Description
This presentation describes about SAP material management implementation at ONGC.
Material Management at ONGC
About The Company
ONGC (Oil and Natural Gas Corporation Limited)
? Contributes over 84 per cent of Indian’s oil and gas production. ? ASIA’S BEST Oil & Gas company, as per a recent survey conducted by USbased magazine ‘Global Finance’.
? Ranked 402 in 2006 in Fortune 500.
? Owns and operates 11000 kilometers of pipelines in India. ? ONGC Group has 14 properties in 10 foreign countries. ? Producing 685 Million Metric Tonnes of crude and 375 Billion Cubic Meters of Natural Gas, from 115 fields.
Legacy System
ONGC Information Management System – Current
IMMS
SHRAMIK
KUBER
EPINET
INFORMATION
MIS
SCADA
INTRANET
PROJECT MONITORING
IMPETUS
IMMS - Integrated Material Management System
?First attempt at converting all data related to materials management into digital format.
?Parallel existence of separate systems such as SHRAMIK, UFSA, EPINET & IMMS
?Simplicity of the organization earlier resulted in significant time saving and improvement in efficiency
Reasons for Switching over from Legacy system to SAP
? Lack of access to information: ?Needed information may not be available ?Needed information may not be easily accessible ? Technology environment is obsolete:
?Poor integration of systems ?Inability to maintain the current systems ?Lack of capacity of the current systems ?Difficulty in remaining compliant with regulations
? Service delivery is ineffective and inefficient ? Some business processes are out of date
Final Preparation before system Implementation
Shift focus from “getting system ready” to “getting the organization ready to use the system.”
?
Convert Data
?Master Data ?Transactions
? ? ? ?
End-user Training Deploy Front-end Finalize Support Strategy and Prep Help Desk Schedule Interfaces
Materials Management – Business Process Reengineering
An organization fundamentally and radically redesigns its business process to achieve dramatic improvement. It includes from the restructuring of an organization to the redesigning of individual processes ? The paper invoice transmittal process will be eliminated ? The Requisition and Purchase Order processes will be standardized ? Purchase Order transmittal to vendors will be automated where appropriate
ERP Benefits ? Process Improvements: ?eliminate redundant transactions and multiple reconciliations. ?More efficient job rotation process ?More efficient staff and succession planning ? Information Technology: ?Reduced support costs. ?Reduced infrastructure costs.
? Strategic Direction:
?Improved resource allocation ?More flexible organization ?Better future decision making.
ERP – The Good
? Integration = Better operations: ?Processes run more smoothly ?Single view of data ?Business rule enforcement
? Reduced costs:
?Manufacturing ?Inventory carrying costs ? Standardization: ?Data & Processes
Materials Management – New System Benefits
? Improved efficiency for end-users: ?Standardized requisition process ?Reduced reliance on paper processes ? Integrated System (FI, CO, FM, GM, CM, HR) ? All data in one system will reduce the effort required to maintain unnecessary batch processes, interfaces and shadow systems ? Higher Data Quality
? Improved access to document flow (REQ/PO/GR/Invoice/Check)
? Authorized users will be able to view and monitor the status of their requisitions on-line
Materials Management – New System Benefits (contd.)
? Streamlined reporting process: ?Real Time Reports – Drill Down Functionality ?Fewer Printed Reports
? Semi-automated/Automated Process: ?Transmission of Purchasing Documents via EDI/FAX/Email
The need for Information
Vision
An Integrated, Flexible and Standardised Information Systems architecture to position towards fundamental competitive advantage
for Enterprise-wide Transformation.
SAP
Function based Organisation, Multiple stand alone packages, Time lag between market realities and decision making
Current Reality
THREE TIER STRUCTURE
Corporate Data Center TIER -3
Data
Drilling at IDT
ICE
TIER -2
Data Data
EPINET
EPINET
TIER -1
Process Complex
GGS
HAZIRA Plant
Process Complex
GCS CTF Typical On-shore Asset
URAN Trombay
Western Offshore Assets
MM Functionality in SAP
Purchasing Receiving Inventory Management Warehouse Management
SD
Sales & Distribution
FI
Financial Accounting
MM
PP
QM
Materials Mgmt.
CO
Controlling
Production Planning
AM
Quality ManagePM ment Plant Maintenance
LDM
Lifecycle Data Mgmt
Client / Server ABAP/4
CIN
SAP R/3
Fixed Assets Mgmt.
EC
IM PS
Project System
Enterprise Controlling
Investment Mgmt
IS-Oil
Materials Management Overview
Objective - Materials Management
? Integrated system for Material Planning, Procurement, Payment and Inventory Management.
