SAP APO PPDS For Automotive PDF

Automotive with DI46C2 (SAP R/3)
IBS Manufacturing, IBU Automotive SAP AG
SAP AG
TAAP1W
Automotive with DI46C2 - 1
New Processes supported by SAP APO 3.1

Supply Chain Planning Supply Chain Execution Supply Chain Coordination Supply Chain Networking Supply Chain Design Procurement Demand Planning Supply Planning Distribution Planning Transportation Execution Production Planning Foreign Trade/Legal Services Transportation Planning Fulfillment Coordination
Manufacturing
Order Promising & Delivery
Warehouse Management
Supply Chain Event Management
Supply Chain Performance Management
Supply Chain Portal
Collaboration Services
Supply Chain Integration
SC Planning Integrated Supply&Production Planning Shelf Life (Production Planning) Forecast Consumption based on DP Char. Extended Demand Prioritization in CTM Extended Order Generation (*)
SC Execution Multilevel ATP Campaign Planning Order Driven Final Mix & Packaging IPPE based repetitive Manufacturing(**)
SC Collaboration Collaborative Management of Delivery Schedules (CMDS)

(*) process requires industry solution mySAP Mill Products (**) process requires Industry Solution mySAP Automotive
SAP AG 2002, Title of Presentation, Speaker Name 2
Integrated S&P Planning overlay between SNP & PP/DS Bjoern Bernard Shelf Life Enhancements only in PP/DS
SAP AG
TAAP1W
Process Enhancements with SAP APO 3.1

Supply Chain Planning Supply Chain Execution Supply Chain Coordination Supply Chain Networking Supply Chain Design Procurement Demand Planning Supply Planning Distribution Planning Transportation Execution Production Planning Foreign Trade/Legal Services Transportation Planning Fulfillment Coordination
Manufacturing
Order Promising & Delivery
Warehouse Management
Supply Chain Event Management
Supply Chain Performance Management
Supply Chain Portal
Collaboration Services
Supply Chain Integration
SC Planning Model Consistency Checks Descriptive Characteristics in CTM Mass Maintenance Tools for Master Data
SC Execution Order Fulfillment with GATP Transportation Management PP/DS with comprehensive integration to R/3 Advanced Block Planning Multi-Line Model Mix Planning (**) Rapid Planning Matrix supporting activities (**)
(*) process requires industry solution mySAP Mill Products (**) process requires Industry Solution mySAP Automotive
SNP Model Consistency Check Planning of Scheduling Agreements integration R/3 APO Mass Maintenance Tools for Master Data Model Consistency Checks
SAP AG
TAAP1W
Repetitive Manufacturing with iPPE
Contents:
This process describes how to execute Repetitive Manufacturing in APO on the basis of the integrated Product and Process Engineering. Scheduling and material requirement calculation in APO is carried out as takt-based scheduling. You can enter the backflush data for the production backflush in APO. The backflush data is then posted in the DI System. This procedure is very fast and is therefore ideal for planning high configurable products with a large number of components. Solution based on Discrete Industry system and APO designed for Automotive and High-Tech manufacturing
SAP AG
TAAP1W
Unit Objectives
At the conclusion of this unit, you should be able to: Understand the Automotive Manufacturing scenario based on Discrete Industry system (DI46C2) and SAP APO 3.1 Have a basic knowledge about the principles of the SAP APO functions used in this scenario Have the awareness about the business processes where its recommended to use such a scenario
SAP AG
TAAP1W
SAP APO and SAP R/3 in Automotive System

Rapid Planning Matrix
Planning in APO
CMP ACT FLO
liveCache
iPPE
Collective Order
CIF
CMP ACT FLO
Execution in R/3
iPPE
SAP AG
TAAP1W
Automotive Functions in SAP APO: Planning Process
R/3-DI
SD
PP/MRP
Postings (MM/IM)
Customer Customer requirements requirements 04/15/00 - 20 units
iPPE
1
04/15/00 - 20 units 04/16/00 - 15 units 04/16/00 ... - 15 units ...
MM MMDelivery Delivery Schedules Schedules

(R/3 or APO) (R/3 or APO)
04/15/00 - 200 pcs 04/15/00 - 200 pcs 04/16/00 - 150 pcs 04/16/00 ... - 150 pcs ...
APO
3
Model Mix Planning and Sequencing
4 3
APO-PP/DS
Backfl ush
Production Tracking
iPPE
4
BOM Explosion: RPM
Component Requirements
Trigger Backflush
6
Event
PCS
Order Headers
Action Handler
Process Steps Create Master Data (iPPE) ... Initialize CIF Interface Create Sales Orders Run Model-Mix Sequencing Explode Requirements in the RPM MM Planning of Components Action Handler Execute Backflush
SAP AG
TAAP1W
Challenges from Engineering to Production
C1
C2
C3
C4
Product-Engineering Product-Engineering
ACT ACT40 40
ACT ACT31 31
ACT ACT32 32
Process-Engineering Process-Engineering
Line 1
ACT ACT20 20
ACT ACT10 10
Production Production
Station 1 Station 2 Station 3 Station 4
Time-to-Market
Time-to-Customer
SAP AG
TAAP1W
Takt-based Scheduling
Line
Station 1 Takt-based Scheduling Takt time very fast, since
Station 2 Takt time
Station 3 Takt time
lead time = number of Takts * Takt time

as compared to lead time scheduling lead time = sum of all operation durations
With takt scheduling the lead time equals the number of takts multiplied by the takt time. The system does not calculate the lead time based on the duration of single operations. Thus, scheduling enables you to execute high volume scenarios with short system response time. Note: Takt = Tact
SAP AG
TAAP1W
Data and Object Model for iPPE
Product Variant Structure ... and relationships between all objects Routings and Activities
ACT 40 ACT 31 ACT 32
CMP
ACT
FLO
ACT 20
ACT 10
Factory Layout
Line 1
iPPE
Station 3 Station 4
Station 1
Station 2
SAP AG
TAAP1W
Product Variant Structure (PVS): Concept

