ACO MM TBP 23 Glass Product Creation Process.V4.2

ACO_MM_TBP_23_Glass Product Creation Process.

To Be Process

Glass Product Creation Process

TBMD03 - Glass Product Creation Process.V4.2Version: -3.8

Status:-Released

Author:-CDB

Date last update: 19/11/2002

Date printed: 28/1/2005

Table of content

21Document updates and validations

32Scope

32.1Scope overview

32.2Process map

42.3Application architecture (global)

42.4Cross references

53Process

53.1Core model - process flow and description

53.1.1ZNOM Creation

83.1.2ZPRO Creation

113.1.3FER1 & HLB1 Creation

133.2Country specific - process flow and description

144Business Rules

144.1Core model Business rules

144.1.1Material type

144.1.2Transition phase from ZPRO to FER1

174.1.3Product Description

184.1.4Product ID

274.1.5SAP products creation

304.1.6Data Collection Management

314.1.7Rules on Blocking products and Flagging products for deletion

334.2Country specific Business Rules

335Key elements of SAP implementation

335.1Core model Key elements of SAP implementation

335.1.1SAP Objects creation process

335.2Country specific Key elements of SAP implementation

335.3Summary

336Organizational roles and impacts

347Application specific development requirements

348Key volume & performance indicators

1 Document updates and validations

Updates

DateVersionAuthorComment

31/05/02V1CDBDocument creation

14/06/02V2CDBIn revision

24/06/02V3CDBIncludes Key Users notifications

27/06/02V3.2CDBIncludes Blocking rules on SAP products and Product Description modification

04/07/02V3.3CDBModification of the SAP objects creation process after validation by KU

10/07/02V3.4CDBComplement on the Product Id management & on the blocking rules

22/07/02V3.5CDBMaterial Master Maintenance and modification of HLB1 creation

0108/02V3.6CDBValidation of the Process Owner

17/09/02V3.7CDBZPRO requires Routings but does not require BOMs (refer to p10 and p26)

Upgrade of the Product ID definition

19/11/02V3.8CDBModifications based on KU comments

22/11/02V4.0CDBModifications based on KU comments

05/02/03V4.1CDBModifications based on KU comments on the Description

12/09/03V4.2CDBThe Local D.S. is in charge of ZPRO MRP view creation + Modification of PID rules related to roofmaker

28/01/05V4.3MGOModifications based on KU comments

Validations

DateVersionValidation Resp.Comment

01/08/02V3.6JGIValidation of the TBP.v3.6

19/11/02V3.8KUValidation of the TBP.v3.8 by Key Users

22/11/02V4.0JGIValidation of the TBP. V4.0

2 Scope

2.1 Scope overview

The subject of this procedure is the description of the rules to be applied to the Creation and the Modification of SAP products.

This To-Be-Process is defined for the perimeter of Saint-Gobain Sekurit Avenir V2 Project.

The products considered in this To-Be-Process are automotive manufactured glass products (windscreens, backlites, sixlites, sunroofs) without packaging elements.

Regarding SAP, the Material Types to be taken into account are ZNOM, ZPRO, FER1 and HLB1 (refer to the document TBMM02 Material Master Management for more details on it)

2.2 Process map

The following charts describe the different possible scenarios of creation of glass products throughout a projects span life, from the nomination of Saint-Gobain Sekurit as developer until the phase of mass production. The Quotation phase is out of the scope of this procedure. The detailed rules of the quotation phase are included in the To-Be-Process TBMD04-Pricing Procedure.

Each product created in SAP relates to a physical product (product that has to be manufactured), except for the ZNOM that corresponds to a virtual product in which are stored characteristics, costing and pricing information.

2.3 Application architecture (global)

This Glass Product Creation Process could span over other applications as the Product Lifecycle Manager. However, these systems and their related interfaces are not part of this To-Be-Process.

2.4 Cross references

This document could refer to other To Be Processes as:

TBMD01 - Product Characteristics

TBMD04 - Pricing Procedure

TBMD02 - Revision Level

TBMD06 - Logistic Flow and Master Data Creation

TBMM02 Material Master Management

TBPDC07 Prototype Management

AIG-MD-001-Product Description

3 Process

3.1 Core model - process flow and description

The process flows laying out the Glass Product Creation Process differ depending on the type of product to be created:

ZNOM: Products whose development has been officially granted by the customer to Saint-Gobain Sekurit.

