Export Packing SAP Framework

Context

CKD and SKD export packing involved packed and unpacked material states and several packing configurations. These needed to be represented properly in the SAP manufacturing structure. Packing materials also had no MRP: they were bought manually without coordination, with no tracking, accountability or audit.

My involvement

I contributed to an SAP-based framework that separates packed and unpacked material states, so packing interacts properly with production and material planning. It covers two packaging variants across seven motorcycle models.

• Finished materials and intermediate material structures
• BOM logic and MRP consumption for packing materials
• New material codes, BOMs and work centres, with MRP runs aligned to day-wise export demand
• Periodic audits to find and resolve packing discrepancies

Outsourcing box assembly

Materials Management used to buy 13 separate wood items, which were cut into 16 sizes to build six side walls for every box in-house. Under the new model, raw materials are issued through Outside Processing (OSP) and a contractor supplies finished box subassemblies for final packing. This removed on-site carpentry, which also improved HSE.

Result

Packing capacity rose from about 450 to about 540 units a day, roughly a 15–20% gain in packing productivity. It also brought earlier visibility of packing-material shortages and better control through audits.