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SAP系统实施

XXXX目录PP03-ProductionPlanningNovember2000ContentsTopic1:Sales&OperationPlanningTopic2:DemandManagementTopic3:MasterProductionSchedulingTopic4:MRPRunTopic5:CapacityPlanning&SchedulingPlanninglevelsProfitablyanalysis-Revenueplans-Salesplans(quantities)-SalesandOperationsPlanning-Salesplan-ProductionplanMasterPlanning-Demandprogram-AdjustedmasterplanMaterialRequirementsPlanning-Dependentrequirements-Masterplan-ProcurementplanRegion1Region2ProductgroupAssembly1Assembly2Part1Part2Product1Product2o.k.?o.k.?o.k.?o.k.?Feedback/correctionsCO/PASOPMPMRPProductGroupsHierarchyDetergents52DishwashingsoapPowderLiquidsLemonLiquid5lLemonLiquid2lgroupingofMaterialsorProductGroupsplantdependentproportionalfactors30%70%50%50%ProductGroupStructureProportionalfactorMat.1Mat.20.7 0.3ProductgroupAggregationfactor1 1.1ProductgroupMat.1Mat.2UnitconversionMat.1inkgMat.2inPC0.001 0.05ProductgroupintoMultipleassignmentMat.1PG1PG2TextPlanning:OverviewSalesProductionStocklevelTargetstocklevelDays'supplyTargetdays'supplyProductgroup XJ12-13

SwitchPlant 9999

PhiladelphiaVersion 000 Annualplanning1994 activeM01/1994 M02/1994 M03/1994 UnitPlanningData:CreatingaSalesPlanCO/PACO/PAfieldnameVersionFromTo

Measure-Inv.salesqty.- . . .DistributionValue OP From ToSales 100 == 01/94 12/94ProductionTargetstock 10 = 01/94 03/94TargetsupplyVISInfostrukturVersionFromTo

Measure-Inv.salesqty.-Returns . . .01/94 03/94Prod.grp. xyz-12Plant 0001Version 000 Annualplanning1995

01/94 02/94 .......Sales .......Production .......Stock ........ . . .. . . .. . . .ForecastInteractivegraphicsGeneratingaProductionPlanW29/94 W30/94 M08/94 M09/94Sales 50 70 220 250Production 50 70 220 250W29/94 W30/94 M08/94 M09/94Sales 50 70 220 250Production 60 70 250 250Targetstocklevel 10 10 40 40W29/94 W30/94 M08/94 M09/94Sales 50 70 220 250Production 80 40 330 265Targetday'ssupply 3 0 11 11SynchronoustosalesTargetstocklevelTargetdays'supplyVersionManagementFromversionToversionPeriodfromtoCopying

Activate Delete Version Status....000001002003........................Deleting/activatingMemberproportionsSumofmembervaluesProductgroupDisaggregationPGmembers Proportion ...... ...... ......XYZ-12L-10,6XYZ-12L-20,3SelectionofPGmembersDisaggregationbasisAutomaticproductionplancreationDisaggregationstrategyProductgroup X47-12L Plant0001SalesProductionStock01/9502/9503/95.....SalesProductionStock1.0001.1001001.0001.1001001.0001.100200...............tototo9701.000301.2101.3001201.1201.000240...............tototoProductgroup X47-12L Plant0001SalesProductionStockTargetstockDays'supplyTargetsupply01/9502/9503/95.....300.000300.000390.000400.00010.0001300.000300.0001.0001..............................kgkgkgkgtotoTransfertoDemandManagementAccessedviaDisagg.strategyProductgroupMaterialProductionorsalesdirectfrommaterial ProductionorsalesasproportionofproductgroupplanningAllmaterialsinproductgrouptransferredVersionentered:systemcheckswhetherversionexists/isactiveforallproductgroupmembersand,ifnecessary,issuesawarningInitialversion:activeversiondeterminedpermaterialVersionentered:systemcheckswhetherversionexists/isactiveand,ifnecessary,issuesawarningInitialversion:activeversiondeterminedAllmaterialsinproductgrouptransferredVersionentered:systemcheckswhetherversionexists/isactiveforallproductgroupmembersand,ifnecessary,issuesawarningInitialversion:activeplanningversiondeterminedfortheproductgroupDisaggregationtomateriallevelwhendatatransferredProductgrouprelevanttoMRPisdeterminedVersionentered:systemcheckswhetherversionexists/isactiveforproductgrouprelevanttoMRPand,ifnecessary,issuesawarningInitialversion:activeversiondeterminedforproductgrouprelevanttoMRPDisaggregationtomateriallevelwhendisaggregationiscarriedoutDemoforSOPNowit’stimetodothesystemdemo:MaintainSOPContentsTopic1:Sales&OperationPlanningTopic2:DemandManagementTopic3:MasterProductionSchedulingTopic4:MRPRunTopic5:CapacityPlanning&SchedulingPlanninglevelsProfitablyanalysis-Revenueplans-Salesplans(quantities)-CO/PASalesandOperationsPlanning-Salesplan-ProductionplanSOPMasterPlanning-Demandprogram-AdjustedmasterplanMPMaterialRequirementsPlanning-Dependentrequirements-Masterplan-ProcurementplanMRPRegion1Region2ProductgroupAssembly1Assembly2Part1Part2Product1Product2o.k.?o.k.?o.k.?o.k.?Feedback/correctionsLogisticschainCapacity

