PPDS-Overview.ppt

ProductionPlanning DetailedScheduling Dr StephanKreiplSCMSolutionManagementSAPAG ProductionPlanning PP DSOverview DetailedScheduling PP DSinSAPSCM5 0 Optimization IndustrySpecificPlanningProcesses ComponentsofSAPSCM5 0Solution DemandPlanningSupplyNetworkPlanningServicePartsPlanningProductionPlanningDetailedSchedulingTransportationPlanningVehicleSchedulingGlobalAvailabletoPromiseTradePromotionsPlanning SupplyChainPlanning SupplyChainExecution MaterialsManagementManufacturingServicePartsExecutionWarehouseManagementTransportationExecutionTradePromotions ForeignTradeOrderFulfillment SupplyChainCollaboration InventoryCollaborationHub SupplyChainVisibility PerformanceManagement SupplyChainEventManagement SupplyChainAnalyticsEnterprisePortal SupplyChainIntegration ExchangeInfrastructure Auto IDInfrastructure CompositeApplications1 MasterDataManagement BusinessIntelligence NetWeavercomponents SupplierManagedInventoryResponsiveReplenishmentDistributedManufacturing 1comingin2006 online OnlineIntegrationintoExecution ExecutionwithSAPR 3 PlanningwithSAPAPO ChangeofworkcenterRe schedulingmanual automaticVisualizationOptimization Prod OrderPurch Order CustomerRequirement CustomerOrder ForecastRequirement PlannedOrderPurch Requ ChangeofworkcenterStatuschangeConfirmationGoodsreceipt plannedorder ProductionPlanning OrderConversion Consumption Prod OrderPurch Order PlannedOrderPurch Requ online online online SupplyNetworkPlanning SupplyChainPlanningMatrix SupplyChainDesign StrategicNetworkPlanning SupplyNetworkPlanning Procurementplanning Demandplanning GlobalATP IntegrationbetweenPP DSandotherplanningmodules SupplyChainDesign StrategicNetworkPlanning SupplyNetworkPlanning Procurementplanning Demandplanning GlobalATP Example BucketorientedCTP PP DSbucket basedcapacitychecks DesiredDate PlanningDirection PlanStart PP DS SNP SNPPlanningonlyinSNPhorizonReleaseSNPOrdersonlyinPP DShorizonRespectPP DSordersasfixedcapacityreductionmaterialflow PP DSRespectpeggedSNPOrdersasduedatesNocapacityreductionButmaterialflowNorestrictionsforschedulingPP DSorders IntegrationbetweenSNPandPP DS I PP DSHorizon PP DS SNP SNPPlanningonlyinSNPhorizonReleaseSNPOrdersonlyinPP DShorizonRespectPP DSordersasfixedcapacityreductionmaterialflow PP DSRespectpeggedSNPOrdersasduedatesNocapacityreductionButmaterialflowNorestrictionsforschedulingPP DSorders IntegrationbetweenSNPandPP DS II PP DSHorizon CustomersexpectquickanddefinitelyagreeddeliverypromisesFlexibleProductionAvailabilityofcomponentsandproductionresourcesProductiononcustomerdemand variantconfiguration specialreceiptsandBOMCrossplantplanning Productionlocationsareconnected ProductsundAssembliesareplannedtogetherCoordinationwithsalesplanning roughcapacityplanningandproductionplanningProductiontakingintoaccountcapacities sequences restrictionsanddependenciesPermanentcoordinationofPlanningandExecutionVisualizingofplanningresults criticalsituations KPIs alerts Challengesinproductionplanning LimitationsofMRPplanninginSAPR 3 NoconsiderationofcapacitiesinplanningrunNoflexibleanduser definedheuristicsOptimizationonlywith3rdparty systemsChangesareonlytakenintoaccountforthenextMRPrunLimitedpossibilitiesofinteractiveplanning BenefitsofPP DSplanning Materialandcapacityplanninginoneplanningprocess optional Datedeterminationbasedonactualcapacityloadincl confirmations increaseofplanningaccuracyVisibilityonthematerialflow pegging SystemsupportstheplannerwithalertsSimulationcapabilitiesAutomaticselectionofsourcesofsupplyDetectbottlenecksandtechnologicalalternativesonresourcesChangeoversaredynamicallycalculatedandcanbeautomaticallyoptimizedSafetyandstabilityinplanningdecreasessafetystocksImprovedanalytics