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Name: Design AP YARA v1.1.doc Version: 1.1 Created: 10 April 2007 Updated: 8-Jun-2007
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Detailed Design Advanced Planning
Infor Supply Chain Planning
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Copyright 1996-2007, Infor IP Holdings C.V. and/or its affiliates or licensors. Page 2 of 62
Detailed Design Advanced Planning
Infor Supply Chain Planning
Executive Summary
This document contains the structure to describe the usage of AP within Yara.
In chapter 2 the link to the detailed definition document is made. The key
requirements in this document function as a starting point for the AP design
Chapter 4 describes brief the roles and responsibilities in the rest of the
project. Of course, most of them are already addresses and known. A number
of them with a higher level of detail are described here.
Chapter 5 gives the starting point of the tests of this design. It also shows the
important point that changes (and errors) on this design should be
documented and approved.
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Table of Contents
DOCUMENT APPROVAL...............................................................................................2
EXECUTIVE SUMMARY.................................................................................................3
TABLE OF CONTENTS..................................................................................................4
1 INTRODUCTION .................................................................................................6
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1 Introduction
The document will describe in detail the setup of the model with all related
elements. Important in here is the integration with the (Oracle based)
integration hub, but also the plan sheets and workflows are mentioned.
The model is created in AP version 5.0.5 and has already 3 pilot models
available (from BR, SA and UK). The pilot models for global, FR and IT will be
released shortly.
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This section is copied from the Detailed Project Definition. This chapter will
contain both RP and AP related topics.
In some countries (for example the US) all warehouses are managed
individually, more commonly however (Italy & France) warehouses are
grouped together for planning with the sales forecast netted off against a total
Legal Company (in the case of Italy) or a number of grouped warehouses (in
the case of France). This netted requirement is then typically aggregated by
region and ultimately by Legal Company to provide a total view of
requirements for a specific Legal Company.
As the plan evolves the regional planning teams are responsible for providing
updated demand data and reacting to communications from the global
planning teams in situations where there are supply shortages. The regional
planning teams are also responsible for bidding on any excess volumes
(arbitration) that become available from the global production sites.
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The BOM can be fixed in that the raw materials (RM) are defined
included the relative quantities. Possibly, several alternative fixed
BOMs are known and available for selection.
The BOM can also be variable so that all possible RMs are defined,
while the exact draw quantities are calculated based on the target
chemical composition. The resulting formula is relative over time, so
that the same end product (=blend) can have several formulas over
the time horizon to achieve the best possible mix.
RMs for blending are in fact main fertilizer products produced in OPP/TPP/JV
plants. Next to blended products, hubs also sell these main products directly
(not blended) which generates in the end both independent and dependent
requirements for main products. The capacity planning of a hub consists of
three groups:
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3 Detailed Scope
The table below shows an overview of (AP) models and links in the various
parts of Yara. The MLT models are built in 2 phases in the time between now
and January. In the budget phase (until September 2007) the budget plan for
2008 is prepared. In the phase between September and January 2008 the
plan is extended and made ready for monthly planning cycles. After January
2008 the planning cycle is extended with a ST feasibility study with increased
complexity over a shorter horizon.
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The first template is the model to be used by the blending hubs. This model
has both a structure for the formula with predefined ingredients (with a
predefined draw quantity per ingredient) and a structure with variable draw
quantities for a set of ingredients where usage is done based on
specifications (the variable BOM)
The second template is used for Global planning and other (sales) regions
where the end results of the model above combined with information of the
other solutions in the supply chain is used as input of this model. This model
has only a fixed BOM structure, but can have a multilevel BOM where this is
not used (often) in the blending model.
The models for South Africa and United Kingdom have the possibility to add a
variable BOM. Once a model uses the variable BOM the fixed BOM will no
longer be interfaced from the ERP system(s). The BOM information needs to
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The second model is a model with a similar setup on supply, transfer, sales
and (fixed formula) production. The transfer is still in but is not foreseen to be
used. The model is adapted for manual maintenance.
3.1.1 Products
Products can be classified into
end products
intermediate products
raw materials (ingredients, raw materials and packaging materials).
This classification differs from market to market and therefore from model to
model.
End products are sold to customers and are produced out of several other
intermediate products and / or raw materials. A number of products act both
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The products being planned within AP are the so called planning products.
These are not the actual products as they can for example be found in the
ERP systems. Similar products existing in reality are grouped into planning
products that are planned as single items.
