Upload
aerona
View
39
Download
2
Embed Size (px)
DESCRIPTION
Implementation of an R/2-R/3-coexistence scenario at a chemical fibers producer with six plants in three countries. B. Boes LindhEnka GmbH Wuppertal Dr. Reinhardt KochGesellschaft für Rationalisierung Aachen Presentation given at the SAP-R/2-infoday at Wiesloch April 13th 1999. - PowerPoint PPT Presentation
Citation preview
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 1
ENKA-Competence in Viscose
Implementation of an R/2-R/3-coexistence scenario
at a chemical fibers producer with six plants in
three countries
B. Boes Lindh Enka GmbH Wuppertal
Dr. Reinhardt Koch Gesellschaft für Rationalisierung Aachen
Presentation given at the SAP-R/2-infoday at Wiesloch April 13th 1999
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 2
ENKA-Competence in Viscose
Target:RF, RV, RK-E, FI, FI-AA, MM, PP, PM, CO as well as
non-SAP-systems for human resources and consolidation
Implementation of an R/2-R/3-coexistence scenario at a chemical fibers producer with six plants in three countries
Starting Position:RF, RA, RV, RK-E and non-SAP-systems for pur-
chasing, inventory control, controlling, calculation, maintenance, human resorces, consolidation
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 3
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 4
ENKA-Competence in Viscose
Company and products (1)
ENKA group ENKA GmbH & Co. KG GermanyENKA bv. NetherlandsViskotex Sp.z.o.o. Poland
Head quarters and central sales: WuppertalSales offices in Mailand, Lyon, Barcelona, Horn (CH)Turnover 1997: 513 Mill. DMMarket share: 50% (Western Europe) 12% (worldwide)Plants:Ede NL 12.500 jatoKelsterbach D 12.000 jatoObernburg D 8.000 jatoElsterberg D 5.000 jatoOberbruch D 4500 jatoGorzow PL 12.000 jato (textile processing)
ENKA-Competence in Viscose
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 5
ENKA-Competence in Viscose
Company and products (1)
ENKA is the world's biggest producer of viscose-filament denierand mixtured yarn (PA/PE)Denier interval from 67 to 660 dtex (=gramsper 10 km)
Warp beam production
Delivery types Cones and X-wound bobbins 65% of shipments
Warp beams 35% of shipments
Spinning process Spool
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 6
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 7
ENKA-Competence in Viscose
Starting situation of IT-systems and processes (1)
RF/RA Accounting and Asset ManagementRV Sales and DistributionRM Finished Goods InventoryRK-E Profitability AccountingPAISY Human ResourcesHyperion Consolidation
Sta
nd
ard
so
ftw
are
PLINS Product Calculation and Production AccountgPLACOS Cost Recording and Cost Center AccountingLEE Project and Investition ControllingPURSTIC Purchasing
IBM
-MV
SM
VS
Se
lf d
eve
lop
ed
SW
NEC Inventory Control (raw mat./supplies per plant)INSIDE Maintenance orders (per plant)NLV Administration of warp beam productionAKZOInst Maintenance messages
DP
PX
PC
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 8
ENKA-Competence in Viscose
Starting situation of IT-systems and processes (2)
RF
RK-ERVRM-MAT
RA
Custo-mers
Supp-liers
PURSTICPurchas.
LEEProjects
HyperionConsolid.banks
PAISYHuman res.
PLACOSActual costs
NECInventory
INSIDEMaintenance
NLVBeam prod.
ES/9000 per plant!
AKZOInstMessages
PLINSCalculation
PLINSPC-part
MVS-Host based
ES/9000-based
PC-based
To be re-placed by R/3
To be re-placed by R/3
SAP R/2 und Batch-Systems
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 9
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 10
ENKA-Competence in Viscose
inclusive Releasechange3.0f to 3.1I
2000
The way to R/3 in two steps
Two step procedureStep 1 Migration of non-SAP-systems
to FI as the leading accounting system in five phases!
Plant Oberbruch and head quart.
1998 1999
Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez Jan Feb Mrz
Plant Kelsterbach
Plant Obernburg
Plant Elsterberg
Plant Ede NL
today!
RV RK-E Migration
Step 2: Lead time yet to be determined!
Step 1: 20 months lead time
All plants in old systems Plant Oberbruch and head quart. in coexistence phasePlant Kelsterbach in coexistence phasePlant Obernburg in coexistence phase
Plant Elsterberg in coexistencePlant Ede in coexistence
Step 2 Migration RV, RM, RK-E to R/3
En
kain
R/3!
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 11
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 12
ENKA-Competence in Viscose
Coexistence R/2 with R/3 during step 1 (1)
Principals of the R/2-R/3-Coexistence strategie
No changes on the R/2-side because
- Different companies of the concern are in the same client and use the same R/2-modules and processes. Each change needs numerous negotiated agreements.