ZPRO: Prototypes

FER1: Finished Products

HLB1: Semi-Finished Products (related to FER1)

Refer to the document TBMM02 Material Master Management for more details on these material types

3.1.1 ZNOM Creation

The ZNOM products can only be created once Saint-Gobain Sekurit has been officially selected by the customer as products developer. The goal here is to track the first agreements in terms of price between Saint-Gobain Sekurit and its customer, as well as the costs calculation on whose basis the commercial quotation was done.

In this sense, besides the GLASSPRODUCT characteristics, a specific class with 4 further characteristics will be created on the ZNOM Material Master Records, the purpose being to store the following information (refer to the To Be Processes TBMD01-Product Characteristics for more details):

Prototype Cost Quotation

Prototype Sale Price

Serial Product Cost

Serial Product Sale Price

After having got the nomination from the customer, the modification and / or creation of a new product, during the development phase or in the phase of mass production, will not generate any change in the existing ZNOM products neither the creation of a new one.

It is not allowed to modify any of the above mentioned values as they are part of the products history. However, in case of serious error during the process of data entering, the OEM Data Specialist, after having got a written instruction from the IKAM, is authorized to proceed with the amendment.

The procedure for the creation of ZNOM products is detailed in the following flowchart.

1. OEM nomination letter verification and confirmation

Responsible: International Key Account Manager (IKAM)

Trigger: The customer has selected Sekurit as developer for a new project (reception of a nomination letter).

Action Items: The IKAM verifies that the OEM nomination letter matches with the Sekurit quotation, and confirms that Saint-Gobain Sekurit has been nominated as developer.

Lead-Time: 2 working days.

Distribution List: The IKAM gets in touch with the OEM data Specialist to confirm the Saint-Gobain Sekurit nomination.2. Data Entry and Verification

Responsible: OEM Data Specialist

Trigger: Once the IKAM has confirmed that Saint-Gobain Sekurit was appointed as developer.

Action Items: The OEM Data Specialist is in charge of creating the ZNOM product in SAP R3. The required data are downloaded from the Product Lifecycle Manager to the Material Master Record (automatic interface between SAP and the Product Lifecycle Manager to be implemented).

In parallel, the OEM data specialist enters in the system (both in the ZNOM product and in the Product Lifecycle Manager) the price information transmitted by the IKAM. This information can not be other than the official agreement reached between Saint-Gobain Sekurit and its customer.

Lead-Time: 1 working day

Distribution List: not applicable as next step is under OEM Data Specialist responsibility too.

3. Product Creation Notification


Trigger: the ZNOM product has been created in SAP.

Action Items: The OEM Data Specialist is in charge of generating a Notification of New SAP product Creation.

Lead-Time: performed simultaneously to Data entry & verification

Distribution List: The notification is forwarded to the IKAM.

3.1.2 ZPRO Creation

A ZPRO product is created for any Prototype which has been ordered by or has to be delivered to a customer of Saint-Gobain Sekurit.

The procedure for the creation of ZPRO is detailed in the following flowchart. This procedure is applicable at any step of the project life span (before, during and after the SOP - Start Of Production)

The whole lead-time for the ZPRO creation depends on the specific characteristics of each project. Therefore this procedure cannot rule a specific lead-time on. It must be managed by the project leader on case-by-case basis.

However, as a general indication, the overall lead-time should not exceed to 10 consecutive working days.

1. Parts Creation Request

Responsible: International Project Leader (IPL)

Trigger: Product Request confirmation received from Saint-Gobain Sekurit in an official and written way. This document will contain the necessary information on price and date of delivery. The corresponding Purchase Order will mandatorily follow, the KAM being responsible for getting the order and communicating it to the IPL. No prototype can be delivered without having got from the customer the related Purchase Order.

Action Items: the IPL gets in contact with the International Key Account Manager (IKAM) in order to obtain his agreement for initializing the ZPRO creation procedure. There is no a formal procedure to get the IKAM agreement.

Lead-Time: 2 working days

Distribution List: Once the IKAM agreement has been given, the IPL gets in touch with the OEM Data Specialist in order to initialize the Prototype Creation Form.

2. Parts creation form initialization


Trigger: Part Creation Request received from IPL.

Action Items: the OEM Data Specialist initializes the Prototype Creation Form that will contain all the information required for the Material Master Record creation in SAP (refer to Data Collection Management paragraph for more details on the different types of required data).