Product structure for highly variant products
New structure elements: nodes and variants Multi level hierarchy and multiple usage of the nodes Direct product reference
Product Lifecycle Management (PLM)

Consistent data basis for different views of the product Modeling of functional structures (no reference to a material number)
Logistics
Basis for efficient material requirements planning (RPM)
The goal of the PVS is to provide a redundancy-free description of products or product families that have many variants, as well as a consistent data basis for all enterprise areas that work with the product structure or parts of it. The PVS offers an integrated data model that serves as the basis for an efficient IT management of the product structures. In addition, you can use it to adequately portray the product creation process (with the main focus on Product Data Management) and also production (the main focus being rapid requirements planning the rapid planning matrix which is executed in the APO system)..
SAP AG
TAAP1W
Engineering Change Management as part of the iPPE
Material
Master Data Variant Configuration Document Management

W O R K F L O W
Engineering Change Management
Classification
CAD Interface
An integrated solution for the Product Data Management (PDM) throughout the supply chain is displayed by the integrated engineering change management (ECM). ECM is a central, integral part of product data management (PDM) in the SAP R/3 System and ensures a complete history of any changes made to product data. The components of ECM are: Master data management (material master records, PVS, Activity Modes) Document management Classification CAD interface Workflow Configuration
SAP AG
TAAP1W
Use of Lines
Capacity planning in Repetitive Manufacturing Line Balancing Determination of supply areas for PVS components Demand planning in the Rapid Planning Matrix Backflush
SAP AG
TAAP1W
Calculation of Exact Component Demand times
Line 1
Station 1
Station 2
Station 3
Station 4
Takt time
Takt time
Takt time
Takt time
ACT ACT 1 1
ACT ACT 2 2 ACT ACT 3 3
ACT ACT 4 4
ACT ACT 5 5
C1 C1
C2 C2
C3 C3
C4 C4
C5 C5
C1 Requirement:
C2 & C3 Requirements:
C4 Requirement:
C5 Requirement:
Order Start
Order Start + 1 Takt
Order Start + 2 Takts
Order Start + 3 Takts
Because each component is assigned to a specific activity and the activity is assigned to a line (via the line balance) we can know, based on the simple takt scheduling logic, exactly when the components will be needed.
SAP AG
TAAP1W
Production Resources in iPPE

Line Net
Line 1 RES1 RES2
Line 2 RES3
Line 3
ACT Head
ACT1 RES1 ACT2 RES2 ACT3 RES3
Li ne
Ba la nc e
The same resource can be assigned to activities and line objects. This is either the Human Resources or the Production Resource.
SAP AG
TAAP1W
New Node Types DI4.6.C2

ALG
Alternative Line Group (ALG):

Contains alternatives, under which Line nodes can be assigned. Only one Line node can be assigned per alternative (for use with order activities). Are assigned directly underneath the Line Net or can represent a Line structure (access) itself. Relationships can exist at Line level or Alternate Line Group level.
Line Net
Part Line Net:

Represents the part (number of) Line nodes within the complete Line Net available. Technical: Alternative Segment on the Line Net nodes Collects Line nodes that have to be a part of the specified Line Net. Can be specified in the production version as a specific production line access object.
Line Area
Line Area
Is an additional structuring of Line nodes which are part of a Line Net. Has no other function and can not be used in the production version.
SAP AG
TAAP1W
SAP AG
TAAP1W
Big Picture
Model Mix Planning
Sequencing
A1 A2 A3 X1
A1 B1 A2 B2 A3 X2 X1
C1 B1 C2 B2 C3
C1 C2 C3
X2
Reservation Planning
Re-Sequencing
SAP AG
TAAP1W
Model-Mix Planning: Situation
Orders
Line network
Restrictions
Quantity Distance X in Y
Block Equal distribution Position
Objective
Generation of a feasible and optimal plan for configurable products with high volume Adherence to promised delivery date
Business value
Balanced usage of production resources Early identification of potential bottlenecks Reliable delivery date leads to increased customer satisfaction
Purpose: Determine the sequence of orders on line segments and determine the start and end date of the orders, so that specific goals can be pursued under consideration of certain restrictions. Constraints: Production of variants or configurable products in model-mix Production on lines with restricted production rates (finite capacity) Sequence or quantity restrictions at characteristic level (variants) Aims: Day and/or shift packages (period segments) Full and even capacity utilization of production line Order sequence in short-term horizon (for example, X days) Precise determination of component requirements (to the hour/minute)
SAP AG
TAAP1W
Model Mix Planning and Sequencing: Result
Sequence
based on takts
Model Mix
based on buckets (Day/Week/Month)
3
4
3 4 3
3
now
future
X days from today
SAP AG
TAAP1W
Example: Model Mix Planning (1)

Model Mix Sales Orders
Production line 1
This Week, Day X
Week 1
Week 2
Week 3
Week X
1. Period-oriented planning
SAP AG
TAAP1W

