Sr. SAP MM/PP/QM Consultant

Location:

Posted:

September 23, 2011

Resume:

Experience Summary:

Babu Palavala is SAP supply chain architect and Quality Management Specialist. He has more than twelve years of consulting experience in implementing SAP solutions. He has excellent communication skills, client relationships and delivery excellence for delivering projects on time within budget. His functional areas of SAP expertise include Materials Management, Quality management, Production, APO and its integration with Financials, Plant Maintenance and Project Systems. He has nine full life cycles implementation experience consisting of business process re-engineering, blueprinting, designing, end-to-end testing, implementation and production support.

SAP Expertise: ECC MM: Purchasing, Inventory Management, ship-direct, Stock transport orders, Vendor and customer returns, Sub-Contracting, VMI, EDI 850/852, Release procedures, Invoice Verification, Forecasting and MRP, External Service Management and SRM for MRO materials.

ECC QM: QM in Procurement, Production and Delivery inspection, Inspection Plans with multiple specifications, DMR Rules, Defects Processing with Quality notifications, Inspections Points during in process inspection, Inspection with Handling units, FMEA, Audit Management Certificates of analysis during deliveries

ECC PP/PI: Bill of Materials, Routings, MRP, Work Centers, Master Recipe, Batch Management, SOP, Production and Process Orders Creation, Confirmations, Kanban and ECM and MES solutions

APO: Demand and Supply Network Planning, Planning object structure, Planning Areas, Planning Books, Storage Bucket Profiles, forecasting profiles, Release profiles, life cycle planning, location split and product split, Info Cubes, Info Sources and CIF

Industry Expertise: Aerospace & Defense, Manufacturing, Distribution, Mill Products, Medical Equipments, Utility, Auto, Life Sciences, Chemicals

Other Expertise: ECC 6.0, DIMP 5.0, SRM, APO, SAP FI /CO, ABAP/4, EBP, BW

Positions Held: Project Manager, Managing Consultant, Quality Assurance Executive

Education: Ph.D. in Quality management

M.S. Production Engineering

SAP Certification in Manufacturing

Awards: IBM distinguished award for delivery Excellence

Best paper awards during technical conferences

IBM consultant certification exhibiting role-model consultant qualities

Relevant Experience:

Client: Honeywell, Feb 2011 to Present

Industry: Aerospace & Defense

Project Scope: Global Template implementation of FI, CO, SD, MM, PP, QM and PS modules

Specific Role: As supply chain lead consultant responsible for rolling out global template for various plants, monitoring the factors impacting scope, and schedule and necessary change management actions to meet the project deliverables

SAP Functional MM/PP/QM

• Conducted business blueprint workshops on production, procurement and quality management.

• Created to-be Business process procedure documents outlining the QM requirements and developed functional/technical specifications needed for enhancements and interfaces with non-SAP legacy software.

• Configured SAP QM module fully for goods receipt inspection, in process inspection, delivery inspection, results recording and usage decision with digital signature and processing of nonconforming material using quality notifications.

• Maintained QM master data including inspection characteristics, inspection plans, routings, work centers, sampling procedures, dynamic modification rules, and quality info records

• Developed to-be processes for vendor returns (RTV) and subcontracting

• Worked on 8130 tag issues and Certificate of Conformance

• Developed a process for external operations to create Purchase requisition during release of the order and its inspection during goods receipt

• Worked on Kanban process for external procurement and also with JIT calls

• Automatic Purchase order, ERS and Consignment settlement has been established.

• Maintained info records, contracts, scheduling agreements and special procurement keys for STO and sub-contracting

• Worked on Production Order Execution using MES /MWB systems with Splitting and Scrapping. Defined different order types for repair and Projects.

• Developed a process to monitor shelf life of products during goods receipt.

• Developed several integrated scenarios for procure to pay and plan to produce teams

Client: Owens-Illinois, May 2010 to Feb 2011

Industry: Chemicals

Project Scope: Global Template implementation of FI/CO, SD, MM, APO, PP and QM modules

Specific Role: As supply chain architect responsible for rolling out global template for various plants, managing the assigned resources, monitoring the factors impacting scope, and schedule and necessary change management actions to meet the project deliverables

SAP Functional APO /MM/PP/QM

• Conducted business blueprint workshops Demand planning, Manufacturing execution and Quality management.

• Designed SAP QM module fully for goods receipt inspection, in process inspection, delivery inspection, results recording and usage decision with digital signature and processing of nonconforming material using quality notifications.

• Inspection with Handling Unit Management (HUM) during goods receipt for production orders

• Developed calibration inspection process using PM and QM modules

• Developed a prototype model to understand FMEA and Audit management functionality and its use.