planningFinal

costingInvoice

verificationConvertWarehouseProduction

orderShed.agreementPurchase

requisitionOrder

processingPurchase

functionsPlannedordersPurch.ordersMRPDependentreqmtsReservationsSD

processingMPSDemand

managementCustomer/

plannedindependent

requirementsCreatingthedemandprogrambyenteringplannedindependentrequirementsManual

maintenanceMPS/MRPCopyfrom

salesplanCopy

from

productionplanMaterialRequirementplannumberDemandprogramMonitoringchangestoreferencesRequirementsplanMaterialQuantityDate/periodQuantityDatePlannedind.reqmtsDateQuantityPlannedind.reqmtsMaterialAMaterialBDemandProgramVersionXXinactiveVersion01inactiveVersion00activePlannedindependentrequirementsDay/week/month/postingperiodTimeMaterialAPlanning

strategyTotalquantityReqmtstypeDemandProgramPlannedind.reqmtsPeriodPeriodSplittingSplittingTotalquantity+splittingperiod

orquantityperperiodsQuantitiessplitoversmallerperiodsSplittingRequirement:AutomaticallyGoodsissueProductionIndep.reqmt

WithdrawalReductionReducingindependentrequirementsWarehousePlanningStrategiesMake-to-stockproductionMake-to-orderproductionProductionbylotsizePlanningwithfinalassemblyPlanningwithoutfinalassemblyPlanningwithplanningmaterialPlanningatassemblylevelMake-to-StockProductionDemandprogramMRPWarehousestock

FinishedproductSalesorders

fromstockR

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d

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i

o

nMake-to-StockProductionNetReqmtsplanningGrossreqmtsplanningIR Plannedindep.reqmtsWS WarehousestockPO PlannedorderWSWSIRIRIRPOPOPOWSWSIRIRIRPOPOPOMake-to-OrderProductionProductionInvoicingMRPGoodsissueDeliverySalesorderStocksPlannedActualReductionIndividualcustomerreqmtProductionbyLotSizeSalesorderStockreqmtsMRPWarehousestock

FinishedproductDeliverySalesorderSalesfromstockR

e

d

u

c

t

i

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R

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R RequirementsPO PlannedorderPOPOPORRRRRRQuantityQuantityTimeTime03/0103/0703/1403/2103/0103/0703/1403/21ProductionbyLotSizeforSales&StockOrdersPlanningwithFinalAssemblySalesorderIndep.reqmts.Warehousestock

FinishedproductProductionQuantityTimeIndependentreqmtsConsumingPlanningQuantitieswithCustomerRequirementsQuantityTimeCustomerreqmtsQuantityTimeConsumptionorincreasingthemasterplanConsumptionModePlannedindependentrequirementsCustomerreq.TimeBackwardconsumptionBPBackwardconsumptionperiodBPForwardconsumptionTimeForwardconsumptionperiodFP12Backward/forwardconsumptionTimeFPBPFPAvailabilityCheckAccordingtoATPLogic(Masterplan)Stock(+)Stock(-)StockSalesorders ProductionreqmtsManualreservations MaterialwithdrawalsSalesordersATPquantitiesProductionandPlannedordersTimeSalesorderAvailabilityCheckDuringRequirementsAllocationTimeIndependentreq.IRIRSOSOTimeAllocationKAIRSO05/0106/0105/1005/20CompletelyconfirmedPartiallyconfirmedRestcanbedelivered1.6.PlanningwithoutFinalAssemblySalesorderIndep.reqmts.CustomerstockFinishedproductProductionWarehousestockAssembly01WarehousestockAssembly02FinalassemblyPlanningwithMake-to-OrderProductionPlanningfinishedproductPlanningInd.reqmts.SalesorderPUSHPULLHighvaluematerials-determinepercustomerLowvaluematerialsStockinglevelPlanningwithPlanningMaterialSalesorderIndep.reqmtsProductionWarehousestockAssembly01WarehousestockAssembly02FinalassemblyCustomerorderFinishedproductPlanningmaterialDemoforDemandManagementNowit’stimetodothesystemdemo:TransferSOPtoDemandManagementContentsTopic1:Sales&OperationPlanningTopic2:DemandManagementTopic3:MasterProductionSchedulingTopic4:MRPRunTopic5:CapacityPlanning&SchedulingMasterProductionSchedulingManuallyreprocessingmasterschedule

