Product Planning and Detailed Scheduling (PP/DS)

Transcription

1 Product Planning and Detailed Scheduling (PP/DS) This case study describes implementation of the production planning process of SNP-Scheduling agreements as part of the Heuristic-based and Optimization-based planning using the detailed scheduling planning board and taking into account maximum vendor capacities when dealing with exceptional cases. Product SAP SCM Release 7.03 G.B.I. Level Undergraduate Intermediate Focus PP/DS Authors Hristina Ivanova Version 3.04 Last Updates March 2017 MOTIVATION This course is specifically designed for UA faculty members who want to introduce SAP Supply Chain Manager (SCM) in a supply chain management course. Because of prior requirements we have an SNP-Production plan. This one is not very accurate yet. Through Production-detailed planning, it is possible to map this plan precisely and up to the second to eliminate any existing inadmissibility PREREQUISITES Required Knowledge Basic knowledge of production planning and scheduling Recommended Knowledge Basic understanding about the connection of SNP and PP/DS NOTES You must have completed the section one till four and six of this training before starting this section SAP SE

2 Process Overview Learning Objective Understand the Production Planning / Detailed Scheduling (PP/DS) and get an overview of the process. Scenario In this case study, you will implement the SNP for DXTR1000 into PP/DS-orders; afterwards you will create a new optimization profile and do the production planning. At the end, you will simulate an engine failure and a rush order. Time 60 min At the end of this module you will have: converted SNP-orders to PP/DS-orders created an optimization profile performed the product planning simulated an engine failure and a rush order used the Detailed Scheduling Planning Board The graphic below displays the complete process and at which point we are currently. SAP SE Seite 2

3 Table of Contents Process Overview... 2 Introduction Production Planning / Detailed Scheduling (PP/DS)... 4 Step 1: Conversion of the SNP Planning Results... 8 Step 2: Creating an Optimization Profile Step 3: Perform Product Planning Step 4: Engine Failure Simulation Step 5: Detailed Scheduling Planning Board Step 6: Rush Order SAP SE Seite 3

4 Introduction Production Planning / Detailed Scheduling (PP/DS) Task Learn about PP/DS and the Planning Boards we will use in this case study. Time 15 min Production Planning / Detailed Scheduling (PP/DS) In essence, the demanded plan of PP/DS can be interpreted as a short-term and detailed procurement planning. There are independent requirements that can be used as a starting point for the planning (results of demand forecasting (DP) and sales orders). Ideally, and if possible, these requirements must be met in a timely manner. If this is not possible, then PP/DS will make additional possibilities for production and detailed planning available. Capacity constraints can already be accounted for in the planning of requirements. Also the multi-level system scheduling problems can be viewed and resolved with help of pegging, assumptions are solvable, etc. A variety of other functions are provided mainly for capacity planning and optimization of a production plan. In PP/DS, the short-term horizon, enables you to edit your planning with exact start and end times up to the second. This allows you to better respond to blocking problems or exceptional cases and solve them optimally. Product Planning Board The production planning table provides possibilities to highly versatile advanced planning options. It represents a powerful tool for which it carries out and evaluates the planning of APO-PP/DS: it can be displayed in a wide variety of charts areas. Depending on the selection of the charts, the product plan table can be customized into different tasks. The navigation tree in the upper left-hand edge of the screen displays the work scope of the product planning table. You use this navigation to define which objects you want to display in the individual views. You can group the navigation tree into different categories (for example: according to planner, product group, location, and resources). The process field selection in the lower part of the screen you can choose the plans you like to have displayed (Periodic Product Overview, Periodic Resource View, Alert Monitor, Quantity Graphic). In addition, Capacity Planning can be carried out in the corresponding fields of the product planning table. In the Resource View (Periodic) the demand and supply of resources are displayed and their usage is determined in percentage. SAP SE Seite 4