? Maintenance of RFQ and Price comparison of Quotations for all the tenders in the system to facilitate faster purchase decisions. ? Availability of Purchase Order history, Quotation price history, Purchase price history. ? Flexibility to repeat same item many times in the purchase documents. ? Elimination of transactions such as Goods Reservation and Goods Issue in case of materials procured for direct consumption. ? Facility to reference data from one purchasing document to another ensuring greater accuracy in purchase data. ? Efficient standard reporting to carry out analyses for purchasing documents for better procurement planning
Materials Management in ONGC - 1
?Materials Planning & Indenting ?Direct Creation of Indent ?MRP ?Re-Order Level Planning ?Procurement of Materials ?Stores, Spares, Capital Items ?Procurement for Consumption ?Procurement of Services ?Engineering, O &M , Turnkey, Rate Contract etc.
Materials Management in ONGC - 2
?Inventory Management, ?Goods Movements ? Warehouse Management ?Storage Bins, Stock Placement, Stock Removal ?At major stores in each region (e.g. Nhava) ? Quality Management for Incoming Materials
Materials Management Process Flow
PURCHASING BASIC DATA
? Material ? Vendor ? Purchasing info record ? Service Master ? Service specifications ? Purchase requisition
? ?
SD
PP
MRP Direct requisition
Third-party order Requirements Service / spare parts
? RFQ/Quotation
? ?
Purchasing information system
?
Vendor evaluation
Material/service Price comparisons Price comparison list
PM
QM FI
? Purchasing
?
Inspection lot
G/L accounts Cash management and forecast
? Classification
? Conditions
?
Purchase orders Outline agreements
INVENTORY MANAGEMENT
? ? ? ? ?
Goods receipt/issue Transfer posting Quantities and values Physical inventory Storage bins Check and post Price update
WM Warehouse CO PS
Cost center / Budget Project
INVOICE VERIFICATION
?
?
Materials Management Organizational Structure - 1
?Company code
? An Organizational unit for which self contained set of accounts can be drawn up for the purpose of external reporting. ? 19 Company Codes (MUM,JVA,AMD,etc.). AMD,ANK,MHN,BDAcompany codes are relevant for Western Onshore.
?Plant
? An Organizational unit serving to subdivide an enterprise according to production, procurement, maintenance and materials planning aspects. ? Each Asset, Each Basin, Drilling Services, Logging Services, Well Services, Engg Services, Institutes, RO, HO, HQ
Materials Management Organizational Structure - 2
Western Onshore Assets / Basins
Western Onshore Asset Ahamedabad Asset(20A1) Ankleshwar Asset (21A1) Mehsana Asset(22A1) Western Onshore Forward Basin (20B1) Ankleshwar Basin(21B1) Western Onshore Basin,Baroda(23B1)
Services/RO
Institutes
Processing Plants / Customer Loc
Drilling Services(20D1)
Regional Lab(23R2)
GandarPlant (21P1)
Well Services (20W1)
IRS, Ahamedabad (20T1)
Logging Services (20L1)
Engineering Services(20E1) Geophysical Services(23G1)
)
Baroda RO(23R1) HSE,Baroda (23H1)
Materials Management Organizational Structure - 3 ?Storage Locations is location within a Plant where Inventory is Stored. Storage Locations for ONGC are defined at the following levels:
?
Stock Holders (logical division of big stock sheds), Rigs, OSVs, MSVs, active SBMs, Group Gathering Stations, GCS, Central Tank Forms
Materials Management Organizational Structure - 4
? Purchasing Organization
? Responsible for procuring materials or services for one or more plants
? Purchase Organizations in ONGC
? ? ? ?
Materials Purchase Organization: PMAT Services Purchase Organization: PSRV Development Purchase Organization: PDEV Stock Transfer Purchase Organization: PSTO
Materials Management Organizational Structure - 5
? Purchasing Group
? A purchasing group is responsible for procurement of material and services. ?Purchasing Groups in ONGC ? First Digit: Location:
? ?
Ahmedabad – D Baroda – B …
? Second Digit: Department:
? ?
QAD – Q Asset MM – 1 …
? Third Digit: Sub-group within the department:
?
Indigenous stores: 1 ? Indigenous spares: 2 …
Material Indenting
SAP Concepts in Indenting
? Account Assignment: ? Material is sometimes procured not for stock, but for consumption at a Cost Center/ Project etc. The Account Assignment Category defines the type of account assignment. Important Account Assignment categories are:
?
K: Cost Center ? P: Project
?
Q: Project make-to-order …
? Data that needs to be entered in the Account Assignment tab of item details depends on the Account Assignment Category.