Production line 1
This Week, Day X
Week 1
Week 2
Week 3
Week X
1. Period-oriented planning
SAP AG
TAAP1W

Production line 1
This Week, Day X
Week 1
Week 2
Week 3
Week X
1. Period-oriented planning + Quantity restriction

SAP AG
TAAP1W

Production line 1
This Week, Day X
Week 1
Week 2
Week 3
Week X

SAP AG
TAAP1W

Production line 1
This Week, Day X
Week 1
Week 2
Week 3
Week X

SAP AG
TAAP1W

Production line 1
Day 1
Day 2
Day 3
Day X
2 . Sequencing
SAP AG
TAAP1W

Production line 1
Day 1
Day 2
Day 3
Day X
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
1. Not two in a sequence
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
1. No two in a sequence
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
a) No two in a sequence
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
a) No two in a sequence b) At least two red cars in sequence
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W

Model Mix
Restrictions:
Production line 1
Day 1
Day 2
2 . Sequencing
SAP AG
TAAP1W
Sequencing: Restrictions
Types of restrictions
Quantity (position) Spacing K in M Block Even distribution Position
e.g. number of V8 engines <= 200 pieces per day e.g.: max every third engine is US version e.g.: three air condition out of five vehicles e.g.: at least 2 engines for RH-drive vehicles in a row
Basic information
Created within a planning version Assigned to a production line Uses characteristics
e.g.: active version or simulation version e.g.: body shop, paint shop, assembly line e.g.: engine type, US version, air condition
SAP AG
TAAP1W
Restrictions Weighting & Validity
Weighting
Restrictions are grouped into two categories:
Hard Soft (= 0) (= 1, 2, ..., 9).
Validity
Validity has two categories:
Time: interval (e.g from t1, to t2 and from t3 to t4 ... ) Location: assignment to a Line net Line Line segment
SAP AG
TAAP1W
Optimization Algorithms: Procedures - overview 1
Genetic Sequence Optimizer

Single line (multi line available with APO 3.1) All types of restrictions Hard and soft weighting of restrictions (Hard violation means no result) Due date Finite
Linear Program Algorithm

Multi-line (daily buckets) Quantity restrictions and transformed spacing Hard and soft weighting of restrictions Due date Finite
SAP AG
TAAP1W
Optimization Algorithms: Procedures - overview 2
Prioritized Equal Distribution Heuristic

Single line Quantity, M of N restrictions, spacing, position No different weighting of restrictions Hard means violation only if there is no other way -> Typically at the end of the sequence Finite
Percentage Smoothing Heuristic

Single line Smoothing on product variant level No restrictions, only capacity Finite
Interface for Customer heuristics
SAP AG
TAAP1W
Procedures
Sequencing
= Order sequence on lines
Bucket-oriented Model Mix

= Distribution of orders to lines and to time buckets
Horizon 1 (e.g. 2 days) Manual Planning / Correction Single items All restrictions
Horizon 2 (e.g. 2 days) Procedure I

(e.g. genetic algorithm)
Horizon 3 (e.g. 5 days)

Procedure II ( e.g. heuristic with restrictions)
Horizon 4 (e.g. 2 month)

Procedure III (e.g. equal distribution)
Single items All restrictions
Quantities per period e.g. only quantity and capacity restrictions
Quantities per period only capacity restrictions
SAP AG
TAAP1W
Sequencing: Interactive planning
Restrictions
Planned Orders
Unscheduled Orders
SAP AG
TAAP1W
Model Mix Planning and Sequencing in SAP APO 3.1
Model Mix Planning and Sequencing in SAP APO 3.1
SAP AG
TAAP1W
Line Net
A typical example for a line net of an OEM is
assembly line I
A1
buffer
C1 B1 X2 B2 C2 C3
planning segment group of alternative lines
A2 A3
X1
assembly line II
F1 D1
planning segment
Y1
E1
Y2 F2
SAP AG
TAAP1W
Partial Line Nets
In general the products are not buildable on the whole linenet. Therefore one defines partial line nets and then assigns the products to the partial line nets by their production versions.
A1 B1 A2 A3 X1 B2 X2
C1 C2 C3
SAP AG
TAAP1W
Capacities and Restrictions

The planning is based on the following assumptions :
max 25 sedan per day ... ... ...
A1
12 PCS / H
C1
max 2 in 4 air conditioning ...
B1
X1
max 15 RED per . day ..
A2
min distance 1 ... for convertibles
X2
C2
1 PCS / 10 MIN
B2
A3
C3
1. Each line has a capacity profile. 2. One can assign spacing restrictions to the lines. 3. One can assign quantity restrictions to the lines or the groups of alternative lines.
SAP AG
TAAP1W
Conversion
The capacity profiles and the spacing restrictions are converted into quantity restrictions, for example
A1 B1 A2 A3 X1 B2 X2
C1 C2 C3
A3. C2.
capacity: min distance 1 for convertibles * 16 PCS / shift
max 8 convertibles per shift
Rate 1 PCS / 10 MIN
shift duration 8 H / shift
max 48 PCS per shift
C3. air conditioning *
max 2 in 4
capacity: 20 PCS / shift
max 10 air cond. per shift
SAP AG
TAAP1W
Paths through the Line Net