5 The Product View (Periodic) provides information on the resources required for a product to be produced during a specific period of time. In addition detailed information such as available quantities, day s supply and the receipts, and dates are also displayed and totaled periodically. APO-Product plan board can be used to plan products and capacity utilization on the resource; it is particularly useful for repetitive manufactures (the manual line utilization planning with simultaneous monitoring capacity). Therefore, it facilitates a simultaneous product and capacity planning. It is particularly useful to monitor the resources view activities that are related to the periodic product view. The Product View (Periodic) makes it possible to monitor every product (or make changes; careful attention should be paid to the color highlights in the input-ready areas or fields) the range, the additions and the planned independent requirements. Furthermore, you can use the periodic product view to plan in an aggregated way and use the view to show the detailed information. The Resource View (Periodic) displays the absolute and the relative capacity of resources and it sort it according to the displayed orders. Detailed Scheduling Planning Board Detailed Scheduling Planning Board is a primary tool for Capacity Planning. You use the Detailed Scheduling Planning Board for the: - Graphical Representation of the planning situation You can graphically represent different aspects of scheduling in the charts of the Detailed Scheduling Planning Board. As an example, you can show the situations of operations on resources over time and the development of the resources utilization or pegging relationships between orders. - Interactive solution of planning problems You can perform interactive scheduling on the detailed scheduling planning board to solve scheduling problems such as sequence or date problems on resources. Various scheduling functions and heuristics are available in addition to manual scheduling with Drag & Drop. Views When you access the Variable view, you must select a suitable overall profile in the planning board to obtain the desired results. In view 1, view 2 und views 3 profiles are preset and specified by SAP. When you call up the Variable view, you can always change the work area before you start the planning board. Work Area With the help of the work area you specify which objects will be displayed in the planning board. SAP SE Seite 5

6 The work area specifies a defined selection of resources, orders and products, which are determined by the system and transferred to the planning board according to the following options: - The system identifies all products in the work area that were prespecified to orders. Then the system determines the processes and resources that will be used. - For every pre-specified Order the system determines the processes and the required resources. - In the work area every detail specific Resource is directly relevant in the planning board. Based on these resources, the system determines the objects that will be displayed in the various charts. Functions The DS planning board has the following features and tools are available: - Detailed Scheduling Functions The system automatically uses detailed planning functions once you start planning operations or process in the DS planning board. For example, during scheduling, it can automatically adjust the setup times. Or consider the Blocks in Block planning. You can control detailed scheduling with the help of detailed scheduling strategies that specify in a strategy profile. You can changes the detailed scheduling strategies anytime. - Optimization To optimize the schedule, you can call up optimization in the DS planning board. - Functions for Order Processing You can also create or delete orders, change the order quantity, and switch the source of supply within the DS planning board. (See Process Orders in the Detailed Scheduling Planning Board). - Interactive Block Maintenance You can call up block maintenance in the DS planning board and interactively change blocks. - Campaign Planning You can process campaign in the detailed scheduling planning board. - Alert Monitor You can call up the plan monitor in the DS planning board to display scheduling problems. SAP SE Seite 6

7 - Plan Monitor You can call up the plan monitor in the DS planning board to evaluate the planning quality according to user-defined criteria and key figures. - Legend The meaning of the various graphical representations for rows, orders and operations in the DS planning board is explained in a legend. You can also change the display of rows and graphical objects in the legend. - Simulation Versions In the directly called up detailed scheduling planning board, you can also save the simulation version without changing the planning version. To continue editing a simulation version at a later date with the DS planning board, call up the simulation version in the DS planning board area menu. The case study will narrow the focus on only one of these functions. SAP SE Seite 7

8 Step 1: Conversion of the SNP Planning Results Task Convert SNP-orders to PP/DS-orders (plan orders) in a short-term planning horizon. Time 5 min In order to transfer the planning results, you need to first convert the existing planned orders into PP/DS-Planning orders. Follow the following Menu Path: SAP Menu Advanced Planning and Optimization Production Planning Environment Conversion of Supply Network Planning -> Production Planning Enter the following information: Planning Version: 000 Product: Location: DXTR1000 DL## Propagation Range: SAPALL Heuristic: SAP_SNP_SNGL Menu Path 000 DXTR1000 DL## SAPALL SPA_SNP_SNGL to execute. You will see all orders that are listed in PP/DS horizon. Notice, however, that some orders are behind (the horizon amounts to 50 days). The reason is that the release dates have already been listed in the Horizon. SAP SE Seite 8

9 to get to change mode and then select all entries by clicking on in the upper right corner. for Order Conversion and select Convert SNP Orders. You notice, the category of all entries changed from SNP:PL-ORD to PlOrd.. to save and on to go back. to return to the SAP Easy Access menu. Optional check: Go to the Product View: SAP MENU Advanced Planning and Optimization Production planning Interactive Production planning Product View Select the Product DXTR1000 and the Location DL## and from Planning Version 000 click on. SAP SE Seite 9