Some of these data (as the Characteristics) are available in the Product Lifecycle Manager, whose automatic interface with SAP constitutes a must to be implemented by the Product Lifecycle Manager Workgroup.

Lead-Time: 2 working days

Distribution List: the OEM Data Specialist gets in contact with the involved Local Data Specialists to get the necessary data that are available at local level.

3. Data collection & verification

Responsible: Local Data Specialist & Local Project Leader(s) (LPL)

Trigger: Requests of information received from the OEM Data Specialist.

Action Items: the Local Data Specialists are in charge of collecting the necessary local data by getting in touch with the involved departments. Once those data have been collected, the LPL verifies the consistency of the information before releasing the information. Lead-Time: As this task is strongly dependent on the type of project, a general lead-time can not be defined. Thus it is to be determined by the IPL at the moment of initializing the procedure.

Distribution List: Once collected and verified, the information are forwarded from the Local Data Specialists to the OEM Data Specialist.4. Product Data consolidation


Trigger: Necessary local data received from Local Data Specialists.

Action Items: the OEM Data Specialist is in charge of consolidating the local data collected by the Local Data Specialists, as well as of verifying that the whole Creation Form has been filled-out.


Distribution List: the next step can be performed either by the OEM Data Specialist himself, or by a SAP Data Entry Expert (under the responsibility of the OEM Data Specialist).5. Data Entry & verification


Trigger: Once the Prototype Creation Form has been consolidated

Action Items: Based on the information provided by the Creation Form the OEM Data Specialist is in charge of creating the ZPRO product in SAP R3, excepted the MRP views that will be created locally. Since some of the information is stored in the Product Lifecycle Manager an automatic interface with SAP R3 is to be implemented.

The OEM Data Specialist is responsible for checking that all the necessary data have been entered in the system as well as the consistency of the entered data with the major SAP managements rules.


Distribution List: The OEM Data Specialist communicates the ZPRO creation to the involved Local Data Specialists.

6. Local Data Entry

Responsible: Local Data Specialist (plant level)

Trigger: The ZPRO has been created in SAP by the OEM Data Specialist.

Action Items: creation of the MRP views of the new ZPRO, and the related routing. Refer to To-Be-Process TBMD06 - Logistic flow and master data creation for more details on those actions. Lead-Time: 1 working day.

Distribution List: The Local Data Specialist informs the OEM Data Specialist that the MRP views have been created and the ZPRO is ready for production.

7. Product Creation Notification


Trigger: The prototype is ready for production in SAP.

Action Items: The OEM Data Specialist releases a Notification of New SAP product Creation.

Lead-Time: 1 working day.

Distribution List: The notification is distributed to the IPL, LPL(s), the Logistics Department(s) and any other Department relevantly involved in the project.

3.1.3 FER1 & HLB1 Creation

A FER1 product and its related HLB1 are created for any Serial Product which has been ordered by or has to be delivered to a customer of Saint-Gobain Sekurit.

The procedure for the creation of FER1 & HLB1 is detailed in the following flowchart. This procedure will be applicable at any step of the project life span (before, during and after the SOP - Start Of Production date).

The whole lead-time for the FER1 and HLB1 creation depends on the specific characteristics of each project. Therefore this procedure cannot rule a specific lead-time on. It must be managed by the project leader on case-by-case basis.

8. Parts Creation Request

Same process as for the ZPRO creation procedure, except for the triggering action. Actually, the Project Leader (International or National) can initialize the FER1 creation for one of the following reasons:

The product has been validated by the customer for mass production (refer to the chapter Transition phase from ZPRO to FER1 of the document)

The product has to be integrated into the next year Budget

Remark: In case the SGS Customer asks for a new revision level with no impacts for SG Sekurit, then the OEM Data Specialist will be in charge of updating the Revision Level Field in all the related SAP Products. No additional step in the creation process will be required.

9. Parts creation form initialization

Same process as for the ZPRO creation process

10. Data collection & verification


11. Product Data consolidation


12. General Data Entry & Verification


13. Local Data Entry & cost control

Responsible: Local Logistics Department and Local Controlling Department (plant level)

Trigger: General Data Entry fulfilled by the OEM Data Specialist.