Materials Procurement Cycle-General Flow in SAP
`
Material procurement Overview
Receipt of PR
•PaulConnelly •Date
•Transfer
•9,500
•- •User department •- •PM Plant Maintenance •- •PS Project System •RFQ Bid invitation (RFQ) Maintain Quotation
Invoice verification
•PO •Invoice
•? •=
Goods Receipt
Quality Inspection
Price comparison
PO Monitoring
Vendor selection
PO Release Creation of PO
Issue LOI
Indenting Scenarios in ONGC
Project
Maintenance
PR Creation Production
PR Approval Budget Check
Direct
Sent to concerned MM dept for procurement
Emergency
Capital
Others
The Purchasing process
RFQ
PO
Purchase Requisition
RFQ
Outline Agreement
Outline Agreement
PO
PO
Creation of Purchase Requisition
Displaying and Releasing Purchase Requisition
Request For Quotation Screen
The Planning and Indenting process in ONGC
?
Planning and Indenting Process covers planning of material requirement and creation of Indents.
?
?
Planning can be automatic planning through MRP run or manual creation
All the indents generated will have Budget check.
?
?
All the indents will go through release strategy
Any changes in quantity/value in the indent will trigger the release strategy again.
Features of the new Indenting process
? Budget Check will be automatically done through Fund center ? Indents generated from MRP will have single line item only . They will be consolidated later
?
All items of a Purchase Requisition should be created with the same BDP clause code
? The document type has to be entered very carefully, keeping in mind the purpose of the indent.
SAP concepts in Indenting
? Item Category ? Specifies the type of purchase being done for the item. Ex. Subcontracting, Service items
? Procurement of Services & Service Lines ? Services (item category D) are often composed of different Service Lines, detailing the constituent services
? Outline Agreements ? Long term contracts with vendors specifying certain criteria of supply. Release orders are issued against a contract
SAP Concepts in Indenting
? Document Type ? This is used by the system to differentiate between purchase requisitions of different types, arising from different business scenarios.
Indent Type Requisition through MRP Spares Items Manual Stores Items Manual Capital Items Manual Document Type in SAP NB MMNT MPRJ MCAP Business Scenario Requisitions generated through MRP Manual Items for spares items (ZSPR Material Type) Manual Requisitions for Stores items Requisitions for Capital Items Consolidated Requisitions (Generated through consolidation program) Manual Requisition for Rate Contract
Consolidated PRs Rate Contract Manual
MNOP MRCT
Purchase Order
Purchase Orders – some concepts
? Stock material: Material that will go into inventory when it arrives is stock material.
?
Valuation & Split Valuation: Material stock is valuated based on a standard/moving average price. Split valuation allows you to value the same material at different prices, depending on the valuation type (Ex. Imported/ Indigenous)
?
Purchasing for Consumption - Acct Assignment & Acct Assignment Objects: Material is sometimes purchased for consumption at a Cost Center/ Project etc.
Purchase Orders: some Concepts
? Item Category: Specifies the type of purchase being done for the item. Ex. Subcontracting, Service items
?
Procurement of Services & Service Lines: Services are often composed of different Service Lines
?
Outline Agreements: Long term contracts with vendors specifying certain criteria of supply. Release orders are issued against a contract
Purchase Order Processing
PO creation
PO Release by creator
Fund Check
PO
Final Release
of PO by CSA
placement
and Monitoring
as per BDP
Creating Purchase Order
Purchase Order Report
Planned Purchase Order Approval Report
Types of Purchase Orders
? MM Department:
? Standard Indigenous PO: Against tendering & hand quotations ? PO with reference to Indigenous Rate Contract
? Import PO with reference to Import tendering & Rate contract
? PO for Board purchase
?
Indentor
? PO for petty purchases, hand quotations ? Emergency PO – Indigenous ? Emergency PO – Import
? Subcontracting PO
Procurement Of External Services
Procurement of External Services Cycle
Indent - Tender - Contract - Payment
•Determination of r equirements
•Date
•PaulConnelly
•Transfer
•9,500
•- •User department •- •PM Plant Maintenance •- •PS Project System•RFQ •Service specifications are created •. •Vendor•selection
•Payment
•PO •Invoice
•? •=
•Invoice verif •.
•Service acceptance •Service entry Sht •Bid invitation (RFQ)
•PO monitoring • Purch. order
•Maintain and compare quotations
Example : Up-gradation Contract , Revamping
IMPORTANT FIELDS IN PR - 1
1. Header Text : Enter Name of Work 2. Item Category : Should always be „D? for services. 3. Account Assignment Category : „U? or as applicable: If Account Assignment category is inputted (other than „U?) in the PR fund details to be maintained
{ applicable account assignment codes:
„K? = Cost Center, „F? = Production Order or Maintenance Order, „P? = Project/ WBS element, „U? = Unknown } 4. Item short text : Short text for the services.