10 All planning orders should now be displayed in PP/DS-Horizon. Some or a few should, based on the above mentioned reason, have been converted to the PP/DS Horizon. Click to go back. to return to the SAP Easy Access menu. SAP SE Seite 10

11 Step 2: Optimization Profile Task Create an Optimization Profile. Time 5 min Production planning requires a different Optimization Profile than the Supply Network Planning. Follow the following Menu Path: SAP Menu Advanced Planning and Optimization Production Planning Environment Current Settings Maintain Optimization Profiles Menu path. Enter GBI-## as Optimzn Profile and Optimizing Profile GBI-## as description next to it. Under Basic Settings enter: Maximum Runtime: 00:05:00 Makespan: 1 Maximum Delay Costs: 1 Total Delay Costs: 1 GBI-## Optimizing Profile GBI-## 00:05: SAP SE Seite 11

12 Press Enter. You will be prompt to select at least one order from the Order Processing tab. Select External Procurement. External Procurement You will switch automatically to the Resource Processing tab. A resource network priority must be selected. This must be entered by default even so we won t need it. Enter for Lowest Resource Network Priority A at the bottom of the screen. A SAP SE Seite 12

13 Press Enter. In the following screen, enter for End of Optimization Horizon the relative Start of Day as SAP SE Seite 13

14 the Order Processing tab to return to the order categories. Select the check boxes for Stock Transfer, TLB Shipment and Consider Planned Delivery Time. Stock Transfer TLB Shipment Consider Planned Delivery Time to save. If you are asked for a customizing request, choose your respective request or create a new one., enter SCM Case Study GBI## as Short Description and press to save. Once you have a request, this one will be automatically filled in the next time. SCM Case Study GBI## Confirm the customizing request by clicking on. Click to return to the SAP Easy Access menu. SAP SE Seite 14

15 Step 3: Product Planning Task Perform the Production Planning. Time 10 min Follow the menu path: SAP Menu Advanced Planning and Optimization Production Planning Interactive Production Planning Product Planning Table Enter: Planning Version: 000 Planning Horizon: From To Location: Product: today 1 Month from today DL## DXTR1000 Menu path 000 today 1 Month from today DL## DXTR1000 to execute. SAP SE Seite 15

16 If the PPT Initial View pops up, please choose the view SAP_SCO. for user settings. Switch to Charts tab if another one was opened. In case this is not already present, change the view for Chart 1 to Resource View: Periodic and for Chart 2 to Product View: Periodic. Resource View: Periodic, Product View: Periodic SAP SE Seite 16

17 . For Variant enter GBI-## and for Description enter User Profile GBI-##. GBI-## User Profile GBI-## to continue. Scroll through the resource view. As you notice the product view scrolls automatically as you scrolling down the resource view. SAP SE Seite 17

18 In the resource view you can see the daily workloads of our Work Center. Additionally, in the product view, you can also view productions and delivery details available for these days. While you are scrolling compare the values. Perhaps, you will find overloading information in between. Select a value and double click on it. A detail list view will open. Here you will see the product and resources amount required for the production. Your values may look like this. to close detail view. You can start a new optimization run from the Product Plan Table.. In the Settings for Optimization window set the End of Horizon one day later and click on. The screen will switch to the PP/DS Optimizer. One day later SAP SE Seite 18

19 for Optimization Profile. Choose your own profile GBI-## and click on corner. in the right lower GBI-## to adopt. Start the Optimization Run by clicking on. This could take up some time, because the optimizer tries to improve the solution. Nevertheless, after five minutes the run will be finished at the latest (based on our optimization profile). SAP SE Seite 19

20 At the end you will see the optimization log, which will look like this. to go back and take a look at the current values. Notice the changes in the Product Planning Table. There should be no more overload. SAP SE Seite 20

