This document describes an MRP and inventory performance management system implemented at a valve manufacturing company. The 11-slide presentation covers the following key points: 1. The system interfaces with various SAP modules to improve planning and inventory processes across functions like production, materials, and marketing. 2. Major automated processes enabled by the system include production planning/scheduling, inventory analysis, scrap analysis, and sales forecast integration. 3. A demonstration of the production planning/scheduling module shows benefits like improved visibility, inventory control, and coordination between departments.

1. Total Number of Slides: 11
REVL ( KML Division)
MRP & INVENTORY PERFORMANCE MANAGEMENT SYSTEM

2.  About MRP & Inventory Performance Management System
 System Interface with SAP R/3
 Design Objective
 Major Processes – IT Enabled
 Production Planning/Scheduling Process – Module Demonstration
 eMIS
 Benefits Derived
Slide No : 2
Contents

3.  Business Productivity Tool for High Variety Valve Manufacturing
Slide No : 3
Technology : Client / Server
Platform : Sybase
 IT System - Interfaced with Modules of SAP ( MM / PP / QM / SD )
About MRP & Inventory Performance Management System

4.  To Make IT Simple And Adoptable
 To Improve & Support Various Internal Processes
 To Mobilize SAP Data Across the Functions
 To Provide Instant Visibility / Inventory Performance
across the Plant
Slide No : 4
Objective

5. Slide No : 5
SN Modules Processes/Work Flow Addressed SAP
Interfaced
Respective Areas of Functions
1 Product Info Management - Product Database
- Drawing Release / Access to Operation Team
- To help rationalization of Stage Codes
Engineering
2 Sales Forecast [AOP/Orders] - SBP / AOP RM Requirements
- Integration of Customer Orders with Production Planning
Module
Marketing
3 Sales / Production Rolling
Plan
- Online Capturing of MTS/ MTO Requirements
- Production Planning based on Plant Capacity
- Daily/Weekly Plan Vs Actual Monitoring & Review
a) Cellwise
b) Segementwise
c) Customerwise
- Generation of RM Shortage List / Monitoring & Review
- Plan Amendments
Production Planning & Control
4 Inventory Ageing Analysis - Monitoring and Review of Stock Ageing ( RM, WIP, FG ) Materials / Manufacturing / Marketing
5 Inventory Analysis - Indirect Material Inventory Analysis Materials
6 Scrap Analysis - In Process Scrap Analysis and Monitoring Manufacturing
7 Rework Analysis - Rework Accounting / Monitoring & Review Manufacturing
8 Sales Analysis - Sales Analysis Marketing
9 Assets - 2D Barcoding of Assets and Verification
Finance
10 MRP DRM Performance - MRP DRM Monitoring / Review MRP
Major Process – IT Enabled…….

6. Slide No : 6
SN Modules Processes/Work Flow Addressed SAP
Interfaced
Respective Areas of Functions
1 Product Info Management - Product Database
- Drawing Release / Access to Operation Team
- To help rationalization of Stage Codes
Engineering
2 Sales Forecast [AOP/Orders] - SBP / AOP RM Requirements
- Integration of Customer Orders with Production Planning
Module
Marketing
3 Sales / Production Rolling
Plan
- Online Capturing of MTS/ MTO Requirements
- Production Planning based on Plant Capacity
- Daily/Weekly Plan Vs Actual Monitoring & Review
a) Cellwise
b) Segementwise
c) Customerwise
- Generation of RM Shortage List / Monitoring & Review
- Plan Amendments
Production Planning & Control
4 Inventory Ageing Analysis - Monitoring and Review of Stock Ageing ( RM, WIP, FG ) Materials / Manufacturing / Marketing
5 Inventory Analysis - Indirect Material Inventory Analysis Materials
6 Scrap Analysis - In Process Scrap Analysis and Monitoring Manufacturing
7 Rework Analysis - Rework Accounting / Monitoring & Review Manufacturing
8 Sales Analysis - Sales Analysis Marketing
9 Assets - 2D Barcoding of Assets and Verification
Finance
10 MRP DRM Performance - MRP DRM Monitoring / Review MRP
Major Processes - IT Enabled………..

7. Slide No : 7
Production Planning / Scheduling Process @ KML Division

8. Slide No : 8
 To Automate Production Planning Work Flow
 To Enable On-line Review of Various Operational Performance
a)Inventory Performance
b)Manufacturing Performance
c)SAP DRM Performance
 To Automate Creation and Distribution of MIS reports
( Plan Vs Actuals / Scrap / Inventory / Ageing Status to entire Operation Team )
 To Improve WIP Accounting.
 To Establish Effective Co-Ordination among Functions
( Marketing / Production / Materials )
 To Improve MRP accuracy / results
Production Planning/Scheduling Module - Purpose

9. Software Demo
Slide No : 9
Software Demo

10. Slide No : 10
Company Level
- Absolute System Driven Production Planning Process
- Improved End To End Visibility And Effective Management of Inventory
More importantly proactive prompting of systems factual data in a standard form, drives each one to act quickly / appropriately.
Plant Level
- Improved Production Target Setting Process for the Month
- Better Capacity Planning / Utilization
- Control Over WIP
- Improved Material Accounting
Marketing
- Improved CFI
- Simplified, Flow of Orders & Schedules
Shop Floor
Manager Level
- Improved Daily Review Over Plan Vs Actual Production
Cell Leader Level
- Improved PDCA for achieving Daily Average Output
- Improved Accountability Over WIP
Quality
- Quick Analysis / Control over Scrap on Daily Basis
Materials
- Improved Planning & Positioning of RM @ Plant
User Level
- User Friendly
- Menu Driven ( No need of transaction code )
- No Wait Time / Follow-up for MIS
Benefits Derived @ all levels

11. Slide No : 11
Thank You