Action Items: Creation of HLB1, MRPs views, BOMs, Routings, Production Versions, Schedule Header, Calculation and update of costs. Refer to chapter SAP objects Creation Process for more details on those actions. Lead-Time: 1 working day

Distribution List: The Local Controlling Department informs the Local Data Specialist that the standard costs have been calculated and updated.14. Product Verification

Responsible: Local Data Specialist

Trigger: The Local Data Specialist gets from the Local Controlling Department a written notice specifying that the products costs have been validated.

Action Items: After having verified that all the created SAP products contain all the compulsory information, the Local Data Specialist releases them for production.


Distribution List: The Local Data Specialist informs the OEM Data Specialist that the products have been locally validated and are ready for production.15. Product Creation Notification


Trigger: the products have been validated by the Local Data Specialist.

Action Items: The OEM Data Specialist releases a Notification of New SAP product Creation.


Distribution List: The notification is distributed to the IPL, the LPL(s), the Logistics Department(s) and any other Department relevantly involved in the project.

3.2 Country specific - process flow and description

Not applicable.

4 Business Rules

4.1 Core model Business rules

4.1.1 Material type

The four Material Types that are managed within this To-Be-Process are the following: Finished Products (FER1

A Finished Product in terms of SAP is a sellable product, either to an external client, or to another SEKURIT entity.

Semi Finished Products ( HLB1

The semi-finished product is a part of another product, a step of an internal transformation process within the same SEKURIT entity. Prototypes ( ZPRO

Used for the creation of prototype product or initial samples

Used also to manage the R&D developments. In each plant one specific ZPRO (without any duration life) will be created before the go-live for these types of development. Products selected for development ( ZNOM

Used once SEKURIT has been appointed as developer by the customer

This material type is mainly used to store the prices agreed with the customer during the quotation phase as well as the costs calculations on whose basis the prices were quoted.4.1.2 Transition phase from ZPRO to FER1

As described in the process map laid-out in this document, the ZPRO can be created either for the prototypes and initial samples during the development phase (before SOP), or for the initial samples related to the modifications (new revision level or version) during the serial production.

The object of this paragraph is to focus on the transition phase between the delivery (to the Customer) of the latest prototypes (pre-serial) and the first serial products.

More precisely, the process will be the following:

1. SGS delivers for approval some initial samples (ZPRO) to the customer

2. Once the initial samples fully match with specifications, the Customer informs the Project Leader or the Key Account Manager about the validation of these products for mass production.

3. The Project Leader or the Key Account Manager initializes the request for FER1 / HLB1 creation (refer to chapter 3 - core model - process flow and description FER1 & HLB1 creation)

4. The OEM Data Specialist creates the FER1 in SAP.

5. For each plant where some stocks of ZPRO are remaining, the Local Logistics Department will be informed by the development department (on the behalf of the Project Leader) that the remaining initial samples can be transferred in CIM+ on the new FER1 reference.

6. SGS can only deliver now the serial products to the customer.

4.1.3 Product Description

The product description of the Master Data Records (FER1, HLB1, ZPRO and ZNOM) is automatically generated on the basis of the aggregation of a set of characteristics from the GLASSPRODUCT class (refer to TBMM01 Product Characteristics for the detailed definition of this class).

E.g.:

CITN68--S3L01AB+0.PICA.TE--.-WP-G---.X--The structure of this Product Description is the following:

12345678910111213141516171819202122232425262728293031323334353637383940

e.g.:CITN68--S3L01AB+0.PICA.TE--.-WP-G---.X--

1234567891011121314151617

1) Product ID: 17 characters (refer to the following chapter for a detailed definition of the product ID)

2) Car Model: 4 characters

3) Glass Type: 1 character (T for Tempered, L for Laminated, D for Double Glazing, M for Multi-Laminated, O for Others)

4) External Color: 1 character (color letter as defined in the classification)

5) Internal Color: 1 character (color letter as defined in the classification) or - for No applicable

6) PVB: 1 character (S for Standard, A for Acoustic, H for HUD, T for Tinted, O for Others, - for No Applicable)

7) Heated: 1 character (C for heatable by coating, W for heatable by wires (Totally or Partially) P for heatable by silk print (Totally or Partially) or - for Not Applicable)

8) Antenna: 1 character (W for Wires, P for Printed, L for Layer or - for No Antenna)

9) Alarm: 1 character (W for Wires, P for Printed or - for No Alarm)

10) VIN Label: 1 character (V for VIN Label or - for No VIN Label)

