SUNEEL R S

SAP PP / PP-PI Consultant

SUMMARY

• SAP Production planning consultant with 9+ years of experienced in SAP PP, PP-PI, PP-VC,   and supporting experience in MM, QM, PM, DMS, and PLM., with 5+ years of Functional experience in Manufacturing Industry.
• Experienced with 3 full life-cycle implementations in PP, PP-PI, and support in MM, QM, and PLM.
• Experienced in Implementation, business process designing, and production support.

• Experienced in all the phases of the full life cycle implementation, requirements gathering, conducting workshops, Blueprint, realization, Unit testing, Integration testing, go live preparation, and production support.

• Experienced in sap discrete, repetitive manufacturing, variant configuration, and process industry with industrial experience in engineering, electronics and communications, pharmaceuticals, chemical, and polymer industry.
• Designing and configuring sales and operational planning (SOP), demand management, MRP / MPS, flexible planning, and long term planning.
• Capacity planning, planned orders, production orders, process orders, special procurement, collective orders, and direct production.
• Designed and configured the functionality of batch management, classification, with integration of batch search strategy, batch derivation, batch derivation, configuration of batch information cockpit.
• Configured make-to-order, and make-to-stock, configure to order, and configuring custom scenarios, requirement classes and manufacturing strategies.
• Integrated PP with MM, SD, FI / CO and PLM
• Configured MRP processes, inventory management process, and experienced in defining custom MRP procedures.
• Worked on inventory management processes, purchasing, stock transport, consignment, sub contracting, external processing, and operational outsourcing.

• Experienced in configuring co-product process in process industry, generating collective orders for product and co-product, integrating planning of product with co-product.
• Experienced in process industry, recipe management, process instruction sheets (pi-sheets), and custom developments..

• Well versed with components of product life cycle data management. document management, integration of PLM, DMS with PP, MM, and QM.
• Implemented document management system with configuration of custom document types, status management, solid works, engineering documents, and drawings.

• Experience in handling QM master data, configuring basic data for inspection planning, quality inspection, quality control and notifications, quality in purchasing, quality in in-process, final inspection, other inspection, and QM in delivery process.

• As part of project requirement, successfully designed, and seamlessly integrated business by using variant configuration with various business teams to meet the specific business requirements.

• Experienced in manufacturing, planning, designing, research and development, process development, projects, quality management and supply chain management, document management, engineering and change management processes.

• Well-versed productive working relationships with clients and staff, and excellent management, and leadership skills.
• Talented in analyzing problems, developing simplified procedures, and finding innovative solutions.

• Promising team player, result oriented, and committed to time lines, and flexible to changes.

• Excellent training skills, and effectively provided training to key users, and supported in providing training to end users.
• Strong ability to communicate effectively with all levels of personnel, ensuring business continuity, and optimal application functionality.

Functional Skills:

• Configuration of MRP processes, production orders, process orders, repetitive manufacturing, direct production, KANBAN, variant configuration, classification, batch management, recipe management, capacity planning, capacity leveling, demand management, engineering change management, document management, and status management.
• Setting up PP master data, MRP, BOM, variant BOM, routings, work centers/ resources, resource net works, shop floor control, planned order management, flexible and long term planning.
• Scheduling batch jobs for MRP processes, capacity leveling, document management, and archiving.
• Expertise in configuration of process industry solutions, recipe management, resources, process order configurations, and formulae for recipe management, batch management, and QM process related to process industries, and pi sheets.
• Experienced in writing functional specifications for custom developments, reports, enhancements, specifications for load programs PP / PLM master data, and experienced in testing programs and validating the results to ensure the technical functionality.
• Expertise in handling custom tables, views, writing queries for quick data reviews validations, and to extensively use variant configuration, variant BOM functionality.
• Integrated pp, pp-pi with mm in goods movement, back flushing, automatic goods receipt, STO process, reservations, production order, planning, purchase requisition, MRP process, sub-contracting, external operations, and operational outsourcing.
• Integrated pp with SD in availability check, variant configuration, requirement types, make to order, and configure to order processes.
• Integrated pp with QM in in-process inspection in production order release in discrete manufacturing, and goods receipt inspection for discrete and repetitive manufacturing.

• Extensively integrated engineering change management for master data changes, integrated document management system with complex document types, and status management.