Note: The aggregated level in Brazil does not contain packaging information.
This packaging information is replaced by a common packaging type in the
aggregator group.
On product level the total cover stock is given. This number of weeks worth
of stock is valid for the whole supply chain. E.g. 10 weeks worth of stock for
the whole of Brazil.
The service level per product is calculated in the product class and in the
customer class.
Budget project phase In the budget phase of the project only the planning
products or aggregates are used. The planning is on all levels a one off-plan
(a budget for 2008) not supported by workflows. All models (blending, sales,
global) are used to calculate this budget plan.
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Balancing project phase In the balancing phase the models for global and
production hubs (IT and FR) are finalized. These models are expanded with
workflows to make a month to month planning possible. The models will
operate manual where needed/possible/agreed. The communication between
global and markets is firmed.
Post Optimizing project phase In the phase after the 1st of January 2008
the model usage in Brazil will be expanded by using a set of workflows to
increase complexity in the model. The model will be used to see if the
aggregated model is still feasible on a short term taking all products and
discrete constraints into account. And to determine in which weeks vessels
are preferred to arrive.
3.1.2 Locations
All relevant locations physically available in a supply chain are translated in
the AP model. Both MLT and ST model have the same locations. Locations
can be stock keeping or non-stock keeping.
In the budget phase location do not have links with locations. Production is
grouped in a number of locations to represent the budget per location. All
warehouses, ports and other locations are left out.
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Types of locations:
Port
Production
Stock
Port + Stock
Port + Stock + Production
Stock + Production
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On the location for the global location the port of destination is handled as a
sub-location. This enables the global sites to see the destination on the
supplier relationship. The sub locations are also available in the global model
to see the shipments to the individual ports.
Since the global models will have blending models as customer and the
blending models will have the global model as supplier we can make a joined
example:
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Blending Global
Main Location Sub Location Vendor Customer Sub Location Main Location
Porsgrunn Port Porto Porsgrunn Yara Brazil Not in use Porsgrunn
Alegro Porto Alegro
Porsgrunn Port Capetown Porsgrunn Yara South Not in use Porsgrunn
Africa
Capetown
Sluiskil Port Capetown Sluiskil Yara South Not in use Sluiskil
Africa
Capetown
If drill down information is needed, this will be generated with the use of
queries in AP. These queries select e.g. in the global model all the ports for
Yara South Africa. By applying different queries, different drill down structures
can be used.
3.1.3 Products@Locations
In the product at location class the products (and aggregates) are made
specific per location. When a product has been processed / used / produced
at a certain location a production@location record will be generated.
The Max Inventory property in the P@L class is product driven. E.g. if for
raw materials it is allowed to store materials and for finished products it is not,
the max inventory on finished products needs to be set to 0. If there is a
physical constraint on space, the constraint needs to be added to the location.
The default max inventory is 999.999.999
The Monthly Holding Cost can either be a penalty or actual costs. In most
cases this is a fixed amount per month.
The Budget is property to compare the budget quantity with the forecast
quantity. There is no relationship between the two properties. The budget is
visible and can be used in determining the order-quantity in the customer
allocations. This functionality will be used at global. There is both a production
and a sales budget.
The Hist Production is a property (in the global model only) to show the
production of global sites in a number of months of history.
Market Focus
Blending Brazil MLT Forecast customer forecast on aggregate
Orders not in use
Budget not in use / reference only
Delivery purchasing receipts + transports
receipts
Shipments transport shipments
ST Forecast customer forecast on aggregate
Orders customer orders on blend
Note: only one active per bucket
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If products@locations are not available and a sell cannot be fulfilled, this will
lead to either:
Lost sales there is not enough material and its not possible to
resupply stock by producing or purchasing (upfront) or
Backlog the point of satisfying the sell is postponed until the
material is available. If it is not possible to get material at all, this will
still lead to lost sales.
Lost sales and Backlog are the objectives in the solver with the highest
objective. It is an indication per customer allocation if it is allowed to generate
backlog (per default is yes)
Stock (with possibly Safety Stock) is also monitored at P@L level. Each
product is monitored at P@L level and both product and location level in total.
Safety stock is either a cover stock (used in hubs because forecasted
products are different from the storage items) or based on a forecast
inaccuracy calculation (maybe to be used in a later stage).
