This document provides an overview and timeline for an ERP implementation project. It includes: 1. An overview of the key ERP modules to be implemented, including sales, production planning, materials/purchasing, quality control, and portals. 2. A schedule of CFT (Cross Functional Team) meetings to collect requirements and demo prototypes for each module across June-November 2012. 3. Details of the CFT meeting scope, which involves confirming processes/flows, identifying requirements, risks, business rules and master data for each module. 4. Milestones showing targeted demo dates for the main modules between June-December 2012. The document provides a high-level snapshot of the

1. P/L (IT) HOD DIRECTOR MD
PROD MAT QC DEVP TECH FIN HR ADMIN GP
1

2. ERP OVERVIEW
• QR Barcode Invoice 1. CUSTOMER PLAN
• Customer trim in based auto invoicing 2. DISPATCH
SALES • FG & SFG Inventory
• PDA based POP
3. RECEIPTS PROTO AUG DEMO AUG
4. TAXATION
• Sales Return
• Multi level BOM
• Model wise - car value analysis 1. CAR BOM
BOM • Introducing LTP & STP 2. MATERIAL BOM
• D+2 Planning 3. DLY/ MTHLY/ YRLY PLAN’G
PROTO JUN DEMO JUL
PPC • Automatic purchase schedule by STP 4. EASIER PLANNING MODEL
• Kanban & Lean Management
KEY FUNCTION
• Inventory Levels - R/M, LP, CKD,
• Automated PO schedule 1. PURCHASE REQUEST
MATERIALS/ • Lean Inventory through Purchase scheduling 2. PURCHASE PLANNING
PURCHASE PROTO JUL DEMO JUL
• Systemised CKD costing 3. WAREHOUSE
• Barcode (PDA) based Material Transfer
4. CKD SUB MODULE
• Cost History
1. COST CENTERS
• Internal Cost/Management Accounting
COSTING/ • WIP STOCK Monitor
2. PRODUCT COSTING
3. WIP STOCK PROTO JUL DEMO SEP
PRODUCTION • Statistical Process Control (SPC)
4. PRODUCTION PLAN’G - 4M
• 4M Calculation
• Kiosk based Quality POP 1. INLINE QC
QUALITY • DCR & CounterMeasure 2. INCOMING QC
PROTO JUL DEMO SEP
CONTROL • Inline, Incoming & Customer PPM 3. FINAL INSPECTION
• Vendor Performance Rating 4. PPM CALCULATION
5. VENDOR QC
• Employee Portal 1. WORK FLOW
• Reporting Portal 2. APPROVAL SYSTEM
PORTALS • Budgeting 3. VENDOR QC
PROTO OCT DEMO NOV
• Online Reports and Approval 4. VENDOR PO & PAYMENT
• Supplier Portal Like VAATZ

3. CFT MEETING SCHEDULE & SCOPE
CFT Meeting Schedule
BOM Production Material Purchase Costing Quality TM Sales HR Reporting Vendor MIS
Meeting 1 11-Jun 18-Jun 25-Jun 09-Jul 02-Jul 16-Jul 23-Jul 30-Jul 06-Aug
Requirement will be
Meeting 2 13-Jun 20-Jun 27-Jun 11-Jul 04-Jul 18-Jul 25-Jul 01-Aug 08-Aug collected during the
discussion with CFT on
Meeting 3 15-Jun 22-Jun 29-Jun 13-Jul 06-Jul 20-Jul 27-Jul 03-Aug 10-Aug
other Modules
Meeting 4 20-Jun 27-Jun 04-Jul 18-Jul 11-Jul 25-Jul 01-Aug 08-Aug 16-Aug
Meeting 5 06-Jul 06-Aug 31-Jul 31-Jul 03-Sep 12-Sep 27-Sep 30-Aug 16-Oct 15-Oct 19-Oct 08-Nov
Level Meeting Scope
1 • Application Flow Confirmation
• Requirement Collection templates will be shared
• Process Function and Activity Identification
• Risk Area Identification
• 1st level BR Identification
• Master Data Identification
2 • Data Element Identification
• Integration BR Identification
• Master Data Confirmation
• New Process Changes Identification
3 • Proposed Model Presentation
• Feedback Session
4 • Feedback Incorporation
• Final Proto Type Presentation
5 • Application Module Demo 3

