LO230 - Capacity Planning

LO230 Capacity Planning LO230

R/3 System Release 46C 05/08/2001

0

LO230 Capacity Planning.............................................................................................................................................0-1 Copyright ..................................................................................................................................................................0-2 Production Planning..............................................................................................................................................0-4 Prerequisites ..........................................................................................................................................................0-5 Target Audience....................................................................................................................................................0-6 Introduction...............................................................................................................................................................1-1 Course Goals .........................................................................................................................................................1-2 Course Objectives .................................................................................................................................................1-3 Course Content......................................................................................................................................................1-4 Overview Diagram 1 .............................................................................................................................................1-5 Main Business Scenario ........................................................................................................................................1-6 Overview...................................................................................................................................................................2-1 Overview: Objectives............................................................................................................................................2-2 Overview Diagram 2 .............................................................................................................................................2-3 Overview: Business Scenario................................................................................................................................2-4 Integration of Capacity Planning (1).....................................................................................................................2-5 Capacity Planning Environment (1)......................................................................................................................2-6 Planning Views .....................................................................................................................................................2-7 Capacity Planning / Elements ...............................................................................................................................2-8 Work Center Data .................................................................................................................................................2-9 Types of Display .................................................................................................................................................2-10 Overview: Summary ...........................................................................................................................................2-11 Capacity Evaluation ..................................................................................................................................................3-1 Capacity Evaluation: Objectives ...........................................................................................................................3-2 Overview Diagram 3 .............................................................................................................................................3-3 Capacity Evaluation: Business Scenario ...............................................................................................................3-4 Capacity Planning Environment (2)......................................................................................................................3-5 Procedure in Capacity Evaluation .........................................................................................................................3-6 Capacity Planning Phases .....................................................................................................................................3-7 Standard Overview................................................................................................................................................3-8 Selection and Display Parameters .........................................................................................................................3-9 Cumulated Display..............................................................................................................................................3-10 Period Split..........................................................................................................................................................3-11 Detailed Capacity List and its Functions.............................................................................................................3-12 Structure of a Profile ...........................................................................................................................................3-13 Structure of a Set.................................................................................................................................................3-14 Functions in the Variable Overview....................................................................................................................3-15 Capacity Planning Environment..........................................................................................................................3-16

Configuration Sequence Capacity Planning (1) ..................................................................................................3-17 Capacity Planning / Overall Profile Evaluations.................................................................................................3-18 User Parameters - Evaluation..............................................................................................................................3-19 Selection Profile (Capacity Evaluations) ............................................................................................................3-20 Options Profile (Capacity Evaluations)...............................................................................................................3-21 Extended Evaluation (Standard Overview).........................................................................................................3-22 Extended Evaluation (Detailed Capacity List) ....................................................................................................3-23 Structure of a Profile (Extended Evaluation) ......................................................................................................3-24 Structure of a Set (Extended Evaluation) ............................................................................................................3-25 Capacity Evaluation: Summary...........................................................................................................................3-26 Data used in the exercises ...................................................................................................................................3-27 Capacity Evaluation Exercises ............................................................................................................................3-29 Capacity Evaluation Solutions ............................................................................................................................3-34 Capacity Leveling (Part 1) ........................................................................................................................................4-1 Capacity Leveling (Part 1): Objectives .................................................................................................................4-2 Capacity Evaluation ..............................................................................................................................................4-3 Capacity Leveling (Part 1): Business Scenario .....................................................................................................4-4 Capacity Planning Environment (3)......................................................................................................................4-5 Capacity Leveling Measures .................................................................................................................................4-6 User Interface for Capacity Leveling ....................................................................................................................4-7 Capacity Planning Table (Tabular Form)..............................................................................................................4-8 Capacity Planning Table .......................................................................................................................................4-9 Dispatching .........................................................................................................................................................4-10 Dispatching Procedure ........................................................................................................................................4-11 Types of Dispatching (tabular)............................................................................................................................4-12 Capacity Leveling (part 1): Summary .................................................................................................................4-13 Capacity Leveling (Part 1) Exercises ..................................................................................................................4-14 Capacity Leveling (Part 1) Solutions ..................................................................................................................4-16 Available Capacity....................................................................................................................................................5-1 Available Capacity: Objectives.............................................................................................................................5-2 Overview Diagram 5 .............................................................................................................................................5-3 Available Capacity: Business Scenario.................................................................................................................5-4 Capacity Planning Environment (4)......................................................................................................................5-5 Capacities at a Work Center..................................................................................................................................5-6 Available Capacity at the Work Center.................................................................................................................5-7 From Work Time to Operating Time ....................................................................................................................5-8 Maintaining Available Capacity using Shift Sequences .......................................................................................5-9 Available Capacity in the Work Center ..............................................................................................................5-10 Available Capacity/Maintenance Variants..........................................................................................................5-11