... . . .
B1
The line net is decomposed into the possible paths. For simplicity not all paths are shown in the sketch.
A3
X1
X2
C1
Based on this decomposition a restriction can be assigned to several paths (although its basically assigned to just one line).
A3
X1
B1
X2
C2
A3
X1
B1
X2
C3 C1
max 2 in 4 air cond.
SAP AG
TAAP1W
. . . ...
Furthermore certain products can only run on certain paths depending on the production version.
A3
X1
B2
X2
no red colour
The Planning
... . . .
B1
A linear program will now assign the orders to the paths while respecting the restrictions and production versions.
A3
X1
X2
C1
A3
X1
B1
X2
C2
A3
X1
B1
X2
C3 C1
A3
X1
B2
X2
SAP AG
TAAP1W
. . . ...
The Result
The model mix plan is obtained by adding the paths loads segment by segment :
A1 B1 A2 B2 A3
C1
C2
C3
SAP AG
TAAP1W
From Buckets to Positions

At a certain point one has to create a sequence out of the bucket orders (bucket size can be shift or day). Since one has already considered aggregated spacing restrictions in the model mix planning it should basically be possible to obtain a feasible sequence out of the bucket orders.
C1 B1 A2 A3 Planning segment X1 B2 C3 X2 C2
The sequence is built in the planning segment and will later on also be manipulated there. The result is propagated to the other segments.
A1
Gap: Since the sequence is built on the planning segment and simply propagated without any further re-sequencing in the buffers, only restrictions from the planning segment will be taken into account during this process.
SAP AG
TAAP1W
Line Switch
Due to unplanned down times or problems with the supply to line there can be the need to change the path of an order.
Obviously only those lines can be chosen which belong to the partial linenet in the production version.
A1 B1 A2 X1 B2 X2
C1 C2 C3
Assume there are problems on line A2 and C2. Therefore the paths of the green car has to be changed.
A3
SAP AG
TAAP1W
Rapid Planning Matrix (RPM)
Rapid Planning Matrix (RPM)
SAP AG
TAAP1W
Alternatives in Requirements Planning

1. Rapid Planning Matrix (explosion type=4)
APO
liveCache
2. Order Network iPPE RTO (explosion type=3)

APO
liveCache
3. MRP (PVS)
4. MRP (BOM)
R/3
R/3
Optimized for high volume scenarios
Optimized for real time planning
PVS Explosion
BoM Explosion
There are several options for planning products. Depending upon the need for various functions, like rapid planning, highly configurable products, or integration back to standard R/3 functions a customer may choose a combination of these planning options. For example, the higher level more expensive parts can be planned within APO and the lower level or consumption based materials can be planned in the R/3 system.
SAP AG
TAAP1W
Classic MRP: Performance Bottlenecks

Maximum bill of material contains 40,000 components 30,000 individual customer orders
Storage on a relational database means movement of 60 Gigabyte of data Explosion of maximum BOM order by order means more than one Billion checks of effectivity-parameters and selection conditions
Solution: Keep Data in RAM in optimized form

liveCache main memory database Matrix form for data storage, object oriented access simultaneous BOM explosion for all orders -> RPM (Rapid Planning Matrix)
liveCache
Maximum BoM has 40,000 components including all historical changes Exploded customer order has 2,000 components of the maximum BoM selected results in storage of 60 Gigabyte dependent requirements in R/3-MRP in database in relational form need to write and read that amount of data during an MRP-run Explosion must look at all historical changes at a component variant 1.2 billion checks of effecitivity parameters in the worst case 1.2 billion checks of selection conditions LiveCache storage in RAM instead of disk forces optimized form (little memory usage): matrix representation matrix representation allows simultaneous explosion of all orders instead of order by order RPM is the name of this new algorithm
SAP AG
TAAP1W
Contents of Logical Matrix
1 Assy View
Components Mat A Mat B Mat C Mat D
Orders
Data of assembly orders

Order Order Order Order Order Order 01 02 03 04 05 06
Bumpers green Bumpers white Bumpers red Navigation Advisor GPS Engine 2.5 Disk
x x
x x x
x x x
x x x
x x x x
x x x
3
BOM-Explosion - interpretation of effectivity - interpretation of dependencies
The first step is to convert the assembly view of the PVS into a flat list of the master data material number, quantity, selection condition, effectivity parameters Second step is to include the assembly orders: due date quantity configuration Third step explode the BoM for the orders a cross means: component selected for order one cell in the matrix = one bit 30,000 orders, 40,000 components about 350 Megabytes
SAP AG
TAAP1W
Functions Using Logical Matrix I
Reading and Interpreting Columns

Component list for selected order
Backflush Sequenced JIT calls Sequencing
Bumpers green Bumpers white Bumpers red Navigation Advisor GPS Engine 2.5 Disk

Order Order Order Order Order Order 01 02 03 04 05 06 ...
x x
x x x
x x x
x x x
x x x x
x x x
.. .. .. .. .. ..
Access to component list via Logical Matrix From the top

Write: MRP (daily)
Backflush (every two minutes) Impulse Read: All functions which need: - BOM of the order - Component requirements Examples: Component MRP, Backflush, Delivery schedules... (update dates every two minutes)
SAP AG
TAAP1W
Functions Using Logical Matrix II
Reading and Interpreting Rows

Reporting
Stock/requirements list Coverage calculation Delivery scheduling Pull-list
Bumpers green