11) Logo: 1 character (G for With Logo or - for Without Logo)

12) Rain Sensor: 1 character (R for Rain sensor or - for No Rain sensor)

13) Mirror Bracket: 1 character (M for Mirror Bracket or - for No Mirror Bracket)

14) Infra Red reflecting: 1 character (K for KAPPA, A for AIRCO, P for PET, S for SRF, O for Other, or - for No Solar Control)

15) Extrusion: 1 character (X for Extruded or - for Not Extruded or Later Extruded)

16) Encapsulation: 1 character (Y for Encapsulated or - for Not Encapsulated or Later Encapsulated)

17) Primer: 1 character (P for Primer or - for No Primer)

4.1.4 Product ID

4.1.4.1 Objectives

The main advantages of managing the Product ID on the Material Master Record are the followings:

Having a meaningful and unique identification for each physical Product.

Ensuring the traceability of a product before its creation in SAP

Following-up (in SAP or in the Product Lifecycle Manager) the evolution of the cost all over the entire life of the product

Providing an exploitable link between the different intermediate products (all FER1 and HLB1) for the calculation of the consolidated margin.

This Product ID will be managed in SAP as a characteristic of the Product Classification as defined in the document TBMM01 Product Characteristics

The product ID will be printable on the internal and external labels of the racks.

Moreover, it will be possible to barcode it on internal labels (compliant with the font 3 of 9)

Any update of the Product ID must be triggered by an Official Request of the Customer of Saint-Gobain Sekurit: new OEM revision level or new OEM part number.

For more details of the impacts of the revision level on the Product Id, refer to the To-Be-Process TBMD02 - Revision Level.

The Product ID must be created / updated in the Product Lifecycle Manager and downloaded in SAP system, or be manually entered in the Material Master Record.

4.1.4.2 Product ID structure

The structure of this Product ID is composed of two main parts:

A fixed aggregation of characteristic values defining the project the product belongs to.

A group of five meaningful indexes or indicators defining the different versions and evolution of the product.

E.g.:

4.1.4.3 Product ID definition

This paragraph gives a detailed definition of the Product ID, based on the following example:

CITN68--RDL01BCA0

123456789

1) Car Brand or Roof Maker: 3 characters (if a Roof Maker has been specified in the classification, the user will be free to use it instead of the Car Brand)

The case of the roof: FABA.

When creating a material corresponding to a roof, it is impossible to put the Car Brand in the Classification (characteristics) and therefore in the PID, as the final client is not always known and, as the exactly same roof can be used for different cars (different car brands).

Instead of putting the Car Brand in the Product ID, we will put the Roof maker.

This solution does not imply organizational change neither local development, it is just necessary to know the process to create such a material:

- When completing the Classification, in the Car Brand field, put Unknown.

- In the Roof maker field put the name of the Roof maker.

The system will automatically take the Roof maker, as the Car Brand is set as unknown, and put it in the description (development already done in SAP for that operation).

In the same logic, when entering manually the Product ID (last characteristics), remember to begin the PID by the 3 first letters of the Roof maker (same process as with Car Brand).

2) Development Code: 5 characters.

3) Glass Position: 2 characters.

4) Side: 1 character (R for Right, L for Left or - for No Applicable).5) Glass Version Index: 2 numerals.

Index corresponding to a set of functional features of the product.

The exhaustive list of these features is:

Glass Type

External Color

Internal Color

Infra red reflecting

Mobile

Heated

Antenna (Yes/No)

Alarm (Yes/No)

PVB

Shade Band Color

Logo (Yes/No)

VIN Label window

Number of holes

Printing (Yes/No)

Special functions

Any variant/modification of one or several of these functional features will initialize a new Glass Version.

N.B.: Modifications that only affect the extrusion, the encapsulation and / or the Pre-assembly will not have any impact on the Glass Version

Example: Peugeot 206 Windscreen

Customer referenceDifferentiating FeaturesGlass Version

8200677480Green, with Primer01

8200677493Green, without Primer01

8200677527Grey, with Primer02

8200677614Grey, without Primer02

8200677628Green with VIN Label03

8200677701Grey with VIN Label04

6) Evolution index for glass: 1 letter.

Initialized to A, this index will change whenever, further to the Customers request, there is a change of the geometrical features of the glass product.

