MODULE CURRICULUM DOCUMENT

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1 MODULE CURRICULUM DOCUMENT MANUFACTURING AND LOGISTICS APPLICATIONS (C362) Approved by: Boo Chong-han Director, School of Infocomm Date of Approval: 20 March 2015 Submitted by: Wong Huan Leong Senior Lecturer Effective Date: AY2015 Semester 1 Document Status: New Document Manufacturing and Logistics Applications Page 1

2 SECTION 1: MODULE RUBRIC Module Provider: Supported Departments: School of Infocomm (SOI) NA Credit Units: 4 Total Curriculum Hours: 60 SECTION 2: MODULE OVERVIEW This module aims to develop a comprehensive understanding of the knowledge, skills and techniques required by students who intend to work as IT professionals in the manufacturing and logistics area. The knowledge and skills garnered by students will allow them to implement and/or customize IT systems that support the manufacturing and logistics business functions and processes of a business. The module coverage will include: Role of corporate structure in a Enterprise Resource Planning (ERP) system and an overview of how IT systems support businesses and their processes Pricing, partners management and inventory changes in an Order-to-Cash (OTC) cycle. Production strategies, demand forecast and Sales & Operation planning (S&OP) Special procurement processes and inventory changes in a Purchase-to-Pay (PTP) cycle Production cycle in discrete and process manufacturing Inventory Costing methods and the impact of the costing methods to Sales, Cost of Goods Sold (COGS) and profit Quality control cycle and qualtity management process Electronice Data Interchange (EDI) Logistics services which include warehousing, transportation and third party logistics (3PL) services To attain the graduate outcome of basic competency with flagship business applications/software and tools that support the above business functions, such as the SAP ERP system, laboratory exercises will be designed to provide opportunities for students to practice and demonstrate technical skills as well as content knowledge. Laboratory exercises will be designed in relation to manufacturing and logistics business processes so that students can relate how business in these domains functions. This is an advanced module where students should preferably have undertaken a foundational module on business functions and business processes such as the C360 Enterprise Solutions for Business module. Manufacturing and Logistics Applications Page 2

3 SECTION 3: MODULE OUTCOMES AND LEARNING OUTCOMES Module Outcomes 1. Design and describe the organization units used in a corporate structure for an ERP system to support manufacturing and logistics processes Learning Outcomes 1.1 Describe the organization units in an ERP tool 1.2 Design a corporate structure that will support Orderto-Cash (OTC), Purchase-to-Pay (PTP), production and inventory management processes 1.3 Explain how IT systems helps in supporting businesses and their processes 2. Describe pricing procedures and the partners functions used within an OTC Cycle and use an ERP tool to demonstrate the relevant system functions 3. Define various production strategies, explain the forecasting, operation planning and control processes and use an ERP tool to demonstrate Sales and Operation Planning (S&OP) and Material Requirement Planning (MRP) 2.1 List the stages of the OTC cycle and identify the important data associated/required at all the stages 2.2 Explain the relationship and cardinality between the documents used in an OTC cycle such as quotation, sales order, transfer order, delivery order and billing document 2.3 Distinguish and describe the usage of different partner functions (Sold-To, Ship-To, Bill-To and Payer) in the OTC cycle 2.4 Identify the different pricing conditions (Unit Price, Discounts, Surcharges, Tax) used in an OTC cycle and calculate the net price during sales 2.5 Use an ERP tool (SAP) to demonstrate the pricing and partner functions, and analyse material s inventory movements at different stages 3.1 Define production strategies used in manufacturing and logsitics (Make to Stock, Make to Order, Assemble To Order, Engineer To Order) 3.2 Describe the fundamentals of forecasting 3.3 Identify different forecasting methods under the Quantative and Qualitative categories 3.4 Compute forecasts using Moving Average and Exponential Smoothing methods 3.5 Recognise the importance of forecasting accuracy 3.6 Measure forecast accuracy using the Mean Absolute Deviation (MAD) method 3.7 Desribe the Sales & Opertaion Planning (S&OP) processes 3.8 Explain the Material Requirement Planning (MRP) processes for finished product 3.9 Explain the Material Requirement Planning (MRP) processes for components used in the production of a finished product 3.10 Perform MRP calculation for a finished product 3.11 Perform MRP calculation for components used in the production of a finished product 3.12 Use an ERP tool (SAP) to demonstrate the S&OP processes and analyse the MRP results Manufacturing and Logistics Applications Page 3