andreportingtoolsSeamlessintegrationtootherAPOmodulesandR 3 ProductionPlanning PP DSOverview DetailedScheduling PP DSinSAPSCM5 0 Optimization IndustrySpecificPlanningProcesses MasterdataProductionPlanning ProductionPlanning R 3 CoreorDIMP ProductionProcessMasterDatainSCM5 0 APO5 0 PPM iPPE CIF BillofMaterial Routing Recipe PP DS DP SNP CTM iPPE DIMPonly MMP Seq RPM Recipe Routing PDE ProductionDataEngine ThemasterdataisstoredinspecificProductionDataStructures PDS inPDE Thestructureandcontentisoptimizedfortheplanningapplications DP SNPetc ProductionDataStructures PDS SCM5 0 ExternalInterfaces BAPIs forcreatingandreadingPDSPushProductionwithPDSImprovementsforCharacteristics dependentplanningImprovedCDPfunctionalitywithPDSPDSenablingofBAPIfortrimoptimizedordercreationMaintenanceofadditionalPDSdatafieldsinSAPERPSNPrelevantfields costs bucket consumptionetc PI2004SP10orPI2005 ResourceMasterData CapacityProfile EnhancedMaintenanceforResourceCapacityProfile NavigationwithCalendar DisplayofShiftsandDays Mass changeofshifts MasterdataProductionPlanning ProductionPlanning ProductionPlanningOverview ProductionPlanningdeliversashorttermproductionplanthatmatchesoverallsupplytodemand givenavailableresourcesandproductionmethodology KeyFunctionalityMulti levelproductionplanningBucket orientedCapable To PromiseOrderPeggingSupportslotquantitycalculationsandsourcingUseexistingorowndevelopedheuristicsSupportthefollowingModels MaketoStockMaketoOrderMaketoOrderwithOrderBOMEngineertoOrderProjectManufacturingFlowManufacturingCapacityLeveling KeyBenefitsDetermineshow when andwhereresourcesandmaterialsshouldbedeployedtoaccomplishtheproductiongoals Masterplanningformaterialsandcapacity resourceloads Plantomeetproductiontargetsontimeandatthelowestcostofinventory Standardlots Shortagequantities Least unit costprocedure externalprocurement Part periodbalancing YourPlanningProcedure StandardorIndividualPlanningProcedures Heuristics ProductPlanningTable Navigationonproducts workcenters Navigationonproducts lines workcenters Selectionofcharts Periodicdisplayofcapacityload ProductionPlanning PP DSOverview DetailedScheduling PP DSinSAPSCM5 0 Optimization IndustrySpecificPlanningProcesses DetailedSchedulingOverview DetailedProductionSchedulingdeterminesoptimalproductionsequenceforexecution tomeetdeliverycommitmentsbasedonactualconstraintsontheshopfloor KeyFunctionalityCapacity LoadOptimizationOptimalSequencingFlexible GraphicalActivitySchedulingDueDateManagementForwardandBackwardSchedulingWhat ifAnalysis SimulationPlanMonitorConfigurableExceptionAlertMonitorProductionOrderRelease KeyBenefitsOptimalproductionsequencethatisfeasibleandcanbeexecuted Allowssimulationofvariousplanningscenariostodetermineoptimalschedule Optimizationbasedonactualconstraintsensuresreliabledeliveryduedatepromises StrategyProfile Oneimportantprofilefordetailedschedulingisthestrategyprofile Thesettingsinthestrategyprofiledefineforexampleifinfiniteschedulingisusedornot ifforwardorbackwardschedulingisdoneetc Differentstepsduringtheproductionplanningandschedulingprocesscanusedifferentschedulingprofiles SomeSchedulingModes partofthestrategyprofile E D C B A F G Selected operations A B C D E F G operation not selected A B C D E F G Findslot Insertmode A B C D E F G Infinitesequencing Multi levelSchedulingFramework Motivation Resource3 Resource2 Resource1 B0 B1 B2 A2 A1 A0 C1 C2 C0 SchedulingProblem HighComplexity MaterialFlowNotCorrelatedtoResourceOrderMovingBottlenecks DependingonOrderMix StableForwardHeuristic sinceSCM4 1 