SUMMER TRAINING REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE

AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY - INFORMATION TECHNOLOGY

AT

(Noida)

UNDER THE GUIDANCE OF: UNDER THE GUIDANCE OF: UNDER THE SUPERVISION OF
MR. DHIRAJ PATHAK MR. SAGAR BHALLA MR. ANURAG DUBEY
(Software Engineer) (Software Engineer) (Head-HR Department)

BY

SHREYA BHARTI
(1403213098)

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 PREFACE

This report documents the work done during the summer internship at
CEBS Worldwide, Noida under the supervision of Mr. Dhiraj Pathak,
Software Engineer.

This project attempts to bring under one cover the entire hard work and
dedication put in by me in the completion of project work.

I have expressed my experiences in my own simple way. I hope who goes

through it will find it interesting and worth reading. All constructive
feedback is cordially invited.

SHREYA BHARTI

INFORMATION TECHNOLOGY

ABES EC, GHAZIABAD

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 CERTIFICATE FROM THE ORGANISATION

This is to certify that Ms. SHREYA BHARTI, student of pre final year, pursuing
Bachelor of Technology from ABES ENGINEERING COLLEGE,
GHAZIZBAD has successfully completed the PROJECT REPORT in our
organisation in the topic titled, TRAINING IN ADVANCE JAVA. The
training was of one and a half months from 13th May onwards. During her project
tenure in the organisation/company, we find her hardworking, sincere and
diligent person and her behaviour and conduct was good.

We wish her all the best for her future endeavours.

Mr. DHIRAJ PATHAK Mr. ANURAG DUBEY

(Head, HR Department)

CEBS Worldwide, Noida

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 ACKNOWLEDGEMENT

It is not possible to prepare a project report without the assistance and

encouragement of other people.

On the very outset of this project I would like to express my sincere gratitude and
heartfelt obligation towards all the personages who have helped me in this
endeavour. Without their active guidance, help, cooperation and encouragement
I would have been headway in the project.

I am ineffably indebted to Mr. Anurag Dubey for conscientious guidance and

encouragement to accomplish this assignment.

I am extremely thankful and pay my gratitude to my faculty Mr. DHIRAJ

PATHAK for his valuable guidance and support on completion of this project in
his its presently.

I would like to express my special thanks to Mr. SAGAR BHALLA for his
support, cooperation and help for completion of this project.

I extend my gratitude to CEBS Worldwide, for giving me this opportunity. The

work culture in company really motivates.

I also acknowledge with deep sense of reverence my gratitude towards my parents

and family members who have always supported me morally as well as
economically.

I owe my wholehearted thanks and appreciation to the entire staff of the company
for their cooperation and assistance.

I hope that I can build upon the experience and knowledge that I have gained and
make a valuable contribution towards his industry in coming future.

Any omission in this brief acknowledgement does not mean lack of gratitude.

Thanking You

SHREYA BHARTI

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 TABLE OF CONTENTS

About Mahindra Rise 7-16

Introduction 7
Three Pillars of Mahindra 8
10 Major Business Sectors 9
Vision & Core Purpose 10
Company Policies 11
Awards & Recognization 12
Manufacturing Culture & Plant Excellence 13-15
Organisation Structure 16

About Haridwar Plant 17-19

Introduction 17
Organisation Structure 18
Haridwar Plant Products 19

Supply Chain Management 20

Process Flow 21

Material Flow 22

VIN Classification 23

Model Codes 24-25

About SAP 26-28

ABC Analysis 29

Production Planning & Control 30-33

Role 30-31
Working 31-32
SAP Commands used 32-33

Material Master in SAP 34-40

MM01 34
Basic View 35
MRP View 1 36-37

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 MRP View 2 38
MRP View 3 39-40

Rejection Posting 41-43

Plant Rejection 41-42
Vendor End Rejection 43
Process Rejection 43
SAP Commands used 43

Scrap Disposal 44-46

Scrap Management 44
Procedure 45
SAP Commands Used 46
PR to PO Process 46

Annual Physical Inventory Process 47-65

Benefits of IT to Industry 66-68

Introduction 66
Damage Case Portal 67-68

References 69

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 ABOUT

The Mahindra Group is an Indian multinational conglomerate holding

company headquartered at Mahindra Towers in Mumbai, India, with operations in over 100
countries around the globe. Founded in 1945 as a steel trading company and in 1947, the
Group entered auto manufacturing to bring in the iconic Willys Jeep (under license) on to
Indian roads. The founders, K.C and J.C. Mahindra, believed that introducing new modes of
transportation held the key to Indias prosperity, so one of their first goals was to build
durable, rugged vehicles that could handle the rough Indian terrain. Mahindra is making in
India since 1947. In the 1950s and 60s, the Group diversified into businesses like Steel,
Tractors, and more. Over time the Group consolidated its position in Automobiles, Tractors
and Steel and entered promising sectors like IT, Hospitality, Financial Services, Components,
Aerospace and Logistics, led by the goal of providing products and services that support
prosperity.

Today, the Group is a $17.8 billion global corporation employing more than 200,000 people
across the globe. The Groups flagship company, Mahindra & Mahindra, is a leader in the
tractor and utility vehicles space.

The Mahindra Group (Mahindra), a federated group of companies based in India,

developed a new core purpose to connect with its global stakeholders.

As Mahindra expanded globally, it was not able to connect its existing core purpose
and positioning statement to the global arena and across the business since 947.

So the top management at Mahindra decided to revisit its core purpose and positioning
statement in a bid to unify all its business.

They launched a new tagline for the group RISE.As a part of initiative Mahindra made
some changes internally as well as externally to articulate the new core purpose and
vision.

The challenges Mahindra faced was how to embed the new core purpose and
positioning.

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 3 PILLARS OF MAHINDRA RISE

The spirit of Rise is based on following three brand pillars:-

Accepting No Limits Alternative Thinking Driving Positive

Change
Ambitious Out-of-box solutions Improve quality of life

Challenges Limits New/super technology Improve business

performance

Risk Appetite Customer-focused Provide access to products

innovations

Game Changing Affordable technology Green products/services

Growth-Oriented Frugal mindset Make technology

affordable

Agility with discipline Customer-centricity

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 THE 10 MAJOR BUSINESS SECTORS

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 VISION

The vision of the company is to be among the top 10 global players in the world.

This we wish to achieve through BHAG.

BIG HAIRY AUDACIOUS GOAL

BHAG encourages companies to define visionary goals that are more strategic
and emotionally compelling. These goals help align employees of the business to
work together more effectively.

"A true BHAG is clear and compelling, serves as unifying focal point of effort,
and acts as a clear catalyst for team spirit. It has a clear finish line, so the
organization can know when it has achieved the goal; people like to shoot for
finish lines."

CORE PURPOSE

We will challenge conventional thinking and innovatively use all our resources
to drive positive change in the lives of our stakeholders and communities across
the world, to enable them to Rise.

