1.

Sales order feasibility check:

Movement Plans (demand as captured in the legacy system by the
marketing division of SAIL) will be converted to presales order (in SAP as
quotation) after checking the following criteria:
 Material available as material master in the system.
 Available lengths for cut material in Z-table.
 Error log, in a presentable format, for the MPs not converted to
Presales order.

2. Presales order creation and Sales order conversion

 MPs will be converted to presales orders automatically (interface).
 Presales order with single line item will be converted to sales order
automatically (using custom program).
 Presales orders with multiple line items (alternate item) will be
converted to sales orders manually (using custom program), after
selecting one line item which is to be produced.
 Sales orders will have the characteristics as given in the MP.

3. Product Allocation check

The instance sales order is created; it will go for allocation check against
MAP.
 A sales order will be either fully allocated or not allocated. Partial
allocation will not be allowed.
 A report will be available showing allocated and unallocated sales
orders.
 MAP may be modified manually to accommodate an unallocated
sales order, if required.

4. Tentative Rake formation

 Planning horizon for PPDS planning run will be 15 days.
 Sales orders’ items which are having requirement date as the last
date of the month will not be relevant for rake planning till 16 th of the
month because of the planning horizon.
 The last date of receiving sales orders for CRM is 11 th of the month.
 The last date of receiving sales orders for HR coil is 25 th of the
month.
 The last date of receiving sales orders for HR plate / sheet is 18 th of
the month.
 By default, the delivery date of the MP will be copied in the delivery
date at the header of the sales order and the last date of the month
will be the requirement date of the line item.
 Once a sales order / item is planned in a rake, the requirement date
of the sales order / item will be changed to the rake dispatch date
by the rake planning program.
  If the rake dispatch date is within the planning horizon, the sales
orders / items planned in the rake will be considered for production
planning run.
5. Rake modification in 4 days horizon
 If one sales order dispatch has to be replaced by another sales order
then through a Z-development, the user will remove the first sales
order from the rake and choose the second sales order.
 The removed sales order will again be available for rake planning and
will not be available for production planning in PPDS. (APO
development)
 If a sales order / item is removed from a rake, by using rake
modification program, the requirement date of the sales order / item
will be changed to the last date of the month.

6. Rake dispatch
 Indent preparation (Z-program) program will fetch all the sales orders
planned for dispatch in a given date.
 The user will enter the final quantity and remarks in the indent
preparation.
 Once saved this will be available as past indent report for a date.
 Past indent report for a date will be sent to the loading department as
hard copy printout.
PPDS production planning steps:
7. PPDS scheduling steps:

HRCF CRM
downstream

Tandem Mill

6 Pickling line

3HSM
2

SMS 4 4
a b

Order creation after PPDS planning heuristic run based on rake planned date.
Sequencing of HSM planned orders according to Coffin profile by custom developed
program.
Sequencing of SMS according to Top-down heuristic respective to HSM coffin
profile.
SMS individual sequencing
4a 11 heat sequences will be created in SMS2 by custom
developed program. Extra heats will be stocked.
4b SMS1 heat will be according to the point 3.
HRCF and CRM will be planned according to Bottom-up heuristic respective to HSM
coffin profile.
Sequencing in CRM lines will be done according to the shops’ constraint by custom
developed heuristic.
8. (Step 1) PPDS production planning steps:
 PPDS will consider the sales orders, which are part of a rake, for
production planning. This is controlled by planning horizon.
 In the production planning run planned orders for finished goods to
liquid steel will be created.
 PPDS will not create planned orders for hot metal (i.e. Blast
Furnace).
 During planning run, various characteristics’ values will flow as
defined in object dependencies.
 All the characteristics for which flow of value is required from top
level to any down level will be made APO relevant.
 All APO relevant characteristics are not netting relevant in
production planning run. BADI - /SAPAPO/RRP_PLANNING is
being used to define which APO relevant characteristics are to be
considered for netting.

9. (Step 2) HSM mill will be planned according to coffin profile.

 Planned order will be created for HR coil based on above planning
run.
 The sequencing of the orders according to the coffin shape will be
done manually by using custom program.
 After sequencing of the orders according to the coffin shape, the
sequenced orders will be fixed, so that future planning runs does
not affect these scheduled orders.

10. (Step 3 & 4) Sequencing of SMS according to Top-down heuristic

respective to HSM coffin profile.
 (Step 4a) CCD & SMS2
1. Orders of similar grades will be clubbed to create one sequence
of 3300 Ton.
2. SMS2 heats will be scheduled and sequenced according to the
11 heat sequence in CCD.
3. SMS2 planned orders will be created by fixed lot size of 300Ton.

 (Step 4b) Slabbing mill & SMS1

1. Slabbing mill and SMS1 will be scheduled by Top-down
approach according to the HSM rolling program.
2. SMS1 planned orders will be created by fixed lot size 130Ton.
3. For every four 28-ton ingot, one 17-ton ingot will be generated
and will be mapped as byproduct in BOM.

11. (Step 5) HRCF and CRM will be planned according to Bottom-up

heuristic respective to HSM coffin profile
  Daily planned orders of HRCF & CRM shops will be scheduled by
running Bottom-up heuristic against the HSM schedule (conforming
to coffin profile).
 The HRCF shearing line, for HR sheet & plate, will be scheduled by
Bottom-up approach according to the HSM mill.
a. In Shearing line 1 shearing blades and side trimming blades are
changed on weekly-off days, which will be maintained in resource
of Shearing line 1. In Shearing line 2 the blade change is carried
out daily and will be maintained as planned downtime for the
resource.
b. Orders, of a given day, will be sequenced from thinner to thicker
and then from wider to narrower by using custom schedule
sequence heuristic in DS planning board.
c. In shearing line 1, trimmed and untrimmed coils will be planned
separately.
d. In shearing line 2, all coils of 2.5 mm and below thickness will be
planned together (up to a limit of 10 coils per day) for a day
manually.