3.1.4 Suppliers
All parties delivering goods to the supply chain are suppliers. This is of course
the case for TPP products which are purchased products. Also the OPP
products are handled via a supplier relationship. In the global model, the
purchase requirements on the various OPP suppliers will be handled as
demand.
In the Blending and Complex region models there is a location at the sending
facility (e.g. Porsgrunn). This location is linked (in supplier allocations) to the
supplier.
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In the budget phase the connection with suppliers is directly on the producing
locations. In the optimizing phase the relation is moved to the initial receiving
point. E.g. if the receiving point is the habor in Capetown the supplier relation
is raised on the Capetown location.
The Min and Max purchase qty show boundaries per product/supplier how
much is allowed to buy. A contract obligation should be entered here
The Purchase Lead Time is the time between ordering and receiving of the
goods. Since there is a location in the port of the sending OPP facility, this is
the time between ordering and the boat leaving the port.
The Purchase Unit Cost is the total purchase cost price per 1 UoM. If there
is no price available a penalty can function too. The higher the penalty, the
more difficult it is to buy at this supplier
The Hist Purchase is a property (in the global model only) to show the
purchases for global sites in a number of months of history.
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Since the global purchases are handled via a port of origin, the supplier
relationship is managed on port of origin (e.g. the supplier allocation for
Porsgrunn is related to the location Porsgrunn and not to the blending unit to
process the materials in).
On TPP the general rule is to buy OPP first before entering a TPP value.
Since this calculation is based on costs, the lowest costs will have preference
(if TPP is cheaper, it will use TPP first). The maximum purchase is used to
build in a maximum from a specific supplier/product
3.1.6 Customers
Customers determine the (external) demand from the market. The amount of
detail is identical to the sales forecast. At this moment the sales forecast has
the level of sales manager or (below that) sales supervisor as lowest level.
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In case of a blending hub model, the demand comes from sales planning.
This forecast with external demand shows the quantity that is prognosed to
be sent to customers. Derived from the requirements plan(s) the global, Italy
and France model can derive dependant demand. The customers in such a
model are the regional market. A change in sales planning could lead to a
change in requirements plan and could lead to a change in global planning.
Forecast group demand and sales prices for end products are imported from
the DP demand forecast. Demand for intermediates and raw material is
derived requirement which is calculated from preceding processes, required
for the production of the end product.
In the ST model in stead of the demand forecast the Open Sales Orders of a
forecast group will be imported. These open sales orders will be considered
as committed demand, and therefore AP will always try to fulfill this demand
(like it does for demand of forecast groups with a 100% service level).
The price property is used for relative importance in case there is a choice
which product will be added to lost sales. The product with the highest margin
will have the preference to be delivered over the product with a lower margin.
The Hist Sales is a property (in the global model only) to show the deliveries
from global sites in a number of months of history.
The Arbitration Sales is a property (in the global model only) to show the
arbitration sales from global sites in a number of months of history.
3.1.8 Routes
The route class is used to identify the ship sizes, route costs and route
durations.
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Ship size: the ship size is a batch size. It calculates the needs for full ships. It
indicates the number of ships with the tonnage per ship to the global
planning. When a full ship is confirmed, the actual tonnage of the transport
can be different. Therefore the ship size is ignored when looking into the in
transit stocks. Note: the linear solver does not create full loads, the discrete
solver, takes boat sizes into account. It will show a number of boats as
number, not rounded to full figures.
Because there are various ships on a route, the resource route should be
made unique for each boat size. The route is used to build up the (product
and route specific) transport network
If (in the UK case) the quantity varies per ship, an extra route for small
quantities is needed. This special route (against a high penalty with e.g. a
quantity of 100 TNE) enables it to make smaller ships
Route cost: a boat size will determine the discharge costs and transport
costs. If there is a fixed price per ton, the costs can be used at transport level.
If there is a charge per vessel, the routes class needs to be used.
3.1.9 Transfers
The transfers are the connections between locations. The transfers are
product and route specific.