• Successfully designed, seamlessly integrated business by using variant configuration with variant BOM, complex dependencies selection condition, pre condition, procedures, dependency nets, and constraints.
• Effectively worked on design and development of variant BOM, super BOM, super task lists, class items, configurable items – KMAT, KMAT - phantoms, variants and complex configuration profiles.
• Maintained variant tables to efficiently store combination of the consistent values, and effectively used selection condition, preconditions, procedures and constraints with variant table.

• Configured engineering change management (ECM) for pp master data, and approval processes, status management, and status networks.
• Worked on configuring custom document types in document management, status management, revision level, archiving process to mange old document types.
• Extensively worked on classification, serialization and batch management, batch determination, batch search strategy in production and sales process, active ingredients, and batch specific / proportionate units of measure.
• Worked on co-product configuration, co-product handling, process order for co-productions, and settings for co-product.

• Customized the MRP list and the stock requirement list by using the customer exit to show additional information required by the client.
• Configured material management master data, purchasing processes, sub contract, 3rd party activities, stock transfer processes, purchase order authorization, inventory management, and shipping process.
• Experience in configuring QM in purchasing, in-process inspection, in delivery process,  other inspections, in recurring inspection, in case of SLED, in process industry, with batch management in discrete, repetitive manufacturing, variant configuration and process industry.

• Skilled in writing queries to develop simplified reports in pp, pp-pi, mm, sd, and qm to quickly review the data.
• Worked on legacy system migration work bench (LSMW) to upload PP, PLM master data.

Key Achievements

• Designed and implemented features (phantom items) for effective forecasting and planning using planning strategy at phantom item, which resulted in over 20% forecast accuracy and improved supply chain planning.
• Implemented variant configuration to with complex dependencies.
• Designed complex pi sheets, complex recipe formulae for process industry to provide excellent interface with shop floor to execute the processes effectively.
• Configured custom manufacturing strategies to meet the manufacturing and finance requirements.
• Designed complex document types, status management, and integrated with engineering change management.

PROJECT DESCRIPTION

Confidential,
 CA
Project Implementation
PP Lead Consultant
SAP ECC 6.0
Project Description: Aptina is a leading semi conductor Industry, with has global presence in Image Processing. Aptina contributes major Imaging requirements for Mobile, Camera, and Automobile Industry. 

Responsibilities:

• Prepared blueprint, conducted workshops, designed business process and prepared functional specifications for semi conductor industry.
• Preparing functional specifications for custom developments in PP and MM.
• Configured batch management, batch derivation, batch search strategy, and configured batch management cockpit.
• Scope involve complicated model to track processes executing at sub contractor location.
• Configuration of custom designed scenarios for semi conductor industry.
• Configured production order process with external processing, and sub contracting.
• Managing long lead times of semi conductor industry, and managing complex design selection, and critical materials, which has huge financial impact.
• Configuration of batch management, batch derivation, and batch genealogy.
• Configured complex co products and integrated with costing.

• Integration of pp with SCM, DM, MM, SD, and FI / CO
• Make to order  variant configuration, design and development
• Designing complex batch search strategy to select complex characteristics.

Confidential,
Raleigh NC
Project support 
PP, PLM Lead Consultant
SAP ECC 6.0

Project Description:

ASC Signal is pioneer in signal processing equipments; with hundreds of product range widely used in communications. The scope of the project is to extend new plants and reengineering the processes.

Responsibilities:

• Re engineered the production processes to meet the new plant requirements.
• Designed custom reports for pp, mm and DMS, and provided functional specifications for custom reports in pp, DMS and specifications for DMS load programs.
• Configured MRP, capacity planning, and document management.
• Scheduled batch jobs for MRP, capacity planning, and DMS.
• Set up the pp master data for over 10 plants.
• Developed processes for operational out sourcing, and external processing.
• Defined custom manufacturing strategy to meet the business requirements
• Configured custom document types, solid works, engineering change management, status management and work-flow settings.
• Involved in de-bugging and testing programs and custom developments for document management system and engineering.
• Managed 200GB+ documents with over 10 document types, and complex version management for data migration.
• Provided user training for key users, and provided go-live support.

