0 valutazioniIl 0% ha trovato utile questo documento (0 voti)
42 visualizzazioni47 pagine
This document discusses short term planning processes in SAP. It outlines steps like balancing production capacity for the next 0-13 weeks based on demand and supply, sequencing planned orders into a production schedule, and adjusting setup times if using a setup time matrix. Key tools for short term planning include the capacity evaluation tool, planning table, and graphical planning table for balancing production, and setup groups and keys can be used for sequencing orders to reduce setup times.
This document discusses short term planning processes in SAP. It outlines steps like balancing production capacity for the next 0-13 weeks based on demand and supply, sequencing planned orders into a production schedule, and adjusting setup times if using a setup time matrix. Key tools for short term planning include the capacity evaluation tool, planning table, and graphical planning table for balancing production, and setup groups and keys can be used for sequencing orders to reduce setup times.
This document discusses short term planning processes in SAP. It outlines steps like balancing production capacity for the next 0-13 weeks based on demand and supply, sequencing planned orders into a production schedule, and adjusting setup times if using a setup time matrix. Key tools for short term planning include the capacity evaluation tool, planning table, and graphical planning table for balancing production, and setup groups and keys can be used for sequencing orders to reduce setup times.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 Month Plan mySAP Balance the short-term capacity plan, based on the balanced long term plan Create a production schedule for the next period Communicate the new production schedule to Execution Create a material procurement schedule for the next period Communicate the new material schedule to suppliers Short Term Planning Process - Purpose mySAP Material Planning and Scheduling Production Planning and Scheduling Update Supply Parameters Short Term Planning - Work Process Steps Review demand / supply balance (0-3 months) Resolve capacity issues Sequence planned orders (inside PTF) Adjust setup times (if used at your site) Adjust planned orders to daily rate (if needed) Create and publish production schedule Review material schedule (Supplier scheduling) Generate and distribute supplier schedule report Resources - intervals of available capacity, efficiencies (if applicable) Recipes - rates Quotas mySAP UPDATE SUPPLY PARAMETERS: Intervals of Available Capacity Quotas, possibly time-phased safeties Pay special attention to recipe rates (and efficiency rates if used) Run Automatic Leveling refresh program (resets quotas and deletes SAF1 elements) if you are using it to do balancing These updates are typically done on Fridays before the weekend MRP run and new Demand pass Short Term Planning - Update Parameters mySAP EVALUATE/BALANCE PRODUCTION: Evaluate demand/supply balance for weeks 0-13 Adjust intervals of available capacity, if appropriate, to address key imbalances (e.g.. more shifts, weekends, flex teams, etc.) Move orders manually, or run Automatic Leveling, to resolve the majority of the capacity issues (as applicable for your site) Resolve remaining capacity issues according to your operating strategy Short Term Planning - Balance Production mySAP EVALUATE/BALANCE PRODUCTION TOOLS: Capacity Evaluation Tool (Method A) - Same tool used in Long Term Planning - Use weekly view for shorter horizon - Useful for evaluation and limited manual changes Planning Table (Method B) - Spreadsheet-style design - Useful for evaluation and more extensive changes - Useful for manual balancing across lines Short Term Planning - Balance Production mySAP Short Term Planning - Balance Production Evaluate Capacity - Weeks 0-13 (Method A) mySAP Short Term Planning - Balance Production Planning Table (Method B) mySAP Balance Production - Planning Table Planning Table Flexible period splits Alternate version mySAP Balance Production - Planning Table Planning Table Double-click to view individual orders mySAP Options to Resolve Capacity Issues Move production to another line in the same period Move production to another period on the same line (advance production) Move production to another facility - interplants or - contract manufacturing Add short term capacity Evaluate safety targets mySAP Automatic Leveling in the Short Term Horizon Run Auto Leveling Program mySAP Automatic Leveling Summary of Weekly Capacity Adjustments mySAP Schedule Planned Orders Objective: Create a sequenced production schedule which leads to corresponding material supply schedule Work Processes: Sequencing orders inside PTF If needed, break large orders into daily If needed, adjust setup times Creating a production schedule mySAP Sequence Planned Orders Time Sequencing / Scheduling Capacity Planning A A C A C B M T W Th F S S M T W Th F S S Downtime Downtime A B C A B A C PTF There