IMPORTANT FIELDS IN PR -2
5. Delivery date : Expected Date of Completion 6. Plant which is requesting for hiring of services. 7. Purchasing Group : The group responsible for purchasing the services . 8. Requisitioner : Person/Department requesting for services 9. Material / Service Group : The group of the service being indented 10. Tracking No : A field which can be used to search/track PR 11.Contract Number is mandatory while creating PR for Work Order.
IMPORTANT FIELDS IN PR - 3
12. Service Line Items : Service no/Activity no qty and value
13. Delivery Text : Duration for which the contract is required.
(eg. “for a period of 3 years” )
14. If Service no are not used then proper G/L account has to be entered.
15. BDP Clause code in Customer data field – The Service Group should be replicated in BDP Clause.
Stock Transfer
Stock Transfer
? Stock Transfer: ? Stock Transfer are used to remove materials from storage in one storage location and place them in another storage location.
? Stock transfers can occur at three different levels:
?
Stock transfer from Company to Company ? Stock transfer from plant to plant ? From storage location to storage location (in the plant)
Stock Transfer
? One Step Stock Transfer:
? Two Step Stock Transfer:
Two-Step Stock Transfer
Stock Transfer Thru? Inventory Management
Plant to Plant Across Company
Plant to Plant Within Company
Storage Location to Storage Location within Plant
Stock Transfer via STO Invt. Mgt. Route
Stock Transfer via Stock Transport Orders (Inventory Management route – For Split Valuated Material):
Baroda Ahmedabad
Unrestricted use stock
Stock Transport Order
Post Goods Issue w.r.t Stock Transport Order
Stock in Transit
Goods Receipt
Unrestricted use stock
J1IL
Stock Transport Order – Complete Process
?Display Stock Overview ?Create Stock Transport Order ?Inform the Stockholder / Store in-charge to deliver the material ?Print Stock Transport Order, if required ?Get approval of concerned officer from supplying plant on printout, if required
Note: STO is required to move goods to offshore or move goods from offshore location or move materials from one plant to another plant. STO is NOT required to move goods from store to offices like Vasudhara Bhavan.
Goods Receipt Process
Goods Receipt:
? Goods Receipt: ? A goods receipt (GR) is a goods movement with which the receipt of goods from a vendor or from production is posted. A goods receipt leads to an increase in warehouse stock. ?101 – GR for Purchase order
Goods Receipt Process
MATERIAL RECEIPT FROM VENDOR AGAINST PurchaseOrder:
Direct from Vendor Through C&F
OTHER RECEIPTS:
Return from Users Adjustment of Surplus Stock
DISCREPANCY HANDLING:
?Discrepancy due to Short supply ?Discrepancy due to Breakage / Damage ?Discrepancy due to Rejection at destination
Goods Receipt from Vendor
Purchase Order •Stock items
Generation of QCC if not done at source
INWARD ENTRY
Vendor
Goods receipt
A Material
RECEIPT SECTION GRV Preparation
Stock
GRV Taken on Charge STOCK HOLDER
Goods Receipt from Vendor thru’ C&F
Purchase Order
•Stock Items
C&F Section
Vendor
INWARD ENTRY
Generation of QCC if not at source
A Material
Stock
Goods receipt
GRV Preparation
RECEIPT SECTION STOCK HOLDER
Inventory Management
Inventory management comprises of eight processes: ?Goods Receipt ?Goods Issue ?Stock Reservation
?Stock Transfer
?Material Requirement Planning ?ABC Classification ?Physical Inventory ?Replenishment Area Management (expensed unofficial inventories)
Inventory Report
MRP Report
Benefits – Inventory Management
? Improved flexibility and growth with new bar coding technology ? Real-time updating of transaction ? Integration with Materials Management and General Ledger ? SAP bar code communication technology forms part of the SAP system ? Place material orders directly via a front end
? Storage Location configured for separate stock planning (individual MRP areas)
? MRP can adjust re-order levels (par?s) based on actual usage
Future of ERP ???
? Synchronization – Product codes of different types need to be synchronized by probably using bar coding system
? Internet – continue to help organizations integrate data and process across functional departments
? Interface – customizable employee browsers ? Wireless technology – support a mobile workforce ? EDI Transmission of Purchasing Documents (Campus)
66
BIBLIOGRAPHY
? Mr. ? Mr. ? Mr.
N.C.Pandey, DGM, Drilling, ONGC Mumbai P.C. Agarwal, DGM (E&T), ONGC Mehsana
S.R.Pandey, Director, Gujarat Electricity Regulatory Commission document of ONGC
? Tender
? http://www.ongcindia.com ? http://indscan.weblogs.us/archives/189 ? http://www.sensorsmag.com/articles/0999/105/main.shtml ? http://www.foxboro.com/us/eng/newsandevents/news/news/
020806SCADAworkshop.htm
? http://www.offshorecoms.com/about.php ? http://science.howstuffworks.com
Thank You
doc_576021519.pptx
This presentation describes about SAP material management implementation at ONGC.