Maintaining and Assigning Factory Calendar.....................................................................................................5-12 Work Center Hierarchy .......................................................................................................................................5-13 Configuration Sequence Capacitiy Planning (2) .................................................................................................5-14 Shift Sequences and Shifts ..................................................................................................................................5-15 Available Capacity: Summary ............................................................................................................................5-16 Available Capacity Exercises..............................................................................................................................5-17 Available Capacity Solutions ..............................................................................................................................5-21 Capacity Requirements and Reduction .....................................................................................................................6-1 Capacity Requirements and Reduction: Objectives ..............................................................................................6-2 Overview Diagram 6 .............................................................................................................................................6-3 Business Scenario .................................................................................................................................................6-4 Capacity Planning Environment (5)......................................................................................................................6-5 Planning Levels.....................................................................................................................................................6-6 Determining Capacity Requirements ....................................................................................................................6-7 Formulas ...............................................................................................................................................................6-8 Link between Formula and Standard Values ........................................................................................................6-9 Setting up a Formula ...........................................................................................................................................6-10 Examples of Formulas.........................................................................................................................................6-11 Capacity Reduction .............................................................................................................................................6-12 Determining Remaining Capacity Requirements................................................................................................6-13 Capacity Requirements and Reduction: Summary..............................................................................................6-14 Capacity Requirements and Reduction Exercises ...............................................................................................6-15 Capacity Requirements and Reduction Solutions ...............................................................................................6-18 Scheduling.................................................................................................................................................................7-1 Scheduling: Objectives..........................................................................................................................................7-2 Overview Diagram 7 .............................................................................................................................................7-3 Scheduling: Business Scenario..............................................................................................................................7-4 Work Center and Lead Time Scheduling ..............................................................................................................7-5 Lead Time Scheduling - Basics.............................................................................................................................7-6 Scheduling / Time Elements in an Order ..............................................................................................................7-7 Scheduling Types..................................................................................................................................................7-8 Today Scheduling .................................................................................................................................................7-9 Scheduling / Performance Efficiency..................................................................................................................7-10 Correction of Execution Time.............................................................................................................................7-11 Distribution of Capacity Requirements...............................................................................................................7-12 Distribution Basis................................................................................................................................................7-13 Scheduling: Summary .........................................................................................................................................7-14 Scheduling Exercises ..........................................................................................................................................7-15 Scheduling Solutions...........................................................................................................................................7-17

Capacity Leveling (Part 2) ........................................................................................................................................8-1 Capacity Leveling (Part 2): Unit Objectives .........................................................................................................8-2 Overview Diagram (8) ..........................................................................................................................................8-3 Business Scenario .................................................................................................................................................8-4 Capacity Planning Environment (1)......................................................................................................................8-5 Capacity Planning Table .......................................................................................................................................8-6 Types of Dispatching (Graphical) .........................................................................................................................8-7 Dispatching Operations.........................................................................................................................................8-8 Planning Details at the Work Center / Capacity....................................................................................................8-9 Lead Time Scheduling - Finite Scheduling.........................................................................................................8-10 Finite Scheduling ................................................................................................................................................8-11 Rescheduling / Deallocating ...............................................................................................................................8-12 Midpoint Scheduling I.........................................................................................................................................8-13 Midpoint Scheduling II .......................................................................................................................................8-14 Structure of a Profile (Leveling) .........................................................................................................................8-15 Dispatching to Freely-Definable Period split......................................................................................................8-16 Enhanced Handling Functions 1 .........................................................................................................................8-17 Strategy Profile ...................................................................................................................................................8-18 Planning Direction ..............................................................................................................................................8-19 Dispatching at the Earliest Time .........................................................................................................................8-20 Planning Strategy: Strategy Profile .....................................................................................................................8-21 Treatment of Queue Time ...................................................................................................................................8-22 Use of Order Floats / Operation Floats ...............................................................................................................8-23 Various Functions ...............................................................................................................................................8-24 Configuration Sequence Capacity Planning (3) ..................................................................................................8-25 Capacity Leveling - Overall Profile ....................................................................................................................8-26 Standard Overall Profiles for Capacity Leveling ................................................................................................8-27 Control Profile.....................................................................................................................................................8-28 Selection Profile..................................................................................................................................................8-29 Planning- (Scheduling) Levels ............................................................................................................................8-30 Time Profile ........................................................................................................................................................8-31 Evaluation Profile ...............................................................................................................................................8-32 List Profile ..........................................................................................................................................................8-33 Profile for Capacity Planning Table (tab.) ..........................................................................................................8-34 Period Profile ......................................................................................................................................................8-35 Profile for Capacity Planning Table....................................................................................................................8-36 Check Report / Overall Profile............................................................................................................................8-37 Requirements Grouping ......................................................................................................................................8-38 Requirements Grouping - Example Group..........................................................................................................8-39

