Profileimage by Sastry Karunakar Sr.  SAP S/4  Hana PP PM QM Consultant from Vadodara

Sastry Karunakar


Last update: 23.11.2020

Sr. SAP S/4 Hana PP PM QM Consultant

Graduation: BE(Metallurgy)
Hourly-/Daily rates: show
Languages: German (Elementary) | English (Native or Bilingual)




SAP S/4 HANA PP, PM. QM module consulting and solutioning / prototyping and onfiguration, Fiori 6.0 ODATA service activations.
Have good consulting and solutioning experience using all R/3 ECC 6.0 versions as well.
Data Migration Experience using LTMC data migration workbench and LSMW tools

Project history

Sr. SAP PP-QM Consultant
06.2013 - today
Project # 5 (Apr-14 - Till Date )
Alembic Pharmaceuticals Ltd : Vadodara
Onsite Support :
Implementation of Long Term Planning , Campaign based production in SAP ECC6.0, and resolve support Issues in PP-QM related to MRP, Stocks , Performance issues in LIS reports, resolve inconsistencies in MRP run, Stock requirement list etc.

Offsite Support : GSP Crop science Ltd .

Streamlining of MRP process and automation, routine support issues in PP-QM areas.

Other Tasks: Quick configuration and prototyping for Textiles, Steel Metal / Foundry Industry Production Scenarios including lot of subcontracting in manufacturing.

Project # 4 (Jun-13 to Apr-14 )

Client : KPMG

SAP Implementation project at Biotech Vision Care Pvt Ltd. Biotech vision care pvt ltd is a reputed manufacturer of eye lenses of various brands , Prefilled Syringes and Vials for various health applications, and Eye surgery equipments.

Requirement gathering, Blueprint, Realization and testing , Go-live and Post Go-live Support - PP Discrete , PP-PI-QM modules for its manufacturing operations in Ahmedabad and Stock Distribution Centers (CFA's).
Quick prototyping and testing of complicated PP-QM scenarios for MRP, Demand management, Shop floor execution, Production / process order confirmation, Standard reports / custom reports, Interface with barcode machine, Quality inspection plans and master data planning, configuration, Quality certificates development as per requirement. . Development of custom process form for printing process instructions / operations for execution of process orders, and feeding information to Lathe, milling, combo machines. Prepare FS and Co-ordination with ABAP for Enhancements, custom reports etc.

Delta Sys-Tech ( India ) Pvt Ltd
SAP PP-QM Consultant & Team Lead
12.2012 - today
Project # 2 : Major Steel Plant - Cold Rolling sector of a well known business conglomerate.

Handling a team of 12 plus for a multi-site implementation and support project for Steel Plant and Engineering sector in the capacity of a Team lead.

Conducting SAP Re-implementation feasibility study , Configuring and creating prototype business model in SAP server and demonstrate SAP business functions for PP-QM with integration in MM, SD, FI-CO, and Batch management modules, for a steel major in Cold rolling and speciality steel . Complete analysis of business and business requirement gathering , preparation of business blue print, configuration document for PP-QM, Batch management modules and presentation .

Major high lights during prototyping:

Study of Variant Conguration .
Co-ordinated with ABAP team and Implemented user exit EXIT_SAPLV01Z_002 for selecting desired batch number range object based on material type, Batch Derivation.

Delta Sys-Tech ( India ) Pvt Ltd
SAP PP-QM Consultant & Team Lead
12.2012 - today
Project # 3 : Engineering Sector - Well known EPC project engineering company engaged in the manufacture of Project goods for manufacturing sugar plants , Distillary and Alcohol-Ethanol Plants, Power Generation Plants catering to Atomic energy and Nuclear Power, Defence Laboratories, Oil and Gas Companies,OEM equipments for Cement Industry, Steel industry, Paper Industry, Material Handling Industry, General Heavy Engineering.

SAP Team Lead for Support project in PP, MM, SD, PS, FI, CO.
Co-ordination for timely resolution of tickets related to PS, PP, MM, CIN, SD, CO , FI, for onsite and remote support.
End user training for PP users , LSMW for BOM, Routing mass upload for each project item.

Major Highlights of support :

1) Automation of Purchase requisition through MRP run. Manual PR system closed.

2) Control of GR through activation of PR release and PO release strategy and implementation of User exit M06E0004 for controlling qty changes, price changes and delivery date changes in PO, and system prompts for Re-release of PO.

3) Testing of complete Cycle for Project creation, MRP, production planning, confirmation, Costing, Dispatch with ref to WBS element.
4) Co-ordination for resolving CIN issues and application of SAP notes for J2iun run time errors , and RGSUM errors.

Erplogic (India) Pvt Ltd
Associate Consultant - SAP
08.2011 - 12.2012
Project #1
Participation and contributions in Realization, Final Preparation, End user Training and Manual preparation, Go-live and Post Go-live Support Phases of SAP PP module (Onsite / Offshore) of the SAP implementation project for 9 plants at one go for a large iron ore mining group.