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 AWARDS AND RECOGNIZATION:-

The only Tractor Company in the world to have been awarded the Deming
Prize and the Japan Quality Medal.

One of Forbes Global 2000 most Powerful Companies of the World.

Ranked amongst Top 10 Global Companies for Leaders by AON Hewitt.

National Award for Excellence in Corporate Governance by the Institute

of Company Secretaries of India.

Business Todays Best Companies to Work For award in Engineering &

Automotive categories.

Ranked No. 1 by The Economic Times in its annual The Best Companies
for CSR listing.

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 MANUFACTURING EXCELLENCE & PLANT CULTURE
It is rightly said that There is always room for improvement.

5S and KAIZEN two of the many ways to that room.

Changes brought are over a period of time not immediate.

Group participation and incentives spreads healthy competition among employees.

5s productivity method

5S was developed in Japan and was identified as one of the techniques that enabled Just
in Time manufacturing.

The list describes how to organize a work space for efficiency and effectiveness by
identifying and storing the items used, maintaining the area and items, and sustaining
the new order.

The decision-making process usually comes from a dialogue about standardization,

which builds understanding among employees of how they should do the work.

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 KAIZEN

Derived from Japanese (Kai-change for & Zen-better).

Can be interpreted as continuous improvement.

Even small continuous improvements have potential to bring about large change.

In business, kaizen refers to activities that continuously improve all functions and
involve all employees from the CEO to the assembly line workers.

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 The small-step work improvement approach was developed in the USA under Training
within Industry program (TWI Job Methods).

Instead of encouraging large, radical changes to achieve desired goals, these methods
recommended that organizations introduce small improvements, preferably ones that
could be implemented on the same day.

CRUSADE 1.O
First Time Right
Every Time Right
Delightful Customer Experience

CRUSADE 2.O
First time Right
Every Thing Right
Differentiated Customer Experience

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 ORGANISATION STRUCTURE

Chairman Managing Director

Board OF Directors

Executive Director

Automotive Farm Heavy

Division CE Division CE Vehicles CE
EEEEEE

Automotive Division CE

Accounts HR Manufacturing CDMM SSU Quality

Head Department Head Head Head Head
Head

Manufacturing Head

Chakan Kandivali Nasik Plant Haridwar Zahirabad

Plant Head Plant Head Head Plant Head Plant Head

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 About Haridwar Plant

Inaugurated in December 2005, the Haridwar plant currently manufacturers the Bolero,
(passenger & load), Alfa (passenger & load) and Champion range of Mahindra products. For
the past two years, the plant has earned the distinction of having one of the highest production
capacities amongst other automotive plants of Mahindra. It is the companys sole automotive
plant in North India.

Mahindra & Mahindra Ltd. (M&M Ltd.), Indias leading SUV manufacturer has achieved a
production milestone of 7 lac vehicles from its automotive plant in Haridwar, Uttarakhand. The
Haridwar plant achieved this milestone in less than 10 years. The plants earlier production
milestone of 6 lac vehicles was achieved in November 2014 and since then it has taken just ten
months to reach the 7 lac vehicles production mark.

Speaking on the milestone, Pravin Shah, President & Chief Executive (Automotive),
M&M Ltd. said, This remarkable achievement is a significant moment for us in our
automotive journey and bears testimony to the relentless effort put in by each member of our
Haridwar plant. The plant has constantly achieved manufacturing excellence and reflects the
commitment and spirit of accepting no limits in keeping with our Rise philosophy. I am sure
that this milestone will be a stepping stone to many more accolades for our Haridwar plant in
times to come.

Mahindras Automotive Sector is a full-range player with a presence in almost every segment
of the automobile industry from commercial vehicles (3 wheelers / light commercial vehicles
and heavy commercial vehicles), utility vehicles, sports utility vehicles (from entry level to
premium SUVs), sedans and electric vehicles. The companys world-class automotive
manufacturing facilities are located in Chakan, Nasik, Haridwar, Zaheerabad, Kandivali and
Igatpuri, which is the location of its engine plant. These automotive plants boast of fully
equipped manufacturing facilities in the Press Shop, Body Shop, and CED Line, Paint Shop
and Assembly and many have won accolades since inception.

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 HARIDWAR PLANT ORGANISATION STRUCTURE

HARIDWAR PLANT HEAD

Manufacturing SCM Head PE Head Quality

Head Head

HR Head Accounts Admin ER Head

Head Head

Manager 1 Manager 2 Manager 3

Assistant
Manager

Team
Leader

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 Haridwar Plant Products

BOLERO

ALFA PASSENGER

ALFA LOAD CARRIER

ALFA CHAMPION

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 SUPPLY CHAIN MANAGEMENT

Supply Chain Management (SCM), the management of the flow of goods and services,
involves the movement and storage of raw materials, of work-in-process inventory, and of
finished goods from point of origin to point of consumption. Interconnected or interlinked
networks, channels and node businesses combine in the provision
of products and services required by end customers in a supply chain. Supply-chain
management has been defined as the "design, planning, execution, control, and monitoring of
supply chain activities with the objective of creating net value, building a competitive
infrastructure, leveraging worldwide logistics, synchronizing supply with demand and
measuring performance globally."
SCM practice draws heavily from the areas of industrial engineering, systems
engineering, operations management, logistics, procurement, information technology, and
marketing and strives for an integrated approach. Marketing channels play an important role in
supply chain management. Supply chains were originally defined as encompassing all activities
associated with the flow and transformation of goods from raw materials through to the end
user, as well as the associated information flows.

Functions
Procurement
Inventory/Stores
Production Planning & Control

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PROCESS FLOW

Part Creation

Purchase Order

Schedule Raise

Material Dispatch

PCS

Unloading

GRN

STORES

Line Feeding

Vehicle Assembly

Back Flashing

Quality Inspection

RFD

BILLING

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MATERIAL FLOW

IUTN

Main Material Gate

DOCK

Cante PC Hardwa Stora

en Stor re Store ge
Shed e Rack
Stora s
ge

Tri
m
Line

Engine Assembly Chassis Line

Line

Mai
n
Line

End
Fin Line End
al Testing Product
Lin
e

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VIN CLASSIFICATION
VIN stands for Vehicle Identification Number.

M A 1 X K 2 W J X H 5 D 2 3 74 6

WMI VDS VIS

WMI: - World Manufacturer Identification

VDS: - Vehicle Description Section

VIS: - Vehicle Indicator section

23746 - > The last five digit number gives the serial number.

D- > It denotes the month.

5- > It denotes the Plant Number.

H- > It denotes the year.

X- > It denotes the transmission.

WJ- > It denotes the engine type.

2- > It denotes the drive type.

XK- > It denotes the model.

1- > It denotes the Manufacturer Code.

A- > It denotes Auto motive division.

M- > It denotes Mahindra.