• Designed repacking and resorting production orders with HUM and on line and off line secondary operations on the production order, assigning mould to the production orders, adding negative components to receive into inventory as by-products.

• Development of new process for forecasting using Demand planning, procurement planning for raw materials, production order execution of Molten glass and glass container and SKU orders with Batch management

• Configuration of APO-BI and DP –creation of info objects, info cubes, configuration of DTP etc for the forecast and history data loads ,remote cube for reporting.

• Setting up of planning areas, MPOS, Planning books, forecast profiles, release profiles to send forecast to SNP and setting up phase-in and phase-out profiles for Life Cycle planning, realignment and consensus based planning

• Lead the Configuration build activities, conference room pilot sessions with stake holders and integration test preparation and execution and data conversion activities for supply chain.

Client: Honeywell, Apr 2007 to Apr 2010

Industry: Aerospace & Defense

Project Scope: Global Template implementation of FI, CO, SD, MM, PP, QM and PS modules

Specific Role: As Quality Management lead consultant responsible for rolling out global template for various plants, monitoring the factors impacting scope, and schedule and necessary change management actions to meet the project deliverables

SAP Functional MM/PP/QM

• Conducted business blueprint workshops on production, procurement and quality management.

• Maintained QM master data including inspection characteristics, inspection plans, routings, work centers, sampling procedures, dynamic modification rules, and quality info records

• Developed a detailed Risk release process (source substantiation) in SAP for releasing the components (SS2) to higher assemblies.

• Designed purging process using SAP Quality Management module.

• Qualifications were defined and assigned to work Centers to check the right person to do NDT, AIR flow, water flow, GSI, final audit inspection.

• Involved in SPOC (special purchase order conditions in procurement) design process.

• Worked on Production Order Execution using MES /MWB systems with Splitting and Scrapping. Defined different order types for repair and Projects.

• Developed a process to monitor shelf life of products during goods receipt.

• Defects recording and reporting to dashboard for vendor evaluation.

• Quality management module was fully integrated with supply chain and manufacturing processes.

Client: IBM/CMC, DEC 2006 to March 2007

Industry: Manufacturing, recycling and marketing of steel and other metals

Project Scope: Global Template preparation and implementation of ECC 6.0 with APO

Specific Role: As supply-chain lead consultant responsible for blueprint preparation using SAP Mill Products and assisted for project scope, planning and reporting activities

SAP Functional PP/QM/APO Role

• Developed to-be processes for Melting, Rolling and finishing processes

• Developed to-be processes for Scrap and Recycling

• Developed to-be processes for Joist, Rebar and structural Fabrication.

• Maintained BOMs, Work centers, Routings, operations & sub operations

• Worked on process batch and original batch to track heat number

• Evaluated present QM legacy system and mapped into SAP

• Configured QM module for procurement, in process, and delivery inspection and Quality notification process defined for processing defective parts for, internal, vendor and customer complaints.

• Worked on design requirements of quality certificates (MTR)

• Closely worked with APO team for feasibility of DP and SNP

Client: IBM/WelchAllyn, FEB 2006 to Dec 2006

Industry: Medical Equipment Manufacturing and Distribution

Project Scope: Rapid implementation of SAP using Global template for Mexico operations

Specific Role: As project Manager cum Supply-Chain team lead responsible for leading the client from Project Preparation to Go-live & support phases of the project and managing the scope, budget and resources

SAP MM /PP/QM Role:

• Defined and configured purchasing, inventory and invoice verification modules to meet the business requirements.

• Worked on both discrete manufacturing and repetitive Manufacturing processes

• Defined MRP planning strategies, consumption logic and maintaining PIRs for various product lines.

• Developed Kanban system with summarized JIT Calls for external procurement and inter-company stock transfers with scheduling agreements using kanban process

• Developed a process to determine number of kanbans required automatically by distributing (smoothing) the dependent requirements between start and finish date using a distribution key

• Defined the efficient QM process for receiving inspection, in process inspection and final good receipt inspection for various medical devices

• Defined electronic signatures in usage decision and results recording processes to meet the cGMP requirements

Client IBM/ Bayer, August 2005 – Feb 2006

Industry: Healthcare and Biological Products Manufacturing

Project Scope: Process Design and Implementation of SAP MM, FI, QM, PP/PI,SD and DMS.

Specific Role: As a QM project lead responsible for leading the client from blueprinting phase to go-live, replacing legacy systems, research and implementation of new functionality, managing the assigned resources, monitoring the scope and schedule and mitigating risks

• Extensive evaluation of Bayer US legacy system and mapping to SAP and modifications to global template.