StableForwardHeuristicForwardplanning resolvebacklogLateoperationswillbeplannedtothefutureCapacityoverloadsareeliminatedThesequenceofoperationsisnotchangedUsingthesameresourceExistingoperationsontheresourceswillbemovedtothefutureRelationsandmaterialconstraintswillbeconsideredCustomerdemandscanbeviolated ExtendedBackwardHeuristic sinceSCM5 0 FreecapacityavailableonfiniteresourcesAlternative finite resourcesOrderprioritiesSetupsequenceConfirmedquantitiesofcustomerorders TheExtendedBackwardHeuristic partofthethenewlyinSCM4 1introducedMulti Level SchedulingFramework inSCM4 1 Stableforwardheuristic performabackwardschedulingofoperationsstartingattheirduedatesinordertogetafeasibleproductionplantakingintoaccount Error TolerantSchedulingSolutioninSCM5 0 Solutionstrategyforcombinedproblems dateandcapacityproblems orproblemswithdifferentsolutionpossibilities liftingofconstraintsinthefollowingsequence scheduleinfinitelyorscheduledeallocatedbreakdynamicpeggingedgesbreakfixpeggingedgesbreakcross orderrelationshipsbreakorder internalrelationships UntilAPO4 0 Schedulingworkswiththe All or nothing principle Eitherallactivitiesinaplanningstepcanbescheduledornoneofthem GraphicalPlanningTable Stockview Productview Resourceview RessourcePlanningTable TabularSchedulingBoardSequencingwithPick DroporDrag DropSequencingwithHeuristicsandOptimizerSequencingwithClipboardResourceutilizationandalertvisualization Alternativewayofsequencingtographicalschedulingboardforpeoplewhoprefertoworkwithtables IndustrySpecificPlanningProcesses ProductionPlanning PP DSOverview DetailedScheduling PP DSinSAPSCM5 0 Optimization PP DSOptimizer ThePP DSoptimizerispartofDetailedSchedulingandtriestosequencetheoperationsinsuchawaythatcertainobjectivefunctionsareminimized Itispossibletoconsideramongotherthefollowingobjectivefunctions DelayReductionMakespanMinimizationSetupMinimizationModecostsThePP DSoptimizerdoesnotcreateanddeleteplannedordersnordoeshechangetheorderquantity Thesechangesaredoneduringproductionplanning OptimizationTargetsinScheduling Tradeoff B A C Setup Setup Customerorders C B A A A Setuptimesinpaintshop Prod A B C A 0 10 20 B 30 0 10 C 40 30 0 Setuptimeinminutes ProductA whitecolorProductB orangecolorProductC bluecolor time 203030 1010 Setup OptimizerProfile PP DSOptimization I SCM5 0 Schedulingwithadditionalprioritization ATPcategory customerorderpriority Example Schedulesalesordersinfrontofstockorders PP DSOptimization II SCM5 0 CompactPlanningAchieveshortestorder individualmake spanExplanationToolTellreasonsforexceptions e g latebecauseofblockedresource EnhanceddefinitionofoptimizationhorizonsExample Startatmondaymorning Limitinglatenessofordersbydeallocatinglateoperations SCM4 1 IndustrySpecificPlanningProcesses ProductionPlanning PP DSOverview DetailedScheduling PP DSinSAPSCM5 0 Optimization Industryspecificplanningprocesses Overview Industry specificPlanningandSchedulingenablespecialplanningprocessestailoredtoindustry needs DiscreteIndustriesAutomotiveIndustriesSequencingandmodel mixplanningonproductionlines determinationandoptimaldistributionandsequenceofordersIndustrialMachinery ConstructionProject orientedManufacturingAerospace DefenseCustomizationwithOrderBillofMaterial ProcessIndustriesMillIndustriesBlockplanning Planningwithcharacteristics pre assignmentofproductioncapacitiesChemical PharmaceuticalIndustriesProductioncampaignplanningandoptimizationFoodIndustriesPlanningwithshelf lifeHighTechCDP CharacteristicDependentPlanning CMDS CollaborativeManagementofDeliverySchedules BlockplanningCampaignPlanningShelfLifePushProductionModel MixPlanningandRPMProject