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 BOLERO MODEL CODES
MODEL CODE MODEL DESCRIPTION
BOLERO LX 2WD 7 SEATER NON AC
BB726F5B7U4WD BS4
BOLERO SLE 2WD 7 SEATER AC &
BB726F5S7U4WD PS BS4
BOLERO SLX 2WD 7 SEATER AC &
BB726F5XH7U4WD PS BS4
BOL ZLX MICROHBD 2WD 7STR
BB726F5ZSH7U4WD ACPS BS4
BOLERO PLUS 2WD 9 SEATER NON
BB727F4L9SFU4WD AC BS4
BOLERO PLUS 2WD 9 SEATER AC
BB727F4LA9SFU4WD BS4
BOLERO PLUS 2WD 9 SEATER NON
BB727F4P9SFU4WD AC PS BS4
BOLERO PLUS 2WD 9 SEATER AC PS
BB727F4PA9SFU4WD BS4
BOLERO PLUS AMBULANCE NON
BB727F4L5AU4WD AC BS4
BB727F4LA5AU4WD BOLERO PLUS AMBULANCE AC BS4
BB727F4R7U4WD BOLERO DI 2WD 7str. N/A BS4
BB727F4R8U4WD BOLERO DI 2WD 8str. N/A BS4
BB727F4RA7U4WD BOLERO DI 2WD 7str. A/C BS4
BB727F4RA8U4WD BOLERO DI 2WD 8 str. A/C BS4
BH826F4B7U4WD U108 LX 2WD 7STR LCCR BS4
BH826F4S7U4WD U108 SLE 2WD 7STR LCCR BS4
BH826F4XH7U4WD U108 SLX 2WD 7STR LCCR BS4
BH826F4ZSH7U4WD U108 ZLX 2WD NGT LCCR BS4
BB4210CBNXFCRU4MS BOLERO CBC- BS4
ALFA MODEL CODES
MODEL CODE MODEL DESCRIPTION
ALFA DELUXE BS4 BLACK
1AM2FT4TSLEC1BY YELLOW
ALFA DELUXE BS4 GOLDEN
1AM2FT4TSLEC1GY YELLOW
1AM2FT4TSLEC1TY ALFA DELUXE BS4 YELLOW GREEN
ALFA DELUXE BS4 SOLITAIRE
1AM2FT4TSLEC1WS WHITE
1AM2FT4TSLEC1WR ALFA DELUXE BS4 A0WARM RED
1AM2FT4TSLEC1NB ALFA DELUXE BS4 A0NISAN BLUE
1AM2FT4TSLRB1BY ALFA CHAMP BS4 BLACK YELLOW
1AM2FT4TSLRB1TY ALFA CHAMP BS4 YELLOW GREEN
ALFA CHAMP BS4 SOLITAIRE
1AM2FT4TSLRB1WS WHITE

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 ALFA CHAMP BS4 GOLDEN
1AM2FT4TSLRB1GY YELLOW
1AM2FT4TSLRB1BL ALFA CHAMP BS4 BLACK
1AM2FT4TSLRB1WR ALFA CHAMP BS4 A0WARM RED
1AM2FT4TSLRB1NB ALFA CHAMP BS4 A0NISAN BLUE
ALFA LONGER BS4 GOLDEN
1AM2FT1TJLVB1GY YELLOW
ALFA LONGER BS4 TORTOISE
1AM2FT1TJLVB1TG GREEN
ALFA LONGER BS4 SOLITAIRE
1AM2FT1TJLVB1WS WHITE
1AM2FT1TJLVB1BL ALFA LONGER BS4 BLACK
1AM2FT1TJLVB1WR ALFA LONGER BS4 WARM RED
1AM2FT1TJLVB1NB ALFA LONGER BS4 NISSAN BLUE
1AM2FT1TJLMB1GY ALFA LC BS4 GOLDEN YELLOW
1AM2FT1TJLMB1TG ALFA LC BS4 TORTOISE GREEN
1AM2FT1TJLMB1WR ALFA LC BS4 WARM RED
1AM2FT1TJLMB1WS ALFA LC BS4 SOLITAIRE WHITE
1AM2FT1TJLMB1NB ALFA LC BS4 NISSAN BLUE
1AM2FT1TJLMB1BL ALFA LC BS4 BLACK
ALFA LC W/DOORS BS4 SOLITAIRE
1AM2FT1TJLTB1WS WHITE
ALFA LC W/DOORS BS4 GOLDEN
1AM2FT1TJLTB1GY YELLOW
1AM2FT1TJLTB1BL ALFA LC W/DOORS BS4 BLACK
ALFA LC W/DOORS BS4 TORTOISE
1AM2FT1TJLTB1TG GREEN
1AM2FT1TJLTB1WR ALFA LC W/DOORS BS4 WARM RED
ALFA LC W/DOORS BS4 NISSAN
1AM2FT1TJLTB1NB BLUE

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 ABOUT SAP
SAP stands for Systems Applications and Products in Data Processing.

It is a German multinational software corporation that makes enterprise software to manage

business operations and customer relations.SAP founded in and around 1972 by five IBM
engineers Hopp, Wellenreuther, Hector, Tschira, and Plattner. SAP is headquartered
in Walldorf, Baden-Wrttemberg, with regional offices in 130 countries. The company has
over 335,000 customers in over 180 countries.

SAP is the fourth largest software company in the world.

The SAP R/3 is a business software package designed to integrate all areas of business.
It provides end to end solution for financials, manufacturing, logistics, distribution, etc.
All business proposes are executed in one SAP system and sharing common
information with everyone.

VERSIONS OF SAP: -

SAP R/1: - The first version of SAP software was launched in and around 1972 known as the
R/1 system. R stands for real time data processing. It is one tier architecture in which three
layers Presentation, Application and Database are installed in one system/server.

(One Presentation + Application + Database)

SAP R/2: - In 1979 second version of SAP R/2 was released with IBMs database and a
dialogue- oriented business application. SAP R/2 to handle different languages and currencies.
R/2 is two tier architecture in which three layers Presentation, Application and Database are
installed in two separate servers.

(Server One Presentation, Server Two- Application + Database)

SAP R/3: - SAP upgraded R/2 to R/3. SAP R/3 is the client/server version of the software and
it is three tier architecture in which three layers Presentation, Application and Database are
installed in three server/system.

(Server One Presentation, Server Two Application, Server Three Database)

Presentation: - It is a layer where the user works with SAP GUI. It interacts with
database layer via application layer.
Application: - It interacts between presentation and database layer.
Database: - It is a central database that stores all the data of ERP SAP systems.

SAP R/3 Modules and Integration

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SAP Functional Modules

FICO Finance and Control

PP Production Planning
MM Material Management
SD Sales & Distribution
HR Human Resources
CRM Customer Relationship Management

SAP Technical Modules

ABAP Advanced Business Application Programming

XI Exchange Infrastructure
Net Viewer
Basis
BIW Business Information Warehousing

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SAP MM (Material Management) is one of the important modules in SAP ERP software
and it supports the procurement and inventory functions occurring in day to day business
operations. This MM module contains many aspects such as purchasing, goods receiving,
material storage, consumption based planning, and inventory. SAP module is fully integrated
with other modules in the SAP R/3 system such as FICO, SD, Quality Management (QM),
Plant Maintenance (PM), PP, Warehouse Management (WM).