4. CFT Meeting Schedule & Methodology
A SNAPSHOT
A Snapshot
Application Req. Process 1st Level
Master
Meeting 1
flow Collection Function & Risk Area Business
Data
Confirmati Templates Activity Identify Risk
Identify
on sharing Identify Identify
Integration Identifying
Data Element Master Data
Meeting 2 Identification
Business
Rules
Conformation
New Process
Changes
Proposed
Feedback
Meeting 3 Model
Presentation
Session
Final Proto
Incorporation
Meeting 4 of feedback
type
presentation
Application
Meeting 5 Module Demo

5. Milestones CALENDAR – MODULE DEMO
MILESTONES – MODULE WISE
MILESTONES AT A GLANCE
DEMO
Jan Feb March April May June July August Sep Oct Nov Dec
EXAMPLE TEXT
2012
2013

6. CALENDAR – CFT SCHEDULE
June 2012
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
WEEK 1 1 2 3
Project AS IS – SYSTEM STUDY and REAL TIME GAP ANALYSIS Execution Plan for All Modules
Kick Off by Leiten Team
WEEK 2 Meeting 4 5 6 7 8 9 10
BOM, PPC BOM ,PPC BOM ,PPC
CFT Meet FLOW TO BE
WEEK 3 11 12 CONFIRM 13 14 PRESENT 15 16 17
PRODUCTION PRODUCTION
PRODUCTION FLOW CONFIRM
CFT MEET TO BE
BOM, PPC -
WEEK 4 18 19 PROTO 20 21 PRESENT 22 23 24
MATERIAL MATERIAL
FLOW CONFIRM
MATERIAL
CFT MEET TO BE
PRODUCTION
WEEK 5 25 26 PROTO 27 28 PRESENT 29 30
WEEK 6 6

7. CALENDAR - CFT SCHEDULE CALENDAR – CFT SCHEDULE
July 2012 July2012
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
WEEK 1 1
COSTING FLOW
COSTING CONFIRM
COSTING
CFT MEET MATERIAL- PROTO TO BE
WEEK 2 2 3 4 5 PRESENT 6 7 8
PURCHASE PURCHASE PURCHASE
FLOW CONFIRM TO BE
CFT Meet
COSTING- PROTO
WEEK 3 9 10 11 12 PRESENT 13 14 15
QUALITY FLOW QUALITY
QUALITY CONFIRM
CFT MEET TO BE
PURCHASE -
WEEK 4 16 17 PROTO 18 19 PRESENT 20 21 22
TM TM
FLOW CONFIRM
TM
CFT MEET TO BE
QUALITY -
WEEK 5 23 24 PROTO 25 26 PRESENT 27 28 29
SALES
CFT
WEEK 6 MEET. 30 31 7

8. CALENDAR - CFT SCHEDULE CALENDAR – CFT SCHEDULE
August 2012 August 2012
MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY
SALES FLOW
CONFIRM
TM - PROTO
WEEK 1 1 2 3 4 5
HRM HRM FLOW HRM
CONFIRM TO BE
CFT MEET SALES - PROTO
PRESENT
WEEK 2 6 7 8 9 10 11 12
REPORTING
VENDOR HRM- PROTO
PORTAL
WEEK 3 TO BE 13 14 15 16 17 18 19
WEEK 4 20 21 22 23 24 25 26
WEEK 5 27 28 29 30 31
WEEK 6 8

9. ERP – DATA FLOW

10. MANUFACTURING
BOM MANAGEMENT
PPC/MRP
COSTING
PRODUCTION / SHOP FLOOR
TECHNICAL AND MAINTANENCE

11. B.O.M.
BOM TFT
A Permanent Task Force Team (TFT) is necessary to maintain BOM in ERP.
Approver Director
Development
Initiator I/C Person I/C Person I/C Person
Information to others after creating BOM
HMI Daimler AL Nissan
Request to Create Master, BOM
Supporter Purchase Production Finance
(Purchase Price) (Routing) (Ledger Code)
Creator IT Person
& TL
11

12. B.O.M.
Bill of Material - Definition
A Bill of Materials (BOM) is a detailed list of all parts and subassemblies that are
required to build a specific product, including the quantity necessary for each unit
produced.
BOM Data Entry Screen BOM Tree View
12