Cumulation of Available Capacity / Capacity Requirements..............................................................................8-40 Cumulation of Available Capacity using Period Split ........................................................................................8-41 Capacity Leveling (Part 2): Summary.................................................................................................................8-42 Capacity Leveling (Part 2) Exercises ..................................................................................................................8-43 Capacity Leveling (Part 2) Solutions ..................................................................................................................8-49 Extended Planning Functions....................................................................................................................................9-1 Extended Planning Functions: Unit Objectives.....................................................................................................9-2 Overview Diagram 9 .............................................................................................................................................9-3 Business Scenario .................................................................................................................................................9-4 Sequencing 1 .........................................................................................................................................................9-5 Sequencing 2 .........................................................................................................................................................9-6 Sequencing 3 .........................................................................................................................................................9-7 User Exits.............................................................................................................................................................9-8 Additional Functions 1..........................................................................................................................................9-9 Additional Functions 2........................................................................................................................................9-10 Material Stock Curves.........................................................................................................................................9-11 Planning in Non-Work Periods / Fixing..............................................................................................................9-12 Temporarily Saving Results of Planning.............................................................................................................9-13 Mass Processing..................................................................................................................................................9-14 Capacity Planning with Production Versions......................................................................................................9-15 Notes on Documentation.....................................................................................................................................9-16 Extended Planning Functions: Summary ............................................................................................................9-17 Extended Planning Functions Exercises..............................................................................................................9-18 Extended Planning Functions Solutions..............................................................................................................9-26 Detailed Planning....................................................................................................................................................10-1 Detailed Planning: Unit Objective ......................................................................................................................10-2 Overview Diagram 10 .........................................................................................................................................10-3 Detailed Planning: Business Scenario.................................................................................................................10-4 Application Criteria for Splits .............................................................................................................................10-5 Levels of Detail...................................................................................................................................................10-6 Capacity Assignments.........................................................................................................................................10-7 Qualifications - Objectives..................................................................................................................................10-8 Qualifications - Abilities Required .....................................................................................................................10-9 Qualifications - Assignments ............................................................................................................................10-10 Requirements Profiles .......................................................................................................................................10-11 Splitting and Allocating ....................................................................................................................................10-12 Ranking List......................................................................................................................................................10-13 Types of Split ....................................................................................................................................................10-14 Confirmation of Splits.......................................................................................................................................10-15

Detailed Planning: Summary ............................................................................................................................10-16 Detailed Planning Exercises..............................................................................................................................10-17 Detailed Planning Solutions..............................................................................................................................10-21 Integration ...............................................................................................................................................................11-1 Integration: Unit Objectives 1 .............................................................................................................................11-2 Integration: Unit Objectives 2 .............................................................................................................................11-3 Overview Diagram 11 .........................................................................................................................................11-4 Integration: Business Scenario ............................................................................................................................11-5 Integration of Capacity Planning (2)...................................................................................................................11-6 CRP Along the Process Chain.............................................................................................................................11-7 Planning Phases...................................................................................................................................................11-8 Integrated Planning Levels..................................................................................................................................11-9 Simultaneous Use of Different Planning Levels ...............................................................................................11-10 Overall Profiles in the Applications ..................................................................................................................11-11 Integration Types ..............................................................................................................................................11-12 Integration: Sales and Distribution (SD) ...........................................................................................................11-13 Integration: Sales and Operations Planning - Planning Table (SOP) ................................................................11-14 Integration: MRP/MPS......................................................................................................................................11-15 Integration: Long-term Planning 1....................................................................................................................11-16 Integration: Long-term Planning 2....................................................................................................................11-17 Available Capacity and Requirements Versions ...............................................................................................11-18 Integration: Repetitive Manufacturing (REM)..................................................................................................11-19 Repetitive Manufacturing with Production Versions ........................................................................................11-20 Integration: Shop Floor Control (SFC) .............................................................................................................11-21 Integration: Unit Summary ...............................................................................................................................11-22 Integration Exercises.........................................................................................................................................11-23 Integration Solutions .........................................................................................................................................11-27 Appendix.................................................................................................................................................................12-1 Change Mode and GUI Status.............................................................................................................................12-2 Layout of the Planning Table ..............................................................................................................................12-3 Chart Sequence ...................................................................................................................................................12-4 Chart Sequence (cont.) ........................................................................................................................................12-5 Actual Capacity Requirements............................................................................................................................12-6

LO230 LO230 Capacity Planning

Capacity Planning © SAP AG 1999 © SAP AG

R/3 System Release 4.6B March 2000 50034893

Copyright

Copyright 2001 SAP AG. All rights reserved. Neither this training manual nor any part thereof may be copied or reproduced in any form or by any means, or translated into another language, without the prior consent of SAP AG. The information contained in this document is subject to change and supplement without prior notice. All rights reserved.