OrientedManufacturingCustomizationwithOrderBOM BlockPlanning IBUMillProducts Mining Examples Example MaterialStructureinthePaperIndustry Product1 Product2 Product3 Product4 Product6 Product5 Standard Sheet Cutter reels Finished Product MaterialsManagement MaterialsManagement MaterialsManagement Rawmaterial Pulp MaterialsManagement BlockPlanning BusinessRequirementCombineoptimalresourceutilizationandprecisecustomerduedatesConsiderconstraintslikeminimalandmaximallotsizes setuptime fixedmaintenanceintervalsetc PlanbottleneckresourcesinanearlyplanningphasewherethefinalproductsandproductcharacteristicsarenotknownSolutionDefinetimeintervalsonaresourcewhereproductswithcertaincharacteristicscanbeproducedOperationsofordersarescheduledintomatchingblocks 100to gradeA grammage180 120to A 200 75to C 150 ProductxyA 180QualitySWidth1000 ProductvbA 200QualityMWidth1200 BlockPlanningProcess Step1 ProductionPlanning InfiniteMRPrun SchedulingoftheordersintotheblockStep2 DetaildScheduling CreatefinitescheduleStep3 Adjustblocklimits rescheduleblocks BlockplanningCampaignPlanningShelfLifePushProductionModel MixPlanningandRPMProject OrientedManufacturingCustomizationwithOrderBOM CampaignPlanning IBUChemie Examples Idea Aproductioncampaignisaseriesofproductionprocesses charges inanoptimalsequence withinacertaindefinedstartandend inanuninterruptedsequenceonadedicatedproductionline GeneralapproachinAPO Eachchargeiscorrespondingtoanorder Sotheproductioncampaignisacollectionofplannedordersand orprocessorders Eachorderiseitheramemberofonecampaignornone Singleandmultiproductcampaignsaresupported IdentificationofcampaignswithR 3campaignnumberandAPOcampaignnumber Onetoonerelation ProductionCampaignPlanning BusinessBackground TheCampaignPlanningscenarioisoftenfoundinProcessIndustryenvironmentsTypicallylongprocessdurationsand ormultipleproductionstepscharacterizethesescenariosAtthesametimesequencedependingset uptimeshavetobereduced minimizedOftentimesliquidproducts components bulkand oractiveingredientmaterialsareplanningobjectsofcampaignsThegoalofCampaignPlanningistoreducestorageandset upcostssimultaneouslyinanintegratedscenario ProductionCampaignPlanning BlockplanningCampaignPlanningShelfLifePushProductionModel MixPlanningandRPMProject OrientedManufacturingCustomizationwithOrderBOM ShelfLife IBUCP Examples ShelfLife Idea Storage MonitoringofremainingshelflifePlanning Consumptionofabatchbetweenmaturitytimeandexpirationdate Batchusagedeterminedbyusabilityrequirements Alerts ShelflifeviolatedMaturitytimeviolatedMax UsabilityviolatedAbouttoexpire Stock Availabilitydate Expirationdate ShelfLife Definitions Productionview Maturitydate Period requiredbytheproduct beforeitisreadyforproductionorsalesShelflife PeriodduringwhichtheproductcanbestoredAvailabilitydate EarliesttimeofuseExpirationdate Timeafterwhichtheproductcannolongerbeused BlockplanningCampaignPlanningShelfLifePushProductionModel MixPlanningandRPMProject OrientedManufacturingCustomizationwithOrderBOM PushProduction IBUCP Examples Component PushProduction Capacity drivenOrderCreation CapacityPush TheProblem UnusedCapacityForecastorcustomerordersdonotconsumeproductioncapacitycompletely Insomeindustries e g consumerproducts businessstrategyistoeliminate whitespaces andfill upcapacitiestofullloaduntilendofdayorshift TheGoal DecisionsupportProvideatoolfortheplannertofillupwhitespaceswithorders Decisionshouldbebasedonstocklevel days supply etc TheSolutionNewheuristic Capacity orientedOrderCreation CDOC Displayofpotentialstartandenddates possibleproductsDecisionsupportAutomaticordercreation Capacity drivenOrderCreation CapacityPush