The exhaustive list of these features is:

Composition (thickness)

Commercial surface

Antenna (design)

Alarm (design)

Shade Band (dimension)

Label (design)

Holes position or diameter Printing (design & face of printing)

Logo (design)

Contour

Shape (curvature)

Tolerances & general specifications

Connectors (number, type & position)

Edge type

7) Evolution index for Encapsulation / Extrusion: 1 character

This index will change whenever, further to the Customers request, there is a change of the encapsulation and/or extrusion process of the product.

When the encapsulation and/or extrusion process takes place in the underway Plant or in any up-stream Plant the index will be a letter (from A to Z).

When the encapsulation and/or the extrusion process takes place in any down-stream plant the index will be +.

When the product is not Encapsulated nor Extruded all along its whole production process the index will be -.

8) Evolution index for Pre-assembly: 1 character

This index will change whenever, further to the Customers request, there is a change of the pre-assembly process of the product.

When the pre-assembly process takes place in the underway Plant or in any up-stream Plant the index will be a letter (from A to Z).

When the pre-assembly process takes place in any down-stream plant the index will be +.

When the product is not pre-assembled all along its whole production process the index will be -.

9) Indicator for pre-assemblys sequencing: 1 numeralThis index allows distinguishing the different pre-assembly sequencings between SGS entities.

This index will change whenever several pre-assembly sequencings are carried-out for the same final product (sold to an External Customer). Each index will characterize a pre-assembly process.

However, as this index is only related to internal pre-assembly flows, the product sold to an External Customer, or without preassembly on it, will always have this index set to 0 (non used)

4.1.4.4 Product ID indexes management

Each time the Glass Version Index changes (new functional feature), all the 3 evolution indexes will be re-initialized at the initial position (A)

The 3 evolution indexes will evolve individually

The Glass Version Index (related to the manufacturing process in the glass plant) will prevail on the evolution indexes. If both occurs at the same time (for example thickness and color), only the new version will be considered.

The Indicator for pre-assemblys sequencing will not change for a modification of the type of pre-assembly (except if it only impacts the plant where it takes place).

4.1.4.5 Examples of Product ID on simple Flows

Assumptions:

Extrusion / Encapsulation takes place in an Extrusion / Encapsulation Plant

Pre-assembly takes place in a Service Center

Example #1: Extruded and Pre-assembled Product

Example #2: Extruded and not Pre-assembled Product

Example #3: Pre-assembled and not Extruded Product

Example #4: Not Extruded and not Pre-assembled Product

4.1.4.6 Example of Product ID on multiple Flows

Assumptions:

Extruded and Pre-assembled Product, with different pre-assembly flows

Extrusion / Encapsulation takes place in an Extrusion / Encapsulation Plant

In this example, the different pre-assembly operations take place in different places, but the product sold to the OEM is always the same

4.1.4.7 Product ID for HLB1

The Product ID of an HLB1 will be equal to the one of its related Finished Product (within the same plant).

When two different finished products are composed of the same physical semi-finished product (e.g.: the Left and Right Side glass before bending), the related HLB1 could also be the same for both, as in terms of Planning Production there is no need of distinguishing them. In this particular case, the SAP product and the product ID could be also the same for the two physical semi-finished products (e.g.: the Left side HLB1 could be used for both Left and Right side FER1). This common product ID will be chosen by the Local Data Specialist.

However, some of these particular cases should be followed-up with attention as they can have impacts on the reliability of the Consolidated Margin (e.g.: a glass before the printing could be the same for a sixlite with or without the Alarm).

4.1.4.8 Reliability of the Product ID

In order to improve the reliability of the Product ID, the following checks will have to be proceeded:

Consistency check on the characteristics

A specific development will be put in place in order to check the consistency of the characteristics (car brand / roof maker, development code, glass position and side) with the fixed part of the Product ID. This program will be triggered before saving the Material Master Record in SAP (development in the SAP user-exit)

For more details on this specific development, refer to the related AIG.

Uniqueness of the Product ID

A specific will be put in place in order to check the uniqueness of the Product ID of the FER1 in SAP. This program will be triggered before saving the Material Master Record in SAP (development in the SAP user-exit)

For more details on this specific development, refer to the related AIG.

Monthly Report on the consistency between BOM and Product ID

The report will display for the final FER1 (sold to the OEM) the SAP codes and associated Product ID of all the intermediate products (FER1 & HLB1) in order to check the consistency of the product ID.