Order Order Order Order Order Order 01 02 03 04 05 06 ...
From the Left Aggregation to time buckets
Bumpers white Bumpers red Navigation Advisor GPS Engine 2.5 Disk
x x
x x x Day 1
x x x
x x x
x x x x Day 2
x x x
.. .. .. .. .. ..
Component Bump red GPS Disk

Day 1 Day 2
...
1 1 3
0 3 3
Aggregation in customized time buckets: Hour Shift Daily ...
Time buckets are created for component requirements Requirements from Matrix Time buckets are input for MRP requirements In APO: As APO orders (e.g. purchase orders) In R/3: As delivery schedules (daily requirements only) Size of time bucket is variable Short term horizon with more precise than long term horizon
SAP AG
TAAP1W
Integration of Line Design Information
Matrix Order
A1 A2 A4 A5 X X X X X X
Line Design
start times body paint assembly K1, K2, K3, K4, K5, K6, RP1, RP1, RP2, RP2 , RP3 , RP4 , T = 0 T = 10 T = 20 T = 20 T = 30 T = 40
RP 3 RP 2 RP 2
A3
RP 1 RP 1
X X X X X X
X X X X X X
X X X X X X
X X X X X X
X X X X X X
RP1, RP2, RP3: Reporting points per line defined in Line design
SAP AG
TAAP1W
A6
Scheduling Components using Line Design
Subdaily on Supply Area Level

ACT 1
Takt 1
C1
uctio
ACT 2 ACT 3 Takt 2
C2 C3
Matrix Order
Line Design C4
start times body paint assembly A1 A2 A3 A4 A5
RP 1
Prod
ACT 4
Takt 3
RP 3
RP 2
RP RP 2 1
ACT 5
C1, T1, T = 0
+ + + +
+ + + +
+ + + + X X
+ + X X X X
+ + X X X X X X X X X
C5
C2, T 2 T = 10 C3, T 2, T = 20 C4, T3 T = 20 C5, T4 ,T = 30 C... T ...
+ X X X
SAP AG
TAAP1W
A6
Rapid Planning Matrix (RPM) in SAP APO 3.1
Rapid Planning Matrix in SAP APO 3.1
SAP AG
TAAP1W
RPM - Activity Matrix
Planning production activities per order (analogous to components) Necessary information from the iPPE routing
Order Order Order Order Order Order 01 02 03 04 05 06
Install Xenon light Fit air conditioning Fit navigation system Fit childs seat Polish wheel rims Check oil
x x
x x x
x x x
x x x
x x x x
x x x
Integration: Backflush (Posting all activities performed, capacity reduction) Controlling (Value of all activities per vehicle, resource capacity) Model-mix (Material matching of necessary activities against resources)
SAP AG
TAAP1W
Activity Matrix: Calculation of Actual Resource Requirements in Sequencing

Challenge: Optimization of utilization of stations when manufacturing variants New: The Activity Matrix allows the calcualtion of actual resource requirements per station Aggregation of all activities which are carried out at a station Matching of actual working hours with working hours available Production scheduler can adjust resource availability to requirements
SAP AG
TAAP1W
Activity Matrix: Integration with Action Handler

Line Change: Vehicle was planned on one line, but is manufactured on another: Automatic recognition when passing the corresponding reporting point or tracking point Automatic adjustment of the components and activities in the matrices Example:
Vehicle passes tracking point: Planned: Final assembly on Line C2 Actual: Vehicle is assembled on line C1 Technique: Change of Production Version: RPM: Change of matrix (Components and activity) Required: New BoM explosion and correction of requirements
A1 B1 A2
C1
C2
SAP AG
TAAP1W
Activity Matrix: Integration with Action Handler

Mixed Order Some components are in the matrix, some are in the APO order network Components can be dynamically moved from the matrix into the order network (with firming etc.) Unrestricted pegging for important components Example:
Vehicle passes tracking point Components for line segment have to be fixed (until backflush), and shop floor papers are printed Vehicle is produced according to shop floor papers Technique: Components are moved from the matrix to a order network Mixed order: Some components are stored in the matrix, other are stored in order networks Additional functions: Specific components for MTO can always be planned in order networks in order to ensure full traceability via the pegging function
A1 B1 A2
C1
C2
SAP AG
TAAP1W
Manufacturing Execution: Action Handler
Production Action Handler
SAP AG
TAAP1W
Overview
Actions to do
Production Tracking
Trigger JIT for a component
Backflush Backflush Backflush
Tracking point 1
Tracking point 2
Tracking point 3
Event
Event Production Control System / Assembly Control System
Event
Line Line
Station Station 1 1
Station Station 2 2
Station Station 3 3
SAP AG
TAAP1W
Action Handler & SAP Business Workflow

SAP APO
Tracking Tracking evaluation evaluation
Action Action Handler Handler
Actions Event Event Manager Manager Analyse Analyse event event and and dispatch dispatch to to action action
Triggers Get Sequence Feedback Warehouse pull Customer Function Module Realtime Realtime Trackinginformation Insert & Update Server Delayed Delayed (FIFO (FIFO Queue) Queue)
Trackin gpoint with event and action informations
RFC with Tracking point & order & Customer data

Tracking point S01 Tracking point S02
Event
Client
Event
Production Control System / Assembly Control System Station Station 1 1 Station Station 2 2 Station Station 3 3 Station Station n n
Line Line
SAP AG
TAAP1W
Action Handler Standard Actions

Save Tracking data
Business Add-Ins to insert additional customer data into standard tables with customer includes.
Order Modify
Adjust order start time (example vehicle leaves Paint Shop) Change activity status
Backflush
PBS = painted body storage (buffer after paint shop) Prerequisite for WIP-counting (supply area inventory): action handler provides the actual sequence!!!
SAP AG
TAAP1W
Interaction of Action Handler and Backflush
ACT 1
RP 1
C1
tion
ACT 2 ACT 3
C2 C3
du c
Goods Issue Load Reduction.