Market Focus
Blending Brazil MLT Show the in transit stock
ST In transit stock is used to determine the arrival week
South Africa MLT Show the floating stock
United MLT Show the floating stock
Kingdom
Production France MLT No transfers foreseen in this model
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The Lead Time is in days. Since the bucket size is months (except for the ST
Brazil model), the lead-time will be displayed in months: < 15 days: no lead-
time showed; > 15 days: lead-time is showed as 1 month difference
The minimum transfer quantity is a minimum per bucket per product. Note:
this property makes the model discrete. An increase in calculation time is
expected. Example: to use a transfer you need at least 10000 ton. Quantities
below 10000 ton will either be raised to 10000 (which created stock) or
moved to another period to be more effective with other deliveries
3.1.10 Resources
Resources are the machines on the various (production) locations. In general
at blending sites similar production lines are modeled as one resource per
location. On global sites, production lines are modeled as one unit (if
possible). Only if the capacity is non-transferable and critical, each resource
is modeled. E.g. 2 blenders which perform the same task can be modeled as
one resource with a common capacity. In case of a blender and a packaging
line, this could be modeled as 2 resources if the capacity is constrained.
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The Min batch size is a level to start production. This will only be used in the
Global model
3.1.12 Processes
The processes are grouping structures for producing products. Each process
will have a product and a version attached to it. The version indicated to
enable more than one version on one location. With version it is possible to
have more than one BOM or Routing on a location to produce the same
product.
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The process is the high level holding place for a formula (Bill of Material) and
a resource allocation (Routing). Product with an alternative resource
allocation and/or formula within the same location are handled with a version
within the process.
The alternative process holds the combination of the alternative process and
the alternative routing.
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3.1.13 Formulas
Formulas are the representation of the Bill of Material (BOM). There will be 2
types of records:
For each BOM is applicable: the SUM of outflow = the SUM of inflow. If there
are BOMs where this rule does not apply, an extra ingredient or a by-product
should be added. In the blending model this represented as (all) Outflow =
(all) Variable Inflow + (all) Fixed Inflow. The outflow is shown as Production
(or Yield). A counter counts all inflow products. This counter could be set to a
maximum but this is not foreseen (it makes the calculation discrete).
The condition that the quantity of inflow should equal the quantity of outflow is
only applicable in the blending optimization model. In the global models this
could differ.
Whenever a hub wants to use variable BOMs, all data entry will be manual.
Even the available (fixed) BOMs in SAP will not be used to prevent double
counts.
In general only critical raw materials are added. Critical means they are
important in the planning process 1,5 year upfront. Example: in a packaging
operation the product itself is a critical material. The empty bigbags are not.
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quantities. These raw materials influence the NPK specifications and are
critical raw materials. Also S (sulfur) can be seen as fixed ingredient.
3.1.14 Parameters
The parameters show the 3 basic parameters the variable BOM uses. All
ingredients have a portion of these parameters. By adding ingredients the
blended product should also be in specification according to these
parameters.
N Nitrogen
P Phosphorous
K Potassium
Note: There is the possibility to add an extra parameters At this moment the
S component is not going to be added as variable BOM. This would have a
large effect on the number of records and the calculation time (see Model size
calculation for the implications). The S component is going to be added as a
fixed ingredient in the BOM (see formula).
Per outflow product and per inflow product the specifications are known.
These specifications of the outflow and the sum of ingredients should match.
Example:
In the example the produced aggregate has NPK values of 10-23-10. There
are 3 ingredients possible 16-16-16, 02-40-00 and 14-03-18. By adding
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quantities of these ingredients, the specification of the blend should match the
given NPK values.
3.1.15 Specifications
3.1.16 Recipes
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The recipe allocation is the link from parameters at inflow level to the
parameters at outflow level.
This setup will be generated via product families in the integration hub. See
for an explanation.
The whole supply chain (see the solution map for the details) the bucket size
is set to months. The Brazilian region has the preference to work in weekly
buckets in the first quarter. Doing so, the region will be enabled to store data
(on purchasing) on weekly buckets which will give a clearer picture on stocks.
MLT model - There are maximum 18 months in the mid long term plan. On
blending hub the level is planning product (or aggregator level in case of
Brazil). On global level this is planning product level too. In general conditions
the MLT in the hubs is 6 months of plan on screen. This is a rolling horizon
Once a year the plan is extended with a full new (budget) year. The global
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plan is stable on one year. Months in the past are frozen and once a year the
plan is expanded with a new budget year.
In the global model there is a fiscal and a fertilizer year (July June). Before
expanding the year with a new budget year the plan is expanded with a
fertilizer year. The expansion works according to the described system with
budget
ST model the first month is a split-up in weeks of the first bucket. Since the
opening balance should be synchronized with the opening balance of the
MLT model. In this model the purchases are frozen and the model is
recalculated using orders in stead of forecast.