Confidential,
Alexandria LA,
Olive Branch MS
Project Implementation
PP / MM Lead Consultant
SAP ECC 6.0

Project Description:

AFCO is a leading fabrication company, with over thousands of fabrication products.  

• Full life cycle implementation, prepared blue printing, gathered business requirements.
• Configured complex business requirements related to planning and shop floor control, production orders, and process orders.
• Designed and configured MRP processes and inventory management process.
• Configured demand management requirements for different product segments.

• Configured MPS, and MRP and setup process.
• Integrated production planning with QM, MM, SD, and FI/CO.
• Configured capacity leveling, strategy profiles, and scheduled auto dispatching jobs.

• Developed unit testing, end to end test scripts, integration testing, and simulation testing, and tested with different variants and variant parameters.
• Interacted with business process experts, and trained business users.
• Successfully configured sub contracting, operational out sourcing processes.
• Effectively used variant configuration for effective BOM handling, and to meet the variant customer requirements, and thus enhanced efficient management.
• Worked on custom designed BW reports for production planning, MM, and SD.
• Customized PRT selection process with custom program to select efficient PRT.
• Involved in redesigning the process, converting legacy data to sap standard using LSMW.

Confidential,NJ                                 
Project Implementation
PP, MM Consultant
SAP ECC 4.7

Project Description:

Rexam is a global leader in packaging industry (CPG), with over thousands of products in hundreds of categories. The company is a leading manufacturer of packaging materials for food, cosmetics, pharmaceuticals and health care products.
Scope if implementation: FI/CO, SD, MM, WM, PP, and QM

Responsibilities:

• Full life cycle implementation for new plants, from gathering the business requirements for packaging industry, closures, and pharma, applications.
• Involved in business re-engineering, designing the project requirements, and transforming to specifications.
• Configured the master data, BOM, work centers, routings, profiles, and shop floor control.
• Designed complex formulae for work centers, and defining work center constants.
• Configured demand management requirements for different SBU.

• Customized MPS, and MRP, and setup process sequence.
• Effectively implemented batch management, and classification system.
• Integrated production planning with QM, MM, WM, SD, and FI / CO.
• Configured capacity leveling, strategy profiles, and scheduled auto dispatching jobs.

• Developed unit testing, end to end test scripts, integration testing, and simulation testing, and tested with different variants and variant parameters.
• Worked on shop floor documentation, handling units, packaging, labeling and quality management certificates and quality documentation.
• Interacting with business users to understand the business process requirements, and re engineering for optimal implementation.
• Developed training documents for key users, and provided training for key users.
• Effectively used solution manager for effective issues tracking and resolving.
• Worked on solution manger for effective project administration, issue management, and tracking configuration.
• Worked on custom designed BW reports for production planning, quality management, material management, and ware house management.

Confidential,NJ
Project Implementation
PP / PP-PI Consultant
SAP ECC 6.0

Project Description:

Merck is a global leader in health care products, pharmaceuticals, with over thousands of products. The company is a manufacturer of pharmaceuticals, health care, and specialty chemicals.
Scope of implementation:  FI/CO, SD, MM, PP / PP-PI, and QM

Responsibilities:

• Gathering the business requirements for API (active pharmaceutical ingredients), branded formulations.
• Involved in business re-engineering (pp/pp-pi), modifying the business process, and transforming business requirements to specifications.
• Configured the master data, BOM, work centers, resources, routings, master recipes, and shop floor control.
• Writing complex formulae for work centers, resources and defining work center constants.
• Allocating work centers, resources, capacity planning, mapping the work centers, resources routings, and master recipes.

• Configured batch management, and classification system.
• Implemented process instruction sheets (pi sheets) with complex formulae.
• Implemented shop floor documentation to meet GMP, and FDA requirements.
• Configured complex packing instructions, and configured complex label requirements for pharma industry.
• Integrated production planning with quality management QM.
• Configured availability checks, and integrated with production planning to have plant level check during order creations and to ensure availability at the line level during order release.

• Provided key user training, production support, and developed test scenarios for unit testing and integration testing.

