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White Paper on ASCP RP Integration

Contents
Solution Summary ........................................................................................................................................ 2 A Day in life of ASCP-RP Planner: .............................................................................................................. 2 A Day in Life Implementation/Execution Steps: .......................................................................................... 4 ASCP-RP Integration Implementation Guidelines: .................................................................................... 11

Solution Summary
Before 12.1.3.8, there was no capability to integrate ASCP and RP plans. The new solution provides this ability. ASCP planners can now use RP capability to perform simulations on top of ASCP plans. This feature provides the ability to better respond to dynamic changes that occur between two ASCP plan runs (typically intraday). The effect of dynamic changes (like changes in supply, demand, BOM/Routing, resources and lead time) can be simulated using RP on top of the last ASCP plan run.

A Day in life of ASCP-RP Planner:


Typically, ASCP is run as a job, nightly. The ASCP planner comes in the morning, validates the ASCP plan output, takes necessary corrective action, and releases orders to execution system. During the day, if any dynamic changes happen with respect to demands, supplies, resources, BOM/Routing then the planner would like to see the effect of these changes. He/she can use the RP simulation capability to simulate these changes. The following process flow shows the typical steps a planner needs to perform to carry out a simulation

1. Run ASCP Plan : This will be typically done in the nighly job mode. So ASCP planner does not need to run the plan again in the morning. 2. Edit and Firm Order Dates : Planner will validate the plan and will make the appropriate changes in the supplies by changing the quantity or order dates.

3. Release Orders : Planner will release orders to the execution system. IntraDay Events trigger the following process flow : 4. Invoke Rapid Planning: Planner can take advantage of the RP simulation capabilities. RP can be invoked in the ASCP workbench by following a onetime set up, which is discussed in detail under Implementation section. 5. Create a baseline RP plan: This is essentially creating a copy of the selected ASCP production plan. A RP baseline plan can be created either from the ASCP responsibility or from the RP responsibility. This process is discussed in more details under the implementation section.

6. Copy baseline plan to a new RP Simulation Plan: Its always advisable to keep the baseli ne plan, which actually mirrors the ASCP plan, and create a new RP simulation plan to perform all simulations. This way, the RP simulation can be compared to the baseline plan. 7. Apply Plan input changes to the simulation plan: Planner needs to enter/modify/change the plan inputs to perform a simulation. 8. Specify what portions of the baseline plan are to be treated as firm: Planners need to have some control over the extent to which the baseline ASCP plans output can be changed in the RP simulation plan. This can be achieved by defining Incremental Replan Scope attributes. This is discussed in more detail under implementation section. 9. Run the Simulation Plan: Run the newly created RP Simulation plan. 10. Compare output of the Simulation Plan and the Baseline plan: Use the RP compare plan feature to compare the two plans. This is discussed in more details under the Implementation section. 11. Release Orders from RP Simulation Plan: Once simulations are completed, planned orders can then be released to the execution system. 12. Firm selected RP plan output to use in next ASCP plan run: Planners can decide to firm some of the planned orders. These orders can be fed back to the next ASCP plan run. 13. Use RP simulation set in next ASCP plan run: The Simulation set used in the RP plan can be used in next ASCP plan that is run.

A Day in Life Implementation/Execution Steps:


Steps 1,2,and 3 are standard steps in the ASCP planning flow. 1. Run ASCP Plan: As part of daily process, continue to run the ASCP production plan in the nightly job mode. 2. Edit and Firm Order Dates : As part of daily tasks , Planner will validate the plan and will make the appropriate changes in the supplies by changing the quantity or order dates. 3. Release Orders : Once plan is analyzed , Planner will release orders to the execution system. 4. Invoke Rapid Planning: Rapid Planning Simulation can be invoked from the ASCP workbench or by using Rapid Planning Responsibility. To Invoke Rapid planning from ASCP workbench we need to first enable Rapid Planning Simulation as a one time set up. ASCP workbench>Preferences>Other. Check the option Enable the Rapid Planning Simulations.

5. Create a baseline RP plan: RP Baseline plan is essentially a copy of the Production ASCP plan. This can be done either from the ASCP responsibility or from the RP responsibility in the following way: a. To copy a baseline plan within ASCP Responsibility, Go to Workbench>Plan>Open Simulation and copy the ASCP plan to an RP plan. User can either create a new RP plan or specify an existing RP plan. If a new RP plan is used, then specify the Plan Name, Description and Simulation Horizon.

b. To copy baseline plan using RP Responsibility, use the Rapid Planning Copy plan process. 6. Copy baseline plan to a new RP Simulation Plan: Using the Rapid Planning Responsibility, copy the baseline RP plan to a new RP simulation Plan. All the simulation needs to be run using this new RP Simulation Plan. 7. Apply Plan input changes to the simulation plan: Based on what intraday event has occurred, the Planner needs to change the inputs to perform the Simulation. 8. Specify what portions of the baseline plan are to be treated as firm: If Planner needs to limit changes to the ASCP plans output then some Supplies need to be firmed. The firming of supplies is done by defining Incremental Replan Scope and Supply Selection Criteria. There are 3 LOV as shown below: a. Freeze existing plan/replan new demands only: This is same as current incremental planning mode where existing plan is considered firm and only new demands are planned. b. Freeze selected supplies/Replan all demands: In this mode, only the supplies defined using Supply Selection Criteria will be considered firm and RP will not change those supplies. c. Freeze all except selected supplies/Replan all demands: In this mode, all the supplies defined using Supply Selection Criteria will be considered un firm and all other supplies will be firmed.