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The switch from MLT model to ST model will be done in the same model.
With a workflow (see Planning Workflows) the calendar is split into week
buckets. This will automatically divide the month quantities into smaller
weekly quantities. When this plan is edited the quantities are stored in weekly
quantities. This makes it possible to redo this exercise multiple times. See the
example screenshots
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This ST calculation is done in a model which is used for the MLT calculation.
The model is saved separately and can be consulted separately. There is not
an aggregation step foreseen from ST level back to MLT level.
3.3 Optimizations
Linear solver
Discrete solver
Since the linear solving is a much faster way of solving, a 2 layer solve is
proposed. An initial solve with a linear solver is performed to see if the
problem is feasible. If the problem is feasible the second solve run is started
to give an exact answer. This is performed in a workflow.
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Objectives of a solver
(with a weight per
objective).
The solver needs fine tuning on the objectives. By changing the weights the
result of the solver is changed. In the picture above, generating lost sales is
10000 times more important than generating transport cost. Both solvers are
available in the blending model. But if the problem is not discrete, the discrete
one will not be used.
The solvers are also available in the global model but will not be used initially.
If a model is too large to solve in one run (see Model size calculation) the
problem can also be solved in phases. This could be a time phasing:
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But could also be a solve based on functionality. First solve the production
problem and then the transport (and purchasing problem). The place where
this could be applicable is on the Brazilian ST model. A detailed roll out plan
will be made after 1/1/2008. All workflows, solvers and integrations will be in
before 1/1/2008
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Another solution to limit the size of the model can be by adding a split in the
model:
One model that solves in one bucket of a month all products to see if
the agreed purchases can still cope with the blending plans for orders
A second model to determine on a weekly basis the delivery plan in
order to assign an appropriate week for a (global) delivery.
One important statement is the use of discrete constraints. This will have a
significant impact on solving times. At this stage it is not possible to estimate
a solving time. Discrete will slow down the (solving) process seriously.
In cases where the data load is substantial (e.g. the Brazil ST model) the
connection to the database should be optimized and be as short and with the
highest bandwidth possible.
In case of models with a lot of variables (e.g. the Brazil ST model) the
memory usage should be optimized and as high available for calculation as
possible. A server environment would be the preference.
Models with a limited number of resources (data load) and therefore a limited
number of variables for solving the model, can also be applied on local
machines. However, a Citrix environment could be seen as preference to
generate a uniform and controlled solution with standardized structures and
backups.
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See the technical document for further information about this subject.
Each model triggers a set of records in the master data and the transactional
data. The views contain all records for a specific profile. If records are visible
under two profiles, the records are visible twice.
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Interface name YBBR YBBR YBSA YBUK YPFR YPIT YGNI YGUR YG YGCN YG
(ST) NPK ALL
IH_AP_Product_AG X - X X X X X X X X -
IH_AP_Product_BL - X - - - - - - - - -
IH_AP_Locations X X X X X X X X X X -
IH_AP_Product_ X - X X X X X X X X -
Locations_AG
IH_AP_Product_ - X - - - - - - - - -
Locations_BL
IH_AP_Suppliers X X X X X X X X X X -
IH_AP_Supplier_Allocations X X X X X X X X X X -
IH_AP_Customers X X X X X X X X X X -
IH_AP_Customer_ X X X X X X X X X X -
Allocations_AG
IH_AP_Customer_ - X - - - - - - - - -
Allocations_BL
IH_AP_Routes X X X X - - - - - - -
IH_AP_Transfers X X X X - - - - - - -
IH_AP_Resources X X X X X X X X X X -
IH_AP_Resource_ X X X X X X X X X X -
Allocations_AG
IH_AP_Processes_AG X X X X X X X X X X -
IH_AP_Processes_BL - X - - - - - - - - -
IH_AP_Formulas_AG X X X X X X X X X X -
IH_AP_Formulas_BL - X - - - - - - - - -
IH_AP_Parameters X X Future Future - - - - - - -
IH_AP_Specifications_AG X X Future Future - - - - - - -
IH_AP_Specifications_BL - X - - - - - - - - -
IH_AP_Recipes_AG X X Future Future - - - - - - -
IH_AP_Recipes_AG - X - - - - - - - - -
IH_AP_Recipe_ X X Future Future - - - - - - -
Allocations_AG
IH_AP_Recipe_ - X - - - - - - - - -
Allocations_BL
IH_AP_Forecast X X X X X X X X X X -
IH_AP_Orders - X - - - - - - - - -
IH_AP_Budget - - - - X X X X X X -
IH_AP_hist_Sales - - - - X X X X X X -
IH_AP_hist_Purchase - - - - X X X X X X -
IH_AP_hist_Production - - - - X X X X X X -
IH_AP_Stock_AG X X X X X X X X X X -
IH_AP_Stock_BL - X - - - - - - - - -
IH_AP_Stock_InTransit_AG X X X X X X X X X X -
IH_AP_Stock_InTransit_BL - - - - - - - - - - -
The YGALL model will be filled by exporting all resources and plans from the
YPFR, YPIT, YGNI, YGUR, YGNPK and YGCN models and import them into
one model. This model is used for viewing only. The stock could be imported
(and with that the product, location and product@location interface) if stock all
around the world should be visible. This is done with a report from the
database. Rosstock and other possible sites are initially not interfaced in the
all model. Information can be obtained from the database on a report.