SAP PP (Production Planning) is used to plan and control the manufacturing activities of a
company. It consists of all system configuration, master data and complete solution to produce
process. It handles all business process related to production of a company. In SAP R/3 system
modular data is classified as master data and transaction data where the master data is defined
as the individual module objects. PP master data is used before use of transactions. SAP
encompass all activities like Material Requirement Planning (MRP), Bill of Material (BOM),
Automatic material requisition based on MRP, capacity planning, etc.

All the details of manufacturing process can be record and track, e.g. planned cost, actual cost
and material flows. Production Planning module is fully integrated with other SAP modules
such as sales and distribution (SD), Material Management (MM), FICO (Financial Accounting
and Controlling), Plant Maintenance (PM) and Logistics Execution (LE).

Advantages of SAP: -

SAP software manages these business management tasks in modules that all work
together in one system by sharing information.
Making Planning, Scheduling, Tracking and Management easier leaving more time for
us to perform value added work.
Ability to provide clear cut jobs roles with authorizations.
Cost saving on overheads such as Stationery, File storage, etc.
Standardization of business processes.
No duplicate data.

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 ABC Analysis
In materials management, the ABC analysis (or Selective Inventory Control) is
an inventory categorization technique.

ABC analysis divides an inventory into three categories-

"A items" with very tight control and accurate records,

"B items" with less tightly controlled and good records, and

"C items" with the simplest controls possible and minimal records.

The ABC analysis provides a mechanism for identifying items that will have a significant
impact on overall inventory cost, while also providing a mechanism for identifying different
categories of stock that will require different management and controls.
The ABC analysis suggests that inventories of an organization are not of equal value. Thus, the
inventory is grouped into three categories (A, B, and C) in order of their estimated importance.
'A' items are very important for an organization. Because of the high value of these 'A' items,
frequent value analysis is required. In addition to that, an organization needs to choose an
appropriate order pattern (e.g. Just- in- time) to avoid excess capacity. 'B' items are important,
but of course less important than 'A' items and more important than 'C' items. Therefore, 'B'
items are intergroup items. 'C' items are marginally important.
There is no fixed threshold for each class, different proportion can be applied based on
objective and criteria. ABC Analysis is similar to the Pareto principle in that the 'A' items will
typically account for a large proportion of the overall value but a small percentage of the
number of items.

Examples of ABC class are

A items 20% of the items accounts for 70% of the annual consumption value of the
items.
B items - 30% of the items accounts for 25% of the annual consumption value of the
items.
C items - 50% of the items accounts for 5% of the annual consumption value of the items.

80-20 Rule
i) A 20% of items; 80%of value

ii) B 30% of items; 15%of value

iii) C 50% of items; 5%of value

PPC (Production Planning & Control)

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 The Role
PPC plays an active role from the procurement of the material to the final dispatch
of vehicle from the plant. Their main objective is to ensure the smooth functioning
of the production line without any line loss.

PPC daily activities involve the following: -

1) Planning: - PPC makes daily plan which is share with all through IPMS (Integrated Planning
Management Server). PPC ensures daily production as per the plan.

2) Report Generation

(a) Vehicle Status Report: - IQ09 is the SAP movement used to give the status of the vehicle.
It gives the information that whether the vehicle is in FAI (Final Acceptance Inspection), CAI
(Customer Acceptance Inspection), RFD (Ready for Dispatch), RFI (Ready for Inspection).

(b) Dispatch Information: - ZSDS04 is the SAP movement used to know the number of
vehicle dispatched.

(c) Vendor Aid: - gives the information about the vehicles which are tested at vendor aid
ou0tside the plant.

(d) Production Status: - The role of PPC is to share everyday production detail model wise
with the whole team as well as with high level authorities.

3) Colour Plan Monitoring: - PPC ensures the SUB 1 TON production as per the colour plan
is provided to them by CPPC (Central Production Planning & Control).The production should
not exceed the plan in any reason.

4) Back flushing: - is the process of generating the vehicle in the system. It means the inventory
of raw material consumed in the vehicle decreases and finished goods increases. This activity
is done continuously. If system status is AVLB it means back flashing is pending and if it is
ESTO it means back flashing is done. If back flashing is pending for very long then PPC checks
the issue in manual back flashing at individual level.

5) Pull list download: - is the shortage list of the current day due to which back flashing cant
be done in the system. This list is given at the material gate so that PCS (Physical Count Slip)
and GR (Goods Receipt) of that material can be generated first.

6) Shortage Meeting: - This meeting is conducted by PPC with the SCM (Supply Chain
Management) team and MLL (Mahindra logistics) team to discuss about the material that can
be short for next two days. ZPP66_OPT is the SAP command used for shortage download.

7) Aggregate Tracking with MLL Team: - The two days sequence Plan (2DSP) made by
PPC on the basis of aggregates (Engine, Axle, Transmission) available from IUTN (Inter Unit
Transfer Node). Aggregate information is provided by MLL to PPC.

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8) Vehicle Aging Tracking: - It involves tracking of those vehicles which are in aging. A
vehicle is said to be in aging if it is not dispatched from the plant on the allotted date. They
may have some quality related issues or any other reasons.PPC monitors the issue and takes
the required action.

9) Loss Review: - PPC is asked to prepare a report on daily line loses. The reason of loses can
be shortage of material on line or may be supply failure, etc.

WORKING OF PPC:-
At the end of every month CPPC sends the monthly plan to PPC as per the market
demand. This plan is known as REVISION 00.

This plan is distributed Plant wise.

In case of any changes arise in the plan then a firm plan REVISION 01 comes at 5th of
the next month. This is known as the firm plan.

PPC then calculates the ADD (Actual Daily Dispatch) according to the plan.

ADD = Plan / Total Working Day

The plan is shared with SCM buyers, Store team and Development team etc.

PPC reduces that month plan to week plan and further that week plan is reduced to two
day sequence plan (2DSP).It helps in better continuity and process establishment.

Material is fed on the line as per the plan. This helps in avoiding line losses.

Back flashing can be done in two ways

a) Manual Back flashing: - MFBF is the T code used in SAP for manual back
flashing. It is done model wise. Only one model can undergo back flashing at a
time. It gives the information about the parts that are short for that model.

b) Auto Back flashing: - ZPP_SAP_MES is the T code used in SAP for auto back
flashing. Here we review the shortage for the overall plan at a time. Multiple models
can be back flashed at a time. If a particular model out of all models has issue in
back flashing then it can be checked at individual level through manual back
flashing.

BOM Verification: - BOM stands for BILL OF MATERIAL. It gives the detailed
description of all the parts along with the quantity required in creating a vehicle. It is
designed by the Plant Engineering (PE) team. It is a monthly activity done for every
model. There are two types of BOM

a) System BOM: - It gives the information at what rate a part is used in creating a
vehicle.