Planner will then have to define Supply Selection Criteria to indicate which supplies are to be considered as firm. Following are the criteria that planners can define. a. Item

b. Org c. Resource d. Item/Supplier/Supplier Site e. Pegged End Demands f. Supplies These criteria are treated as OR criteria and supplies that meet any of the specified criteria are selected and considered as firm. In addition to selecting supplies based on the above criteria, users have the option (for each criteria) to include or exclude a set of related supplies as determined by pegging relationships. If Include pegged upstream supplies is checked, all supplies that peg down to the selected supplies are also included as if they are part of the selected supplies for re-plan. If Include pegged downstream supplies is checked, all supplies that peg up to the selected supplies are also included as if they are part of the selected supplies for re-plan.

9. Run the Simulation Plan: Its important to note that to take advantage of the integration feature and to compare the simulation plan with base plan, RP should be run only in two modes: Incremental replan or without refresh snapshot.

10. Compare output of the Simulation Plan and the Baseline plan: Planner can use the RP Compare Plan feature to compare the two plans. a. The Following new metrics are added to make this comparison more effective. Planner needs to configure these metrics to view under RP Analytics i) ii) iii) iv) v) vi) vii) viii) ix) Total Supply Quantity Planned Order Quantity Make Planned Order Quantity Transfer Planned Order Quantity Buy Planned Order Quantity Work Order Quantity Purchase Orders / Requisition Quant Internal Purchase Orders / Requisition Quantity Total Demand Quantity

x) xi)

Forecast Quantity Sales Order Quantity

b. In the below screen shot, Total Supplies, Purchase Recommendations and Production Recommendations of the two plans are compared using Analytics. The Blue Bars represent data for RP plan RR-RPPL2 and the red bars represent data for RP Plan RR-RPPL2_1

c. A new Supply Order Comparison screen (similar to Sales Order Comparison Screen) is also available to compare the two plans. It allows for easy and accurate comparison of Supply Order Types of Purchase Orders, Purchase Requisitions, and Work Orders. The attributes of Due Date changes and Action changes can be viewed side by side for compared plans.

11. Release Orders from RP Simulation Plan: Once simulations are completed planned orders can then be released to the execution system. Planner needs to first save the plan and then mark the orders for release and then use the Release Plan option to release the marked orders. 12. Firm Selected RP plan output to use in next ASCP plan run: Planner can decide to firm few Supplies in the RP simulation plan. These firm supplies then can be fed back to next ASCP plan run. The Orders can be firmed using the Supply/Demand workbench in RP. To feed the RP firm orders into ASCP , attach the Simulation RP plan to ASCP as shown below. Enter the RP plan name in Snapshot Source for Firm Planned Order.

13. Use RP simulation set in next ASCP plan run: The Simulation set used in RP can be used in next ASCP plan run. Attach the RP Simulation set in the ASCP plan options before launching ASCP plan.

ASCP-RP Integration Implementation Guidelines:


The following points should be noted: 1. ASCP can plan to minute level and is capable of modeling detailed shop floor constraints such as sequence dependent setups, hard links. RP plans at the day level. It is used to get a rapid response to changes in plan inputs without needing to respect all of the detailed constraints. In a constrained mode, RP always runs in the Enforce Capacity Constraints mode. RP and ASCP output comparisons require both plans to use the Plan Option Enforce capacity constraints. RP has global level parameter to control Safety stock. ASCP has an org level control. For most consistent results ensure that all orgs in the ASCP plan have the plan safety stock parameter either checked or unchecked. Since RP currently does not handle all the different modeling constructs and constraints that ASCP handles, the RP and ASCP plan results will be very different if any of the following are found in the ASCP model: a. Process Manufacturing orgs b. Project Manufacturing orgs c. Flow Routings d. Batch-able Resources e. Transportation capacity f. Fixed days of supply order modifier g. Percentage based sourcing splits h. Product family level planning i. Bill of Resources planning. j. Phantom Items.

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7. Since only the demand and supply within the simulation horizon is loaded in RP from ASCP, it is recommended to keep the simulation horizon large enough to minimize end of horizon effects. For an example, if the planner wants to simulate for 30 days and cumulative lead-time is 15 days then it is recommended to set the horizon as 45 days. That ensures that supplies up to 30 days will still be used by the demands within the simulation horizon and will not be dropped.

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