- The dynamics of the business processes dont need an online- coupling between R/2 and R/3.
- The coexistence phase is to be replaced after a time period by the migration from RV and RK-E to SD and CO-PA. The project costs therefore have to be minimized.
- R/3-FI should be the leading accounting system of the ENKA company.
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 13
ENKA-Competence in Viscose
Coexistence R/2 with R/3 during step 1 (2)
Inventory accounting finished goods R/2 und R/3Completion confirmations finished goods R/2 und R/3Customer orders for warp beams R/2 und R/3 (als PP-Auftrag)Customers R/2 und R/3
Profitability analysis R/2Sales R/2
Accounts receivable R/3Suppliers and accounts payable R/3Assets Accounting R/3Inventory accounting raw materials and supplies R/3Inventory accounting semi finished goods R/3Cost accounting R/3Product calculation R/3Project- and investition cost accounting R/3Maintenance management R/3Production orders (half- and finished goods) R/3Completion confirmations half finished goods R/3
What does R/2? What does R/3?
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 14
ENKA-Competence in Viscose
banks
HyperionConsolid.
CustomersRF
RK-ERVRM-MAT
FI
PM CO MM PP FI-AA
SuppliersCustomers
InhouseBanking
InhouseHedging
PAISYHuman res.
AKZOInst
Bau
mau
fträ
ge
Bau
mrü
ckm
eld
un
g
Alle
RM
-Bel
ege
Mat
eria
lstä
mm
efü
r F
F‘e
Co
stp
rice
fü
r F
F‘e
(fix
+va
riab
el)
RV
,- D
X-
un
d A
B-B
eleg
e
Geg
enb
uch
un
g
FI-
Sal
den
fü
rR
F-S
ach
kon
ten
Wäh
run
gsk
urs
e
Overdue-list
Interfaces between SAP R/2 und SAP R/3
Coexistence R/2 with R/3 during step 1 (3)
SF
Kre
dit
kon
tro
lle
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 15
ENKA-Competence in Viscose
Semi finished goods and transactions: only in R/3!
Raw- mat.
Semi-f. goods
Semi-f. goods
Fin.-goods
Coexistence R/2 with R/3 on the materials level
CostCntr
CostCntr
CostCntr
MMMM
COCO
PPPP
PP-order PP-order PP-order
WA WE
LART
Shop floorCompletion
confirmationCompletionconfirmation
RM-MATRM-MAT
Weighting
Spoolsin colli
Delivery
Retoureback to
production
RM-SST
all RM-Documents
bac
k to
pro
du
ctio
n
DeliveryRetoure
Weighting
WE
Finished goods and finished goods transactions: in R/2 and R/3!Finished goods transactions: first in R/2 and then in R/3!
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 16
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 17
ENKA-Competence in Viscose
Phases of productive usage during step 1 (1)
- The shift to R/3 happens "one location at a time" and "one after the other"
nn
21
SA
P R
/2
TR
21
49
LE
21
53
WV
21
03
WK
21
20
WK
21
14
WK
21
BA
LO
AU
61
WM
21
76
WE
21
13
FE
54
40
FE
54
TR
FE
54
51
LA
54
SA
P R
/3
TR
21
49
LE
21
53
WV
21
BA
LO
AU
RV-Documents RM-Documents
R/2-R/3-Coexistence
after phase 1
- Each location has one or more business areas (BA). One BA belongs either to a group of productive or non-productive cost departments.
- The business area TR is not dedicated to a location. It's only for sales. TR will shift to R/3 in the first phase.- Productive business areas coexist in R/2 und R/3. Non productive business areas are only in R/3. Balances are transfered from FI to RF every month to BAnn.
Consolidation
Transfer of balances
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 18
ENKA-Competence in Viscose
Phases of productive usage during step 1 (2)
nn
21
SA
P R
/3
TR
LE
21
49
LE
21
53
WV
21
BA
LO
AU
RV-Documents RM-Documents
- The R/3-balances will be transfered once per month to R/2 for the profitability analysis and for the consolidation.
03
WK
21
20
WK
21
14
WK
21
61
WM
21
RM-Documents
- Each shift of a location from R/2 to R/3 will let behind an unused business area in R/2 for the site-areas!
- After the shift of the last location (phase 5) RF will only have the postings of RV and RK-E and the business area nn for the transfer of balances.
