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1、Production PlanningPP/DS OverviewDetailed SchedulingPP/DS in SAP SCM 5.0 OptimizationIndustry Specific Planning ProcessesSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 3Components of SAP SCM 5.0 Solution Demand Planning Supply Network Planning Service Parts Planning Production Planning De
2、tailed Scheduling Transportation Planning Vehicle Scheduling Global Available to Promise Trade Promotions PlanningSupply Chain PlanningSupply Chain Execution Materials Management Manufacturing Service Parts Execution Warehouse Management Transportation Execution Trade Promotions & Foreign Trade Orde
3、r FulfillmentSupply Chain Collaboration Inventory Collaboration HubSupply Chain Visibility & Performance Management Supply Chain Event Management Supply Chain Analytics Enterprise PortalSupply Chain Integration Exchange Infrastructure Auto-ID Infrastructure Composite Applications1 Master Data Manage
4、ment Business Intelligence NetWeaver components Supplier Managed Inventory Responsive Replenishment Distributed Manufacturing1 coming in 2006SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 4onlineOnline Integration into ExecutionExecution with SAP R/3Planning with SAP APOChange of work cen
5、terRe-scheduling manual/automaticVisualizationOptimizationProd. OrderPurch. OrderCustomer RequirementCustomer OrderForecast RequirementPlanned OrderPurch. Requ.Change of work center Status changeConfirmationGoods receiptplanned orderProduction PlanningOrder ConversionConsumption Prod. OrderPurch. Or
6、der.Planned OrderPurch. Requ.onlineonlineonlineSupply Network PlanningSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 5Supply Chain Planning Matrixlong-termshort-termProcurementSalesProductionDistributionSupply Chain Design / Strategic Network PlanningSupply Chain Design / Strategic Networ
7、k PlanningSupply Network PlanningSupply Network PlanningProcurementProcurementplanningplanningDemandDemandplanningplanningGlobal ATPGlobal ATPProductionProductionplanningplanningDetailedDetailedschedulingschedulingDistributionDistributionplanning / planning / DeploymentDeploymentTransportationTransp
8、ortationplanningplanningSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 6Bucket CapacityIntegration between PP/DS and other planning moduleslong-termshort-termProcurementSalesProductionDistributionSupply Chain Design / Strategic Network PlanningSupply Chain Design / Strategic Network Plann
9、ingSupply Network PlanningSupply Network PlanningProcurementProcurementplanningplanningDemandDemandplanningplanningGlobal ATPGlobal ATPProductionProductionplanningplanningDetailedDetailedschedulingschedulingDistributionDistributionplanning / planning / DeploymentDeploymentTransportationTransportatio
10、nplanningplanningExample: Bucket oriented CTP: PP/DS bucket-based capacity checksDesired DatePlanning DirectionTime-Continuous CapacityPlan StartSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 7PP/DSSNPSNP HorizonSNPn Planning only in SNP horizonn Release SNP Orders only in PP/DS horizon n
11、 Respect PP/DS orders as fixedncapacity reductionnmaterial flow PP/DSn Respect pegged SNP Orders as due datesnNo capacity reductionnBut material flown No restrictions for scheduling PP/DS ordersIntegration between SNP and PP/DS (I)PP/DS HorizonSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl
12、/ 8PP/DSSNPSNP HorizonSNPn Planning only in SNP horizonn Release SNP Orders only in PP/DS horizon n Respect PP/DS orders as fixedncapacity reductionnmaterial flow PP/DSn Respect pegged SNP Orders as due datesnNo capacity reductionnBut material flown No restrictions for scheduling PP/DS ordersIntegra
13、tion between SNP and PP/DS (II)PP/DS HorizonSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 9q Customers expect quick and definitely agreed delivery promisesq Flexible Productionq Availability of components and production resources q Production on customer demand: variant configuration, sp
14、ecial receipts and BOMq Cross plant planning: Production locations are connected, Products und Assemblies are planned together q Coordination with sales planning, rough capacity planning and production planningq Production taking into account capacities, sequences, restrictions and dependenciesq Per
15、manent coordination of Planning and Executionq Visualizing of planning results, critical situations (KPIs, alerts)Challenges in production planningSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 10Limitations of MRP planning in SAP R/3q No consideration of capacities in planning runq No fl
16、exible and user-defined heuristicsq Optimization only with 3rd party-systemsq Changes are only taken into account for the next MRP runq Limited possibilities of interactive planningSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 11Benefits of PP/DS planningqMaterial and capacity planning i
17、n one planning process (optional)qDate determination based on actual capacity load incl. confirmations increase of planning accuracyqVisibility on the material flow (pegging)qSystem supports the planner with alertsqSimulation capabilitiesqAutomatic selection of sources of supplyqDetect bottlenecks a
18、nd technological alternatives on resourcesqChangeovers are dynamically calculated and can be automatically optimizedqSafety and stability in planning decreases safety stocksqImproved analytics- and reporting toolsqSeamless integration to other APO modules and R/3Production PlanningPP/DS OverviewDeta
19、iled SchedulingPP/DS in SAP SCM 5.0 OptimizationIndustry Specific Planning ProcessesSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 13lMaster datalProduction PlanningProduction PlanningSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 14R/3(Core or DIMP) Production Process Master D
20、ata in SCM 5.0APO 5.0PPMiPPECIFBill of Material,Routing, RecipePP/DSDPSNPCTMiPPEDIMP only:MMPSeqRPMRecipeRoutingPDE(Production Data Engine)The master data is stored in specific Production Data Structures (PDS) in PDE. The structure and content is optimized for the planning applications (DP, SNP etc.