For more details on this specific development, refer to the TBCO0 - Consolidated Margin.

4.1.5 SAP products creation

In the As-Is situation, some physical modifications can be requested by the Saint-Gobain Sekurits Customer without any change of the Customers Part Number or the Customers Revision Level.

In the To-Be situation, it will not be possible to manage such modifications without changing the Customer Part Number or the Customer Revision Level. Each modification requested by the Saint-Gobain Sekurits Customer has to be linked with a new Customers Part Number or a new Customers Revision Level.

A new SAP product (FER1, HLB1 or ZPRO) can only be created further to a modification requested by the Saint-Gobain Sekurits Customer.

Such a modification can be implemented in two different ways:

New Customers Part number

New Customers Revision Level

German case: In some case, German planners decide to use KAPPA glass instead of AIRCO, without any request from the client. This modification is an internal decision, not asked by the client, we do speak of Technical Version, and therefore this should not entail a change in the SAP code. But on the other hand, the modification affects the material and its characteristics.

In that case, we consider that it is a huge change that impacts the final FER1. So even if it is not a request from the client, we must manage it as a modification of the material and thought change the SAP code.

Whenever we encounter that case, proceed as if we had a modification asked by the client, changing the SAP code (refer to TMMD 02- TBMD03).Belgium case: In case of production for Sekurit entity located in another country, SGSB is obliged to produce with logo type of this country. As they manufacture the same product for Belgian market with Belgian logo, they have to create new SAP code for a product with different logo destined for another country. 4.1.5.1 New Customers Part Number

In case of a new Customers Part Number, new products (FER1/ HLB1 or ZPRO) will be created for all those goods that are physically impacted by the change, knowing that in case of one physical change in a given plant all the HLB1 of this plant must be re-created.

For the products that are not physically affected, it will be necessary to update the Customers Part number and the Revision Level in the Master Data Records.

Three different scenarios can be outlined:

The modification impacts the Glass Plant,

The modification impacts the Extrusion / Encapsulation Plant,

The modification impacts the Pre-assembly Plant.

Scenario 1: the modification impacts the Glass Plant

Scenario 2: the modification impacts the Extrusion / Encapsulation Plant

Scenario 3: the modification impacts the Pre-assembly Plant

4.1.5.2 New Customer Revision Level

Refer to the To Be Process TBMD02 - Revision Level for details on the Revision Level Management.

4.1.6 Data Collection Management

The creation form is the template that contains all the information which is necessary to create a SAP product. Depending on how the information is got, 3 different categories can be distinguished:

Data which are constant so no really subject to collection by the OEM Data Specialist.

Data that are obtained by the OEM Data Specialist by applying the SAP management rules which are defined in the To-Be-Process TBMM02 Material Master Management.

Data whose collection must be ensured by the OEM data specialist by getting in contact with the involved Local Data Specialists.

Remarks:

In case of inconsistency between the SAPs and the Product Lifecycle Managers data, those stored in SAP will prevail.

4.1.7 Rules on Blocking products and Flagging products for deletion

All over its life and due to different circumstances the product can be subject to various status:

Blockage: in some cases it can be decided to block a product for delivery, payment, purchase, selling and / or production. In such a case, the product can not be delivered, paid, purchased, sold and / or produced for a limited period of time, which means until the moment when the exceptional reasons that caused the blockage have disappeared.

Flagged for deletion: the main effect here is the un-operationally of the product except for records purposes. Being flagged for deletion implies to assume that, for structural reasons (i.e. the commercial demand has completely collapsed), the product will not be longer run.

4.1.7.1 ZNOM products

Blocking rules: There are no blocking rules applicable to the ZNOM products.

Deletion: under OEM Data Specialist responsibility, the ZNOM products can be flagged for deletion 5 years after the SOP date.

4.1.7.2 ZPRO products

Blocked for sales: The ZPRO products are automatically blocked for sales at its creation.

Blockage can only be released through written instruction from the KAM to the OEM Data Specialist (MM02 transaction in SAP).

Blocked for production or purchasing: There are no blocking rules applicable to ZPRO products.

Deletion: the ZPRO products can be flagged for deletion 5 years after the creation of the product in SAP.

4.1.7.3 FER1 and HLB1 products

Blocked for production (at creation): The FER1 and HLB1 products are automatically blocked for production at their creation.