items

Checkingandadjustingthe

masterplanformasterschedule

itemsLTLTMaterialrequirementsplanning

(planningtheentireproductionstructure)

MPSrunMSIMSIMSISingle-levelspecification

ofdependentreqmtsPlanningtherestof

theBOMstructureSeparatePlanningRunInteractive

planningSeparate

planningrunMasterscheduleitemsMRPmaterialsMRPo.k.InteractiveMasterProductionSchedulingMasterplan-Automaticplanning-Adjustingplans-Manualchange-DateandquantityoftheplannedorderSimulationCurrentmasterplanAdjustedmasterplanCapacityCapacitycomparisonPlanned/customerindep.reqmtsContentsTopic1:Sales&OperationPlanningTopic2:DemandManagementTopic3:MasterProductionSchedulingTopic4:MRPRunTopic5:CapacityPlanning&SchedulingPlanninglevelsProfitablyanalysis-Revenueplans-Salesplans(quantities)-SalesandOperationsPlanning-Salesplan-ProductionplanMasterPlanning-Demandprogram-AdjustedmasterplanMaterialRequirementsPlanning-Dependentrequirements-Masterplan-ProcurementplanRegion1Region2ProductgroupAssembly1Assembly2Part1Part2Product1Product2o.k.?o.k.?o.k.?o.k.?Feedback/correctionsCO/PASOPMPMRPLogisticchain:overviewSDprocessingIndep.reqmtsDemand

ManagementCapacity-

planningFinalcostingInvoiceverificationMRPConvertWarehouseProductionorderSched.agreementPurchase

requisitionOrderprocessingPurchasingfunctionsDependentreqmtsReservations

PlannedorderPurchase

ordersPlanningproceduresPlanningproceduresMRPConsumption-

basedplanning

ReorderpointplanningForecast-based

planningAutomaticreorderpointManualreorderpointMaterialsplanningproceduresNomaterialsplanningMRPincludingBOMexplosionUsingtheforecastforunplannedadditionalreqmtsUsingtheforecastforthetotalrequirementsMPSrepresentsaseparateplanningrunStockTime

Reorder

pointStart

dateDeliverydateConsumption-basedplanningManualreorderpointplanningAutomaticreorderpointplanningForecast-basedplanning

SafetystockPrerequisitesforMRPrunActivatedValidMRPtypeValidmaterialstatusMaintainMRPdataPlantMaterialCarryingouttheplanningrunMPSMRPCarryingouttheplanningrunI-totalplanningProcessingtype Planningallthematerialsinaparticularplant,or Planningallthematerialswhichhaveunder- goneachangerelevanttoplanning (netchangeplanning)Planninginterval Unlimitedor PlanningintheplanninghorizonPlanningPlantPlannedreceiptsReqmtsTimePlanning

horizonMehrstufigeEinzelplanung PlanungeinergesamtenStücklistenstruktur manuelleÄnderungendesProduktionsplanes

fürjedesMaterialinderStücklistemöglich.EinstufigeEinzelplanung manuelleÄnderungderPlanungmöglich

+Erfassen

+Löschen

+Ändern

+UmterminierenMehrstufigeEinzelplanung PlanungeinergesamtenStücklistenstruktur manuelleÄnderungendesProduktionsplanes

fürjedesMaterialinderStücklistemöglich.EinstufigeEinzelplanung manuelleÄnderungderPlanungmöglich