12. (Step 6) Sequencing in Pickling lines will be done according to the shop
constraint by custom developed heuristic
 For CRM shops the Pickling lines will be considered as bottleneck
resource.
 Once the planned orders for a day is scheduled in Pickling lines
from Step-5, the orders will be sequenced according to the shop
requirements given below:
 Pickling line 1 –
 Coils of thickness 2.5 mm and below, will be processed together
irrespective of width.
 Coils above 2.5 mm, will be processed wider to narrower coils.
Within single width, the thickness will be sequenced from thin to
thick by using custom schedule sequence heuristic in DS
planning board. If thickness jump is inevitable and above
0.3mm, a manual order is created which matches the thickness
range of 0.3mm or less than 0.3 mm for the simultaneous
orders.
 SAILCOR grade orders will be planned together.
 Pickling line 2 –
i. Coils of thickness 1.9 mm will be planned together.
ii. Coils of thickness 2 mm to 2.5 mm will be planned together from
thinner to thicker, irrespective of width.
iii. Coils of thickness above 2.5 mm will be planned from wider to
narrower. Within single width, thickness will be sequenced from
thinner to thicker by using custom schedule sequence heuristic in
DS planning board. If thickness jump is inevitable and above
0.3mm, a manual order is created which matches the thickness
range of 0.3mm or less than 0.3 mm for the simultaneous orders.

13. (Step 7) Scheduling of Tandem mills

  The orders of Tandem mills will be scheduled by using Bottom-up
heuristic against the Pickling lines’ sequence done in Step-6.
1. Tandem mill 1 – Orders, for a given day, will be loaded as
wider to narrower coils and thick to thin coils by using
custom schedule sequence heuristic in DS planning board.
2. Tandem mill 2 – Orders, for a given day, for thinner coils
(<= 0.45 mm) will be clubbed together and orders, for a
given day, for thicker coils (> 0.45 mm) will be clubbed
together.

14. (Step 7) CRM downstream shops’ scheduling

Downstream CRM shops, e.g. Annealing, SPM, DCR, ECL, CAL, HDGL
etc, will be scheduled by Bottom-up approach with respect to Pickling
lines’ schedule.
a. HDGL –
 All thinner gauges (0.45 mm and below) will be planned together
to meet mandrel (420 mm) requirement. Gauges 0.5 mm and
above will be planned together to meet mandrel (600 mm)
requirement.
 By daily planning, orders of a given day will be loaded in a
sequence of thin to thick such that the thickness change is not
more than 0.2 mm between two simultaneous orders by using
custom schedule sequence heuristic in DS planning board. If
thickness jump is inevitable and above 0.2mm, a manual order
is to be created which matches the thickness range of 0.2mm or
less than 0.2 mm for the simultaneous orders.
 To minimize loss, due to beveling at the joint of two coils of
different widths, orders will be loaded in a sequence (narrower to
wider) such that the width difference is at the minimum.
b. CRM slitting line –
 No shop constraint.
c. CRM shearing line –
 Orders, of a given day, will be loaded according to thickness,
thick to thin in shearing line 1 & 2 and thin to thick in shearing line
3. The shearing blade change will be planned as planned
shutdown time. SAILCOR grade coils will be manually clubbed
together for processing for a day irrespective of thickness.
d. DCR –
 No shop constraint.
e. SPM –
 Orders of a day will be sequenced wider to narrower and
gradewise by using custom schedule sequence heuristic in DS
planning board.
f. ECL –
 Orders, of a given, will be loaded in a sequence of thin to thick
such that the thickness change is not more than 0.2 mm between
two simultaneous orders by using custom schedule sequence
heuristic in DS planning board. If thickness jump of above 0.2mm
is inevitable, manually order will be created, which matches the
 thickness range of 0.2mm or less than 0.2 mm for the
simultaneous orders.
g. CCAL –
 Orders, of a given day, will be loaded in a sequence of thin to
thick such that the thickness change is not more than 0.2 mm
between two simultaneous orders by using custom schedule
sequence heuristic in DS planning board. If thickness jump of
above 0.2mm is inevitable, a manual order is created which
matches the thickness range of 0.2mm or less than 0.2 mm for the
simultaneous orders.
 All thinner gauges (0.45 mm and below) will be planned together
to meet mandrel (420 mm) requirement. Gauges 0.5 mm and
above will be planned together to meet mandrel (600 mm)
requirement. This will be achieved as the sorting will based on
thickness.
h. Annealing 1, 2 & 3 –
 Annealing 1, 2 & 3 will be mapped as separate work center, as
for the same material the annealing cycles are different in each
shop.
 The annealing work centers will have multiple capacities with the
number of capacities = maximum number of bases in a shop X 4
X 3 (as maximum 4 coils can be loaded on a base and one
planned order can have only one coil only and 3 is to take care
that a coil can be loaded in any of the 3 shops). This will ensure
that all the orders of annealing for a day can be loaded and not
restricted by capacity.
 For every material 3 production versions (one for each annealing
shop) will be maintained. At the time of production, based on the
annealing shop used the production version will be changed.
 Based on the Bottom-up heuristic with respect to Pickling lines,
planned orders for Annealing lines for a day will be clubbed.
 Orders for a given day will be sorted first on Grade, then Width
and then on Thickness. This will give an optimum loading based
on annealing cycle.
 Optimum loading is loading of coils of same material in one
cycle.
 Visibility of resource availability and utilization is available in
details in the existing Annealing Shop Software and hence not
advisable to track in SAP.