Blockage can be released by the Local Data Specialist (MM02 transaction in SAP) once the Local Project Leader has confirmed in written that the SOP date has been achieved.

Blocked for sales (at creation): The FER1 and HLB1 products are automatically blocked for sales at their creation.

Blockage can be released by the OEM Data Specialist once the KAM informs in a written way that the corresponding Purchase Order has been forwarded by the Customer (MM02 transaction in SAP).

Blocked for production and sales (budget phase): The FER1 and HLB1 products are blocked for production and sales when they have been created for budget purposes.

Blockage can be released by the OEM Data Specialist once the Local Project Leader has confirmed in written that the SOP date has been achieved (MM02 transaction in SAP).

Blocked for production and sales (New Revision Level): The FER1 and HLB1 products are blocked for production and sales when they are created for a new revision level.

Blockage for production can be released by the Local Data Specialist (MM02 transaction in SAP) once the Local controlling has confirmed in written that all the costs have been calculated and updated in SAP, and once the Local Data Specialist has checked that all the SAP objects have been created (refer to the chapter Key elements of SAP implementation).

Blockage for sales can be released by the OEM Data Specialist (MM02 transaction in SAP) once the KAM has confirmed in written that the agreement on the new revision has been reached.

Blocked for payment (conflict with supplier): The FER1 products can be blocked for payment by the OEM Data Specialist upon the written request of the General Manager of the affected Saint-Gobain Sekurit Company. The blockage can be released by the OEM Data Specialist upon the written request of the General Manager of the affected Saint-Gobain Sekurit Company (MM02 transaction in SAP).

Blocked for delivery (conflict with customer): In case of serious conflict with the Customer the FER1 products can be blocked for delivery by the OEM Data Specialist upon the written request of the General Manager of the involved Saint-Gobain Sekurit Company and the one of Sales & Marketing SGSI.

Blocked for purchasing: (conflict with supplier): The FER1 products can be blocked for purchasing by the OEM Data Specialist upon the written request of the General Manager of the affected Saint-Gobain Sekurit Company. The blockage can be released by the OEM Data Specialist upon the written request of the General Manager of the affected Saint-Gobain Sekurit Company (MM02 transaction in SAP).

Deletion: depending on the contract negotiated with the OEM, the FER1 and HLB1 products can be flagged for deletion 10 years or more after the end of Serial Production date, provided there is no stock and / or pending scheduled deliveries.

4.1.7.4 Products created for budget purpose

In the case of products (ZPRO, FER1 or HLB1) created for the budget purpose, these products will be blocked for production, sales, purchasing and delivery. Blockage can be released by the OEM Data Specialist (MM02 transaction in SAP) once the KAM has confirmed in written that the agreement for production has been reached.

4.2 Country specific Business Rules

Not applicable.

5 Key elements of SAP implementation

5.1 Core model Key elements of SAP implementation

5.1.1 SAP Objects creation process

The creation of Material Master Records (FER1 and HLB1) in SAP involves the creation of other SAP objects, such as Purchasing Info Records, BOM, Routings

For a complete and detailed description of the creation process of all these Master Data in SAP, refer to the To-Be-Process TBMD06 - Logistic flow and master data creation

5.2 Country specific Key elements of SAP implementation

Not applicable.

5.3 Summary

Not applicable.

6 Organizational roles and impacts

The organizational roles (OEM Data Specialist and Local Data Specialist) and impacts are detailed in the To-Be-Process TBMD06 - Logistic flow and master data creation

7 Application specific development requirements

To perform this Glass Product Creation Process, the following specific developments are necessary:

Automatic generation of Product Description: a specific program, embedded in the SAP user-exit of the Material Master Record save action, will automatically generate the Product description, based on the Characteristics values of the classification (refer to the document AIG-MD-001-Product Description.doc for more details on this specific development)

Consistency check on the Product ID

Refer to the chapter Product ID and to the related AIG

Uniqueness check on the Product ID

Refer to the chapter Product ID and to the related AIG

8 Key volume & performance indicators

Not applicable.

Plant 3

SAP objects creation

Initialization of Creation Form

Data consolidation

SAP

Plant 1

Data Collection

Plant 2

refer to TBMM01 Product Characteristics

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ACO MM TBP 23 Glass Product Creation Process.V4.2

Documents

Transcript of ACO MM TBP 23 Glass Product Creation Process.V4.2