Material Management at ONGC
About The Company
ONGC (Oil and Natural Gas Corporation Limited)
? Contributes over 84 per cent of Indian’s oil and gas production. ? ASIA’S BEST Oil & Gas company, as per a recent survey conducted by USbased magazine ‘Global Finance’.
? Ranked 402 in 2006 in Fortune 500.
? Owns and operates 11000 kilometers of pipelines in India. ? ONGC Group has 14 properties in 10 foreign countries. ? Producing 685 Million Metric Tonnes of crude and 375 Billion Cubic Meters of Natural Gas, from 115 fields.
Legacy System
ONGC Information Management System – Current
IMMS
SHRAMIK
KUBER
EPINET
INFORMATION
MIS
SCADA
INTRANET
PROJECT MONITORING
IMPETUS
IMMS - Integrated Material Management System
?First attempt at converting all data related to materials management into digital format.
?Parallel existence of separate systems such as SHRAMIK, UFSA, EPINET & IMMS
?Simplicity of the organization earlier resulted in significant time saving and improvement in efficiency
Reasons for Switching over from Legacy system to SAP
? Lack of access to information: ?Needed information may not be available ?Needed information may not be easily accessible ? Technology environment is obsolete:
?Poor integration of systems ?Inability to maintain the current systems ?Lack of capacity of the current systems ?Difficulty in remaining compliant with regulations
? Service delivery is ineffective and inefficient ? Some business processes are out of date
Final Preparation before system Implementation
Shift focus from “getting system ready” to “getting the organization ready to use the system.”
?
Convert Data
?Master Data ?Transactions
? ? ? ?
End-user Training Deploy Front-end Finalize Support Strategy and Prep Help Desk Schedule Interfaces
Materials Management – Business Process Reengineering
An organization fundamentally and radically redesigns its business process to achieve dramatic improvement. It includes from the restructuring of an organization to the redesigning of individual processes ? The paper invoice transmittal process will be eliminated ? The Requisition and Purchase Order processes will be standardized ? Purchase Order transmittal to vendors will be automated where appropriate
ERP Benefits ? Process Improvements: ?eliminate redundant transactions and multiple reconciliations. ?More efficient job rotation process ?More efficient staff and succession planning ? Information Technology: ?Reduced support costs. ?Reduced infrastructure costs.
? Strategic Direction:
?Improved resource allocation ?More flexible organization ?Better future decision making.
ERP – The Good
? Integration = Better operations: ?Processes run more smoothly ?Single view of data ?Business rule enforcement
? Reduced costs:
?Manufacturing ?Inventory carrying costs ? Standardization: ?Data & Processes
Materials Management – New System Benefits
? Improved efficiency for end-users: ?Standardized requisition process ?Reduced reliance on paper processes ? Integrated System (FI, CO, FM, GM, CM, HR) ? All data in one system will reduce the effort required to maintain unnecessary batch processes, interfaces and shadow systems ? Higher Data Quality
? Improved access to document flow (REQ/PO/GR/Invoice/Check)
? Authorized users will be able to view and monitor the status of their requisitions on-line
Materials Management – New System Benefits (contd.)
? Streamlined reporting process: ?Real Time Reports – Drill Down Functionality ?Fewer Printed Reports
? Semi-automated/Automated Process: ?Transmission of Purchasing Documents via EDI/FAX/Email
The need for Information
Vision
An Integrated, Flexible and Standardised Information Systems architecture to position towards fundamental competitive advantage
for Enterprise-wide Transformation.
SAP
Function based Organisation, Multiple stand alone packages, Time lag between market realities and decision making
Current Reality
THREE TIER STRUCTURE
Corporate Data Center TIER -3
Data
Drilling at IDT
ICE
TIER -2
Data Data
EPINET
EPINET
TIER -1
Process Complex
GGS
HAZIRA Plant
Process Complex
GCS CTF Typical On-shore Asset
URAN Trombay
Western Offshore Assets
MM Functionality in SAP
Purchasing Receiving Inventory Management Warehouse Management
SD
Sales & Distribution
FI
Financial Accounting
MM
PP
QM
Materials Mgmt.
CO
Controlling
Production Planning
AM
Quality ManagePM ment Plant Maintenance
LDM
Lifecycle Data Mgmt
Client / Server ABAP/4
CIN
SAP R/3
Fixed Assets Mgmt.
EC
IM PS
Project System
Enterprise Controlling
Investment Mgmt
IS-Oil
Materials Management Overview
Objective - Materials Management
? Integrated system for Material Planning, Procurement, Payment and Inventory Management.