+Erfassen

+Löschen

+Ändern

+UmterminierenPlanningrunII-single-item-planning Multi-level,single-itemplanning PlanningacompleteBOMstructure Optionofmanuallychangingthemasterplan

foreachmaterialintheBOM

Single-level,single-itemplanning Optionofmanuallychangingplanning

+create

+delete

+change

+rescheduleReceiptsTimeIssuesMRPlistandcurrentstock/requirementslistIssues/receiptsStocks/requirementsPlanning

resultsPlanningMRPlistCurrentstock/

requirementslistMaterialMRPelementsMaterialMRPelementsMulti-levelplanningstructureE1indep.reqmtsPlannedCustomerPLANNEDORDERDependentreqmtsPLANNEDORDERDependentreqmtsPLANNEDORDERB1R1R1R1B1PLANUNGSLAUFPLANUNGSLAUFPLANNINGRUNPlanningrunNetreqmtscalculationLotsizecalculationSchedulingBOMexplosion/

determiningdependentreqmtsTotalplanningSingle-itemplanningMaintainingplannedorders(in-houseproduction)PlanningrunAutomatic

creationAutomatic

changes/deletion

ifplanningsituationchangesMRPcontrollerManual

creationManual

changes/deletionCollectiveconversion

into

productionorderIndividualconversioninto

productionorderPlannedorderDcurementPlanningrunPlannedorderSchedulingagreementPurchaserequisitionIndividualconversionintopurchaserequisitionCollectiveconversionintopurchaserequisitionLot-sizingprocedures:overviewsLot-sizingproceduresStaticproceduresPeriodicproceduresOptimumproceduresLot-for-LotreorderquantityFixedlotsizeReplenishuptomaximumstocklevelMonthlylotsizeLotsizeaccordingto

flexibleperiodlengthLotsizeaccordingto

thePPplanningcalendarDynamiclotsizecreationPartperiodbalancingLeastunitcostprocedureGroffreorderprocedureDailylotsize

WeeklylotsizeStaticlot-sizingproceduresReplenishuptomax.stocklevelFixedlotsizeLot-for-lotreorderquantityReceiptsIssuesTimePlannedwarehousestock=SchedulingSchedulingLeadtimescheduling

(Determiningthe

productiondates)DeterminingthedeliveryandreleasedatesBackwardschedulingForwardscheduling

orDeterminingthe

basicdatesforproductionBackward

schedulingForward

scheduling

orbyforexternalprocurementforin-houseproductionbySchedulingforexternalprocurement123BackwardschedulingForwardschedulingReleasedateDeliverydateReqmtsdateProcessingtime

forpurchasing

(workdays)Planneddelivery

time

(cal.days)Goodsreceiptsprocessingtime(workdays)Opening

periodReqmtsdateTodayMRPdateSchedulingforin-houseproduction1OrderstartdateOrderfinishdateReqmtsdateOpening

date(workdays)in-houseproduction

date

(workdays)Goodsreceiptprocessingtime(workdays)Backwardschedulingforin-houseproductionOpeningperiodIn-houseproductiontimeGoodsreceiptprocessingtime12OpeningdateOrderstartdateOrderfinishdateReqmtsdateForwardschedulingforin-houseproductionIn-houseproductiontimeGoodsreceiptprocessingtime21Today(Orderstartdate)OrderfinishdateMRPdateLeadtimeschedulingusingtherouting103020OrderfinishdateProductionfinishdateProductionstartdateOrderstartdateOperations(fromtherouting)FloatbeforeproductionFloatbeforeproductionDeterminingthebasicdatesofanorderAssemblyRawmaterialProductOSOFOSOFOSOFIn-houseproductiontimeReqmtsdateProductBackwardschedulingKey:OrderstartdateOrderfinishdateTimeIn-houseproductiontimeOFPlanneddeliverytimeOSProcessingtheplanningresultPlanningrunPlanningresultManualprocessingMRP

controllerExceptionmessages"BRINGFORWARD

OPERATION"

"CANCELOPERATION"MaterialBExceptionmessagesTotalplanning/sngl-itmplanning"CANCELOPERATION""DISPLACEOPERATION""FINISHDATEINTHEPAST""Exceptionduringrescheduling""New;finishdateinpast"MRPlistsSelectionoftheMRPlistsaccordingtoexceptiongroup"Exceptionduringrescheduling"ExceptiongroupsMaterialAReschedulingchecksReceiptsReqmtsEM:CancelorderCancelorder/purchaseorder308/0308/15ReceiptsReqmtsEM:PostponeordertoPostponeorder/purchaseorder208/0308/15ReceiptsReqmtsEM:Bringorderforwardto

Bringforwardorder/purchaseorder108/0307/1507/15ToleranceTolerance08/03PeggingSingle-levelpeggingofsourcerequirements Ordernumber

(Plannedorder,productionorder,purchaseorder,...)

