Oracle APS and GOP Getting

To Automated Sales Order

Scheduling
Mark Hopkins, Xilinx, Inc.
8/23/06

Xilinx Confidential

Topics

Goals of Our GOP Implementation

Where We Are Today
How We Did It
Lessons Learned

Xilinx Confidential

Project Goals
Schedule new sales orders accurately
Hit our first commitment
Minimize reschedules

Preserve excellent on time delivery performance

Manage exceptions, and let the rest happen
automatically
Reduce planner workload and allow them to focus on
model maintenance
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Results: Auto Release And On

Time Delivery

~13k Line Items per month.

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Our Planning Environment

Oracle APS (ASCP and GOP)
Oracle ERP
Order Management, Purchasing, Financials, HR

Custom Systems/Interfaces
Item & BOM Based on Matrix and Legacy
Forecast
Manugistics
Home grown Customer Forecast Management System

Wafers, Piece Parts, WIP tracking

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Whats In Production:
ASCP and GOP
Monthly / Weekly APS Plan for Wafers and Piece Parts (since April
03)
EDD
Unconstrained Plan
Wafer Plan, Piece Parts, Assy, Test, Sort, Bump Capacity

Daily Plan for Assembly Releases (since August 04)

ECC
Output is used for all products assembly starts planning

Daily Plan for GOP (since August 04)

ECC
Almost 100% of incoming sales orders get schedule dates recommended
from GOP
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Our Model
(example from our ATP Plan)
Plan Type:
Cost Based Optimized Plan - HP 64bit Exe
Enforce Material Constrained Plan
Holistic Manufacturing Plan with Project Planning
Time Buckets: 35 days, 10 Weeks
Inputs:
Orgs: 56
Items: 22k
Demands: 19k
BOM's: 17K
Outputs:
Demands: 64k
Supplies: 56k
Pegging: 78k
Res Reqmts: 200k
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Terms
GOP / ATP Global Order Promising / Available To
Promise
CFD Current Factory Date (equivalent to Schedule
Ship Date in Oracle)
OFD Original Factory Date (the first commit on the
sales order)
ATP Override The ability to change the date that GOP
was recommending prior to committing to the customer
Auto Release A sales order that books, gets scheduled,
and committed to the customer with zero planner
intervention
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Standard Oracle GOP Process

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Xilinx Gates in GOP Process

Is part/whs set up as auto release?
Yes: does schedule ship date meet auto
release criteria
No: Does planner agree with Schedule Ship
Date?

Is calendar date blocked?

Is order on hold?
Is order unusually large?
Do we want to force a
particular schedule date to
happen (ATP Override?)

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Demand Management Form

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Getting to 100% Auto Release

Oracle
Need to consider alternate boms, substitute components in ATP/GOP
algorithm. Lack of this functionality causes overly conservative
commitments. In semiconductor mfg, this is needed to recognize bin
downgrades, alternate mask sets.
ATP Algorithm needs to recognize that an order due 3 months from now can
be satisfied with a wafer start. Allow finished goods to show as available for
any new orders.

Xilinx
Data Maintenance. Specifically sourcing rules, and BOMs.
Our current BOM structure does not handle some new products / military
scenarios. We are working on a new item/bom management system that
will give us this.
Lot specific yields for new products.
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Lessons Learned
Need a way to validate / build confidence in production data prior
to exposing to customers
Develop metrics and publish progress
We gave prizes to the first planning teams to hit 3 different milestones

Need to build planners confidence in ATP black box by

developing an understanding of true problems vs. perceived
problems or gross generalizations. Until we could explain each
situation (which was a long process), anything that did not fit
planners mindset was judged as ATP is wrong.
Incremental fixes / enhancements help zero in on the issues
Data maintenance and reporting that identifies data problems is
helpful
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