4 4. Describe Purchase-to- Pay (PTP) and special procurement processes and use an ERP tool to demonstrate the relevant system functions and steps for each process 5. Describe the business processes in a production cycle for both discrete and process manufacturing, and use an ERP tool to demonstrate the relevant system functions 6. Explain different inventory costing methods, identify and compare the direct and indirect costs involved in the production of a finished product 4.1 Identify the stages in a PTP cycle and explain the relationship to Material Requirement Planning (MRP) activities 4.2 Explain the relationship and cardinality between the documents used in a PTP cycle such as purchase requisition, request for quotation, purchase order, good receipt and invoice document 4.3 Describe special prociurement processes in PTP Subcontracting processes Blanket Order processes Supplier Consignment processes Scheduling Agreement processes 4.4 Apply special procurement processes to different purchasing scenarios 4.5 Use an ERP tool (SAP) to demonstrate special PTP cycles, analyse their financial postings and inventory movements 5.1 Identify the master data used in a production cycle 5.2 Identify the stages in a production cycle and their relationships to Material Requirement Planning (MRP) 5.3 Distinguish between discrete and process manufacturing 5.4 Explain the benefits of using backflush strategy in issuing raw materials to production operations 5.5 Use an ERP tool (SAP) to demonstrate a production cycle, analyse inventory movements for operations with and without backflushing strategy 6.1 Distinguish between perpectual and periodic inventory systems 6.2 Explain different types of inventory costing methods Standard Moving Average First In First Out (FIFO) Last In First Out (LIFO) 6.3 Calculate the cost of goods sold (COGS), ending inventory value and gross profit using different inventory costing methods such as Standard, Moving Avegare, FIFO and LIFO 6.4 Explain the impact of an inventory costing method under different business environments 6.5 Describe product costing and distinguish between the direct and indirect costs invoved in a production 6.6 Calculate product cost using material and operation costs 6.7 Use an ERP tool (SAP) to highlight data used in inventory costing and product costing Manufacturing and Logistics Applications Page 4

5 7. Describe the business processes in a quality control cycle, explain quality management processes and standards and use an ERP tool to demonstrate quality control 8. Describe the purpose of Electronic Data Interchange (EDI), map business document to an EDI format and use an ERP tool (SAP) to demonstrate the Business-to-Business (B2B) interface 9. Describe logistics functions and processes, tranportation management and third party logistics (3PL) services and use an ERP tool to demonstrate the transactions and master data for transportation and storage of goods 7.1 Define quality management and the different levels of quality management (Total Quality Management, Quality Assurance, Quality Control and Quality Inspection) 7.2 List and explain the various international quality standards (GMP, ISO, HACCP, RoHS) in manufacturing and logistics 7.3 Describe the stages in a quality control cycle 7.4 List and describe the document and data associated with a quality control cycle 7.5 Use an ERP tool (SAP) to demonstrate quality control cycle and analyse the inventory movement 8.1 Describe EDI in a B2B interface and explain its benefits to businesses 8.2 Identify different international standards for EDI such as EDIFact, ASC X12 and Rosettanet 8.3 List the transmission mediums used for EDI 8.4 Map a business document (Purchase Order) to an international EDI format (EDIFact) and a SAP IDoc 8.5 List business documents which can be transmitted via EDI 8.6 Use an ERP tool (SAP) to demonstrate the conversion of SAP IDoc to business document (sales order), and analyse the data of the document created. 9.1 Define logistics cycle and logistic network 9.2 Identify different modes of transport (air, land and sea) and their services 9.3 Define third party logistics (3PL) and explain the value added services that they provide 9.4 Describe the functionalities of a typical Transportation Management System (TMS) 9.5 Explain the purpose and regulation of custom 9.6 Analyse material safety data sheet (MSDS) used for dangerous goods 9.7 Use an ERP tool (SAP) to demonstrate the transactions and master data relevant for transportation and storage of goods Manufacturing and Logistics Applications Page 5

6 SECTION 4: TEACHING AND LEARNING The teaching and learning approach adopted in this module is primarily problem-based learning. Problem-Based Learning (PBL) The module adopts the typical PBL model which involves students working on one problem a day over a structure of three learning phases and one study period. The characteristics of PBL are as follows: A problem is used to trigger learning of new knowledge and skills Students work in collaborative small groups in the process of learning The main role of a teacher is a facilitator of students learning Students are given the opportunity to construct their own knowledge with the assistance of a facilitator and other suitable scaffolds Students are given the opportunity to undergo individual self-directed learning Students have an opportunity to present their findings/solution Students reflect not just upon what they learn but how they went about learning SECTION 5: ASSESSMENT Assessment Methods Students are assessed based on 2 main components: Continuous Assessment (CA) and Semester Assessments. The students are assessed on their attainment of knowledge and practical skills, engagement with knowledge and practical skills and engagement in collaborative learning for the CA. These criteria focus both on the development of good learning processes and learning behaviors as well as the attainment of skill and knowledge. For the Semester Assessments, the students are assessed on their ability to understand and apply what they have learnt at two points of the semester: Mid Semester Assessment (MSA) and End Semester Examination (ESE). Assessment Weighting The assessment components for this module are the (i) Continuous Assessment (CA) and (ii) Summative Assessment. (SA). The Mid Semester Assessment (MSA) and End- Semester Examination (ESE) will form the SA component. The breakdown in weightings between CA and MSA/ESE is tabulated below. Breakdown between CA and MSA/ESE Weighting (%) CA 30 MSA / ESE 70 The weightings for MSA and ESE are shown below. Breakdown between MSA and ESE Weighting (%) MSA 40 ESE 60 Manufacturing and Logistics Applications Page 6