21 Step 4: Engine Failure Task Simulate an Engine failure. Time 5 min To simulate a failure we reduce the working hours of the relevant resources. Then we start a new optimization run. Look for a day where the Resources WASSY1000 has nearly reached its full 100% capacity and is due in the next 3 weeks. Highlight the column and note the date to yourself. Highlight the whole line of WASSY for Further Processing Functions and select Resource Operating Time from the drop down menu. to switch to change mode in the upper left corner. Look for your date. Change the time to the following 08:00:00 until 12:00:00 and select the next day as Not a Workday. 08:00:00 until 12:00:00, Not a Workday Press Enter. You see, both lines will be adjusted and marked with different colors. The productive time on the first day sinks to 2,55 hours and on the following day to zero, cause that is now a Non-Workday. to go back. SAP SE Seite 21

22 Notice, an overload occurring either on that specific day or/and on one of the next days. to save. SAP SE Seite 22

23 Step 5: Detailed Scheduling Planning Board Task Check engine failure in detailed scheduling planning board. Time 10 min Create a new session by clicking on in the upper toolbar. Follow the Menu Path: SAP Menu Advanced Planning and Optimization Production Planning Interactive Production Planning Detailed Scheduling Detailed Scheduling Planning Board Variable View Menu Path Enter following values: Plng Version: Leave the Period values as they are. In the Resource Tab enter: Location: DL## Select the checkbox for Selected Resources and Finite Scheduling. DL## Selected Resources Finite Scheduling Switch to the Product Tab. SAP SE Seite 23

24 Enter the Product number DXTR1000 and the Location DL##. DXTR1000 DL## to execute in the upper left corner. Now you can see the detailed planning board. The dashed red line represents the current time. If you scroll to the right, you will see the start of our order processing. In the upper part of the screen you will see, how the resource capacities are utilized. At the beginning only WASSY1000 would be loaded, but if you scroll further to the right, then you notice WINSP1000 and then WPACK1000 will be also loaded. The blue bars indicate that a request is being processed here. The green bars represent a set-up process. If a process has a green underline, then this indicates that the process was indented at this point. In the middle of the screen you can see the orders. Based on performance reasons we have implemented orders only for DXTR1000 in PP/DS and these are represented by violet bars. The green bars denote the confirmed in-house processed orders. SAP SE Seite 24

25 At the bottom of the screen you can see the product inventory in the form of histogram. As you can see the product DX1000 inventory is kept constant at 0. Eventually, the stock is increased (blue marked) or decreased (red marked) for a while, but it will be balanced later. In contrast, the inventory for the other displayed products continuously decreases further over time. This is because these are needed to create DXTR1000, but these were not previously implemented by us in PP/DS orders. Right click on the timeline and select Weekly View to get a better overview. The detailed planning board is interactive, however, for more complex problems, it is better to choose a planning method. SAP SE Seite 25

26 and proceed just as in the previous step. After your optimization run is finished and you see the log, click on get back. to to save and then close this session and switch back to the first. If you are asked, if you want to adopt data or save as a simulative version press. In the first session click on to refresh. There should be no overloads anymore. SAP SE Seite 26

27 Step 6: Rush Order Task Plan a Rush Order. Time 10 Min We now simulate an unexpected rush order by creating a new planned order and then we go back and run a new planning again. Create a new session by clicking on in the upper toolbar. Follow the Menu Path: SAP Menu Advanced Planning and Optimization Production Planning Interactive Production Planning Product View *If you are prompted to PPT initial View, select SAP_SCO.* Enter: Plng Version: 000 Product: Location: DXTR1000 DL## Menu Path SAP_SCO 000 DXTR1000 DL##. Switch back to the first session. Look for a date in the Planning Table that is due in the next 10 days and that using almost a 100% of its capacity utilization. Note the date and return to the Planned Order session. Enter following values: Rec./Reqmts Qty: -20 Avail/Reqmt Date: previously noted date -20 previously noted date. SAP SE Seite 27

28 Press Enter, a new screen will appear. to save and close this session. Switch back to the planning board session and click on to refresh in the upper left corner. To carry out this order, we will perform a heuristic run.. Select as used heuristic Planning of Shortage Quantities in the new screen. Planning of Shortage Quantities SAP SE Seite 28

29 . In the popup click on. The heuristic will be executed. You can check its status in the upper right Status box. to go back to the planning board. Notice, the heuristic ignores the resource capacity and it will come to a new overload. and proceed just as in the previous steps. After your optimization run is finished and you see the log, click on get back. to The overload should be resolved. to save and on to go back. to return to the SAP Easy Access menu. SAP SE Seite 29