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All data comes from one database. With the profiles it is ensured that each
product is planned in only one AP model (no overlaps and no gaps). The
profiles select a part of the dataset.
The only way of importing (master) data will be via the Integration Hub. If data
does not exist in the ERP system (SAP, SUN) the data is imported or entered
in the Integration Hub via another method (so called Homeless Data).
The default method of reporting is again via the database via separated
tables in the database. There is no duplication of data. Information that is
imported is not updated and reported, but other data is reported. Example:
the forecast is the ingoing component and the purchasing is the outgoing
data element. If the report should contain master data or ingoing transaction
data, the link is made in the database.
The ST model for Brazil is a more detailed level in the MLT model. With the
use of workflows and a different
set of interfaces more complexity
is introduced. In the first 4 weeks
(exact number to be established)
the orders replace the forecast. In
the rest of the ST model the
orders are visible but the forecast
is still leading.
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The data in all described interfaces comes from the integration hub unless
described different.
3.6.1 Products
The product table can contain both products and aggregated products. Based
on an identifier in AP (a variable) the correct level is chosen. If the identifier is
BL all products will be imported. If the identifier is AG all aggregated products
will be included (where aggregate = name).
3.6.2 Locations
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The connection to the global sites in the blending models is done with
locations and sublocations.
3.6.3 Products@Locations
The initial setup of the P@L class is done in the integration hub. Whenever
there is a new product, the possible locations where this item is used or
produced should be indicated.
There is one unit of measurement of cost in the model. Since costs are only
used to find a minimum cost point, the costs are given in one currency.
Usually this is $ but this could be any currency chosen. As long as all costs
are in the same currency for one given model.
3.6.4 Suppliers
Master data Field / size Description
Name Text Name of a supplier
Description Text Description
Profile Text An identifier per record to receive the correct records per
model
Only active suppliers are imported into AP. Active supplier are supplier
attached to materials that can be bought in the AP model. This selecting is
either done in the integration from SAP where only certain groups of suppliers
are imported and also in the integration to AP where only suppliers are
imported where products exist in the supplier allocation.
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3.6.6 Customers
Master data Field / size Description
Name Text Name of a customer(group)
Description Text Description
Profile Text An identifier per record to receive the correct records per
model
A customer for the blending models is a forecast group and a customer for a
global model is an internal customer (market, warehouse, port etc.)
3.6.8 Routes
In the Integration hub routes are the high level representation of the transfers.
Different modalities of transport (e.g. by plane or by boat) are added here
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3.6.9 Transfers
Transfers are product specific routes
3.6.10 Resources
Master data Field / size Description
Resources.name Text Name of the resources (joined resources / production
lines)
Locations.name Text Name of the location
Description Text Description
Capacity Number Number of hours per week. If 2 lines are handled in one
line, the capacity is multiplied
Extra capacity Number Number of hours per week (overtime)
Capacity multiplier Number 1
Min load Number Between 0 and 100. Gives a minimum load quantity (%)
Profile Text An identifier per record to receive the correct records per
model
3.6.11 Processes
Master data Field / size Description
Products.Name Text Name of the product
Locations.Name Text Name of the location
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3.6.13 Formulas
The formula is used in both variable-BOM setup and the fixed-BOM setup.
With a fixed BOM setup (version V01 V99) the outflow quantities and fixed
inflow quantities are used.