may be earlier weeks already sequenced A B mySAP Short Term Planning - GPT Graphical Planning Table mySAP Sequencing Methods: Manually dispatch each individual order Assign sequence numbers to each order in the selected period and then dispatch the entire group Automatically dispatch multiple orders at the same time by using the Setup Group and Key Automatically creating the optimum sequence (least total setup time) based on setup times defined in a setup matrix Short Term Planning - Sequencing mySAP Manual Sequencing: Use the dispatch button for the first order of the week to assign the correct start time Use the drag and drop method for subsequent orders To change the sequence, either de-allocate orders or move them around within the Work Center window Short Term Planning - Manual Sequencing mySAP Assigning Sequence Numbers: Select all of the orders that you want to dispatch Pull up the Sequence Number Maintenance screen Assign numbers, from 1 to the total number of materials sequenced, with 1 assigned to the first item to be produced To change the sequence assign different numbers Short Term Planning - Manual Sequencing mySAP Short Term Planning - Manual Sequencing Assigning Sequence Numbers mySAP Short Term Planning - GPT Order Selection Selecting Orders in the Graphical Planning Table NOTE: The secondary orders in the week should not be selected initially so that they do not get grouped together mySAP Sequencing using Setup Group Hierarchy SETUP ACTIVITIES: A well thought out logic needs to be applied to the Setup Group hierarchy to produce a good schedule Setup Groups and Keys need to be configured within SAP (plant specific) These keys are then assigned to each recipe at both the operation and phase levels Materials are assigned to the recipes
Short Term Planning - Setup Groups mySAP Brand Code: 11111 22222 33333 44444
Setup Group Example: Group COFFEE COFFEE COFFEE COFFEE Key 030 040 010 020
In this simple example SAP will help you sequence codes in the following order: 33333 44444 11111 22222 OPERATING STRATEGY: Always go from Light to V. Strong to avoid washouts VS S L M Sequencing - Setup Groups & Keys mySAP Sequencing using Setup Group Hierarchy DISPATCHING LOGIC: Select all orders within the desired time frame When dispatching, the system will sequence first by Setup Group and then by Setup Key in numeric-alpha sort order (0 9, A Z) Multiple orders for the same material in a given week should not be selected at the same time. If they are, the system will group them together to run at the same time If materials are selected and assigned to the same recipe, the order of sequence is based on order # Short Term Planning - Setup Groups mySAP Short Term Planning - Setup Groups Assigning Setup Group and Key mySAP Sequencing using Setup Time Minimization: Setup Groups and Keys need to be configured within SAP, and setup times must be used in the recipe formulas A setup matrix must be maintained at the plant or resource level, with values for every combination of Setup Groups and Keys The Setup Groups and Keys are assigned to the recipe at both the operation and phase levels Same techniques for order selection as defined in the previous approach. The system will then create a sequence which delivers the least overall setup time Short Term Planning - Setup Minimization mySAP Short Term Planning - Setup Minimization Selecting User Functions mySAP ADJUSTING SETUP TIMES (IF USING SETUP MATRIX): Required after sequencing (or re-sequencing) and utilizes sequence-dependent setup time information Order setup time based on the prior and current recipe Replaces any default setup times during dispatching; thus, providing the most accurate order start/stop times Requires on-going maintenance of setup matrices in order to have the most accurate order durations NOT needed if you don't maintain a matrix or use the Setup Minimization procedure (built-in to function) Facilitates MPS measurement Changes the capacity utilization for the period Short Term Planning - Setup Time Adjustment mySAP Default Setup Times: Default setup times are average setup times for a material on a specific resource It is stored in the phase of the Recipe, Standard Values It is utilized for the full planning horizon in order to provide accurate capacity evaluation data It is only changed by the Adjust Setup Time process after orders are dispatched inside the PTF It should reflect a 50/50 number to have accurate capacity information outside the PTF Short Term Planning - Setup Times mySAP Short Term Planning - Setup Times Assigning Default Setup Times Average setup time mySAP Setup Time Matrix: Specific sequence-dependent setup times are stored in a named table Each resource must link to a given table, but tables can be shared across resources if all values are same Table keyed to: Plant; table name; predecessor group and key; successor group and key Each entry contains the specific setup time for that changeover Access is by report tree with certain restrictions Tables can be quite large but view