21、)SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 15Production Data Structures (PDS) SCM 5.0q External Interfaces (BAPIs) for creating and reading PDSq Push Production with PDSq Improvements for Characteristics-dependent planningq Improved CDP functionality with PDSq PDS enabling of BAPI fo
22、r trim optimized order creationq Maintenance of additional PDS data fields in SAP ERPq SNP relevant fields: costs, bucket-consumption etc.q PI2004 SP10 or PI2005SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 16Resource Master Data: Capacity ProfileEnhanced Maintenance for Resource Capacit
23、y ProfileNavigation with CalendarDisplay of Shifts and DaysMass-changeof shiftsSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 17lMaster datalProduction PlanningProduction PlanningSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 18Production Planning OverviewProduction Planning de
24、livers a short term production plan that matches overall supply to demand, given available resources and production methodology. Key Functionalityn Multi-level production planningn Bucket-oriented Capable-To-Promisen Order Peggingn Supports lot quantity calculations and sourcingn Use existing or own
25、 developed heuristicsn Support the following Models:uMake to StockuMake to OrderuMake to Order with Order BOMuEngineer to OrderlProject ManufacturinguFlow ManufacturinguCapacity LevelingKey Benefitsn Determines how, when, and where resources and materials should be deployed to accomplish the product
26、ion goals.n Master planning for materials and capacity (resource loads).n Plan to meet production targets on time and at the lowest cost of inventory. SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 19Standard lotsShortage quantitiesLeast-unit-cost procedure (external procurement)Part-peri
27、od balancingYour Planning ProcedureStandard or Individual Planning Procedures: HeuristicsSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 20Product Planning TableNavigation on products/ workcentersNavigation on products/ /lines/workcentersSelection of chartsPeriodic display of capacity load
28、Production PlanningPP/DS OverviewDetailed SchedulingPP/DS in SAP SCM 5.0 OptimizationIndustry Specific Planning ProcessesSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 22Detailed Scheduling OverviewDetailed Production Schedulingdetermines optimal production sequence for execution, to meet
29、 delivery commitments based on actual constraints on the shop floor.Key Functionalityn Capacity-Load Optimizationn Optimal Sequencingn Flexible & Graphical Activity Schedulingn Due Date Managementn Forward and Backward Schedulingn What-if Analysis & Simulationn Plan Monitorn Configurable Exception A
30、lert Monitor n Production Order ReleaseKey Benefitsn Optimal production sequence that is feasible and can be executed.n Allows simulation of various planning scenarios to determine optimal schedule.n Optimization based on actual constraints ensures reliable delivery due date promises.SAP AG 2006, PP
31、/DS Overview SCM 5.0, Dr. Stephan Kreipl / 23Strategy ProfileOne important profile for detailed scheduling is the strategy profile. The settings in the strategy profile define for example if infinite scheduling is used or not, if forward or backward scheduling is done etc. Different steps during the
32、 production planning and scheduling process can use different scheduling profiles.SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 24Some Scheduling Modes (part of the strategy profile)EDCBAFGSelectedoperationsABCDEFGoperationnot selectedABCDEFGFind slot Insert modeABCDEFGInfinite sequencin
33、gSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 25Multi-level Scheduling Framework - Motivation Resource 3Resource 2Resource 1B0B1B2A2A1A0C1C2C0Scheduling Problem (High Complexity):q Material Flow Not Correlated to Resource Orderq Moving Bottlenecks (Depending on Order Mix)SAP AG 2006, PP
34、/DS Overview SCM 5.0, Dr. Stephan Kreipl / 26Stable Forward Heuristic (since SCM 4.1)Stable Forward HeuristicForward planning, resolve backlogn Late operations will be planned to the futuren Capacity overloads are eliminatedn The sequence of operations is not changedn Using the same resourcen Existi
35、ng operations on the resources will be moved to the futuren Relations and material constraints will be consideredn Customer demands can be violatedSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 27Extended Backward Heuristic (since SCM 5.0)q Free capacity available on finite resourcesq Alt