This BOM only has the ingredients which should be used in the correct
quantities on there
There is no possibility the BOM can be variable and fixed at the same time
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The variable BOM has all possible ingredients without mentioning a fixed
inflow Q. The used inflow quantity is calculated with the use of parameters,
specifications, recipes and recipe allocations.
The formula can be multilevel. This means the outflow of one formula
structure is the fixed inflow of the other. Intermediate product can be used in
various Formulas and outflow products can have inflow from more that one
other intermediates.
Once a hub starts to use variable BOMs, all BOMs (also the fixed ones) are
entered and maintained manually. If not there is a link to SAP. The place to
store the manual fixed and variable BOM will be is described in the integration
design
The formulas should only contain active, critical materials. Only relevant
formulas should be imported into AP.
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3.6.14 Parameters
Master data Field / size Description
Name Text Name of the parameter
Description Text Description
Profile Text An identifier per record to receive the correct records per
model
This is manual data in the database. It is not able to extend it after go live.
The interface will only run one time. The data will be used to generate records
for both specifications and recipes
3.6.15 Specifications
Master data Field / size Description
Processes.name Text Name of the process (with version)
Parameters.name Text Name of the parameter
Description Text Description
Distribution Number 0
Max inflow factor Number Between 0 and 999. E.g. if the product is 20/20/20 the N
is 20. The maximum usually is min + 2%
Min inflow factor Number Between 0 and 999. E.g. if the product is 20/20/20 the N
is 20. Usually this is a minimum
Over max penalty Number 9999
Under min penalty Number 9999
Profile Text An identifier per record to receive the correct records per
model
Only variable BOMs are in this table and contains the specifications (of N, P
and K) of the produced products (blends and aggregates)
3.6.16 Recipes
Master data Field / size Description
Products.name Text Name of the product
Locations.name Text Name of the location
Processes.name Text Name of the process (with version)
Parameters.name Text Name of the parameter (N, P, K etc)
Factor Number The factor of the parameter in the inflow. This should be
aligned with specification
Profile Text An identifier per record to receive the correct records per
model
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Note: in MLT the aggregated product is used. Brazil has more than one
planning product per aggregator. Also packaging could be handled in an
aggregated way (where all packaging sizes are aggregated into one code). All
others have a one to one relationship where every planning product is its own
aggregated level. In the ST model (only Brazil) the planning product is
included on all levels.
3.7.1 Forecast
Master data Field / size Description
Products.name Text Name of the product
Locations.name Text Name of the location
Customers.name Text Name of the customer
Forecast Q Number The forecast quantity
Bucket Date The first date in the bucket
Profile Text An identifier per record to receive the correct records per
model
In blending models this interface contains the customer forecast for Sales
Forecasting.
In global (and Italy and France) this contains the netted requirements from the
RP and AP models.
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3.7.2 Orders
For the ST model only. This interface cooperates with the forecast interface.
The forecast interface is at aggregator level and the order interface at blend
level. This has as a result the problem that the forecast cannot be
consumed by the orders. Therefore in week 1-4 the orders are leading and in
week 5-13 the forecast is leading. Only orders/forecast with demand will be
imported in the master data
3.7.3 Budget
With a workflow this data is updated after the budget has been agreed. The
workflow copies the planning data from the budget round into the budget
property which can be used in operational plan as reference.
Hist Sales
Transactional data Field / size Description
Products.name Text Name of the product
Locations.name Text Name of the location
Customers.name Text Name of the customer
Hist sales Q Number The realised order quantity
Bucket Date The first date in the bucket
Profile Text An identifier per record to receive the correct records per
model
Hist Purchase
Transactional data Field / size Description
Products.name Text Name of the product
Locations.name Text Name of the location
Suppliers.name Text Name of the supplier
Hist purchase Q Number The realised purchase quantity
Bucket Date The first date in the bucket
Profile Text An identifier per record to receive the correct records per
model
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Hist Production
Transactional data Field / size Description
Products.name Text Name of the product
Locations.name Text Name of the location
Bucket Date The first date in the bucket
Hist production Q Number The realised production quantity
Profile Text An identifier per record to receive the correct records per
model
3.7.5 Stocks
Stocks
Transactional data Field / size Description
Products.name Text Name of the product
Locations.name Text Name of the location
Bucket Date The first date in the first bucket
Inventory Q Number Quantity inventory
Profile Text An identifier per record to receive the correct records per
model
Negative stocks should be corrected before the solver runs. Negative stocks
are imported but indicated in an exception plansheet. The users responsibility
is to solve the stock issues before running the solver. This could be done by
either setting the negative stock to 0 or correcting the other value (which
should be too high).