5. Confidential,

NJ

Project Implementation and Support
PP/ PP-PI Consultant
SAP 4.7

Project Description

Eisai pharma is a global human health care company, providing wide range of pharmaceuticals. The company has licensing and research tie-ups with major pharmaceutical manufacturing companies and research organizations.
Scope of implementation:  FI/CO, SD, MM, PP / PP-PI, and QM

Responsibilities:

• Configured the master data, multi-level BOM for active pharma ingredients, work centers / resources, shop floor control.
• Created formulae for work centers/ resources including process lines, resource networks, and formulation.
• Designed MRP process flow for MPS and MRP
• Scheduled back ground jobs for MPS, MRP and capacity planning.
• Configuration of batch management, recipe management, active ingredients, batch specific unit of measure, and batch determination.
• Configured complex requirements of co-product, and by – product requirements of pharma industry.
• Configured process orders, collective orders, direct production, and special procurement types.
• Worked on sub contracting, external operations, and scenarios specific to process industry.
• Worked on resources allocation management and planning of scale-up of new product development.

• Developed process information sheets (pi – sheets) for effective user friendly operational excellence.

• Configured engineering change management (ECM) to manage master data changes and integrated document management system to handle complex of pharmaceutical document.

• Provided key user training for standard sap functionality, and developed custom reports for process industry.
• Provided production support, and provided effective support.

6. Confidential,

LA

PP Consultant
Project Support
SAP 4.7

Project Description:

Gaylord chemical is a global leader in heavy chemicals, products. Gaylord chemicals meeting the global demand of heavy chemicals, used for chemical synthesis, life sciences, industrial and petrochemical industries. Their products are widely used pharmaceutical, petro chemical, and industry chemicals.
The company implemented has implemented sap; the project scope was to re engineering the business process in FI / CO, SD, MM, PP, and QM.

Responsibilities:

• Configured production planning master data and configured the business requirements.
• Worked on demand management strategies, forecasting, and planning.

• Created complex formulae for work centers, to meet the process requirements.

• Configured material requirements planning, and master production scheduling.

• Configured shop floor controls, plant parameters, production planning master data settings.
• Configured shop floor documents, packing instructions, and handling units of measure.

• Configured planning strategies for wide range of DMSO, and its derivatives.

• Managed capacity planning, and capacity leveling.

• Worked on classification, characteristics, batch management, batch determination, active ingredients, and batch specific units of measure.

• Involved in project documentation, end user training, and production support.
• Integrated quality specifications with quality management QM.
• Writing documentation, and end user training, and providing support to the end users.

7. Confidential,

Sep 00 – Dec 05

Project Implementation and support
PP/PP-PI Consultant
SAP 4.7

Project Description:

Dr. Reddy’s laboratories are the leading pharmaceutical company, which meeting the major global and domestic pharmaceutical and health care products, with over 500 products, and over 50 products ranges.
The company implemented SAP for FI/CO, SD, MM, PP, QM, and HR.

Responsibilities:

• Gathered business requirements, and mapped process flows to map ERP.
• Configured pp master data for active pharma ingredients (API), and branded formulation plants.
• Designed demand management requirements for API, and formulations.
• Configured planning strategies for wide range of pharmaceutical products, and formulations.
• Gathered PP/PP-PI master data  
• Extensively worked on running master production scheduling (MPS), and material requirements planning (MRP), and scheduled background jobs.
• Configured complex batch management requirements, batch search strategies, and classification requirements.
• Developed custom reports for production, and inventory management.
• Worked on complex shop floor documentation requirements of pharma industry.

• Involved in production support, supporting the business users, and key users.

8. Confidential,

May 95 – Aug 00

Manager, Process / Product development

Responsibilities:

• Actively involved in the process development, manufacturing, planning of new active pharmaceutical ingredients.
• New product evaluation, product deployment at large scale.
• Responsible for product deliveries, and meeting the customer demand.
• Designed the product and process development requirements, capacity calculations, resource management, costing, and strategic development.
• Involved in detailed workflow, and processing activities of manufacturing.
• Effectively implemented good manufacturing practices (GMP), following standard operating procedures (SOP), and involved in maintaining food and drug administration (FDA) standards in the manufacturing facilities of dr. Reddy’s
• Involved in FDA approvals for API manufacturing plants.
• Well versed with pharmaceutical sops, and good manufacturing practices

Education:

B. Tech Chemical engineering From National Institute of Technology (NIT) Warangal, formally known as Regional Engineering College (REC) Warangal, India’s one of the premier engineering institutes.