7 Grading Scale for MSA/ESE The recommended proportion of questions at Competent, Proficient and Advanced level for the module is shown below. For Written Tests: Level of Knowledge and Skills Recommended Proportion in each Test Competent % Proficient % Advanced % A grading scale specifying the performance standards and corresponding percentage of marks to assign the test letter grade is shown below. Performance Standards Students able to answer all questions at Competent Level, most questions at Proficient Level and some questions at Advanced Level Students able to answer all questions at Competent Level and most questions at Proficient Level Students able to answer most questions at Competent Level and some questions at Proficient Level Students able to answer most questions at Competent Level Students unable to answer most questions at Competent Level Percentage (%) of Marks Test Grade 80 and above A 75 to less than 80 B+ 70 to less than 75 B 65 to less than 70 C+ 60 to less than 65 C 55 to less than 60 D+ 50 to less than 55 D (Pass) 40 to less than 50 E less than 40 F SECTION 6: LEARNING RESOURCES The resources used for the conduct of this module are as follows: Software SAP Enterprise Resource Planning (ERP) System (Primary) Microsoft (MS) Excel Reading Materials Concepts in Enterprise Resource Planning, 3 rd Edition, Ellen Monk & Bret Wagner Slack, Chambers & Johnston, Operations Management, 3 rd Edition, Prentice Hall Manufacturing and Logistics Applications Page 7

8 Case Study E-Learning / AV materials Manufacturing and Logistics Applications Page 8

9 ANNEX A: PROPOSED SCHEME OF WORK Learning Outcomes Weeks x 1.2 x 1.3 X 2.1 x 2.2 x 2.3 x 2.4 x 2.5 x 3.1 x 3.2 x 3.3 x 3.4 x 3.5 x 3.6 x 3.7 x x 3.8 x x 3.9 x 3.10 x x 3.11 x 3.12 x x 4.1 x x 4.2 x x 4.3 x x 4.4 x x 4.5 x x 5.1 x x 5.2 x x 5.3 x 5.4 x 5.5 x x 6.1 x 6.2 x 6.3 x 6.4 x 6.5 x 6.6 X 6.7 x x 7.1 x 7.2 x 7.3 x 7.4 x 7.5 x 8.1 x 8.2 x 8.3 x 8.4 x 8.5 x 8.6 x 9.1 x 9.2 x 9.3 x Manufacturing and Logistics Applications Page 9

10 Learning Outcomes Weeks x 9.5 x 9.6 x 9.7 x Manufacturing and Logistics Applications Page 10

11 ANNEX B: TEMPLATE FOR ASSESSMENT SPECIFICATION TABLE Instructions: MCs are required to: prepare a MSA/ESE specification table for each assessment that is set; align to the recommended proportions of questions as stipulated in Section 5, Assessment; and list the following in the/assessment specification table: - The coverage of content standards (e.g. intended Learning Outcomes) of the module; - The knowledge and skills levels (e.g. competent, proficient and advanced) to be assessed; - The assessment s breadth, emphasis and depth (e.g. number of questions and marks accorded for the Learning Outcomes and levels). Assessment Specification Table Template Note: Adjust the recommended proportions for other types of MSA/ESE such as practical tests, assignments, etc. * Each part of the question is be reflected in a separate row, e.g., Q1(a) is one row, Q1(b) is another Knowledge and Skills Standards Content Standards Question No.* Competent Level (Marks) Proficient Level (Marks) Advanced Level (Marks) Total marks: Percentage of marks: <x%+y%+z% = 100%> Recommended proportion: (for written paper) x% y% z% 55 65% 20 30% 10 20% Manufacturing and Logistics Applications Page 11

12 ANNEX C: SAMPLE OF A TEACHING AND LEARNING PLAN Not Applicable Manufacturing and Logistics Applications Page 12

13 ANNEX D: SENATE APPROVAL Not Applicable Manufacturing and Logistics Applications Page 13

14 AMENDMENT HISTORY S/No. Status/ Amendment Description Rev No. Effective Date (Indicate AY) Approval (Attach record of approval) 1 New Release 00 AY2015 Sem Manufacturing and Logistics Applications Page 14