© SAP AG 1999

Trademarks: 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 and Informix® Dynamic ServerTM are registered trademarks 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. Design: SAP Communications Media

Production Planning Level 3

Level 2 LO980 3 days Engineering Change Management LO235

LO210 5 days Production Planning LO215 5 days Production Orders

2 days

KANBAN LO050 5 days Manufacturing Planning & Execution for Discrete & Repetitive

LO205 3 days Basic Data for Discrete Manufacturing LO985

3 days

Classification LO955 3 days Batch Management

© SAP AG 1999

LO206 3 days Basic Data Part 2

LO230

5 days

Capacity Planning

LO225 3 days Repetitive Manufacturing

2 days LO720 CAP Calculation of Standard Values

LO930 2 days Logistics Information System (LIS) Reporting

2 days LO275 Special Features of LIS in Production

5 days LO991 LO990 3 days Variant Variant Configuration Part 1 Configuration Part 2

2 days LO935 Logistics Info Planning

Prerequisites

z LO050 - Planning & control for discrete manufacturing and repetitive manufacturing z LO205 - Basic data for discrete manufacturing z LO215 - Prduction orders

© SAP AG 1999

Target Audience

z Participants

Members of the project team responsible for the implementation of capacity planning

Members of shop floor control

z Duration: 5 days

© SAP AG 1999

Notes to the user The training materials are not teach-yourself programs. They complement the course instructor's explanations. On the sheets, there is space for you to write down additional information.

Introduction

Contents: z Course goal z Course objectives z Course contents z Course overview diagram z Main business scenario z Introduction to course

© SAP AG 1999

(C) SAP AG

LO230 1-1

Course Goals

This course will enable you to: z Understand how to use capacity planning within PP z At the conclusion of this course you will be able to: z Describe connections between the elements of capacity planning z Use the capacity evaluation and the capacity planning tables z Make system settings

© SAP AG 1999

(C) SAP AG

LO230 1-2

Course Objectives

This course will enable you to: z Create available capacities z Execute capacity evaluations z Execute leveling of capacity requirements and available capacities

© SAP AG 1999

(C) SAP AG

LO230 1-3

Course Content

Preface Unit 1

Introduction

Unit 7

Scheduling

Unit 2

Overview

Unit 8

Capacity leveling (part 2)

Unit 3

Capacity evaluation

Unit 9

Unit 4


Extended planning functions

Unit 5

Available capacity

Unit 10

Detailed planning

Unit 6

Capacity requirements / reduction

Unit 11

Integration

Appendix

© SAP AG 1999

(C) SAP AG

LO230 1-4

Overview Diagram 1 Introduction Overview

Work Centers

Capacity evaluation

Work Center

W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2

Available capacity Capacity reqmts / reduction Work Centers Jun' 98

Material

Scheduling

Jul' 98

Order

Capacity leveling (part 2) 100-500

18752

500-300

600001650

100-500

18770

500-300

600001699

Extended planning functions Detailed planning Integration

© SAP AG 1999 © SAP AG

(C) SAP AG

LO230 1-5

Main Business Scenario

z You are running a manufacturing company and aim to deliver materials for orders received by the dates promised. Thus you want to provide available capacity that is sufficient but not excessive to cover requirements generated by orders. This is why you are using capacity planning; for example to spot overloads in time or to carry out leveling for the requirements dates using the capacities available and to fix the requirements.

© SAP AG 1999

(C) SAP AG

LO230 1-6

Overview

Contents: z Integration of capacity planning z Capacity planning environment z Overview of elements and types of display

© SAP AG 1999

(C) SAP AG

LO230 2-1

Overview: Objectives

At the conclusion of this unit you will: z Have an overview of the integration of capacity planning in the PP System and the main elements of capacity planning.

© SAP AG 1999

(C) SAP AG

LO230 2-2

Overview Diagram 2 Introduction

Overview

Arbeitsplätze / Work Center

Capacity evaluation

Arbeitsplatz / Work Center

W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2

Available capacity Capacity reqmts / -reduction Arbeitsplätze Jun' 98

Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699


© SAP AG 1999

(C) SAP AG

LO230 2-3

Overview: Business Scenario

z You are running a manufacturing company and

need an overview of capacity planning. Therefore you want to find out about the capacity planning environment. You are particularly interested in the basic data such as the work center and the pegged requirements.

© SAP AG 1999

(C) SAP AG

LO230 2-4

Integration of Capacity Planning (1)

PP - BD Basic Data PP - MPS Master Prod. Scheduling PP - MRP Mat. Reqmts Planning

PP - PI Process Industries

CO

MM

PP

AM

R/3

PP - CRP Capacity Reqmts Planning PP - SFC Shop Floor Control

FI

SD

Client / Server ABAP/4

QM

PS WF

PM PD

IS

PP - SOP Sales and Operations Planning PP - REM Repetitive Manufacturing © SAP AG 1999

