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1、1SAP SAP 系统实施系统实施XXXXXXXX2目录目录3PP03-Production PlanningPP03-Production PlanningPP03-Production PlanningPP03-Production PlanningNovember 20004ContentsContentsTopic 1:Sales&Operation PlanningTopic 2:Demand ManagementTopic 3:Master Production SchedulingTopic 4:MRP RunTopic 5:Capacity Planning&Schedulin
2、g5Planning levelsPlanning levelsProfitably analysis-Revenue plans-Sales plans(quantities)-Sales and Operations Planning-Sales plan-Production planMaster Planning-Demand program-Adjusted master planMaterial Requirements Planning-Dependent requirements-Master plan-Procurement planRegion 1Region 2Produ
3、ct groupAssembly 1Assembly 2Part 1Part 2Product 1Product 2o.k.?o.k.?o.k.?o.k.?Feedback/correctionsCO/PACO/PASOPSOPMPMPMRPMRP6Product GroupsProduct GroupsHierarchyDetergents52Dishwashing soapPowderLiquidsLemon Liquid 5lLemon Liquid 2llgrouping of Materials or Product Groupslplant dependentlproportion
4、al factors30%70%50%50%7Product Group StructureProduct Group StructureProportionalfactorMat.1Mat.20.70.3Product groupAggregationfactor11.1Product groupMat.1Mat.2UnitconversionMat.1in kgMat.2in PC0.0010.05Product groupin toMultipleassignmentMat.1PG 1PG 28TextPlanning:Overview Planning:Overview SalesPr
5、oductionStock levelTarget stock levelDays supplyTarget days supplyProduct groupXJ 12-13SwitchPlant9999 PhiladelphiaVersion000Annual planning 1994activeM 01/1994M 02/1994M03/1994Unit9Planning Data:Creating a Sales PlanPlanning Data:Creating a Sales PlanCO/PACO/PA field nameVersionFromTo Measure-Inv.s
6、ales qty.-.DistributionValueOPFromToSales 100=01/9412/94ProductionTarget stock 10=01/9403/94Target supplyVISInfostrukturVersionFromToMeasure-Inv.sales qty.-Returns.01/9403/94Prod.grp.xyz-12Plant0001Version000Annual planning 199501/94 02/94.Sales.Production.Stock.ForecastInteractivegraphics10Generati
7、ng a Production PlanGenerating a Production PlanW29/94W30/94M08/94M09/94Sales5070220250Production5070220250W29/94W30/94M08/94M09/94Sales5070220250Production6070250250Target stock level1010 40 40W29/94W30/94M08/94M09/94Sales5070220250Production8040330265Target days supply 3 0 11 11Synchronous to sale
8、sTarget stock levelTarget days supply11Version ManagementVersion ManagementFrom versionTo versionPeriod fromtoCopying ActivateDeleteVersionStatus.000001002003.Deleting/activating12MemberproportionsSum of member valuesProduct groupDisaggregationDisaggregationPG members Proportion.XYZ-12L-10,6XYZ-12L-
9、20,3Selection ofPG membersDisaggregation basisAutomatic production plan creationDisaggregationstrategyProduct group X47-12LPlant 0001SalesProductionStock01/9502/9503/95.SalesProductionStock1.0001.1001001.0001.1001001.0001.100200.tototo9701.000301.2101.3001201.1201.000240.tototoProduct groupX47-12LPl
10、ant 0001SalesProductionStockTarget stockDays supplyTarget supply01/9502/9503/95.300.000300.000390.000400.00010.000 1 300.000300.0001.000 1 .kgkgkgkgtoto13Transfer to Demand ManagementTransfer to Demand ManagementAccessedviaDisagg.strategyProduct groupMaterialProductionor sales direct frommaterialPro
11、ductionor salesas proportionof product groupplanningAll materials in product group transferredVersion entered:systemchecks whether versionexists/is active for allproduct group members and,if necessary,issues a warningInitial version:active version determined per materialVersion entered:system checks
12、 whether version exists/is active and,if necessary,issuesa warningInitial version:active versiondeterminedAll materials in productgroup transferredVersion entered:systemchecks whether versionexists/is active for all product group members and,if necessary,issues a warningInitial version:active planni