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 b) Process BOM: - It gives the stage wise description of the part along with quantity
consumed in vehicle.

When an existing material/part undergoes EN (Engineering Change) then there is a

need to change the BOM of that part or vehicle. The changes in the BOM are made
by PE team.

The changes can be made due to cost saving proposal or may be any concern comes
from dealer end.

The role of PPC in BOM change is that when the existing stock of that material is
consumed then they inform the PE team to made changes in the BOM of that
particular part or vehicle.

Various SAP commands Use by PPC

1) ZPP66_OPT: - It is used for shortage download.

2) MFBF: - It is used for manual back flashing of vehicles.

3) ZPP_SAP_MES: - It is used for automatic back flashing.

4) MMBE: - It is used to check the stock of a part for the current day.

5) ME2M: - It gives the purchasing information of the part.

6) IQ09: - It gives complete information about the vehicle(Vehicle status, when created,
engine details, battery details, VIN no, etc)
.
7) MB5B: - It gives the opening stock details of a part for any day.

8) MB1B: - It is used for stock transfer.

309 -> It is used to transfer stock of a part to another part when a part gets easily
replaced by other part.

310 -> It is used for z-part transfer.

311 -> It is used for stock transfer of common part.

9) CS15: - It is used to check BOM of a part.

10) CS13: - It is used for Z-Part BOM check.

11) CS11: - It is used to download the BOM of any model.

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12) CS01: - It is used for BOM creation.

13) ZSDS04: - It is used to check vehicle dispatch status.

Material Master Data MM01 in SAP

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When we want to use a new material in SAP, we have to define its characteristics, in order to
control its behaviour in all of the transactions.

MM01 is the T-code for part creation in SAP. The execution of the transaction brings us to the
initial screen, which consists of few fields that contain the basic information on our material.

1. Enter Industry sector (mostly used: M-Mechanical engineering)

2. Enter Material type, (it can be FERT, ROH, HALB, HAWA- the appropriate material
type for current material).

The following list shows you the material types contained,

FERT (finished products)

Finished products are produced by the company itself. Since they cannot be ordered by
Purchasing, a material master record of this material type does not contain purchasing data.

ROH (raw materials)

Raw materials are always procured externally and then processed. Since raw materials cannot
be sold, a material master record of this material type contains no sales data.

HALB (semi finished products)

Semi finished products can be procured externally (sub-contracting) as well as manufactured
in-house. They are then processed by the company. A material master record of this material
type can contain both purchasing and work scheduling data.

HAWA (trading goods)

Trading goods are always procured externally and then sold. A material master record of this
material type can contain purchasing and sales data.

Now we can choose which master data to create. We can click on Select View(s) to choose
which views we need to create for the material.

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 Basic views are views with general information about our material.

1. Material description: LCD TV 40" this can be maintained in various languages.

2. Base unit of measure (often referred to as Base UOM): PCS this is the unit of
measure in which material stock is managed. For a TV set, it's natural to be a piece.
We can also use meter, kilogram, or any other unit we have defined and is suitable for
material.
3. Division: 10 Division for the material, we could create divisions 10, 20, 30, 40 for
finished goods, trading goods, services, and other materials, so we can categorize
them in this way. We have selected division 10 for our material since it is finished
goods.
4. General Item category group: NORM Standard item. Used throughout the system,
this indicator has an effect on sales and stock transfer processing as it is used in item
category determination.
5. Weight unit: Kg unit in which product weight is entered.
6. Gross weight: 26,988 gross weight of 1 unit of product in weight unit. Net weight:
24,651 net weight of 1 unit of product in weight unit

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MRP View 1
MRP views are maintained mostly for production purposes. This information is supplied by
the appropriate MRP controller or someone else from production planning team. The only
mandatory field in MRP 1View is Planning type.

ABC indicator: This is an indicator showing the importance of the material in terms of stock
availability.

A the most important materials, that needs to be available for sales in every moment
customer requests it.

B Less important materials that are often supposed to be available but the lack of this material
can happen and is allowed

C Least important materials.

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MRP type: there are various types of MRP that can be utilized. In this case, our MRP controller
signalled that it should be PD default MRP for most of the SAP installations.

MRP type controls which MRP procedure can be used to plan a material and which MRP
parameters can be entered when maintaining material master. We have to enter this MRP type
on MRP 1 view of material master record.
ND - No planning
PD - Planning

MRP controller: MRP controller responsible for production of this material, he manages all
the data in these MRP views, along with the MRP results itself, production planning for this
material etc. It is usual that the MRP controller provides the data for MRP views, or even in
some organizational structures MRP controllers are maintaining these views on their own.

Lot size: defines the procedure used by the system in order to calculate the procurement or
production quantity of the material. It can have values like

MM: - maintained monthly and weekly

MB: - maintained monthly

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MRP View 2
It contains data about Procurement, Scheduling, and Net requirements calculation.

Procurement type: It defines whether material has internal production (our case),
external procurement, or both types of procurements are possible. It also mightn't have
procurement at all.

F: - for external procurement E: - In-house Production X: - Both Procurement Types

Production storage location: maintains the storage location that is copied throughout
the production documents. If this is a production component this marks the location
from which the goods issue is posted, or if it's produced material it annotates a location
to which the material receipt is posted.
Goods Receipt Processing Time in Days: represents needed time in days for goods to
be inspected and placed into appropriate storage location.
Schedule margin key: this represents a key used for determination of the floats
required for scheduling an order. It is defined in customizing and is supplied by your
MRP controller or PP administrator location to be proposed in the purchase requisition.
Stock determination group: this indicator along with the stock determination rule
creates a key for the stock determination strategy.

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 Co-product: if checked, indicates that this material can also be used as a co-product. .
Safety stock: quantity in base UOM to use as a safety stock.
Minimum safety stock: Safety stock in never allowed to drop below this value.

MRP View 3
MRP view 3 contains several valuable fields mostly used by planning functions.

Period indicator: indicates if material is to be planned/forecast monthly, weekly,

yearly, daily etc. This is in most cases set to monthly.
Strategy group: used for grouping the planning strategies, for example, this can be set
to Make to Order, Make to Stock etc. There are a number of options, and this must be
defined by the production planning management. In most cases, material types and/or
material ABC classification influences the decision which strategy group material
should be assigned.
Consumption mode: this controls how system will consume requirements. In
backward mode sales, orders, dependent requirements or material reservations consume
planned independent requirements that lie before the requirements date while in
forward mode they consume planned independent requirements that lie after the
requirements date.

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 Forward consumption period: number of day used as a consumption threshold in
forward consumption mode. Can be set from 1 to 999 days but usually not longer than
several days. We are using 0 since we are utilizing backward consumption mode for
this material.
Backward consumption period: Same as previous except it is used for backward
consumption mode.
Mixed MRP: defines if material is available for subassembly planning and gross
requirements planning.