The PP production planning component consists of several integrated components. Capacity planning is flexible and can be adapted to the relevant point of view. The user has a planning instrument he can use to help in planning limited resources on various planning levels (detailed, production-rate and rough-cut). It can be used for every application area and it has specially-defined functions. Capacity leveling is an integrated component of the following R/3 applications. y SD Sales and distribution y SOP Sales and Operations Planning y MPS/MRP Master Production Scheduling / Material Requirements Planning y REM Repetitive Manufacturing y SFC Production Control y PD Personnel Planning and Development y PI Process Industries y PS Project System y PM/SM Plant Maintenance, Service Management

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LO230 2-5

Capacity Planning Environment (1)

Basic data

Production planning

A Material

PM / PS

Planned orders Production orders Process orders SOP orders

Plant maint. Projects

Bill of material

10

20

Arbeitsplan Routing TskLstGrp

30

40

50

Scheduling

C1

10 Center 1 20 30

t

Capacity requirements

Calendar

4

Capacity evaluation/ evaluation/-leveling

t

Available capacity

© SAP AG 1999

With the help of R/3 basic data such as Material Masters, work plans and work centers, as well as planned orders and production orders, a database is created, which can show the available capacity and the capacity required. Available capacity indicates which activity produces a capacity each day. A capacity is always assigned to at least one work center. Capacity requirements shows how much capacity the individual orders need at a certain point in time. Capacity requirements are determined during lead time scheduling. In Capacity evaluation, these requirements can now be compared with the available capacity. In Capacity levelling, orders can be shared out to avoid overloading. This way it is possible to leverage the suitable resources or to plan optimal scheduling with sort criteria.

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LO230 2-6

Planning Views

SOP

MPS

MRP/SFC

Today

Months later

© SAP AG 1999

There are different planning levels available for the individual application areas. For example, you can plan MRP requirements in the following three ways depending on how specific you want your planning to be: Rough-cut planning with a rough-cut planning profile Production-rate planning with a rate routing or a routing Detailed planning with a routing

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LO230 2-7

Capacity Planning / Elements

Available capacity

Scheduling Capacity requirements Capacity evaluation and -leveling Capacity reduction

© SAP AG 1999

The available capacity represents the capacity available for production. Scheduling the sequence of operations determines the times for the capacity requirements. The system calculates the capacity requirements using formulas and dates and quantities for production. The capacity evaluation gives you an overview of the load and the requirements for production. Capacity leveling allows you to achieve optimal planning and an optimal load. Capacity reduction occurs when operations are confirmed or order quantities reduced or deleted.

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LO230 2-8

Work Center Data

General data

Basic data

z Name and description z Standard values key z Effíciency rate key

Default values

Default values

z Control key z Standard text key z Wage data

Capacity data

Capacity

z Available capacity z Formula key z Individual capacities

Scheduling data

Scheduling

z Scheduling basis z Queue and move time z Formula key

Personnel system data

Assignments

z Labor z Positions z Qualifications

© SAP AG 1999

The work center contains several groups of data that are located on different screens. Only the most important ones are shown in this example.

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LO230 2-9

Types of Display

Capacity evaluation

Diagrams Available capacity

Printing of standard overview and det. cap. list Planing table (tabular) tabular)


Planning table (graphical) graphical)

© SAP AG 1999

Capacity planning uses several types of display. It uses evaluation lists, block diagrams, bar charts, line graphs and Gantt charts. You can also carry out simulations with the planning tables.

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LO230 2-10

Overview: Summary

z You have an overview of the integration,

environment and elements of capacity planning.

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(C) SAP AG

LO230 2-11

Capacity Evaluation

Contents: z z z z z

Capacity overviews Order detail lists Graphics Printing functions System settings

© SAP AG 1999

(C) SAP AG

LO230 3-1

Capacity Evaluation: Objectives

At the conclusion of this topic you will know: z What options there are for comparing the capacity requirements with the available capacity z How to create new overall profiles

© SAP AG 1999

(C) SAP AG

LO230 3-2



Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699


© SAP AG 1999

(C) SAP AG

LO230 3-3

Capacity Evaluation: Business Scenario

z You want to evaluate the work center load for production. You use the capacity evaluation functions to compare capacity requirements with available capacity. You can see the pegged requirements from the results of the evaluation and thus decide whether you need to take measures to keep to the production dates.

© SAP AG 1999

(C) SAP AG

LO230 3-4


Basic data

Production planning

A Material

PM / PS



Bill of material

10

20


30

40

50

Scheduling

C1

10 Center 1 20 30

t


Calendar

4

Capacity Capacityevaluation/-leveling evaluation/leveling Capacity evaluation/-leveling

t

Available capacity

© SAP AG 1999

In the capacity evaluations, the capacity requirements are compared to the available capacity. Capacity evaluation has to perform the following: yDetermination of available capacity yDetermination of capacity requirement yComparison of available capacity to capacity requirement

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LO230 3-5

Procedure in Capacity Evaluation

Accessing Capacity Planning Work center Load Orders ...

Variable Profile 1 ... ...