13、ngversion determined for theproduct groupDisaggregation to materiallevel when data transferredProduct group relevant to MRPis determinedVersion entered:system checkswhether version exists/is activefor product group relevant toMRP and,if necessary,issues a warningInitial version:active version determ
14、ined for product grouprelevant to MRPDisaggregation to material levelwhen disaggregation is carried out14Demo for SOPDemo for SOPNow its time to do the system demo:Maintain SOP15ContentsContentsTopic 1:Sales&Operation PlanningTopic 2:Demand ManagementTopic 3:Master Production SchedulingTopic 4:MRP R
15、unTopic 5:Capacity Planning&Scheduling16Planning levelsPlanning levelsProfitably analysis-Revenue plans-Sales plans(quantities)-CO/PASales and Operations Planning-Sales plan-Production planSOPMaster Planning-Demand program-Adjusted master planMPMaterial Requirements Planning-Dependent requirements-M
16、aster plan-Procurement planMRPRegion 1Region 2Product groupAssembly 1Assembly 2Part 1Part 2Product 1Product 2o.k.?o.k.?o.k.?o.k.?Feedback/corrections17Logistics chainLogistics chainCapacityCapacityplanningplanningFinalFinalcostingcostingInvoiceInvoiceverificationverificationConvertWarehouseWarehouse
17、ProductionorderShed.agreementPurchaserequisitionOrderprocessingPurchasefunctionsPlanned ordersPurch.ordersMRPDependent reqmtsReservationsSDprocessingMPSDemandmanagementCustomer/plannedindependentrequirements18Creating the demand program by entering planned independent requirementsCreating the demand
18、 program by entering planned independent requirementsManualmaintenanceMPS/MRPMPS/MRPCopyfromsales planCopyfromproduction planMaterialRequirement plannumberDemand programDemand programMonitoring changesto references19Requirements planMaterialQuantityDate/periodQuantityDatePlanned ind.reqmtsDateQuanti
19、tyPlanned ind.reqmtsMaterial AMaterial BDemand ProgramDemand Program20Version XX inactiveVersion 01 inactiveVersion 00 activePlanned independent requirementsDay/week/month/posting periodTimeMaterialAPlanningstrategyTotal quantityReqmts typeDemand ProgramDemand Program21Planned ind.reqmtsPeriodPeriod
20、SplittingSplittingTotal quantity+splitting periodor quantity per periodsQuantities split oversmaller periodsSplitting Requirement:Splitting Requirement:AutomaticallyAutomatically22Goods issueProductionIndep.reqmt WithdrawalReductionReducing independent requirementsReducing independent requirementsWa
21、rehouse23Planning StrategiesPlanning StrategiesMake-to-stock productionMake-to-stock productionMake-to-order productionMake-to-order productionProduction by lot sizeProduction by lot sizePlanning with final assemblyPlanning with final assemblyPlanning without final assemblyPlanning without final ass
22、emblyPlanning with planning materialPlanning with planning materialPlanning at assembly levelPlanning at assembly level24Make-to-Stock ProductionMake-to-Stock ProductionDemand programMRPWarehouse stockFinished productSales ordersfrom stockReduction25Make-to-Stock ProductionMake-to-Stock ProductionNe
23、t Reqmts planningNet Reqmts planningGross reqmts planningGross reqmts planningIRPlanned indep.reqmtsWSWarehouse stockPOPlanned orderWSWSIRIRIRIRIRIRPOPOPOPOPOPOWSWSIRIRIRIRIRIRPOPOPOPOPOPO26Make-to-Order ProductionMake-to-Order ProductionProductionInvoicingMRPGoods issueDeliverySales orderStocksPlan
24、nedActualReductionIndividual customer reqmt27Production by Lot SizeProduction by Lot SizeSales orderStock reqmtsMRPWarehouse stockFinished productDeliverySales orderSales from stockReductionReduction28RRequirementsPOPlanned orderPOPOPOPOPOPOR RR RR RR RR RR RQuantityQuantityTimeTime03/0103/0703/1403
25、/2103/0103/0703/1403/21Production by Lot Size for Sales&Stock Production by Lot Size for Sales&Stock OrdersOrders29Planning with Final AssemblyPlanning with Final AssemblySales orderIndep.reqmts.Warehouse stockFinished productProduction30QuantityTimeIndependent reqmtsIndependent reqmtsConsuming Plan