? Maintenance of RFQ and Price comparison of Quotations for all the tenders in the system to facilitate faster purchase decisions. ? Availability of Purchase Order history, Quotation price history, Purchase price history. ? Flexibility to repeat same item many times in the purchase documents. ? Elimination of transactions such as Goods Reservation and Goods Issue in case of materials procured for direct consumption. ? Facility to reference data from one purchasing document to another ensuring greater accuracy in purchase data. ? Efficient standard reporting to carry out analyses for purchasing documents for better procurement planning
Materials Management in ONGC - 1
?Materials Planning & Indenting ?Direct Creation of Indent ?MRP ?Re-Order Level Planning ?Procurement of Materials ?Stores, Spares, Capital Items ?Procurement for Consumption ?Procurement of Services ?Engineering, O &M , Turnkey, Rate Contract etc.
Materials Management in ONGC - 2
?Inventory Management, ?Goods Movements ? Warehouse Management ?Storage Bins, Stock Placement, Stock Removal ?At major stores in each region (e.g. Nhava) ? Quality Management for Incoming Materials
Materials Management Process Flow
PURCHASING BASIC DATA
? Material ? Vendor ? Purchasing info record ? Service Master ? Service specifications ? Purchase requisition
? ?
SD
PP
MRP Direct requisition
Third-party order Requirements Service / spare parts
? RFQ/Quotation
? ?
Purchasing information system
?
Vendor evaluation
Material/service Price comparisons Price comparison list
PM
QM FI
? Purchasing
?
Inspection lot
G/L accounts Cash management and forecast
? Classification
? Conditions
?
Purchase orders Outline agreements
INVENTORY MANAGEMENT
? ? ? ? ?
Goods receipt/issue Transfer posting Quantities and values Physical inventory Storage bins Check and post Price update
WM Warehouse CO PS
Cost center / Budget Project
INVOICE VERIFICATION
?
?
Materials Management Organizational Structure - 1
?Company code
? An Organizational unit for which self contained set of accounts can be drawn up for the purpose of external reporting. ? 19 Company Codes (MUM,JVA,AMD,etc.). AMD,ANK,MHN,BDAcompany codes are relevant for Western Onshore.
?Plant
? An Organizational unit serving to subdivide an enterprise according to production, procurement, maintenance and materials planning aspects. ? Each Asset, Each Basin, Drilling Services, Logging Services, Well Services, Engg Services, Institutes, RO, HO, HQ
Materials Management Organizational Structure - 2
Western Onshore Assets / Basins
Western Onshore Asset Ahamedabad Asset(20A1) Ankleshwar Asset (21A1) Mehsana Asset(22A1) Western Onshore Forward Basin (20B1) Ankleshwar Basin(21B1) Western Onshore Basin,Baroda(23B1)
Services/RO
Institutes
Processing Plants / Customer Loc
Drilling Services(20D1)
Regional Lab(23R2)
GandarPlant (21P1)
Well Services (20W1)
IRS, Ahamedabad (20T1)
Logging Services (20L1)
Engineering Services(20E1) Geophysical Services(23G1)
)
Baroda RO(23R1) HSE,Baroda (23H1)
Materials Management Organizational Structure - 3 ?Storage Locations is location within a Plant where Inventory is Stored. Storage Locations for ONGC are defined at the following levels:
?
Stock Holders (logical division of big stock sheds), Rigs, OSVs, MSVs, active SBMs, Group Gathering Stations, GCS, Central Tank Forms
Materials Management Organizational Structure - 4
? Purchasing Organization
? Responsible for procuring materials or services for one or more plants
? Purchase Organizations in ONGC
? ? ? ?
Materials Purchase Organization: PMAT Services Purchase Organization: PSRV Development Purchase Organization: PDEV Stock Transfer Purchase Organization: PSTO
Materials Management Organizational Structure - 5
? Purchasing Group
? A purchasing group is responsible for procurement of material and services. ?Purchasing Groups in ONGC ? First Digit: Location:
? ?
Ahmedabad – D Baroda – B …
? Second Digit: Department:
? ?
QAD – Q Asset MM – 1 …
? Third Digit: Sub-group within the department:
?
Indigenous stores: 1 ? Indigenous spares: 2 …
Material Indenting
SAP Concepts in Indenting
? Account Assignment: ? Material is sometimes procured not for stock, but for consumption at a Cost Center/ Project etc. The Account Assignment Category defines the type of account assignment. Important Account Assignment categories are:
?
K: Cost Center ? P: Project
?
Q: Project make-to-order …
? Data that needs to be entered in the Account Assignment tab of item details depends on the Account Assignment Category.