In the models other than blending, negative stocks are common and allowed.
The fact that the solver is not used makes this possible.
In Transit Stocks
Transactional data Field / size Description
Transfer.name Text Name of the Transfer (=route + product)
In transit inventory Number Quantity inventory
Q
Bucket Date The first date in the first bucket
Profile Text An identifier per record to receive the correct records per
model
Negative stocks should be corrected before the solver runs. Negative stocks
are imported but indicated in an exception plansheet. The users responsibility
is to solve the stock issues before running the solver. This could be done by
either setting the negative stock to 0 or correcting the other value (which
should be too high).
In the models other than blending, negative stocks are common and allowed.
The fact that the solver is not used makes this possible.
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This chapter will be included in a later stage of the project when the reporting
requirements are known.
In the budget phase the workflows are not established. There will be one-off
workflows to generate a certain behavior or to change mass data.
In the MLT blending model there will be a series of workflows to support the
frequent planning run.
In the MLT global (+FR + IT) model there will be a series of workflows to
support the frequent planning run.
When testing the model more workflows will be created to enable smooth and
easy operation of the AP model.
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A workflow is used to update the budget figures after the budget has been
agreed. This workflow copies the planning data from the budget round into
the budget property which can be used in operational plan as reference.
In the global model all the variable BOM plan sheets are not available (10,
12). The plan sheets are stored in the model. And can therefore be specific
per model. Users should be able to change and create plan sheets. But since
there will be a template model stored which can be used in case of
emergency, the changes need to be applied in 2 models (in the running
model and the template model)
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This section offers clarifications about the planned input of the Infor team in
relation to specific project deliverables.
The data collection in the Budget process will be a manual one. With the use
of spreadsheets we can upload information directly into AP.
Data collection also contains a data cleaning step. The manual data gathering
in spreadsheets will identify certain steps where data appears incorrect.
Correctional actions should take place to improve the data quality.
When doing the testing of the (AP) system, not all data has to be available,
dependant of the type of test
Unit test test with a limited test set the separated functions of each
system
Integration test test with a limited test set all flows from start to finish
Mass data test / User acceptance test test with a full data set all
functions of the system
4.2 Integration
Initially (at the Budget phase) the integration will have a lower priority. Data
that is available will be used via the integration hub. But it is foreseen that
other data will be interfaced through spreadsheets.
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penalty or the weight of the objective can be changed to change the solving
behaviour. This should not be a task in a live environment. If a situation asks
for different behaviours (e.g. in the summer a different behaviour than in
winter), it is better to create two predefined solvers than changing the
objective weights.
After exporting everything to the database also the report section is updated.
Although the queries are in essence simple, an experience AP user who has
received a modeling course is very well capable of expanding the set queries
or developing new applications
4.6 Reports
Reports in AP are all handled via the database. In a later stage of the project
a number of tables will be defined for various areas of reporting:
Stock
Production
Purchasing
Resource utilization
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Sales results
Transport
All sets of data will be stored in the database with a number of identifiers:
Profile
Publish date (or date of first bucket)
Model type (ST/MLT)
Scenario identifier
As long as the new set of exported data is not available in the set of tables,
the records will be inserted as new records. If the set is already available the
database the old publish will be wiped and replaced with a new set of records.
These tables make it possible to create reports in BiW or (via ODBC) in Excel
or Access.
When exporting the data, everything is marked with the scenario identifier.
Only the BASE scenario is handled in the rest of the supply chain.
The result of all the testing done in the various rounds is to:
The main input for the user manual will come from key users supported by
Infor and the main input for the technical manual will come from Infor
supported by the key users. This user manual will serve as input for the
knowledge transfer from key users to users.
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Each testing schedule will have 3 testing periods. The pilot testing, which
contain of a unit test and a integration test. And a User Acceptance Test
The integration test runs with the same small dataset and is run from start to
end. Each model / application / dataset is linked to other components and
especially the cooperation of all individual components is important. Again
test scripts and documenting the results is vital in this test set
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Document control
Explanation
AP Advanced Planning
DP Demand Planning
DF Demand Forecasting
RP Requirements Planning
SP Sales Planning
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