26、ning Quantities with Customer RequirementsConsuming Planning Quantities with Customer RequirementsQuantityTimeCustomer reqmtsCustomer reqmtsQuantityTimeConsumption orConsumption orincreasing theincreasing themaster planmaster plan31Consumption ModeConsumption ModePlannedindependentrequirementsCustom
27、er req.TimeBackward consumptionBPBackward consumptionperiod BPForward consumptionTimeForward consumptionperiod FP12Backward/forward consumptionTimeFPBPFP32Availability Check According to ATP LogicAvailability Check According to ATP Logic(Master plan)Stock(+)Stock(-)StockSales ordersProduction reqmts
28、Manual reservationsMaterial withdrawalsSales ordersSales ordersATP quantitiesATP quantitiesProduction and Planned ordersProduction and Planned orders33TimeSales orderSales orderAvailability Check During Requirements AllocationAvailability Check During Requirements AllocationTimeIndependent req.Indep
29、endent req.IRIRIRIRSOSOSOSOTimeAllocationAllocationKAKAIRIRSOSO05/0106/0105/1005/20CompletelyconfirmedPartiallyconfirmedRest can beRest can bedelivered 1.6.delivered 1.6.34Planning without Final AssemblyPlanning without Final AssemblySales orderIndep.reqmts.Customer stockFinished productProductionWa
30、rehouse stockAssembly 01Warehouse stockAssembly 02Finalassembly35Planning with Make-to-Order ProductionPlanning with Make-to-Order ProductionPlanningfinished productPlanningInd.reqmts.Sales orderPUSHPULLHigh valuematerials-determine percustomerLow valuematerialsStocking level36Planning with Planning
31、 MaterialPlanning with Planning MaterialSales orderIndep.reqmtsProductionWarehouse stockAssembly 01Warehouse stockAssembly 02FinalassemblyCustomer orderFinished productPlanningmaterial37Demo for Demand ManagementDemo for Demand ManagementNow its time to do the system demo:Transfer SOP to Demand Mana
32、gement38ContentsContentsTopic 1:Sales&Operation PlanningTopic 2:Demand ManagementTopic 3:Master Production SchedulingTopic 4:MRP RunTopic 5:Capacity Planning&Scheduling39Master Production SchedulingMaster Production SchedulingManually reprocessing master scheduleitemsChecking and adjusting themaster
33、 plan for master scheduleitemsLTLTMaterial requirements planningMaterial requirements planning(planning the entire production structure)(planning the entire production structure)MPS runMSIMSIMSI40Single-level specificationof dependent reqmtsPlanning the rest ofthe BOM structureSeparate Planning RunS
34、eparate Planning RunInteractiveplanningSeparateSeparateplanning runplanning runMaster schedule itemsMaster schedule itemsMRP materialsMRPo.k.o.k.41Interactive Master Production SchedulingInteractive Master Production SchedulingMaster plan-Automatic planning-Adjusting plans-Manual change-Date and qua
35、ntity of the planned orderSimulationCurrentmaster planAdjustedmaster planCapacityCapacity comparisonPlanned/customerindep.reqmts42ContentsContentsTopic 1:Sales&Operation PlanningTopic 2:Demand ManagementTopic 3:Master Production SchedulingTopic 4:MRP RunTopic 5:Capacity Planning&Scheduling43Planning
36、 levelsPlanning levelsProfitably analysis-Revenue plans-Sales plans(quantities)-Sales and Operations Planning-Sales plan-Production planMaster Planning-Demand program-Adjusted master planMaterial Requirements Planning-Dependent requirements-Master plan-Procurement planRegion 1Region 2Product groupAs
37、sembly 1Assembly 2Part 1Part 2Product 1Product 2o.k.?o.k.?o.k.?o.k.?Feedback/correctionsCO/PACO/PASOPSOPMPMPMRPMRP44Logistic chain:overviewLogistic chain:overviewSDprocessingIndep.reqmtsDemandManagementCapacity-Capacity-planningplanningFinalFinalcostingcostingInvoiceInvoiceverificationverificationMR
