scrap by quality department.
3. Direct procurement of tool:
Direct procurement will be handled by the purchase department separately.
4. Repair of tool
Tool repair refers to resharpening, resizing, rework of jigs, fixtures.
Tool room will raise a production order for tool rework.
A tool reworks production order type ZP01.

Production order will be created manually.

Before releasing the production order operation should be assigned and

components should be assigned for that order. Then production order is
released.
Production order confirmation will be done after the completion of activity and
goods are moved to quality inspection.
After Quality clears the tool is posted to tool crib storage location ready for
usage. If tool is rejected it will be posted to scrap.

1.3 Changes to Existing Organization

Nil

1.4 Description of Improvements and Key Metrics

Cost of the tool room activity can be tracked separately.

1.5 Notes on Further Improvements

NIL

1.6 Functional Deficit and Method to Remove That

NIL

1.7 Interface Requirement

NIL

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1.8 System Configuration Considerations

Tool production/rework order type ZP01 is created.

1.9 File Conversion Considerations

NIL

1.10 Any reports required related to current business process

NIL

1.11 Any document/output would be printed for this business process

NIL

1.12 Authorization Considerations

NIL
Business Roles

Number of Users

Business Manager

Operations Manager

Master Production Scheduler / MRP Controller

Planning Engineers

Nil

Shop floor supervisor

Nil

1.13 End User Training Requirements

Business User Segments

Number of Users

Type of Transaction

Geographical Location

Business Manager

Display, Reports

NAW ,Faridabad

Operations Manager

Display, Change, Reports

NAW ,Faridabad

Master Production Scheduler / MRP

Controller

Display, Change, Reports

NAW ,Faridabad

Planning Engineers

Nil

Create, Change, Display

NAW ,Faridabad

Shop floor supervisor

Nil

Display

NAW ,Faridabad

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Sign-off (Approval) for this document:

Name of Team members:

Organization / Bus. Unit

Mr M P Joshi

NAW

Mr A S Rathor

NAW

Mr N M Ogra

NAW

Ananth Raj (Consultant PP, QM)

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Signature

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2 SAP Standard Reports

SAP Standard Reports

Sl No:

Report Description

01

Stock Overview (MMBE)

02

Production Order Information

System (COOIS)

Selection Criteria
Material, Plant & Storage location

Caritor

List: Item

Header

Profile (Standard)

Material

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

Output
Stock Status at each storage
location
List of Orders based on
Selection Criteria
List of Orders based on
Selection Criteria, with material
components

List: Item

Profile (Standard)

Material

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

List: Confirmations

Profile (Standard)

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

List of Orders based on

Selection Criteria, with
confirmation details

List of Orders based on

Selection Criteria, with Goods
Issue & Receipt details

List: Documented Goods

Movement

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SAP Standard Reports

Sl No:

Caritor

Report Description

Selection Criteria

Profile (Standard)

Production Order

Production Order Type

MRP Controller

Selection status Profile or

System Status

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Output

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3 Custom Developments

Print Requirements
Sl No:

Report Description

Selection Criteria

Output

Development Requirements
Sl No:

Caritor

Report Description

Selection Criteria

Confidential

Output

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