Study of Blue-Prints, Auditing, Requirement Gathering, Unit Testing , Integration testing, Configuration, Co-ordination with ABAP team, BI, and Post-Go Live Support for a multi-site Large Iron Ore Mining Establishment.

Exposure to MTS and MTO scenarios . Strategy no.10, 11, 20, and combination of 10 and 20. Configuration .

Experience of Creating Materials, co-products, Joint production , Production versions, routings , Workcenters, Customising and settings for various standard reports for PP, and solving various issues related to Posting Goods movement during Confirmation , Goods Receipts for Production , Costing Errors, activity confirmation errors, post processing of error records, during Post-Go-Live support and devised improvement methods for ease of confirmations.

Provide Functional Logic to help convert the user-requirement into various BI-reports for PP users, such as Daily Shiftwise Production Report, Target/Actual Material consumption report, Opening and Closing Stock Report for Produced materials /components, etc.

Introduced Mass Operation-Confirmation process which has resulted in increased speed of confirmation process compared to the earlier method of Single Screen confirmation.

Familiar with SAP Solution manager(Incident Management) for production support, timely issues resolving and extended support during critical situations ensuring smooth operations . Experience with Firefighter id for problem solving.

Delphi Computech Pvt Ltd
Associate SAP Certificate – SCM (Manufacturing and Planning) ECC6.0 EHP4 Training
03.2011 - 07.2011
Underwent rigorous hands on training and practice on live IDES server in SAP Logistics PP Module – Planning and Manufacturing ,ECC6.0 EHP4 .

Trained on the basic concepts, Operation and configuration of SAP objects for :

Material Master, BOM, process orders, production orders(PP -SFC), repetitive manufacturing, discrete manufacturing, KANBAN, material types, classification, multiple BOM, Variant BOM, various planning strategies such as Make to stock, Make to order, sub assembly planning, planning with final assembly, Phantom assembly etc and customization of the above to map the business process in to SAP, capacity planning, capacity levelling, using planning table ( Graphical / tabular), scheduling , creating work centers, Capacities, routings, using engineering work bench, MRP, Single level Single Item, Single Item Multi Level, Single Item Interactive, Planning with Planning Table, Stock Requirement List, MRP evaluation, SAP Solution manager, ASAP Roadmaps , customization and configuring using SPRO, basics of APO, SNP, Long term planning, Simulation and transfer of LT planning results to Operative Environment and vice versa, Master schedule, Confirmation of time tickets for production orders, Time Event Confirmation, Goods movement Postings, etc.
Practice and application of T-Codes for above mentioned processes.

Certified on 20th Jul’11 , with first attempt. Certification id: 0008413861

Delta Steel Co Plc
Manager(Production Planning and Inventory Control)
07.2006 - 10.2010
Co-ordination with Electrical, Mechanical, Civil and other support units for reactivation of this comatose unit in Nigeria , Consolidate Project schedules and monitoring them for timely completion of re-activation of the plant for start up.
Co-ordination with SMS, Rolling Mill, Pellet Plant, DRI Plant, and Utilities for Heatwise production, delay, yield and other Key performance indices .
Conceptualization and development of Business model for monthly planning , annual planning.
Preparation of Monthly Production plan and Customer wise Order Processing/ readiness plan & Co-ordination with Billetyard, Quality and Marketing for Sales order compliance.
Release melting plan to SMS, and Mill production schedule to Rolling Mill on a daily basis based on prevailing dynamic condition of the plant.
Preparation of consolidated business plan, production plan, MIS for cross country rolling mills ie DSC, ASCL, NIOMCO plants, and monitoring the Iron Ore movement from NIOMCO, Billet movement to ASCL, Finished goods transfer from ASCL to DSC, and dispatch from ASCL and DSC as per Plan.
Developed Integrated MIS system, which covers day to day , Monthly, Yearly KPI’s , Production , Sales, Receipts and Consumption information.

Contributed to Highest Rolling per day of 629 MT/day in 12 mm Re-bars and 1139 MT per day in 25mm profile Re-bars, by ensuring continuous supply of quality Billets shiftwise with out gap.

Monitoring of Rolling Mill Yield, EAF yield, Caster yield, Ferro-alloy consumption, utilities consumption and co-ordination for implementation of improvement projects as per decisions taken in review meetings.

Made best in class business plans and presentations for tying up Loans for Working Capital and Mordernisation program to the tune of 50 Million USD from various local and international banks……[Additional Responsibility to assist Finance Department]

Delta Steel Co Plc
Dy.Manager (Production Planning and Inventory Control)
12.2004 - 06.2006
Prepared Project Monitoring reports during re-commissioning activities of various Units; monitored incoming materials( Billets ) and outgoing Finished Goods.

Detailed study of Project report of Delta steel Co Plc , study of norms and specific consumptions of raw Materials and consumables for preparation of production plans.

- Co-ordinated with SMS, Rolling Mills, Marketing and QC for Mill Scheduling and Planning, to ensure Zero Stoppage of Production lines due to Billet shortage, scheduling problems, and Utilities problems.
- Documentation for inclusion in DSC Quality Manual for ISO 9000: 2001 in PPC Dept.