Initial screen Settings

Selection

Capacity evaluation Standard overview

Variable overview Detailed capacity list

© SAP AG 1999

Capacity evaluations are basically accessed using two menu options:The menu Work center view accesses evaluations for loads, orders, released orders, order in backlog or overloads.The menu Variable allows you to access evaluations using profiles created for your specific needs. When accessing the capacity evaluation the settings are pulled from the overall profile. This overall profile can be one provided by SAP or a user-specific profile. To access the evaluation via the work center you can use standard profiles and user-specific profiles. You can change display using the menu option Settings. You can use the menu Selection to increase or restrict the selection criteria for the capacity evaluation.

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LO230 3-6

Capacity Planning Phases

Planning phase RoughRough-cut Medium Detailed Characteristics Month

Week

WCtr area

WCtr group Work ctr

Incomplete

Day

Complete

Time

-

Location -

Display of periods Work center hierarchies Planning data

© SAP AG 1999

Capacity planning can use different planning phases. For example, the level of detail of planning can depend on how close the planning date is to the completion date.

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LO230 3-7

Standard Overview

Capacity evaluation

Standard overview

Graphics

Detailed capacity list

Lists Branch

t

Work center

Variable overview

Capacity

Printing

t


© SAP AG 1999

The standard overview compares the available capacity and the capacity requirements for the selected work centers for each capacity category. The loads and remaining available capacity are also listed. From the standard overview you can generate graphics, print lists, maintain work centers and capacities and from the detailed capacity list you can process orders. The standard overview can be limited using minimum and maximum load percentages. You can predefine these in the options profile.

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LO230 3-8

Selection and Display Parameters General Cumulated display

yes / no

Capacity unit

Time unit

Requirement unit

Target / remaining requirement Time segment / Periods

Selection of period to be displayed Period split for display Hierarchy Requirement prioritizing and comparison of offers can be either static or dynamic Distribution Through distribution keys from work center in production orders from operation or work center in network plans / maintenance orders from standard setting of capacity planning per capacity category © SAP AG 1999

The selection and display parameters can be predefined in profiles. They can, however, be changed in the menu settings. You can only update the reading time section via Customizing.

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LO230 3-9

Cumulated Display

Display not cumulated D

Available capacity

B A

C

Cumulated display

D

Available capacity

C

A

B

B

A

A

© SAP AG 1999

The cumulated display has the following significance for the standard overview and the variable overview: yFor every period the capacity requirements and the available capacity result from the sum of the capacity requirements/available capacity in this and the preceding periods. The starting point for the cumulation is the first period displayed. In this way you get an overview of the period available for reducing the capacity requirements.

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LO230 3-10

Period Split

Days 10 Period duration 4 Days 1 Week 3 Weeks 1 Month

20

30

Periods 1

2 1

3

4

5

2

3

6

7 4

1

2

1

© SAP AG 1999

To display the evaluations you can choose between the following period displays: y Month y Week y Day y Factory calendar day y Posting period You use the period duration to define the number of days or weeks for a period.

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LO230 3-11

Detailed Capacity List and its Functions

Capacity Evaluation

Standard overview


Graphics

Lists Branch

Variable overview

Printing

Order

Stock-/ reqmts list

... t

Work center

Capacity

t

Order

Stock-/ requirements list

© SAP AG 1999

In the detailed capacity list the orders and their operations are listed by period depending on the work center selected. They may be sorted, for example, by order number, date, and priority. From this list you can make changes to the work center, the capacity and the order. You can call up additional information on the material and the stock/requirements situation. You can predefine the display using the list profile and change it using the settings menu.

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LO230 3-12

Structure of a Profile

Overall profile

Options profile

Selection profile

List profile

Graphics profile

Order set

Initial set

Capacity category set

Work center set

© SAP AG 1999

The overall profile contains the names of four subprofiles: y The selection profile determines which sets are used to generate the various selection screens and for what period the capacity requirements are read from the database. y The list profile defines the layout of the detailed capacity list and the variable overview. y The graphics profile defines the layout of the graphics. y In the options profile the default parameters are set for the type of display, the display period, the distribution and for branches in change or display mode. y The order set, the capacity category set and the work center set are used for the extended selection.

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LO230 3-13

Structure of a Set

Multi-dimension set

Basic set

Basic set

Basic set

Work center

Capacity cat.

Capacity planner

Value

Variable

Variable

Value

PP-MONT1

&KAPLATZ

&KAPART

101

© SAP AG 1999

It is important to distinguish between basic sets that always refer to one criterion and multidimension sets that group together any number of basic sets. For example, which selection criteria are displayed in a dialog box for selection depends on the basic sets the multidimension set consists of. Multidimension sets are always used in the selection profile, in the combinations and in the column definitions in the variable overview. Whether and how you can specify values for a selection criterion is determined by the structure of the relevant basic set. You can use the basic set to specify: y- whether an individual value or a value range can be specified y- whether the criterion is assigned a fixed value and thus no user specification is required Sets are specified in Customizing for capacity planning and grouped together in a selection profile or in a combination. To make it possible to specify an individual value or a value range for a selection criterion, a variable must be defined for the individual value or for the upper and lower limit of the value range. You create variables in Customizing for capacity planning.