13. B.O.M.
BOM Creation Process
Development Person Master & BOM Responsibility &
IT Team Leader Process Description Output
& Manager Person (IT) Approval
1.Deliver information about new BOM Change Developmen
1 development or new ECO Application t Member
Information of & & Manager
New (Developer delivers sourcing list, BOM
Development application form to IT person in-charge of Sourcing List
/EO Change 3 Master)
2
Receive Review BOM BOM Change Master
2.Check for Consistency and
inquiry of Change Application
Application Completeness after receiving BOM Person (IT)
BOM creation
& Approval Form & application form and sourcing list.
Yes
Approval
If errors are found, Return the paper to
Invalid NO developer,
Sourcing List
[Return]
Sourcing list and BOM change application
form must have Material details & other
required information about that.
3. IT Team Leader verifies BOM IT Team
application form and sourcing list. Manager
Rewritie sourcing NO
list/Check BOM & Educate 4.In accordance with BOM application BOM Change IT Team
Error form, Create Material Master & BOM Information Member
(Master)
5.The IT member is responsible to IT Team
5 create Master and BOM informs to related Member
Inform 4
Completion of teams about the creation / change in
Yes
BOM Creation MASTER & BOM BOM.
[Development,Ma Creation
terials,Sales,Cost Concerned
] Other team members should check the Team
BOM Module that the BOM is updated as Members
requested

14. BOM & PPC / MRP

15. PPC / MRP
Features
Key Functions
Introducing LTP & STP
1. YEARLY PLAN ( JAN – DEC)
2. MONTHLY PLAN
Improved D+2 Planning (QUARTERLY)
3. DAILY PLAN (D+2)
Automatic Purchase Schedule through STP
Kanban, Lean Production & Lean Inventory
Yearly Material Procurement Planning
Yearly Capacity Planning
Yearly Sales Planning

16. PRODUCTION
Delivery

17. PRODUCTION
Features
Key Functions
WIP Stock Monitor 1. PROCESS MASTER
Statistical Process Control (SPC) at all shops 2. MACHINE MASTER
3. PRODUCTION ROUTING
Daily Production Planning through D+2 System MASTER
4. PRODUCTION PLANNING -
Mould History Card (ISO, 5-Star requirement)
4M CALCULATION
Shop-Line-Machine concept for effective costing 5. WIP STOCK
Calculation of Capacity Plan, Productivity, OEE
Integration with Tech Maintenance for 100% uptime
Machine wise UPH, UPMH calculation
4M Calculation

18. PRODUCTION

19. COSTING
Features
Key Functions
Manages Internal Cost/Management Accounting 1. COST CENTERS
2. COST ELEMENTS
Activity based Costing 3. COST ESTIMATION
4. PRODUCT COSTING
Cost History
Automation of Supplementary/ Retro Invoicing

20. TECHNICAL & MAINTANANCE
Features
Key Functions
Maintenance Scheduling & Reminders 1. MAINTENANCE SCHEDULE
2. ASSET MANAGEMENT
Preventive and Predictive Maintenance 3. SPARES MAINTENANCE
4. ENERGY MANAGEMENT
Reducing MTBF through Continuous alerts
M/C Breakdown Analysis
Spares maintenance
Asset Tracking
EB Reading, Diesel Accounting

21. MATERIALS & PURCHASE
Features
Key Functions
Inventory Levels - R/M, LP, CKD, BO
1. MATERIAL PURCHASE
Vendor Rating / Performance
PLANNING
Calculating ITR and Purchase/Sales ratio 2. PURCHASE REQUEST &
Barcode (PDA) based Material Transfer APPROVALS
3. SUPPLIER MANAGEMENT
Crate / Trolley Accounting
4. WAREHOUSE
Automated PO schedule MANAGEMENT
Rate Master creation through Approval system. 5. CKD SUB MODULE
Lean Inventory through Purchase scheduling
Vendor Stock Monitoring
Automated GR (GR through Vendor Portal)
Systemised CKD costing
Systemised billing process for Transporters
Control on Purchase Returns (Qty, Payment)

22. MATERIALS & PURCHASE
PURCHASE
CKD
MATERIALS
Calculating ITR
Automatic GR
Automatic Material through Vendor
Costing system Automated CKD WAREHOUSE
Costing System Portal
Automatic PO as Per
Production Planning Barcode Based GRN
Online PO Approval Direct Link with Centralized Stock
Korean HO & Monitoring System
Trolley & Pallet
Vendor Stock Downloading
Accounting System
Monitoring System Packing List
Automatic Data Automatic BOM
Upload to SAP based Material
Scheduling Flaw less Stock
FIFO based
Transfers
CKD Issue Barcode (PDA) based
Material Issue