38、PConvertWarehouseWarehouseProduction orderSched.agreementPurchaserequisitionOrder processingPurchasingfunctionsDependent reqmtsReservations Planned orderPurchaseorders45Planning proceduresPlanning proceduresPlanning proceduresMRPConsumption-based planning Reorder point planningForecast-basedplanning
39、Automaticreorder pointManualreorder point46Materials planning proceduresMaterials planning proceduresNo materials planningMRP including BOM explosionUsing the forecast for unplanned additional reqmtsUsing the forecast for the total requirementsMPS represents a separate planning runStockTime Reorder
40、point StartdateDelivery dateConsumption-based planningManual reorder point planningAutomatic reorder point planningForecast-based planning Safety stock47Prerequisites for MRP runPrerequisites for MRP runActivatedValid MRP typeValid material statusMaintain MRP dataPlantMaterial48Carrying out the plan
41、ning runCarrying out the planning runMPSMRP49Carrying out the planning run I-total Carrying out the planning run I-total planningplanningProcessing typePlanning all the materials in a particular plant,orPlanning all the materials which have under-gone a change relevant to planning (net change planni
42、ng)Planning intervalUnlimited orPlanning in the planning horizonPlanningPlantPlanned receiptsReqmtsTimePlanninghorizon50Mehrstufige EinzelplanungPlanung einer gesamten Stcklistenstrukturmanuelle nderungen des Produktionsplanesfr jedes Material in der Stckliste mglich.Einstufige Einzelplanungmanuelle
43、 nderung der Planung mglich+Erfassen+Lschen+ndern+UmterminierenMehrstufige EinzelplanungPlanung einer gesamten Stcklistenstrukturmanuelle nderungen des Produktionsplanesfr jedes Material in der Stckliste mglich.Einstufige Einzelplanungmanuelle nderung der Planung mglich+Erfassen+Lschen+ndern+Umtermi
44、nierenPlanning run II-single-item-planningPlanning run II-single-item-planningMulti-level,single-item planningPlanning a complete BOM structureOption of manually changing the master planfor each material in the BOMSingle-level,single-item planningOption of manually changing planning+create+delete+ch
45、ange+rescheduleReceiptsTimeIssues51MRP list and current stock/requirements MRP list and current stock/requirements listlistIssues/receiptsIssues/receiptsStocks/Stocks/requirementsrequirementsPlanningPlanningresultsresultsPlanningMRP listCurrent stock/requirements listMaterialMRP elementsMaterialMRP
46、elements52Multi-level planning structureMulti-level planning structureE1E1indep.reqmtsindep.reqmtsPlannedPlannedCustomerCustomerPLANNED ORDERDependent reqmtsDependent reqmtsPLANNED ORDERDependent reqmtsDependent reqmtsPLANNED ORDERB1B1R1R1R1R1R1R1B1B153PLANUNGSLAUFPLANUNGSLAUFPLANNING RUNPlanning ru
47、nPlanning runNet reqmts calculationLot size calculationSchedulingBOM explosion/determining dependent reqmtsTotal planningTotal planningSingle-item planningSingle-item planning54Maintaining planned orders(in-house production)Maintaining planned orders(in-house production)Planning runAutomaticcreation
48、Automaticchanges/deletionif planning situationchangesMRP controllerManualcreationManualchanges/deletionCollective conversionintoproduction orderIndividual conversion intoproduction orderPlanned orderPlanned order55Determining order proposals for ext.Determining order proposals for ext.procurementpro
49、curementPlanning runPlanned orderScheduling agreementPurchase requisitionIndividualconversionintopurchaserequisitionCollectiveconversionintopurchaserequisition56Lot-sizing procedures:overviewsLot-sizing procedures:overviewsLot-sizing proceduresLot-sizing proceduresStatic Static proceduresproceduresP
50、eriodicPeriodicproceduresproceduresOptimum Optimum proceduresproceduresLot-for-Lot reorder quantityFixed lot sizeReplenish up to maximum stock levelMonthly lot size Lot size according toflexible period lengthLot size according tothe PP planning calendarDynamiclot size creationPart periodbalancingLea