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LO230 3-14

Functions in the Variable Overview

Capacity evaluation

Standard overview


Variable overview

Graphics

Lists Branch

Printing

Detailed capacity list © SAP AG 1999

You can define the form and content of the variable overview. You use it to display any capacity data you wish. In the first column appear the periods. In the following columns you can display, for example, capacity requirements, available capacities and formulas. You can predefine the display using the list profile and change it using the settings menu.

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LO230 3-15

Capacity Planning Environment Display/maintain

Auftragskopf

Arb eitsvorgänge

Materialkompon enten

Fertigungshilfsmittel

Kosten

Plan Soll Ist

100

t

20 50

t

Capacity

Order Work center Material

That´s what I want !

Detailed capacity list 4 434518

759691

Confirmation

Pegged requirements Stock/ reqmts list Goods receipt for order

Display

Maintain

© SAP AG 1999

From the detailed capacity screen you can use the menu Environment to branch to further sections of PP in change mode or in display mode. In the options profile in Customizing you can specify that the system is to branch to orders, the work center and the capacity in change mode or in display mode. You can also get the system to branch by double-clicking on the fields for the order, the work center or the capacity.

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LO230 3-16

Configuration Sequence Capacity Planning (1)

M Maintaining and cumulating available capacity O O D

Creating work center hierarchies Defining distribution of requirements Profiles for capacity evaluations

D Profiles for capacity leveling/extended evaluation

© SAP AG 1999

Legend: M = Mandatory action (mandatory) O = Optional action (optional) D = Action completed as a result of default setting

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LO230 3-17

Capacity Planning / Overall Profile Evaluations

Overall profile

Options profile Selection profile List profile Graphics profile

© SAP AG 1999

The overall profile contains four subprofiles. In the options profile the default parameters are specified for the type of display, the display period, distribution and branching in display or change mode. Most of the settings can be changed in the application using the menu options Settings General for this evaluation run. The selection profile determines which sets are accessed to generate the various selection screens and for which period the capacity requirements are read from the database. The list profile specifies the layout of the detailed capacity list and the variable overview and determines which list is automatically displayed. The graphics profile contains settings for the layout of the various graphics: y Determining the earliest/latest dates of operations y Sort sequence such as date, material number, order number y Displaying columns, bars or lines The line display only makes sense for a cumulative display.

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LO230 3-18

User Parameters - Evaluation

Overall profile evaluation

Parameter / Std profile

Work center view Load

CY1

SAPX911

Orders

CY2

SAPX912

Released

CY3

SAPX913

Backlog

CY4

SAPX914

Overload

CY5

SAPX915

Variable

CY7

© SAP AG 1999

An overall profile can be accessed with the user parameters CY1 - CY7 individually for every user.

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LO230 3-19

Selection Profile (Capacity Evaluations) Overall profile Selection profile

Selection control: Scheduling level:

Selection period for reading from the database (KBED) Selection of KBED records according to detailed-, production rate- or rough-cut scheduling and specifying order categories (take account of scheduling levels table TCX00)

Work center set:

Read KBED records for work center(s)

Order set:

Read KBED records for order type(s)

Capacity reqmts category set:

Read KBED records for capacity reqmts categories

Initial set:

Fields for initial screen

Version of available capacity © SAP AG 1999

You use the selection profile among other things to specify which sets are used to define the layout of the various dialog boxes. You can also specify the database read period in the selection profile in the section Interval period. In the evaluation only those capacity requirements are read from the database where at least one date (for example, the earliest start date) falls in the period defined. The display period (see settings) must also lie in the database read period. During the capacity evaluation you can specify another selection profile with the menu options Planning -> Profiles -> Selection profile.

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LO230 3-20

Options Profile (Capacity Evaluations) Overall profile Options profile

General settings:

Cap. Unit, Remaining requirements, planned requirements, cumulated display, load restrictions

Cumulating available capacity:

Hierarchy: Yes / no, dynamic, hierarchy name

Interval settings:

Start / end of display, period split, cumulate backlog to

Distribution of capacity requirements:

From work center, operation or profile

Goto:

Work center, branches in display / change mode

© SAP AG 1999

The options profile groups together general settings. You can change most of these settings during the evaluation with the menu options: Settings -> General. You can change the following parameters during the capacity evaluation using other menu options or a function key: yValues for the minimum and maximum load displayed in the standard overview yThe standard distribution key for work orders and networks/maintenance orders You cannot change the following parameters during the capacity evaluation: yDate for dispatching the backlog: If remaining requirements are displayed then all the requirements whose finish dates lie before the date for dispatching the backlog are dispatched to the period that contains this date. yIndicator "Production order": The indicator specifies whether you branch to production orders in display mode or in change mode. yIndicator "Planned order": The indicator specifies whether you branch to planned orders in display mode or in change mode. yIndicator "Work center": The indicator specifies whether you branch to work centers or capacities in display mode or in change mode.