23. MATERIALS & PURCHASE

24. MATERIALS & PURCHASE

25. QUALITY
Features
Key Functions
Inline, Incoming & Customer PPM calculation
1. INLINE QC - REWORK,
REJECTION
Kiosk based Quality POP
2. INCOMING QC - REWORK,
Online SPC to send SMS for production quality issues REJECTION
3. FINAL INSPECTION -
Defect Content Report & Countermeasure from Vendor REWORK, REJECTION
4. PPM CALCULATION.
Systemised Debit Advice for rejection 5. VENDOR QC
MANAGEMENT
Interlink with Vendor Portal for Rework / Rejection PPM
Vendor Performance Rating

26. SALES
Features
Key Functions
QR Barcode – Sales Invoice
1. CUSTOMER PLAN
Trim – in based Auto Invoice 2. DISPATCH SUB MODULE
3. RECEIPT SUB MODULE
PDA based POP 4. TAXATION SUB MODULE
Effective D+2 planning system to avoid customer line stop
Proper accounting of Sales Return
Complete capturing of Warranty claim, Cost of Poor Quality
Systemised working of Transport Billing
Crate/ Trolley Accounting

27. SALES
SHOP
FLOOR

28. HUMAN RESOURCE
Features
Key Functions
Centralized Attendance monitoring system
1. ATTENDANCE SYSTEM
2. PAYROLL SUB MODULE
Integrated Pay Roll system 3. TRAINING SUB MODULE
4. APPRAISAL SUB MODULE
HR Training History Module 5. EMPLOYEE DATA BANK
Audit compliances
All EIS Reporting
Leave Approval thru Reporting Portal

29. REPORTING AND APPROVAL PORTAL
Features
Key Functions
Budgeting ( Needs integration with Finance Module) 1. APPROVAL SYSTEM
Integrated Online Report Approval with All Modules in ERP 2. WORK FLOW SYSTEM
Leave Application Approval
Purchase Rate Master Approval
Sales Rate Master Approval
New BOM creation Approval
BOM Modification Approval
Business Trip Approval / Report
Other Approvals
Sharing Company Policy / Process

30. VENDOR PORTAL
Features
Key Functions
Advance Shipment Notice (ASN) with Barcode 1. QUALITY
2. PURCHASE
Purchase Order and Delivery Schedule
GR Inward and Payment Tracking
Quality Tracking, DCR and Counter Measure Action
PPM Status
Performance Rating

31. EXECUTIVE INFORMATION SYSTEM
Features
Key Functions
Direct on-line access to relevant information
Timely and Accurate 1. INTEGRATED WITH ALL
MODULES
Dashboard Reports, Analysis and Graphs
2. DASHBOARD REPORTING
Identifies Trends
3. GRAPHICAL REPORTS
Measures Performance
4. TRENDS
Daily Manpower Summary
5. PLANNING
Daily Absent Ratio
OT Analysis
ITR Trend
Purchase/Sales ratio
Planning Analysis
PPM Status
Top 10 - Worst parts
Sales Trend
Purchase Trend

32. ERP INTEGRATION MODEL
CORE MODULES - SNAPSHOT
MANUFACTURING HUMAN RESOURCE
• BOM Management • Integrated Attendance
• PPC/MRP Monitoring
• Costing • Integrated Pay Roll System
• Quality Control – Inline • Training History
• Production Control • Appraisal Sub Module
• Capacity Planning • Employee Data Bank
• Technical and
Maintenance
QUALITY
• Incoming QC SALES
• Inline QC ERP • Customer Plan
• Final Inspection (FG) (EIS) • Item Configuration
• PPM Calculation • Delivery Schedule
• Vendor Quality • PDA based POP
Management • Sales Return
• Crate/Trolley
Management
PURCHASE MATERIALS
• Purchase Scheduling • Warehouse Management
• Purchase Orders • Movements & Transactions
• Sub Contracting • Costing
• Costing • Quality Control – Incoming
• Goods Receipt • PDA based Inventory
• Accounts Payable Management
• CKD Management

33. ERP INTEGRATION MODEL
EIS
Executive Information System
Reporting & Approval Portal
SD
QC FI Sales
PPC
B
Q
U IL
PR Production
Planning &
O
A Production
L
Control M
I
VENDOR T IC MPS
PORTAL Y Materials, Purchase &
Stores
TM HR CO
Tech & Main
Human Resource Costing
EMPLOYEE
PORTAL