Setup Matrix Generation in a Complex Manufacturing Environment Applies to: Production planning and detailed scheduling Planning and schedule optimization - SCM5.0 or higher Summary Imagine a manufacturing environment where there are many variables that drive the time spent on setting up machine. The changes in the variables would cause the change in the setup time and in a very complex manufacturing scenario the combination of these variables could run into thousands. For example an organization that produces packaging materials could have different setup times when the height and size of the packaging material changes. The setup time also changes when we bring in the type of packaging materials as another parameter. SAP provides the option of setup matrix maintenance where transitions are maintained manually. This will get cumbersome to maintain manually as the combination for transitions increases. SAP has provided a tool to generate the setup matrix automatically for such situations. This document describes the Concepts and Scenarios to generate setup matrix for a complex manufacturing environments. Author: Anand Srinivasan Company: Intelligroup Inc Created on: 10 December 2008 Author Bio: Anand Srinivasan has over 13 years of experience in Supply Chain Management and Project execution. He is a team- oriented Principal Consultant with 10 plus years of experience in SAP (MM, PP, APO-DP, SNP, PPDS and GATP). He was involved in multiple SAP implementation projects, SAP Upgrades and SAP support projects. He has expertise in supply chain process in High tech, Auto, Pharmaceuticals and Machining industry 2008 SAP AG 1
Table of Contents Classical Setup matrix generation...3 Automatic Setup group and setup matrix generation...4 Scenario...4 Brief Description of the Setup matrix generation scenario...4 Define characteristics...4 Define characteristics value matrix...5 Define rules to generate setup groups...7 Define setup matrix rule...7 Generate setup matrix...8 Related Content...9 Disclaimer and Liability Notice...10 2008 SAP AG 2
Introduction to Setup matrix generation SAP provides couple of ways to maintain setup matrix in the system. The classical way to maintain setup matrix is Maintain setup groups Setup groups are defined to identify the setup times required when a job on the work center is succeeded by another job with different material/size/shape/color. Maintain setup matrix define the transitions time between setup groups. The transition time shall be defined for every setup group combination possible Assign the setup groups to Production process model Classical Setup matrix generation The classical way of maintaining setup matrix gets complicated if there are many setup groups. Higher the number of setup groups, higher number of combination is possible between the setup groups. For example If there are two setup groups defined as Setup1 and Setup2. The possible combinations are 1. Setup1 Setup1 2. Setup1 Setup2 3. Setup2 Setup2 4. Setup2 Setup1 5. Start fresh Setup1 Start fresh means if there is no preceding job on the work center and the product with setup group Setup1 is the first job. 6. Start fresh Setup2 - Start fresh means if there is no preceding job on the work center and the product with setup group Setup2 is the first job. If there are three setup groups defined as Setup1, Setup2, and Setup3. The possible combinations are 1. Setup1 Setup1 2. Setup1 Setup2 3. Setup1 Setup3 4. Setup2 Setup2 5. Setup2 Setup1 6. Setup2 Setup3 7. Setup3 Setup3 8. Setup3 Setup1 9. Setup3 Setup2 10. Start fresh Setup1- Start fresh means if there is no preceding job on the work center and the product with setup group Setup1 is the first job. 11. Start fresh Setup2 - Start fresh means if there is no preceding job on the work center and the product with setup group Setup2 is the first job. 12. Start fresh Setup3 - Start fresh means if there is no preceding job on the work center and the product with setup group Setup3 is the first job. 2008 SAP AG 3
Automatic Setup group and setup matrix generation As it can be viewed from the above example that the transition combination multiplies as we add setup groups. To simplify the setup matrix maintenance SAP has provided tool to generate the setup matrix automatically. Setup matrix generation tool generates setup groups and setup matrix based on the rules we define. Following are the steps to be followed to generate setup data 1. Maintain characteristics for variables 2. Define setup transitions for the variables 3. Define rule to generate setup group 4. Define rule to generate setup matrix 5. Generate setup group and setup matrix Scenario Brief Description of the Setup matrix generation scenario Setup transition depends on variables like product family, height and diameter of packaging can. In this scenario setup activities take place due to change in the product family, height or the diameter. Three variables are defined as characteristics PRODUCTFAMILY, HEIGHT and DIAMETER. Variables have three values defined PRODUCTFAMILY CA1, CA2, CA3 HEIGHT 4 inches, 6 inches, 8 inches DIAMETER 2 inches, 4 inches, 5 inches Following steps needs to be followed to automatic setup matrix generation Define characteristics Characteristics should be defined in SCM system. Alternatively these characteristics can be transferred from ECC system as well. The characteristics can be defined using transaction CT04 in APO. Also define the possible values for the diameter 2008 SAP AG 4
Define the variables Height and Product family in the same way. Define characteristics value matrix Define the transition time between 2 inch diameters of can to 4 inch diameter and so on as showed below. To accomplish this step, open the transaction Maintain setup matrices for characteristics values. Define the characteristics value matrix using transaction /n/sapapo/cdps_charmat Click at the Generate setup transitions as indicated by the arrow below 2008 SAP AG 5
Click here It generates the possible combination of setup transitions. Specify the setup time required and save the characteristics value matrix. Repeat this step for other variables as well. 2008 SAP AG 6
Define rules to generate setup groups Open transaction /n/sapapo/cdps_grprule to define rules to generate setup group. Define the prefix which the setup groups should carry and then separate them to identify the transitions between characteristics values (variables) Define setup matrix rule Open transaction /n/sapapo/cdps_matrul to define setup matrix rule. Specify if you want to consider the total of the setup transitions time between variables or maximum. It is also possible to control the calculation through custom defined formula as well 2008 SAP AG 7
Generate setup matrix Now we are ready to generate the setup matrix and setup group. Setup matrix is generated by running the transaction /n/sapapo/cdps_matgen and selecting the rule defined in the previous step. Click on the execute icon and check the results through display setup matrix transaction (transaction /n/sapapo/cdps_setup) Setup group indicating the product belongs to CA1 family and has diameter 2 inches, height 4 inches The transition time between product with setup group ZCA1-2-4 and ZCA1-4-4 is 26 mins The setup matrix is generated with the setup time for the transitions of variables. The setup groups are created with prefix z and separator - as specified in the definition of setup group generation. 2008 SAP AG 8
Related Content 1. SAP Help: www.help.sap.com 2. Classical setup matrix maintenance 3. Setup matrix generation 2008 SAP AG 9
Disclaimer and Liability Notice This document may discuss sample coding or other information that does not include SAP official interfaces and therefore is not supported by SAP. Changes made based on this information are not supported and can be overwritten during an upgrade. SAP will not be held liable for any damages caused by using or misusing the information, code or methods suggested in this document, and anyone using these methods does so at his/her own risk. SAP offers no guarantees and assumes no responsibility or liability of any type with respect to the content of this technical article or code sample, including any liability resulting from incompatibility between the content within this document and the materials and services offered by SAP. You agree that you will not hold, or seek to hold, SAP responsible or liable with respect to the content of this document. 2008 SAP AG 10