REJECTION POSTING
The process of rejection begins when vendor dispatches the material.

Cause of rejection includes the following:

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 Transit Damage: - Damage cause to the material at the time of transportation.
Poor material Handling
Process Rejection: - Damage at the time of Fitment, Welding, Assembly, etc.
Quality Rejection
There are two types of rejection process: -

1. PLANT REJECTION
2. VENDOR END REJECTION

PLANT REJECTION
All the departments submit the rejection report in form of a excel sheet to the concern
agency.
Then that sheet is uploaded at once in SAP.
At the time of execution document numbers are generated for all the parts which
undergo rejection.
With the help of this document number one can easily confirms the movement of
material to scrap yard.
SAP Commands include: -

551 Movement 551 is used under T-Code MB1A in SAP for single part rejection
posting.
ZMMGIUPL It is used in SAP for multiple parts rejection posting.

Single Part Entry for Posting -

Average time consumed 1 Min.

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 Mass Upload for Posting -
Average time consumed 45 seconds

VENDOR END REJECTION

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SAP commands include: -

344 - Movement 344 is used under T-Code MB1B in SAP for rejection posting at
vendor end. It is mostly used for rejection caused due to damage caused in transit.
951 It is used in SAP for rejection posting plus debit to vendor in case of any quality
issue.

Process

At the time of execution of these movements document numbers are generated for
the rejected parts.
These numbers are then forwarded to the concern authority of store.
The authority then does ZMM33N in SAP of these numbers and another document
number is generated.
ZMM13 for Excisable goods and ZMMM14 for Non Excisable goods are done in
SAP of these numbers to generate the invoice of rejected material.

PROCESS REJECTION

It is also known as LINE REJECTION.

It is the rejection at the time of Assembly of parts or vehicle, Fitment, Welding, etc.
It is the result of excessive torque, dampness or may be due to overflow of current at
welding process.
An allowance of 0.5% of overall production is given for process rejection. If the
rejection value exceeds the tolerance level then the loss is bore by the supplier.

SAP Commands include: -

541 - Movement 541 is used under T-Code MB51 in SAP for material transfer from
our stock to vendor stock.
542 - Movement 541 is used under T-Code MB51 in SAP for material transfer from
vendor stock to our stock.
551-O - It is used in SAP for process rejection at vendor end done by us.

SCRAP DISPOSAL

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 SCRAP
Waste that has no economic value or only the value of its basic material content
recoverable through recycling.

SCRAP MANAGEMENT

Manufactures do not plan or intend to make scrap, but depending upon the industry and
product, scrap is produced. BUT depending upon the type of scrap, it may be recycled
back into the production process or sold as a revenue generating product or simply non-
recyclable and the enterprise has to pay for an outside contractor to dispose of the
product.

Waste Management Using 5Rs TECHNIQUE

REDUCE: - It simply means to lessen the amount of trash that will that will
add to the environment.
REUSE: - It means to find other uses for material that are already used.
RECYCLE: - It means creating a new product out of a material that already
served its purpose.
RECOVER: - It means recovering energy that comes from trash itself.
Incineration technology one way of generating energy from waste. It involves
producing electricity by burning garbage in the incinerator. Recovering waste
also involves segregation.
REPAIR: - It means to fix slightly broken things be used again.

REDUCE

REPAIR REUSE

RECOVE RECYCLE

SCRAP YARD

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 It is a place where receiving or handling of scrap is done.

TYPES OF WATE

1) HAZARDOUS WASTE: - Unsafe to use commercially, industrially, agriculturally

or economically.
Ex: - Used Oil, Discarded Container, Adhesives, Carbon Battery, etc.
2) NON HAZARDOUS WASTE: - Safe to use commercially, industrially,
agriculturally or economically.
Ex: - Wooden scrap, Metal scrap, Plastic, Corrugates boxes, Tyre, Rubber.

REASONS FOR SCRAP GENERATION

Change in Design, method, or product.

Mistakes in procurement.
Wrong planning decisions.
Wasteful processes in production.
Inevitable waste during the adjustment of the equipment.
Overall absence of efficiency.

PROCEDURE FOR SCRAP DISPOSAL

Reuse
Return to Supplier
Sale to another Company
Sale to Dealer

FORMS Involved:-

i. All Hazardous waste generated needs to be mentioned in FORM 3 before

moved into Scrap yard.
ii. The contractor must have FORM 10 along with him.
iii. 6 copies of FORM 10 are maintained.

WHITE COPY is generated in order to be attached with FORM5.

YELLOW COPY remains with generator for records.
BLUE COPY is taken by the recycler and submitted to Pollution Control Board.

iv. The transporter must have FORM 11 which shows that he is authorised for
his job as per the regulations set by Pollution Control Board.
v. FORM 4 is maintained by Plant safety officer in order to keep the record of
waste generated.
vi. FORM5 along with white copy of FORM 10 is to be submitted by plant once
in a year to Pollution Control Board. It contains annual report of the scrap
generated by the plant.
vii. Pollution Control Board then matches both the copies submitted by the
generator and the consumer.

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 SAP Commands involved
551 is the moment used in SAP for scrap posting those parts which are used in
vehicle manufacturing.

201 is the moment used in SAP for forceful consumption. It means any part
which is not in BOM but necessary for factory operating supplies. The rate of
such material or part cannot be defined.

202 is the moment in SAP for scrap generation.

VA01 in SAP is used to generate scrap sales order.

VL01N in SAP is used for delivery. It includes information about scrap

contractor, storage location, and quantity.

VF01 in SAP is used to take print of invoice.

PR to PO Process
Purchase Requisition to Purchase Order process involves the following:-

Purchase Requisition is generated for materials/goods which belong to indirect

purchase. It includes consumable products such as paper, machinery spare parts,
stationary, etc.
The necessary requirement of a person of any department is generated in the system.
Then based on Quotation Supplier Sheet the supplier is chosen.

SAP commands involved are:-

ME51 It is used for PR generation.

ZM90 It is used for taking print of PR.
ME21 It is used for generation of PO.
ME22N It is used to download or change the PO.

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 ANNUAL PHYSICAL INVENTORY PROCESS

Physical Inventory Process to be followed in SAP system for both Auto and Manual Tag
Generation

1) To define for Material type for which Physical Inventory not to be taken

T-code: SM30 Table: ZZMM_MTGEXCL (Maintain necessary Material types &

material group).

Here you can maintain scrap material group which will be excluded from inventory.

2) To define Storage Group Description

Storage Group is equivalent to Storage Locations.

E.g. Stg Grp: A2EN01 = A002Engine PU

T-code- SM30 Table: ZZMM_GRPDES (Maintain Storage Groups and Description)

Maintain current fiscal year which would be reflected in Auto Tag Reco in T-code
ZMM_DTS.

Note: If Storage group already defined then no need to create New Storage group

3) Allocating Storage Locations to Storage Group

You can allocate One Storage Location to One Storage Group Only

E.g. Storage locations EN01, EN02, EN04 are assigned to Storage group A2EN01, now
storage location EN01 cannot be assigned to any other Storage group.