? Distinction of developing and implementing Complete planning procedure for Billet Casting, Melting, Rolling Mill Scheduling, Monitoring and formalized the procedure as an ISO Document as well as SOP.

Computer Skills used:
Extensive use of MS Office Products such as Power Point, MS Excel, Word,

Dy. Manager ( Production Planning and Control )
04.2004 - 12.2004
Generate Consolidated Production Plan for SMS, Caster, Hotstrip Mill, Cold Rolling Mill, Skinpassing Mill, Galvanising Mill, Downstream Facilities for Plate Cutting, Slitting Line, Coil Parting and Slitting. Preparation and monitoring of Customerwise linewise production Schedule for all the above facilities.
Co-ordination with Steel Melt Shop, LF, VD/VOD, Caster, HSM, QA, QC,Slabyard & Marketing for achieving daily and campaign wise production schedule ( Melting plan and Rolling schedule)
Prepare Customer wise delivery schedules as per the LC coverage, Vessel Requisition for Exports servicing.
Transmit Hot Strip Mill production schedules to Level-II systems of Rolling Mill for production during each shift.

Distinction of achieving the highest production in the month of May-2004 (197000 MtHRC)
Achieved highest HSM production target in a day i.e. 10637 MT; Supported Melting plan and Casting plan for record production of 64 Hts Casting in a single day during Sep’04.

Extensive use of MS Office Products such as MS Excel,MS-ACCESS.
Application Software : Custom built Oracle based package using Power builder-4.0,SAP R/3
Crystal Reports for Querying Reports.For Production Planning , SAP-R/3 for Material Creation, BOM , Routings, MRP runs, Stock Transfer postings.

Sr. Engineer ( Production Planning and Control )
04.1999 - 03.2004
Prepared shiftwise Rolling Schedules for Hot Strip Mill and Meltplan for EAF/LF/VD/VOD/Caster
- Co-ordination with MeltShop, Caster, Slabyard, Rolling Mill, QA & QC Department.
- Issue of Storage Plan for Coil Inventory and Shifting to Material handling Personnel.
Computer Skills used:
Extensive use of MS Office Products such as MS Excel,MS-ACCESS.
Application Software : Custom built Oracle based package using Power builder-4.0,
Crystal Reports for Querying Reports.
For Production Planning , SAP-R/3 for Material Creation, BOM , Routings, MRP runs,
Stock Transfer postings.

Engineer- Production Planning and Control
04.1998 - 03.1999
Handled the activities pertaining to Production & Despatch of material.
Preparing Rolling Schedules for HSM and co-ordination with slabyard/Caster/Meltshop/HSM/QA/QC/Marketing.

Engineer - Steel Melt Shop
04.1997 - 03.1998
Melting and Supervision of DC EAF Operation, as per standard melting profile / SOP in shifts. Managing DC - EAF Operations ( Control Room plus field activities, co-ordination) independently in shifts. Experience in melting of various grades such as CORTEN, EDD, SIL, CRM, GEN, API, WTP, IF grades.

Excellent Operation and Control of BSE Oxygen Lance Manipulator, Lance changing, Operations of Material Feeding Control Panel and Power input control, Gunning Machine, Fettling Machine, Forklift Operations for Slag door cleaning.

Maintain Excellent Feedrate of HBI as per scrap mix , furnace conditions , power input, and finish heat at least possible Kwh/Tls.

Co-ordination with LF incharge, VD/VOD incharge, Ladle bay incharge, Caster Shift Incharge to ensure good Ladle is available timely for tapping.

Monitoring of furnace refractory condition after every heat, preparation for wash heat incase of excessive wear of furnace bottom and walls and timely information to shift incharge.

Co-ordination with Lime Plant, HBI Plant for SILO filling. Ensure CPC , Gunning Masses are filled in respective bunkers during each heat for trouble free operations. Co-ordination with scrapyard for scrap bucket Preparation and readiness in advance as per grade plan. Periodic cleaning and clearing of fume extraction system cleaning and clearing for efficient Melting.

Slag Door cleaning, Trouble shooting of Operational Problems during Melting, such as Over voltage, Insulating material, Slagpit cleaning, Graphite Electrode Changing, etc and good control over tapping as per melt grade and order requirement.

Achieved Benchmark of 5 heats per Shift on a number of Occasions during my Furnace Shift, with in the specified carbon,Sulphur,Phos and oxygen PPM levels , and satisfactory Temperature levels for Ladle Furnace Engineers and VD/VOD Engineers.

Graduate Engineer Trainee - Steel Melt Shop
08.1996 - 03.1997
- On the job training in DC-EAF Panel Operations, shop floor work and co-ordination activity .
- Elevated as Furnace Engineer there after for
Managing EAF Operations and Melting in Shifts independently.
- Co-ordinated with Mechanical and Electrical Shift In-charge, Refractories for timely completion of shutdown Jobs.


Time and spatial flexibility


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