SA
P R
/2
TR
LE
21
49
LE
21
53
WV
21
03
WK
21
20
WK
21
14
WK
21
BA
LO
AU
61
WM
21
76
WE
21
13
FE
54
40
FE
54
TR
FE
54
51
LA
54
Consolidation
Transfer ofbalances
- Phase 2/3: Two more locations with four business areas are productive
R/2-R/3-Coexistence
after phase 2 and 3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 19
ENKA-Competence in Viscose
Phases of productive usage during step 1 (3)
nn
21
SA
P R
/3
TR
LE
21
49
LE
21
53
WV
21
GB
LO
BK
RV-Documents RM-Documts
R/2-R/3-Coexistence after phase 5
03
WK
21
20
WK
21
14
WK
21
61
WM
21
RM-Documts
SA
P R
/2
TR
LE
21
49
LE
21
53
WV
21
03
WK
21
20
WK
21
14
WK
21
GB
LO
BK
61
WM
21
76
WE
21
13
FE
54
40
FE
54
TR
FE
54
51
LA
54
Consolidation
Transfer ofbalances BK21
13
FE
54
40
FE
54
TR
FE
54
51
LA
54
nn
54
Transfer ofbalances BK54
RV-DocumentsRM-Documts
76
WE
21
RM-Doc.RM-Doc.RM-Doc.
Final situation of coexistence at the end of step 1
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 20
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 21
ENKA-Competence in Viscose
Modeling of the fibers production with PP and CO(1)
Characteristics of the fibers production:
Specialities Product variance by fibers parameters(batches), By products caused by yarn tears(spools below standard weight) and residues, Individual colli administration withfinished goods, Completion confirmationsonly manual (expensive), for half finishedgoods only by counting (no weightingpossible)
Number of prod. steps Spools: 1 Warp beams: 2
Disposition of product. Spools: stock drivenWarp beams: make to order
Material flow chemical part continouslytextile part discontinously
Number of raw materials low
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 22
ENKA-Competence in Viscose
Modeling of the fibers production with PP and CO (2)
Division of production flow in steps with corresponding semi-manufactured goods as base for completion confirmations and
monthly accounting of semi-finished goods
FIFI
routing 1 routing 2 routing 3
Raw-mat.
Semi-f. goods
Semi-f. goods
Fin.-goods
D CD C D C
HF1
HS1 HS2R
HF2
HS3 HS4HF1
FF
HS5 HS6HF2
MMMM
COCO
PPPP
Counting 1 Counting 2 Weighting
D C
new! new!
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 23
ENKA-Competence in Viscose
Modeling of the fibers production with PP and CO (3)
- Calculation of standard price per production step (cost per step)
- Spools of all weight figures for a specified fiber belong to the same material number!
- Inventory measuring unit is kg, but completion confirmation measurung unit is kg or number of spools with full weight or number of spools with smaller weight
- Relation of material number to PP-order - fibers on spools 1:1 „one PP-order per year“ - fibers on warp beams 1:1 plus administration of the
produced batch per RV-orderand RV-position
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 24
ENKA-Competence in Viscose
Modeling of the fibers production with PP and CO (4)
- No PP-planning, ex-post-usage of PP-orders for completion confirmations- Completion confirmations on PP-order for spools automatically coupled with stock receipt- Retrograde posting for raw materials and semi- finished goods- Residues as by products: - no R/3-residues calculation, but residues sales as negative costs added to the main product - residues to finished good stocks with costprice ca. 0 - PP-order only for making completion confirmation of residues to finished goods stock
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 25
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 26
ENKA-Competence in Viscose
R/3-high availability in an R/3-server park
Real time data replication via LAN
MIMIX-SW makes back up for three R/3 productive systems to one backup-system
Hot standby by switching the clients to the backup machine
AS/400 Mod. 53SProduktionFa. HIMA
AS/400 Mod. 53SProduktion
Fa. IPO
AS/400 Mod. S30ProduktionFa. ENKA
Token Ring
MIMIX-SW MIMIX-SW MIMIX-SW
MIMIX-SW
AS/400 Mod. S20Test- und Backupfür ENKA, HIMA,
IPOBS V4R1
Backup-machine also supports the three R/3-test systems
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 27
ENKA-Competence in Viscose
Contents:
- Company and products
- Starting situation of IT-systems and processes
- The way to R/3 in two steps
- Coexistence R/2 with R/3 during step 1
- Phases of productive usage during step 1
- Modeling of the fibers production with PP and CO
- R/3-high availability in an R/3-server park
- Experiences after the first locations shift to R/3
R/2- R/3- Coexistence in chemical fibers production
rk_r299e.ppt / 28
ENKA-Competence in Viscose
Experiences after the first locations shift to R/3
- Modeling all real material flows by material numbers and PP-orders means exhaustive administrative work --> Pragmatic R/3-modeling of the fiber production necessary- The potential of the PP-orders in the fibers production still has to be explored- The integration of PP, MM und CO demands for the integration of production and controlling departmnts. - Transition from batch oriented monthly controlling to online-functions in R/3 needs time.Summary: The concept for R/2-R/3-coexistence is operable and works well. It guarantees the parallel living in both SAP-worlds and a smooth path to R/3!