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Implementation of an R/2-R/3-coexistence scenario at a chemical fibers producer with six plants in

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.

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Implementation of an R/2-R/3-coexistence scenario at a chemical fibers producer with six plants in

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  1. 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

  2. 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

  3. 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

  4. Company and products (1) ENKA group ENKA GmbH & Co. KG Germany ENKA bv. Netherlands Viskotex Sp.z.o.o. PolandHead 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 jato Oberbruch D 4500 jatoGorzow PL 12.000 jato (textile processing) ENKA-Competence in Viscose

  5. Company and products (1) Spool Spinning process Warp beam production 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) Delivery types Cones and X-wound bobbins 65% of shipments Warp beams 35% of shipments

  6. 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

  7. DPPX PC Starting situation of IT-systems and processes (1) RF/RA Accounting and Asset Management RV Sales and Distribution RM Finished Goods Inventory RK-E Profitability Accounting PAISY Human Resources Hyperion Consolidation Standardsoftware IBM-MVS PLINS Product Calculation and Production AccountgPLACOS Cost Recording and Cost Center Accounting LEE Project and Investition Controlling PURSTIC Purchasing MVS Self developed SW NEC Inventory Control (raw mat./supplies per plant) INSIDE Maintenance orders (per plant) NLV Administration of warp beam production AKZOInst Maintenance messages

  8. RF Supp- liers RV RK-E RM- MAT RA ES/9000 per plant! NEC Inventory NLV Beam prod. INSIDE Maintenance Custo- mers Starting situation of IT-systems and processes (2) Hyperion Consolid. banks PURSTIC Purchas. PAISY Human res. LEE Projects To be re-placed by R/3 PLACOS Actual costs PLINS Calculation MVS-Host based PLINS PC-part ES/9000-based PC-based AKZOInst Messages SAP R/2 und Batch-Systems

  9. 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

  10. 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 The way to R/3 in two steps today! 1998 1999 2000 Plant Oberbruch and head quart. Plant Kelsterbach inclusive Releasechange 3.0f to 3.1I Plant Obernburg Plant Elsterberg Step 2: Lead time yet to be determined! Plant Ede NL RV RK-E Migration Step 1: 20 months lead time All plants in old systems Plant Oberbruch and head quart. in coexistence phase Enka in R/3! Plant Kelsterbach in coexistence phase Plant Obernburg in coexistence phase Plant Elsterberg in coexistence Plant Ede in coexistence Two step procedureStep 1 Migration of non-SAP-systems to FI as the leading accounting system in five phases! Step 2 Migration RV, RM, RK-E to R/3

  11. 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

  12. 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 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. - The dynamics of the business processes dont need an online- coupling between R/2 and R/3. - R/3-FI should be the leading accounting system of the ENKA company.

  13. Coexistence R/2 with R/3 during step 1 (2) What does R/2? What does R/3? Profitability analysis R/2Sales R/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 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

  14. RF RV RK-E RM- MAT Gegenbuchung SF RV,- DX- und AB-Belege Costprice für FF‘e (fix+variabel) FI-Salden für RF-Sachkonten Inhouse Hedging Baumaufträge Alle RM-Belege Materialstämme für FF‘e Währungskurse Kreditkontrolle Overdue- list Baumrückmeldung Inhouse Banking banks FI Customers Suppliers Customers PAISY Human res. PM CO MM PP FI-AA AKZOInst Coexistence R/2 with R/3 during step 1 (3) Hyperion Consolid. Interfaces between SAP R/2 und SAP R/3

  15. CO MM Coexistence R/2 with R/3 on the materials level CostCntr CostCntr CostCntr LART Raw- mat. Semi-f. goods Semi-f. goods Fin.-goods WA WE back to production PP WE Delivery Retoure PP-order PP-order PP-order Weighting RM-SST Shop floor Spools in colli Completion confirmation Completion confirmation back to production Weighting Retoure RM-MAT Delivery all RM-Documents Semi finished goods and transactions: only in R/3! Finished goods and finished goods transactions: in R/2 and R/3!Finished goods transactions: first in R/2 and then in R/3!

  16. 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

  17. Consolidation SAP R/2 FE LO FE LA LE LO WE WV LE WK FE WK WM WV WK 21 21 21 21 21 21 21 21 21 54 21 54 54 AU 54 21 AU 21 TR 14 nn TR 49 53 03 20 BA 76 40 13 49 51 BA 53 TR 61 RV-Documents RM-Documents SAP R/3 Phases of productive usage during step 1 (1) Transfer of balances 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 shift to R/3 happens "one location at a time" and "one after the other" - 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.

  18. Consolidation SAP R/2 WE LE WK FE WM LE WV FE LO LO LA WK LE LE WK FE WK WK WK WV 21 21 21 21 21 21 54 AU 54 54 21 21 21 54 21 21 21 21 21 21 AU 20 BA TR TR 14 53 20 03 49 14 03 76 40 nn 53 13 TR 61 49 BA 51 SAP R/3 WM 21 61 Phases of productive usage during step 1 (2) Transfer of balances RV-Documents RM-Documents RM-Documents R/2-R/3-Coexistence after phase 2 and 3 - Phase 2/3: Two more locations with four business areas are productive - 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! - The R/3-balances will be transfered once per month to R/2 for the profitability analysis and for the consolidation. - 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.

  19. FE WK FE WK WK WK FE WK FE FE LA WK FE 54 54 54 54 54 21 21 21 54 21 21 21 54 03 14 51 TR 40 TR 13 20 03 14 20 13 40 Phases of productive usage during step 1 (3) Consolidation SAP R/2 LO LE LE WV WM WE LA BK 21 21 21 21 21 21 54 54 GB TR 49 53 61 76 nn nn 51 Transfer of balances BK21 Transfer of balances BK54 RM-Documts RV-Documents RV-Documents RM-Documts RM-Documts RM-Doc. RM-Doc. RM-Doc. SAP R/3 LO LE LE WV WM WE BK 21 21 21 21 21 GB TR 49 53 61 76 R/2-R/3-Coexistence after phase 5 Final situation of coexistence at the end of step 1

  20. 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

  21. Modeling of the fibers production with PP and CO(1) Characteristics of the fibers production: Number of raw materials low Number of prod. steps Spools: 1 Warp beams: 2 Disposition of product. Spools: stock driven Warp beams: make to order Material flow chemical part continously textile part discontinously Specialities Product variance by fibers parameters (batches), By products caused by yarn tears (spools below standard weight) and residues, Individual colli administration with finished goods, Completion confirmations only manual (expensive), for half finished goods only by counting (no weighting possible)

  22. HF2 FF HF1 D C D C D C D C PP R HF2 HF1 HS5 HS1 HS3 HS2 HS6 HS4 CO Counting 2 Counting 1 Weighting Modeling of the fibers production with PP and CO (2) FI MM Raw-mat. Semi-f. goods Semi-f. goods Fin.-goods routing 1 routing 2 routing 3 new! new! Division of production flow in steps with corresponding semi-manufactured goods as base for completion confirmations and monthly accounting of semi-finished goods

  23. 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-order and RV-position

  24. 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

  25. 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

  26. 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 Backup-machine also supports the three R/3-test systems Hot standby by switching the clients to the backup machine

  27. 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

  28. 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!

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