shift2 shift3 shift1 shift2 shift3 shift1 Capacitynotcompletelyutilized Fullcapacityutilization endofshiftnotused whitespacebetweenorders untilendofshift withproductonlowstock withproductonlowdays ofsupply Fill Up betweenorders BlockplanningCampaignPlanningShelfLifePushProductionModel MixPlanningandRPMProject OrientedManufacturingCustomizationwithOrderBOM Model MixPlanningandRPM IBUAutomotive Examples Orders Linenetwork Model MixPlanning Situation Objective GenerationofafeasibleplanforhighlyconfigurableproductswithhighvolumeAdherencetopromiseddeliverydate Businessvalue BalancedusageofproductionresourcesEarlyidentificationofpotentialbottlenecksReliabledeliverydateleadstoincreasedcustomersatisfaction Restrictions Modell Mix Planung dayx dayx 1 dayy day1 PeriodSlot Sequencing 1 2 RapidPlanning RapidPlanningMatrix RequiredCapabilites ManagementofhighvolumedatawithcomplexproductstructuresIndividualcustomerorderswithconfigurationIncreasedcustomersatisfactionbyfastreactiontoorderchangesFastresponsetoengineeringchangesFlexibleresponsetochangesforcedbysuppliers TheRapidPlanningSolution VeryfrequentandveryfastmaterialrequirementsplanningandresourcerequirementdeterminationIncreasedqualityandmoreaccuratedataBasisforfastdataprovisionforfollow upprocesses OrderBomforproductionbackflush RapidPlanningResult Whichpartsintowhichcar WhichpartdoIneedwhen whereandhowoften Customer forextremelyhighvolumeandmasscustomization RapidPlanningMatrix Everycarisconfiguredindividually Ord 02 Ord 03 Ord 04 Ord 05 Ord 06 RapidPlanningMatrix BenchmarkTest SizeofmaximumBoMofcar1 70 000componentvariantscar2 12 000componentvariants24 000individualordersforcar1 20 000ordersforcar2BoMexplosiononly 19minCompleterequirementsplanning 48min x x x x x x x x x x x x x x x x x x Assemblyorders Components Ord 01 BlockplanningCampaignPlanningShelfLifePushProductionModel MixPlanningandRPMProject OrientedManufacturingCustomizationwithOrderBOM Project OrientedManufacturing IBUIM C IBUA D Examples MTS MTO ETOManufacturingModels Make to StockMake to OrderEngineer to Order Mixofmanufacturingmodelswithinacompanyarecommon Engineer to Order ProjectManufacturingforIM C A D IntegratedprojectandproductionschedulingConstraint basedprojectandproductionscheduling feasibleplansAlertsforearlydetectionofbottlenecksImprovedtransparencyandsimulationScenarioinSAPSolutionManager configurationguideandprocessdescriptionforacceleratedimplementation CompleteETOScenario ProjectPlanning AdvanceProcurement Engineering EngineeringChangeManagement QualityAssurance Control ManufacturingExecution Shipping Assembly Start Up ProductionPlanning Optimization ProductionScheduling ProductionScheduling ProjectPlanning AdvanceProcurement Engineering EngineeringChangeManagement QualityAssurance Control ManufacturingExecution Shipping Assembly Start Up ProductionPlanning Optimization ProductionScheduling Monitoralertsonprojects mainassembliesPegging automaticmatchingofdemandandsupplyVisualizationofcompleteordercontextAlerts Earlywarningsystemlateorders bottlenecksFilteronalertsinordercontext sortlateordersbydelayInteractiveschedulingtoreducelateprojects ordersDetectcriticalpathforordercontextReducebuffersoncriticalpathReducedurationofprojectorderoperationsMulti levelforwards backwardsschedulingInteractiveschedulingtoreducecapacityoverloadEvaluateresourceutilization filteronoverloadAlternativeworkcenters sequences productionversionsSwitchtoexternalprocurement subcontractingWorkovertime runadditionalshiftsAdaptivenessandSimulationWhat ifsimulation comparealternatives NewinSCM5 0 PlanningBoard CriticalPathHeuristic DetailedSched