C4
Pro
ACT 4
RP 2
Event X
ACT 5 C5
SAP AG
TAAP1W
Manufacturing Execution: Backflush
Production Confirmation (Backflush)

SAP AG
TAAP1W
Overview
Solution for high-volume scenarios Usage of Rapid Planning Matrix (RPM) Work in Process (WIP) calculation Sales order specific cost estimate at GR posting Aggregated and parallel GI posting Capacity reduction at reporting point backflush
SAP AG
TAAP1W
Process Overview
APO
CIF
Automotive System
Buffer
Scenario without RPM
RPM scenario
Postings (MM/IM)
SAP AG
TAAP1W
Prerequisites from a Backflush View
APO Orders iPPE

CIF
Automotive System iPPE Material Master

Product Cost Collector Production Versions
Product Master
Sales Orders
CIF
Sales Orders
CIF
Production Versions
CIF
Create iPPE Create production version and maintain iPPE data production version used to determine cost collector Enter REM profile in material master Movement types, batch and stock determination Determine in material master of components whether GI is posted synchronously or asynchronously Create classes und characteristics Create sales orders and assign characteristic values Create product cost collector cost collector set as APO cost collector in first backflush
SAP AG
TAAP1W
Overall Process
APO
Read and check order, write creation document
CIF
Automotive System
Registr. docum.
Receive creation document, generate and write backflush document
No stock/requirement updates. Capacity reduction
Stock adjustments, requirements reduction update of order status
Stocks list of backflushes
Stock posting
APO Backflush Profile flexible access to backflush transaktion backflushing via action handler possible APO orders available Enter backflush data backflushing via action handler possible Capacities are reduced immediately Information for IM transferred to R/3 Automotive System R/3 Goods Movements all GRs and GIs of synchronous materials are posted immediately GIs of asynchronous materials are periodically aggregated and posted Processes can be distributed to several processes and servers Usage of application log instead of document log Postprocessing for failed goods movements Cumulative and individual records Postprocessing records for GRs as well Providing BW with backflush data Archiving functions for backflush tables
SAP AG
TAAP1W
Example Steps: Backflush for Components

1. Explode sales orders 2. Backflush at reporting points 3. CO postings of aggregated goods issues 4. Synchronously posted goods receipts 5. Determination of WIP 6. Backflush with scrap 7. Period end closing 8. Goods receipts with price variances 9. WIP after price changes
SAP AG
TAAP1W
Explode Sales Order
APO
SO1 SO2 SO3 ... ... ... C1 C2 C3 C4 C5 .... X X X X X X X X X X X X X X X X X X X X X
Sales order SO3 Sales order SO3 A140 A140 Mat. No.: A Class Mat. No.: A Class Value Sales order SO2 Value Sales order SO2 assignment A160 assignment A160 Mat. No.: A Class Mat. No.: A Class Value Sales order SO1 Value Sales order SO1 assignment A140 assignment A140 Mat. No.: A Class Mat. No.: A Class Value Value assignment assignment
R/3
iPPE
SAP AG
TAAP1W
Example: Backflush, Initial Situation
Matrix Order
SO 1 SO 2 Line Design (Stations) Body Paint Assembly C1, C2, C3, C4, C5, ... Stat. 10 RP1, T = 0 Stat. 10 RP1, T = 10 Stat. 20 RP2, T = 20 Stat. 20 RP2, T = 20 Stat. 30 RP3, T = 30 X X SO 3
Start Times:
...
... X X X
X X
X X
X X
X X X
X X X X X
RP 1
RP 2
SO6 SO5 SO4 SO3 SO2 SO1
Station 10
Station 20
Station 30
C1
C2
C3
C4
C5
SAP AG
TAAP1W
...
RP 3
Backflush of Sales Order 1 (SO 1) at Rep. Point 1 (RP 1)
APO
C1 C2 C3 C4 C5 .... RP 1 RP 1 RP 2 RP 2 RP 3
SO1 SO2 SO3 ...
...
...
R/3
SO 1 RP 1 C1 1 pc C2 4 pc
0 0
X X
X X X X
X X
X X X
X X
X X X
RP 1
RP 2
RP 3
SO6 SO5 SO4 SO3 SO2
SO1
Station 10
Station 20
Station 30
C1
C2
C3
C4
C5
Backflushing in APO always carried out for a reporting point Reporting point structures can be changed during production One order always refers to exactly one reporting point structure Definition of reporting points in Line Design: Beginning and/or end of line segment No reporting point definition at activities Document-neutral reversal only Reversal always is a posting using opposite movement direction Valuations in Controlling (WIP and GR cost estimate) based on actual postings
SAP AG
TAAP1W
Backflush of SO 1 at RP 3, SO 2 at RP 2
APO
SO1 SO2 SO3
...
...
...
SO 1 RP 1 SO 2 RP 1 SO 1 RP 2 SO 2 RP 2 SO 1 RP 3
C1 1 pc C2 4 pc C1 1 pc C4 5 pc C3 2 pc C4 5 pc C5 1 pc
R/3
0 0 0 0
0 0 0
X X
X X
X X X
X X
X X X
RP 1
RP 2
RP 3
SO6 SO5 SO4 SO3
SO2
SO1
Station 10
Station 20
Station 30
C1
C2
C3
C4
C5
SAP AG
TAAP1W
CO Postings of Aggregated Goods Issues