Materials Procurement Cycle-General Flow in SAP
`
Material procurement Overview
Receipt of PR
•PaulConnelly •Date
•Transfer
•9,500
•- •User department •- •PM Plant Maintenance •- •PS Project System •RFQ Bid invitation (RFQ) Maintain Quotation
Invoice verification
•PO •Invoice
•? •=
Goods Receipt
Quality Inspection
Price comparison
PO Monitoring
Vendor selection
PO Release Creation of PO
Issue LOI
Indenting Scenarios in ONGC
Project
Maintenance
PR Creation Production
PR Approval Budget Check
Direct
Sent to concerned MM dept for procurement
Emergency
Capital
Others
The Purchasing process
RFQ
PO
Purchase Requisition
RFQ
Outline Agreement
Outline Agreement
PO
PO
Creation of Purchase Requisition
Displaying and Releasing Purchase Requisition
Request For Quotation Screen
The Planning and Indenting process in ONGC
?
Planning and Indenting Process covers planning of material requirement and creation of Indents.
?
?
Planning can be automatic planning through MRP run or manual creation
All the indents generated will have Budget check.
?
?
All the indents will go through release strategy
Any changes in quantity/value in the indent will trigger the release strategy again.
Features of the new Indenting process
? Budget Check will be automatically done through Fund center ? Indents generated from MRP will have single line item only . They will be consolidated later
?
All items of a Purchase Requisition should be created with the same BDP clause code
? The document type has to be entered very carefully, keeping in mind the purpose of the indent.
SAP concepts in Indenting
? Item Category ? Specifies the type of purchase being done for the item. Ex. Subcontracting, Service items
? Procurement of Services & Service Lines ? Services (item category D) are often composed of different Service Lines, detailing the constituent services
? Outline Agreements ? Long term contracts with vendors specifying certain criteria of supply. Release orders are issued against a contract
SAP Concepts in Indenting
? Document Type ? This is used by the system to differentiate between purchase requisitions of different types, arising from different business scenarios.
Indent Type Requisition through MRP Spares Items Manual Stores Items Manual Capital Items Manual Document Type in SAP NB MMNT MPRJ MCAP Business Scenario Requisitions generated through MRP Manual Items for spares items (ZSPR Material Type) Manual Requisitions for Stores items Requisitions for Capital Items Consolidated Requisitions (Generated through consolidation program) Manual Requisition for Rate Contract
Consolidated PRs Rate Contract Manual
MNOP MRCT
Purchase Order
Purchase Orders – some concepts
? Stock material: Material that will go into inventory when it arrives is stock material.
?
Valuation & Split Valuation: Material stock is valuated based on a standard/moving average price. Split valuation allows you to value the same material at different prices, depending on the valuation type (Ex. Imported/ Indigenous)
?
Purchasing for Consumption - Acct Assignment & Acct Assignment Objects: Material is sometimes purchased for consumption at a Cost Center/ Project etc.
Purchase Orders: some Concepts
? Item Category: Specifies the type of purchase being done for the item. Ex. Subcontracting, Service items
?
Procurement of Services & Service Lines: Services are often composed of different Service Lines
?
Outline Agreements: Long term contracts with vendors specifying certain criteria of supply. Release orders are issued against a contract
Purchase Order Processing
PO creation
PO Release by creator
Fund Check
PO
Final Release
of PO by CSA
placement
and Monitoring
as per BDP
Creating Purchase Order
Purchase Order Report
Planned Purchase Order Approval Report
Types of Purchase Orders
? MM Department:
? Standard Indigenous PO: Against tendering & hand quotations ? PO with reference to Indigenous Rate Contract
? Import PO with reference to Import tendering & Rate contract
? PO for Board purchase
?
Indentor
? PO for petty purchases, hand quotations ? Emergency PO – Indigenous ? Emergency PO – Import
? Subcontracting PO
Procurement Of External Services
Procurement of External Services Cycle
Indent - Tender - Contract - Payment
•Determination of r equirements
•Date
•PaulConnelly
•Transfer
•9,500
•- •User department •- •PM Plant Maintenance •- •PS Project System•RFQ •Service specifications are created •. •Vendor•selection
•Payment
•PO •Invoice
•? •=
•Invoice verif •.
•Service acceptance •Service entry Sht •Bid invitation (RFQ)
•PO monitoring • Purch. order
•Maintain and compare quotations
Example : Up-gradation Contract , Revamping
IMPORTANT FIELDS IN PR - 1
1. Header Text : Enter Name of Work 2. Item Category : Should always be „D? for services. 3. Account Assignment Category : „U? or as applicable: If Account Assignment category is inputted (other than „U?) in the PR fund details to be maintained
{ applicable account assignment codes:
„K? = Cost Center, „F? = Production Order or Maintenance Order, „P? = Project/ WBS element, „U? = Unknown } 4. Item short text : Short text for the services.