• Designed and configured the efficient QM process for receiving inspection and in-process inspection for fermentation, early good receipt inspection purification, final good receipt inspection for bulking, freeze drying and packing processes with batch management.

• Streamlined the inspections catalogs used for inspection with inspection plan group and group counters for TRD submission process and approval

• Fermentation process was designed innovatively using inspection points concept to inspect samples with regular intervals and ability to take corrective measures quickly throughout the process with a single lot

• Designed inspection plans using multiple specifications for final container inspection

• COA process was designed to print certificates at various levels.

• Defined methodology for maintaining material masters, Recipes, BOMs, vendor masters, source list, outline agreements, purchase info records, outline agreements, release procedures, pricing conditions etc.

• Designed Auto Purchase Order process and ERS functionality for approved Vendors

• Defined and configured MRP process based on movement of materials in the warehouse like fast moving, slow moving and no moving..

• Necessary settings were made to check the shelf life of goods before Goods issue and batch job to move into blocked stock

Client IBM/DTE Energy, Detroit, May 2004 – August 2005

Industry: Utility service provider in the state of Michigan

Project Scope: Process Design and Implementation of SAP R/3 4.7 rel 2 Materials Management Maximo, HR, Work management, FI /CO, SRM etc

Specific Role: As Supply Chain lead consultant designed and configured MM module fully for Purchasing, MRP, Forecasting, Inventory Management, External Services and Account Determination processes for DTE operations.

• Worked extensively on integrating SAP purchasing and inventory modules with Maximo work order system.

• Split-Valuation approach used for valuating the serviceable and unserviceable items in the inventory using batch management.

• Designed, configured and delivered the efficient MRP process for multiple plants with Hub-and-spoke plant configuration.

• Developed sub-contracting process for repairs using recursive BOM’s.

• Worked on service masters, service entry sheet and invoice verification for services.

• Developed VMI processes and communicated using EDI 852 for different Vendors and materials

• Developed and configured KANBAN processes for external and internal procurement processes

• Developed to-be processes for physical inventory, scrap, vendor returns (RTV) and consignment.

Client IBM/General Motors, SPOM, Mexico, April 2003 to May 2004

Industry: Service Parts Operation

Project Scope: Process Design and Implementation of SAP R/3 Materials Management, Sales and distribution and FI /CO Modules for service parts operation of GM

Specific Role: As supply chain lead consultant responsible for design and development of procure to pay process at GM, Mexico

• Configured MM module fully for Purchasing, MRP, Forecasting, Inventory Management, Account Determination, and Invoice Verification for service parts operations.

• Created new purchase requisition types and purchase order types for air-stock, VIP and VIP ship direct procurements and defined release strategies.

• Designed ship-direct procurement process to create automatic purchase requisition during sales order creation

• Designed ASN process and also made appropriate settings not to accept more than purchase order quantity.

• Configured new movement types for post goods issue based on domestic and imported customers.

• Configured valuation and account determination for all material types/movement types used for service parts operation.

• Maintained different payment methodologies in vendor master based on vendor type and also vendor specific tolerances.

• Defined and configured MRP process based on movement of materials in the warehouse like fast moving, slow moving and no moving. Settings are made to calculate automatic reorder point and safety stock with service level.

• Demand based forecasting system has been adopted to capture sales figures into material master for accurate forecasting instead of consumption figures.

Client IBM, Asset Financing and leasing, New York, Jan 2000- Dec 2002

Specific Role: As SAP MM/QM Project lead responsible for design and development of custom solution for receiving the leased assets, inspecting the assets and billing the customers for returning defective products using SAP MM/QM module. A new approach designed to inspect variant configurable materials like RS/6000,AS/400 and DASD in SAP. Developed defect fee structure based on technology levels and also a criteria to exclude some customers from billing. SAP QM module was integrated with various IBM legacy systems like ICFS, RICS etc.

Client: IBM/ NAVSEA, Ship Maintenance and Repair, Aug 1999 - Dec 1999

Specific Role: Played key role as MM/ QM consultant in defining procurement and quality Processes for for US NAVY Ship Maintenance. Purchasing, inventory management, invoice verification and quality management modules were configured to meet the business requirements of Navy. Configured QM module fully for receiving inspection and shelf life monitoring for short life materials with batch management

Client: IBM/Lyondell-Equistar Chemicals, Houston- Mar 1999- August 1999

Specific Role: Extensively involved in post go-live enhancements of MM, PP/ PI and QM in LIMS environment.

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