Backflushed components of SO 1 and SO 2:
Reporting points of cost collector

Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 WIP WIP debit debit 22 44 22 10 10 11 Period 11 Period WIP WIP credit credit 00 00 00 00 00 Scrap Scrap 00 00 00 00 00
SO 1 RP 1 SO 2 RP 1 SO 1 RP 2 SO 2 RP 2 SO 1 RP 3
C1 1 pc C2 4 pc C1 1 pc C4 5 pc C3 2 pc C4 5 pc C5 1 pc
Valuation
C1 C1 1pc 1pc= =100,100,C2 C2 1pc 1pc= =25,25,C3 C3 1pc = 1pc =200,200,-
APO
C1 C2 C3 C4 C5 ... RP 1 RP 1 RP 2 RP 2 RP 3

X X X X X X X X X X X X X X X X X X X X X
C4 C4 1pc 1pc= =10,10,C5 C5 1pc = 1pc =500,500,-
Product cost collector Model series A Class GI C1 200.GI C2 100.GI C3 400.GI C4 100.GI C5 500.-
ACT = 1300.-
SAP AG
TAAP1W
Goods Receipt SO 1, Synchronously Posted

Reporting points of cost collector SO 1 RP 1 SO 2 RP 1 SO 1 RP 2 SO 2 RP 2 SO 1 RP 3 SO 1 GR C1 1 pc C2 4 pc C1 1 pc C4 5 pc C3 2 pc C4 5 pc C5 1 pc
Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 WIP WIP debit debit 22 44 22 10 10 11 Period 11 Period WIP WIP credit credit 11 44 00 55 11 Scrap Scrap 00 00 00 00 00
Product cost collector Model series A Class
Valuation
Comp. Quant. C1 1 C2 4 C3 0 C4 5 C5 1 Price 100.100.0.50.500.750.-
-750.-
APO

GR SO 1
GI GI GI GI GI GR
C1 C2 C3 C4 C5
200.100.400.100.500.-750.-
ACT = 550.-
SAP AG
TAAP1W
Determination of Work in Process (WIP)

Reporting points of cost collector WIP quantity = WIP debit - WIP credit
Comp. Comp. C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 WIP WIP 22 -11 == 11 44 -44 == 00 22 -00 == 22 10 5 = 5 10 - 5 = 5 11 -11 == 00
Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5
WIP WIP debit debit 22 44 22 10 10 11
Period 11 Period WIP WIP credit credit 11 44 00 55 11
Scrap Scrap 00 00 00 00 00
Valuation
1 pc C1 2 pc C3 5 pc C4
550.-
Product cost collector Model series A Class GI C1 200.GI C2 100.GI C3 400.GI C4 100.GI C5 500.GR -750.ACT WIP = 550.= 550.-
SAP AG
TAAP1W
Backflush of SO 3 at RP 2, Scrap
APO
SO1 SO2 SO3
...
...
...
R/3
0 0 0 0
0 0 0 0 0
0 0
X X X
X X
X X X
...
SO 3 RP 1 SO 3 RP 2 C1 1 pc C3 2 pc
Scrap!
RP 1 RP 2 RP 3
SO6 SO5 SO4
SO3
Station 10
Station 20
Station 30
C1
C2
C3
C4
C5
SAP AG
TAAP1W
Backflush SO 3 at RP 2, Scrap
List of compontents for scrap
Comp. Quant. C1 1 C2 0 C3 2 C4 0 C5 0
Reporting points of cost collector

Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 WIP WIP debit debit 2+1 2+1 44 2+2 2+2 10 10 11 Period 11 Period WIP WIP credit credit 1+1 1+1 44 0+2 0+2 55 11 Scrap Scrap 11 00 22 00 00
...
SO 3 RP 1 SO 3 RP 2 C1 1 pc C3 2 pc
Valuation
C1 C1 1pc = 1pc =100,100,C2 C2 1pc 1pc= =25,25,C3 C3 1pc 1pc= =200,200,2 pc C3
APO

C4 C4 1pc 1pc= =10,10,C5 C5 1pc 1pc= =500,500,-
400.-
Product cost collector Model series A Class GI C1 200.GI C2 100.GI C3 400.GI C4 100.GI C5 500.GR -750.GI C1 100,GI C3 400,-
ACT = 1050.-
SAP AG
TAAP1W
Period-End Closing
Reporting points of cost collector WIP quantity = WIP debit - WIP credit
Comp. Comp. C1 C1 C2 C2 C3 C3 C4 C4 C5 C5 WIP WIP 33 22 == 11 44 44 == 00 44 22 == 22 10 55 == 55 10 11 11 == 00
Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5
WIP WIP debit debit 33 44 44 10 10 11
Period 11 Period WIP WIP credit credit 22 44 22 55 11
Scrap Scrap 11 00 22 00 00
Valuation
Scrap
Comp. Quant. C1 1 C2 0 C3 2 C4 5 C5 0
1 pc C1 2 pc C3 5 pc C4
WIP
Price 100.0.400.50.0.550.-
Product cost collector Model series A Class GI C1 200.GI C2 100.500.GI C3 400.GI C4 100.GI C5 500.GR -750.GI C1 100,GI C3 400,550.ACT = 1050.WIP = 550.Scrap = 500.-
SAP AG
TAAP1W
Backflush in SAP APO 3.1
Backflush in SAP APO 3.1
SAP AG
TAAP1W
Overview
iPPE cost estimate (concurrent costing) Sales order costing at goods receipt Posting of material consumption Posting of activities Posting of variances Comprehensive reporting functions in R/3 and BW
SAP AG
TAAP1W
Overview
RPM Order Network Value at GR Quantity or Inventory Management Quantity Costs BW APO3.0 DI4.6C1 Material A Material B APO3.1 DI4.6C2 10 min / Station 1 20 min / Station 2 Reporting Variances Work in Process CO / FI
TP TP
Line Network
TP
TP
SAP AG
TAAP1W
OEM Workshop IAU250: Engineering (iPPE) & Manufacturing