IMPORTANT FIELDS IN PR -2
5. Delivery date : Expected Date of Completion 6. Plant which is requesting for hiring of services. 7. Purchasing Group : The group responsible for purchasing the services . 8. Requisitioner : Person/Department requesting for services 9. Material / Service Group : The group of the service being indented 10. Tracking No : A field which can be used to search/track PR 11.Contract Number is mandatory while creating PR for Work Order.
IMPORTANT FIELDS IN PR - 3
12. Service Line Items : Service no/Activity no qty and value
13. Delivery Text : Duration for which the contract is required.
(eg. “for a period of 3 years” )
14. If Service no are not used then proper G/L account has to be entered.
15. BDP Clause code in Customer data field – The Service Group should be replicated in BDP Clause.
Stock Transfer
Stock Transfer
? Stock Transfer: ? Stock Transfer are used to remove materials from storage in one storage location and place them in another storage location.
? Stock transfers can occur at three different levels:
?
Stock transfer from Company to Company ? Stock transfer from plant to plant ? From storage location to storage location (in the plant)
Stock Transfer
? One Step Stock Transfer:
? Two Step Stock Transfer:
Two-Step Stock Transfer
Stock Transfer Thru? Inventory Management
Plant to Plant Across Company
Plant to Plant Within Company
Storage Location to Storage Location within Plant
Stock Transfer via STO Invt. Mgt. Route
Stock Transfer via Stock Transport Orders (Inventory Management route – For Split Valuated Material):
Baroda Ahmedabad
Unrestricted use stock
Stock Transport Order
Post Goods Issue w.r.t Stock Transport Order
Stock in Transit
Goods Receipt
Unrestricted use stock
J1IL
Stock Transport Order – Complete Process
?Display Stock Overview ?Create Stock Transport Order ?Inform the Stockholder / Store in-charge to deliver the material ?Print Stock Transport Order, if required ?Get approval of concerned officer from supplying plant on printout, if required
Note: STO is required to move goods to offshore or move goods from offshore location or move materials from one plant to another plant. STO is NOT required to move goods from store to offices like Vasudhara Bhavan.
Goods Receipt Process
Goods Receipt:
? Goods Receipt: ? A goods receipt (GR) is a goods movement with which the receipt of goods from a vendor or from production is posted. A goods receipt leads to an increase in warehouse stock. ?101 – GR for Purchase order
Goods Receipt Process
MATERIAL RECEIPT FROM VENDOR AGAINST PurchaseOrder:
Direct from Vendor Through C&F
OTHER RECEIPTS:
Return from Users Adjustment of Surplus Stock
DISCREPANCY HANDLING:
?Discrepancy due to Short supply ?Discrepancy due to Breakage / Damage ?Discrepancy due to Rejection at destination
Goods Receipt from Vendor
Purchase Order •Stock items
Generation of QCC if not done at source
INWARD ENTRY
Vendor
Goods receipt
A Material
RECEIPT SECTION GRV Preparation
Stock
GRV Taken on Charge STOCK HOLDER
Goods Receipt from Vendor thru’ C&F
Purchase Order
•Stock Items
C&F Section
Vendor
INWARD ENTRY
Generation of QCC if not at source
A Material
Stock
Goods receipt
GRV Preparation
RECEIPT SECTION STOCK HOLDER
Inventory Management
Inventory management comprises of eight processes: ?Goods Receipt ?Goods Issue ?Stock Reservation
?Stock Transfer
?Material Requirement Planning ?ABC Classification ?Physical Inventory ?Replenishment Area Management (expensed unofficial inventories)
Inventory Report
MRP Report
Benefits – Inventory Management
? Improved flexibility and growth with new bar coding technology ? Real-time updating of transaction ? Integration with Materials Management and General Ledger ? SAP bar code communication technology forms part of the SAP system ? Place material orders directly via a front end
? Storage Location configured for separate stock planning (individual MRP areas)
? MRP can adjust re-order levels (par?s) based on actual usage
Future of ERP ???
? Synchronization – Product codes of different types need to be synchronized by probably using bar coding system
? Internet – continue to help organizations integrate data and process across functional departments
? Interface – customizable employee browsers ? Wireless technology – support a mobile workforce ? EDI Transmission of Purchasing Documents (Campus)
66
BIBLIOGRAPHY
? Mr. ? Mr. ? Mr.
N.C.Pandey, DGM, Drilling, ONGC Mumbai P.C. Agarwal, DGM (E&T), ONGC Mehsana
S.R.Pandey, Director, Gujarat Electricity Regulatory Commission document of ONGC
? Tender
? http://www.ongcindia.com ? http://indscan.weblogs.us/archives/189 ? http://www.sensorsmag.com/articles/0999/105/main.shtml ? http://www.foxboro.com/us/eng/newsandevents/news/news/
020806SCADAworkshop.htm
? http://www.offshorecoms.com/about.php ? http://science.howstuffworks.com
Thank You
doc_576021519.pptx