T-code SM30 Table: ZZMM_STGGRP (Maintain relationship of Storage Group &

Storage Location).

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Note: If Storage Location already added to Group, then no need to add it to Storage
group again.

4) Maintaining Tag lots or Tag series

Manual Tag punching

T-code- SM30 Table: ZZMM_TAGLOT

Maintain required Tag lots for ease of Tag punching as directed by SCM Coordinator.

Maintaining Tag Number Range for Auto Tag generation

T-code- SNRO Object Name: ZMTAGNUM

Click on Number Range
Enter Storage Group and click on intervals
Click on Interval then enter No 01 Year 2015 From Number 2004000001 and
To Number 2004000500 (As required) Press Enter and Save.
Similarly maintain for all Storage Groups. Please ensure no overlapping / missing Tag
Number Range.

Note: We suggest Tag number should start with the Financial Year as below.

E.g. Storage Group A2EN01: 2015000001 to 2015000500

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5) Auto Tag Creation

T-code-ZMMM4K
Enter Plant : A002
Financial year : 2015
Storage Group : A2EN01
Material type : ROH & HALB
Click on Generate Selected Tags.
Execute in background.
System will create Auto tags For the Parts in Stock.

Download tag allocation file from spool or SM37, which will provide you tag allocation
data which you can use to print tags

Material Type Mtrl Grp Str loc group Qty Val Class Tag No

0001GAN00030N HALB SPR A2TM01 5,700.00 0 2003 1600000001

0001GAN00050N HALB SPR A2TM01 25,977.00 0 2003 1600000002
0001GAN00060N HALB SPR A2TM01 66,483.00 0 2003 1600000003

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0001GAN00080N HALB SPR A2TM01 4,000.00 0 2003 1600000004
0001GAN00100N HALB SPR A2TM01 3,590.00 0 2003 1600000005
000A979 HALB SPR A2TM01 989 0 2003 1600000006
000A992 HALB SPR A2TM01 6 0 2001 1600000007

6) Printing of Auto Generated Tags.

Tcode-ZMM1KN

Enter Plant : A002

Financial year : 2015
Storage Group : A2EN01
Tag Date : 01.02.2015 (Date of inventory)
Tag no : From xxxxxxxxxx To xxxxxxxxxxxxxx
Execute. Print option screen will appear.
Output device : LP01
Click on create spool file (If any tick is on print immediately Remove).
System will create spool file.
Print as normal print process of SAP.
For print special type of stationary is required.

Printing will be in the order of bin location, then material no and finally blank
tags. Each tag is printed in two parts and in one page 3*2 tags will be printed.

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7) Tag reconciliation before tag punching

T-code-ZMM_DTS
Enter Plant : A002
Financial year : 2015
Storage Group : A2EN01
Tag no : From xxxxxxxxxx To xxxxxxxxxxxxxx
Select status as Unused or Cancelled
Execute and Save
To generate tag reco storage group wise, keep tag number field blank and select
radio button Detail report and execute
To print select print command, give Output Device : LOCL

Note: By default status for all tags is Used

8) Download Stock (thru MARD/MC.9) for Halb and Roh

9) Physical Inventory document creation (PID)

For single item T-code: MI01

For storage location
T-code MI31.
While creating for storage location please take following precautions.

Tick mark i. On items w/o zero stock.

ii. Unrestricted stock only.

iii. Freeze book Tick for Indirect material only.

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 iv. Hold process session

Create PID for maximum 100 items only.

Create different Name sessions.

Execute job in background.

Note: Freeze book tick in case of indirect materials only.

Please confirm PID creation thru SE16 ISEG table

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10) Tag Entry/Punching

T-code-ZMM83

For tag entry you have two options:

Manual Tag Punching : For manual/blank tags with

sticker Automatic Tag Punching : For pre-printed/auto tags

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Manual Tag Punching

The CANCELLED TAG shall be entered with status C- please ensure to change
the same from U to C for all Cancelled Tags

Automatic Tag Punching

Enter Plant : A002

Financial year : 2015
Storage Group : A2EN01
Tag no : From xxxxxxxxxx To xxxxxxxxxxxxxx

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 All entered tag series will be displayed with tag no and material, only thing you need to enter
is Quantity.

IMP Notes:
i. For manual tag entry system will ask for tag lots.
ii. Auto tag punching please take care to enter only those tag numbers to be
punched.
iii. If tag range is given, then all the tags to be entered.
iv. For all the tags to be punched PID must be available.
v. In Auto tag, if the Part is found out of auto tag generation, such parts to be
punched through Manual Tag Punching.

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11) Tag Reco after Tag Punching

Once the Tag punching is over the next MAJOR step is to reconcile the Punched
TAG vs.

Physical copy of TAG (output of ZMM_DTS)

Execute the Transaction ZMM20N, the following screen will appear.

Enter the necessary details & select the report option and execute the transaction,
the punched tag detail screen will appear.

Down load the report & reconcile the same with physical copy of each tag
number, note down the corrections, if any.
Once this activity is over you can get the tags corrected from your inventory
representative with transaction MI02 and tab.

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 ZMM47N & MC.9 report shall match for Book Quantity as on 31-Jan.

Reconcile the Physical Stock which you had counted with Book stock as on date
for given Financial Year, Carry out the necessary adjustment in system with prior
approval from account department or as per guideline received from account.
Pl. ensures that all the adjustments are done as on Inventory date 31.01
only.

Data entered in this transaction is stored in Table ZZMM_TAGHDR and

ZZMM_TAGDTL.

Any data to be corrected can be done through SM30- ZZMM_TAGHDR and

ZZMM_TAGDTL.
You can check the same in SE16 ISEG

Sm30 ZZMM_TAGHDR

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Sm30 ZZMM_TAGDTL

12) Report before Reconciliation.

T-code - ZMM47N
This report will display material number, quantity punched through tags and the stock in
PID (system qty)

This report is essential for material reconciliation.

Download this report in excel

13) Reset/Unfreeze and Freeze Book Count.

T-Code MI33.
1. Reset/Unfreeze Book Count.
Enter: PID No for which Book Count To Be Reset.

Click On: Reset Book Inv Balances.

Execute In Background, Job will be generated.

In SM35 Execute in Background

2.Now to Freeze Book Stock Again.
Enter: PID No for which Book Count to Be Freeze

Click on: Freeze Book Inv Balances.

Execute In Background, Job will be generated.

In SM35 Execute in Background

Once the entire reconciliation is over note down/download the Excess

/Shortage report

Enter the necessary details as per you storage location, tick on Book Quantity
and Execute. This will give you the difference in Physical Count and Book
Count.

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 You can also carry out the reconciliation for tag Qty with Transaction
ZMMATMIS during the various stages of reconciliation.

Carry out the

reconciliation as per the
steps shown here. Ensure
that there is no mismatch
at each stage.