can be limited to simplify maintenance Short Term Planning - Setup Time Matrix mySAP Short Term Planning - Setup Time Matrix Setup Time Matrix - Conceptual View Size Rules 1 to 2 90 2 to 1 90 Formula Rules 1 to 2 15 2 to 3 15 3 to 1 60 3 to 2 60 2 to 1 15 1 to 3 60 These rules are used to build the matrix above To Setup Time in Minutes 1 2 3 4 5 6 7 8 size 1 2 1 2 1 2 1 2 matl size formula 1 1 2 2 3 3 1 1 From 1 1 1 0 90 15 90 60 90 0 90 2 2 1 90 0 90 15 90 60 90 0 3 1 2 15 90 0 90 15 90 15 90 4 2 2 90 15 90 0 90 15 90 15 5 1 3 60 90 60 90 0 90 60 90 6 2 3 90 60 90 60 90 0 90 60 7 1 1 0 90 15 90 60 90 0 90 8 2 1 30 0 90 15 90 60 90 0 Material Numbers: 7777xx01 7777xx08 mySAP Short Term Planning - Setup Times SAP Setup Time Matrix mySAP Short Term Planning - Distribute to Daily Rate Distribute to Daily Rate Technique mySAP Short Term Planning - Distribute to Daily Rate Dispatched Orders after Distribute to Daily Rate mySAP Multi-level planning - Example Make/Pack operation A common multi-level planning scenario Only deals with different materials within same location (plant) Intermediate inventory exists between make and pack operations The connection between the two levels are from the BOM explosion Packing Making Intermediate storage Supply Plan mySAP Multi Level Planning - Make/Pack operation Making & Packing operations are de-coupled - Making and Packing are both scheduled - Intermediate inventories are created and can be tracked for cost or regulatory purposes If Making is a constraint, an iterative planning process may be required mySAP Why do we have to plan Making? Execution cannot create inventory without a Process Order A valid material schedule to the suppliers requires proper batch scheduling mySAP Making Capacity Link to Packing Planners Making Planners provide feedback to packing planners regarding the making capacity requirements/constraints If one making system supplies just one packing line, this is easier. - The work process is the same for one or ten packing lines tied to a single making system The type of feedback depends on the time horizon mySAP Making Feedback to Packing Three Types Outside the Packing PTF - Monthly/weekly overloads should be visible well before Packing is ready to do any sequencing. - After looking at its options, Making asks Packing to revise their schedule to balance the Making loads. Inside the Packing PTF - The Making daily load might become a problem (ie too much large size on Wed/Thurs). Making asks Packing to revise their sequence. Last minute schedule changes - Packing planners ask Making for feedback before any packing changes are made. mySAP Making Planning Process Balance Monthly/Weekly loads Once Packing has been sequenced, balance the daily Making load at the highest level (ie, Main mix) Plan subsequent levels of Making, with an MRP run required between each. This is particularly crucial if a lower level is the constraint. The supplier schedule is an outcome from all of the above steps Publish the Making schedule Convert Process Orders mySAP Impact of Packing Changes to Making Making normally does not use a Planning Time Fence (MRP Type is M0) Because of this, an increase in the Packing schedule will result in new, mrp-generated planned order(s) for Making the next day Any new orders will be placed on the date(s) needed to support the Packing schedule, including days that have already been scheduled/sequenced by Making! mySAP Short Term Planning: Smartplanner Overview P&G Supply Chain Product Designed to Supplement SAP R/3 for Detailed Planning and Scheduling 95% of Supporting Data Comes From SAP Developed With AspenTech Software Application (Supply Chain Manager, SCM) Distributed Application That Runs on a Planners PC. Results Backed Up and Saved on a Central Server Two Variations: - Lite automated sequencing and decision support - Full includes Linear Program Optimizer for the generation of a constrained plan
mySAP Short Term Planning: Smartplanner Planning Board mySAP Short Term Planning - Production Schedule The last step in the Short Term Planning work process is to generate a production schedule - Frequency and period covered are plant choices - The schedule lists each process order and planned order to be run, including quantities, times etc. - Schedule can be generated by resource or resource groups and downloaded to Excel mySAP Short Term Planning Production Schedule ZPRS There are several production schedule transactions available. ZPRS is preferred in the PSC (shown above). It is owned by the PE Row. Can display both production and purchasing data (CM). MENU PATH: SAP Menu P&G Report Menu Production Execution ZPRS - Production Schedule Report mySAP Short Term Planning - Summary Shift focus from superior resource in monthly buckets (long term) to individual resource in weekly buckets (short term) Short term planning includes: - Capacity planning and balancing - Production scheduling: Sequencing and adjusting setup times - Supplier scheduling Set up the foundation for daily planning and execution