36、ernative (finite) resourcesq Order prioritiesq Setup sequenceq Confirmed quantities of customer ordersThe Extended Backward Heuristic (part of the the newly in SCM 4.1 introduced Multi-Level-Scheduling Framework (in SCM 4.1: Stable forward heuristic) perform a backward scheduling of operations start
37、ing at their due dates in order to get a feasible production plan taking into account:SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 28Error-Tolerant Scheduling Solution in SCM 5.0Solution strategy for combined problems (date and capacity problems) or problems with different solution poss
38、ibilities lifting of constraints in the following sequence:q schedule infinitely or schedule deallocatedq break dynamic pegging edgesq break fix pegging edgesq break cross-order relationshipsq break order-internal relationshipsUntil APO 4.0: Scheduling works with the All-or-nothing- principle:Either
39、 all activities in a planning step can be scheduled or none of themSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 29Graphical Planning TableStock viewProduct viewResource viewSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 30Ressource Planning Tableq Tabular Scheduling Boardq Se
40、quencing with Pick & Drop or Drag & Dropq Sequencing with Heuristics and Optimizerq Sequencing with Clipboard q Resource utilization and alert visualizationAlternative way of sequencing to graphical scheduling boardfor people who prefer to work with tablesIndustry Specific Planning ProcessesProducti
41、on PlanningPP/DS OverviewDetailed SchedulingPP/DS in SAP SCM 5.0 OptimizationSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 32PP/DS OptimizerThe PP/DS optimizer is part of Detailed Scheduling and tries to sequence the operations in such a way that certain objective functions are minimized
42、. It is possible to consider among other the following objective functions:q Delay Reductionq Makespan Minimizationq Setup Minimizationq Mode costsThe PP/DS optimizer does not create and delete planned orders nor does he change the order quantity. These changes are done during production planning.SA
43、P AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 33Optimization Targets in Scheduling - TradeoffBACSetupSetupCustomer ordersCBAAASetup times inpaint shopProd.ABCA01020B30010C40300Setup time inminutesProduct A: white colorProduct B: orange colorProduct C: blue colortime20303010 10Set-upBACASet
44、upSet-up10 1040Optimal plan for setup and due datesSetupOptimal plan for setupSet-upBACASet-upSetupDelay21SAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 34Optimizer ProfileSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 35PP/DS Optimization (I) SCM 5.0Scheduling with additional
45、prioritization (ATP category, customer order priority)n Example: Schedule sales orders in front of stock ordersSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 36PP/DS Optimization (II) SCM 5.0Compact Planningn Achieve shortest order-individual make-spanExplanation Tooln Tell reasons for ex
46、ceptions (e.g. late because of blocked resource)Enhanced definition of optimization horizonsn Example: “Start at monday morning”Limiting lateness of orders by deallocating late operations (SCM 4.1)Industry Specific Planning ProcessesProduction PlanningPP/DS OverviewDetailed SchedulingPP/DS in SAP SC
47、M 5.0 OptimizationSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 38Industry specific planning processes - OverviewIndustry-specific Planning and Scheduling enable special planning processes tailored to industry-needs.Discrete Industriesn Automotive IndustriesSequencing and model-mix plann
48、ing on production lines, determination and optimal distribution and sequence of ordersn Industrial Machinery & ConstructionProject-oriented Manufacturingn Aerospace & DefenseCustomization with Order Bill of MaterialProcess Industriesn Mill IndustriesBlock planning: Planning with characteristics, pre
49、-assignment of production capacitiesn Chemical/Pharmaceutical IndustriesProduction campaign planning and optimizationn Food IndustriesPlanning with shelf-lifen HighTechCDP (Characteristic Dependent Planning); CMDS (Collaborative Management of Delivery Schedules)SAP AG 2006, PP/DS Overview SCM 5.0, D
50、r. Stephan Kreipl / 39lBlock planninglCampaign PlanninglShelf LifelPush ProductionlModel-Mix Planning and RPMlProject-Oriented ManufacturinglCustomization with Order BOMBlock Planning (IBU Mill Products & Mining) ExamplesSAP AG 2006, PP/DS Overview SCM 5.0, Dr. Stephan Kreipl / 40Example: Material S