Introduction
Discrete Industries Overview mySAP Automotive Portals & Workplaces
IPPE
iPPE Workbench Overview Product Variant Structure iPPE PLM Engineering Change Management Process & Factory Layout Structures
Production Planning Scenarios

Overview Planning Basics and APO Heuristics Planning/Rapid Planning Matrix Model-Mix Sequencing with Restrictions
Manufacturing
Action Handler Backflush
SAP AG
TAAP1W
Copyright
No part of this presentation may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, WINDOWS, NT, EXCEL, Word and SQL Server are registered trademarks of Microsoft Corporation. IBM, DB2, OS/2, DB2/6000, Parallel Sysplex, MVS/ESA, RS/6000, AIX, S/390, AS/400, OS/390, and OS/400 are registered trademarks of IBM Corporation. ORACLE is a registered trademark of ORACLE Corporation, California, USA. INFORMIX-OnLine for SAP is a registered trademark of Informix Software Incorporated. UNIX, X/Open, OSF/1, and Motif are registered trademarks of The Open Group. HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C, World Wide Web Consortium, Laboratory for Computer Science NE43-358, Massachusetts Institute of Technology, 545 Technology Square, Cambridge, MA 02139. JAVA is a registered trademark of Sun Microsystems, Inc. , 901 San Antonio Road, Palo Alto, CA 94303 USA. JAVASCRIPT is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. SAP, SAP Logo, mySAP.com, mySAP.com Marketplace, mySAP.com Workplace, mySAP.com Business Scenarios, mySAP.com Application Hosting, WebFlow, R/2, R/3, RIVA, ABAP, SAP Business Workflow, SAP EarlyWatch, SAP ArchiveLink, BAPI, SAPPHIRE, Management Cockpit, SEM, are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.
SAP AG
TAAP1W

SAP APO PPDS For Automotive PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

SAP APO PPDS For Automotive PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

Automotive with DI46C2 (SAP R/3)

IBS Manufacturing, IBU Automotive SAP AG

Automotive with DI46C2 - 1

New Processes supported by SAP APO 3.1

Order Promising & Delivery

Supply Chain Event Management

Supply Chain Performance Management

Supply Chain Portal

Supply Chain Integration

SC Collaboration Collaborative Management of Delivery Schedules (CMDS)

Automotive with DI46C2 - 2

Process Enhancements with SAP APO 3.1

Order Promising & Delivery

Supply Chain Event Management

Supply Chain Performance Management

Supply Chain Portal

Supply Chain Integration

Automotive with DI46C2 - 3

Repetitive Manufacturing with iPPE

SAP AG 2002, Title of Presentation, Speaker Name 4

Automotive with DI46C2 - 4

SAP AG 2002, Title of Presentation, Speaker Name 5

Automotive with DI46C2 - 5

SAP APO and SAP R/3 in Automotive System

Automotive with DI46C2 - 6

Automotive Functions in SAP APO: Planning Process

Customer Customer requirements requirements 04/15/00 - 20 units

04/15/00 - 20 units 04/16/00 - 15 units 04/16/00 ... - 15 units ...

MM MMDelivery Delivery Schedules Schedules

Automotive with DI46C2 - 7

Challenges from Engineering to Production

Automotive with DI46C2 - 8

Station 1 Takt-based Scheduling Takt time very fast, since

Station 2 Takt time

Station 3 Takt time

lead time = number of Takts * Takt time

SAP AG 2002, Title of Presentation, Speaker Name 9

Automotive with DI46C2 - 9

Data and Object Model for iPPE

SAP AG 2002, Title of Presentation, Speaker Name 10

Automotive with DI46C2 - 10

Product Variant Structure (PVS): Concept

Product Lifecycle Management (PLM)

Automotive with DI46C2 - 11

Engineering Change Management as part of the iPPE

Master Data Variant Configuration Document Management

Engineering Change Management

SAP AG 2002, Title of Presentation, Speaker Name 12

Automotive with DI46C2 - 12

SAP AG 2002, Title of Presentation, Speaker Name 13

Automotive with DI46C2 - 13

Calculation of Exact Component Demand times

ACT ACT 2 2 ACT ACT 3 3

Order Start + 1 Takt

Order Start + 2 Takts

Order Start + 3 Takts

SAP AG 2002, Title of Presentation, Speaker Name 14

Automotive with DI46C2 - 14

Production Resources in iPPE

Line 1 RES1 RES2

ACT1 RES1 ACT2 RES2 ACT3 RES3

SAP AG 2002, Title of Presentation, Speaker Name 15

Automotive with DI46C2 - 15