MaterialnumberPeggingsourcerequirementsMulti-levelpeggingofsourcerequirements Salesordernumberistransferredinmake-to-order

productionPeggingsourceorder,dynamically Determiningallindep.reqmtsthatresultinan order,

(Plannedorder,productionorder,purchaseorder,...)

Salesorder Salesorder SalesorderPeggingsourceorderOrderDemoforMRPRunNowit’stimetodothesystemdemo:MRPRunContentsTopic1:Sales&OperationPlanningTopic2:DemandManagementTopic3:MasterProductionSchedulingTopic4:MRPRunTopic5:CapacityPlanning&SchedulingBusinessBackgroundtoCapacityPlanningCapacityPlanning:ReconciliationoflimitedavailableresourcesandresourcerequirementsObjective:DeviseafeasiblescheduleforcarryingoutoperationsMeansofachievingtheobjective:FindaperiodwithenoughavailablecapacitytocarryouttheoperationFindanalternativeresourcewithremaining capacityAdjusttheavailablecapacityofworkcenter/capacityaffectedIntegrationofCapacityPlanningPPSOPPPMPSPPMRPPPREMPPSFCPPPICapacityPlanningSDPMPMServicePSPDCapacityPlanningEnvironmentPPCapacityrequirementsCapacityevaluationAvailablecapacityBasicdataMasterdataMaterial

Routing

BillofmaterialCalendar Workcentercapacity

Production

planning Plannedorders

Productionorders

...4

Plant

maintenance

ProjectsPM/PS/QMElementsofCapacityPlanningAvailablecapacitySchedulingCapacityrequirementsCapacitydisplayandlevelingCapacityloadreductionAvailablecapacityreferstotheoutputofacapacityexisting

ataworkcenterperworkingdayAvailablecapacityisdeterminedbyworkstart/finishtimes,

breaks,therateofcapacityutilizationandthenumberof

individualcapacitiesinvolvedAvailableCapacityDefinitionTheavailablecapacityisthebasisof:

CapacityplanningFunctionCapacitiesDefinedforaWorkCenterPooled

capacityEnergyWasteMachineLaborTransportWorkcenterWorkcenterAvailableCapacityoftheWorkCenterAvailable

capacityTimehhInterval1Interval1 Interval2 Interval3notaworkingday

accordingtocalendarTimeCyclelengthLengthoftheintervalfromtoABMaintainingAvail.Caps.usingShiftSequenceDay7Day1Day2Shift1ShiftdefinitionShiftsequenceWorkcentersShift2Shift3Shift1Shift2Shift3Shift1Shift2StartFinishBreaks......WorkingHourstoProductiveOperatingTimeTime: Workinghours Workinghours Productive

minusbreaks working

hours

Work -Start -Operating - Capacity - Productive

center -Finish timeper utilization operating

data shift rate timeBreak

timeNumberofhoursTechnicaland

organizational

malfunctionsProductiveOperatingTimetoAvailableCapacityTime: Workinghours Workinghours Productive

minusbreaks working

hoursDataat -Start -Operating -Rateof -Productive

workcenter -Finish time capacity operating

pershift utilization timeBreak

timeNumberofhourstechnicaland

organizational

malfunctionsProductiveoperatingtime

percapacitycategoryOperatingtimeWorkcenterAvailablecapacityX Numberofindiv.capacitiesDatesintheOrderItemOperationComponentsOrderheaderOperationsMaterialcomponentsPRTs

Orderstart/finish(MRP) Scheduledpro.dates Actualdates Earliestdates Latestdates Actualdates RequirementsdateSchedulingOverviewCalculationofplanneddataWrongin-houseproductiontimeinmaterialmaster?PSPSCalculationofproductionorderdates1020304050Floatbefore

productionLeadtimeschedulingIn-houseprod.timelessIn-houseprod.timegreaterthantimeschedulinginroutingIn-houseproductiontimefrommaterialmasterFloatafter

productionRequirementsdateSchedulingForwardschedulingBackwardschedulingSchedulingtocurrentdateNoschedulingSchedulingtypeIftheschedulingrunresultsina