In case of mismatch please contact your Inventory Representative to get the

same corrected before proceeding to next stage.
ACCOUNTS to download all the Excess-Shortage report.
Once all the corrections are done Accounts will give the Go-Ahead signal to
all the PUs to start ENTER COUNT

14) For enter count

T-Code ZMM70A.

In this transaction tag qty entered are for posting. This program will call in the
background standard SAP transaction MI04.

Caution: Material Number with Serial Number profile cannot use this program.

: Material Number with Serial Number profile to be punched manually through

T-code MI04.

Schedule job in the Background.

System will generate Job Number.

Run SM35--- Schedule Job Number in Background.

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 Execute the Transaction ZMM70A, you will get the following screen. Enter the
details and Execute. Please ensure that you are carrying out this activity only
for your storage locations.

After Execution process the session thru T Code SM35 in background.

Select the session created against your User ID. Click on tab and
select the mode of processing Background.
You can check the status of your session thru Analysis Tab.

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 Carry out the
reconciliation as per the
steps shown here. Ensure
that there is no mismatch
at each stage.

Execute T Code MI20 to get the list of Inventory differences.

Match this report with ZMM47N report for Physical count(you will need to have
downloaded copy of ZMM47N). In case if you have missed out any material for
ENTER COUNT then use T Code MI04. Enter the count in the sequence of
valuation Type A002, V1 and V0.

Once the ENTER COUNT activity is over Accounts will download the ISEG
Tables

You can also match the ISEG table and ZZMM_TAGHDR tables using T Code
ZMMATMIS.

After you complete all the reconciliation, only then you can start the ZERO
COUNT
Posting in the system.(YOU NEED TO CARRY OUT THIS AFTER ENTER
COUNT STAGE ONLY-ZMM70A)

15) Enter Zero Count.

T-Code: MI35

You can have the list of PIDs for Zero Count using SE16 ISEG

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 Copy the PIDs from the output here which will be the input for next Transaction.

Execute transaction MI35 and you will get the following screen. Enter the details

Click on the red box as shown and you will get the next screen:

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 First copy the PIDs from the
List derived earlier and then
Click here. All the PIDs copied
Earlier will get uploaded.

Then Execute (or press F8)

The session will get created. Execute the session in the background thru T Code
SM35 as before.

Confirm that all PID is having status counted

16) Report Reconciliation after Count before Posting.

T-Code- ZMM79N.

17) Post Difference.

After this carry out DIFFERENCE POSTING with T Code MI37

Execute the transaction and you will get the next screen:

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 Enter the necessary details like Fiscal Year, Plant, Storage location and Posting
date. Ensure that the posting date is 31.01.XXXX.

Execute and the session will get created.

Execute the Session created in background using T Code SM35.

After the execution is complete Mvt 701 will be posted when the physical
Count is in excess of book Count and Mvt 702will be posted when the
Physical Count is in shortage of Book Count.

In some cases if stock is not available to post the difference, you need to
create the stock for on back dated entry & reverse the same after
Difference posting activity is completed.(on current date)

Schedule job in the Background.

System Will Generate Job Number.

Run SM35--- Schedule Job Number in Background.

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18) Posting without PID

For Any Reason PID is not created and Difference to be Posted

T-Code - MI10

Please enter exact Physical quantity. System will post the difference.

E.g.: System Stock 100 Physical 80 or 110

Post Physical Stock, System will do the plus or minus qty.

19) Report after Difference Posting.

T-code - ZMM_M4RN

20) Deletion of Old PID

T-Code- ZMM8D.

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 Benefits of IT to Industry

The impact of technology in our lives, today, is immeasurable. We use technology every day,
in order to fulfil specific tasks or specific interests. We have specific needs and we want to
have faster technologies.

The evolution of Manufacturing Industry and Processes could be traced along the same lines
as that of IT Industry. One of the basic and common factors in the evolution cycle of these
industries is the reducing Human Interface.

From manual manufacturing processes of yesterday, the industry today has made a shift
towards and has started witnessing the benefits of Digital Manufacturing. Digital
Manufacturing, as the name suggests, simulates all the processes of manufacturing on the
computers to define the most efficient processes for the companies. The entire manufacturing
process right from Assembly lines, human ergonomic simulation, Robotic Simulation, plant
layout, etc. could be defined, developed, implemented and monitored virtually in the 3D
environment. A large number of roles have opened up to facilitate the technology behind the
scenes of the shop floor

This results in enabling companies to achieve utmost production efficiency, in reduced time
and costs thereby facilitating early entry to the market.

ADVANTAGES

Easy access to information at anytime and anywhere;

Efficiency and productivity helping businesses increasing production, saving time
and money in the industry;

Technology and Operations go hand in hand. Technology is used to reduce the time taken in
any operation; technology helps in providing optimized results in minimum time. It reduces
paper work and human efforts.

The live example of how technology benefits industry is DAMAGE CASE PORTAL. This
portal is designed to save time and human efforts.

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Damage Case Portal
It is a portal designed for approval of Transit Rejection cases and debit recovery from
transportation as well as vendor.

PROCEDURE: -

Whenever there is a case of transit damage then dock person immediately gives this
information to the Buyer, Quality head and Logistics.
The quality team then checks if the material can be reworked.
If no then it should be debited to vendor or transporter.
In that case logistics generates the record which include all the details of material- part
no, descriptions, quantity damaged, etc.
Then this record is forwarded to buyer whose responsibility is to calculate the amount
debited.
Then this record is ready for approval from approver.
Once approved then the logistic team debit the amount to either transporter or vendor.

BEFORE

The entire record was maintained on paper.

The whole procedure takes around 150 minutes and also requires man power to float
the information.

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AFTER

To reduce human efforts and the amount of time consumed a portal was designed
known as DAMAGE CASE PORTAL.
Now, the whole procedure takes only 48-49 minutes and doesnt require any man
power.
The logistic team enter all the information regarding damage in the report.
Then at the time of submission of the report an auto generated mail is sent to the buyer.
The buyer then adds the debit details to it and then it is sent to the approver.
If approver approves it then the logistics debit that amount to transporter or vendor.

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 REFERENCES

https://en.wikipedia.org/wiki/Mahindra_%26_Mahindra
https://en.wikipedia.org/wiki/Big_Hairy_Audacious_Goal
http://www.mahindra.com/news-room/press-release/Mahindra-Haridwar-Plant-
crosses-production-milestone-of-7-lac-vehicles
https://en.wikipedia.org/wiki/SAP_SE
http://www.saponlinetutorials.com/what-is-sap-erp-system-definition/
https://en.wikipedia.org/wiki/ABC_analysis
https://www.slideshare.net/Naeemsiddiqui2/inventory-managment-80-20-rule-and-
abc-analysis
http://www.guru99.com/how-to-create-material-master-data.html
http://www.gotothings.com/sapmm002.htm
http://www.guru99.com/material-master-views-ultimate-guide-2.html#C8
https://www.slideshare.net/sinunstah/scrap-management

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