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LO230 3-21

Extended Evaluation (Standard Overview)

Work center view

Indiv. capacity view

Order view

Project view

Printing Standard overview list

t

Work center

Labor

Capacity

t

Det.capacity list

© SAP AG 1999

In the extended evaluation you can display all relevant objects (persons, individual capacities, SOP requirements). You can sort all the lists in any way you like, even in groups.

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LO230 3-22

Extended Evaluation (Detailed Capacity List)

Work center view

Indiv.capacity view

Order view

Project view

Printing Det. capacity list Order

t

Work center

Person

Capacity

t

Operation

© SAP AG 1999

In the extended evaluation you can display all relevant objects (persons, individual capacities, SOP requirements). You can sort all the lists in any way you like, even in groups.

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LO230 3-23

Structure of a Profile (Extended Evaluation)

Overall Overall profile profile

Control Control profile profile

Evaluation Evaluation profile profile

Selection Selection profile profile

Filter Filter set set

Object Object set set

List List profile profile

Time Time profile profile

Period Period profile profile

Requirements Requirements grouping grouping

© SAP AG 1999

The overall profile for the extended evaluation contains six subprofiles whose settings are compatible with one another. You can maintain them in Customizing for Capacity leveling and Extended evaluation. In the selection profile you specify which sets are used for the layout of the various selection screens. In the list profile you specify which list is displayed when you access the extended evaluation. You can branch from one list to another with the menu option Goto. In the time profile you specify for what time period the capacity requirements are read from the database. The database read period, the evaluation period, the planning period and the date for dispatching the backlog are specified in the time profile. All the requirements are accessed that lie wholly or partly in the database read period. In the period profile you specify in which periods the loads are to be displayed. For example, a period can be one day, several days, one week or several weeks. In the options profile you specify the work center hierarchy name for the cumulation of available capacity and capacity requirements and the distribution key. In the control profile you specify the type of presentation and the layout of the data (here lists in period form).

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LO230 3-24

Structure of a Set (Extended Evaluation)

Multidimension Multidimension set set Object Object set set

Basic BasicSet Set

Basic BasicSet Set

Basic BasicSet Set

Basic BasicSet Set

Plant Plant

Work Work center center

CRHDWERKS CRHDWERKS

ARBPL ARBPL

Capacity Capacity category category

Cap. Cap. planner planner group group

KAPAR KAPAR

PLANR PLANR

Value Value

Variable Variable

Variable Variable

Variable Variable

1000 1000

&5KEARBP &5KEARBP

&5KKAPARV &5KKAPARV

&5KPLANRV &5KPLANRV

© SAP AG 1999

It is important to distinguish between a basic set and a multidimension set. The object set stands for a multidimension set. A multidimension set groups together several basic sets. The field names for the selection fields are defined in the basic set. You can specify values or variables for these field names. A default value can be specified for a variable for a particular field name.

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LO230 3-25

Capacity Evaluation: Summary

In this unit you have learnt about: z The procedure with overview lists in the

capacity evaluation z The structure of profiles and sets

© SAP AG 1999

(C) SAP AG

LO230 3-26

Data used in the exercises Explanation of symbols in the exercises and solutions Exercises Solutions Course Objectives Business Scenario

Tips & Tricks Warning or Attention Data in the exercises Type of data

Data in the training system

Plant

1000 and 1200

Material and routings

T-F2## and T-F1## ( T-CV )

Material and rate routing

R-1000

Product group

PG-100

Work centers

T-M##, T-V##, T-L##, T-E##, T-F##, T-P##, V## and KS##

Work center hierarchies

T-V, T-E and H-##

Pooled capacity

VOR##

Capacity category

P##

Grouping key

52

Formula parameters

LO##

Formula key

FO##

Machines

L1##, L2## and L3##

Overall profiles

Z##SFCG011, Z##SFCG002

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LO230 3-27

Z230-GES## Activity group

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SAP_LO_PP_PRODMAN

LO230 3-28

Capacity Evaluation Exercises Unit: Capacity Evaluation Topic: Standard Overview At the conclusion of these exercises, you will be able to: • Use the standard overview in the capacity evaluation • Change the display You are a capacity planner and have to show an overview of the capacity requirements versus the available capacity for your organization. To do this, you choose the standard overview in the capacity evaluation and, if necessary, switch to the cumulated display.

1-1

Look at the capacity loads for your work centers using your capacity planner group 0## in the standard overview. 1-1-1 In which evaluation period were the capacity requirements read? ______________________ 1-1-2 Specify the menu path that you would use to find this out. _____________________________________________________ 1-1-3 Change the settings in such a way that only those periods are displayed with a load greater than 40%.

1-2

Now call up the standard overview for the work center T-M##. 1-2-1 Change the display for the standard overview by defining a period as three days. 1-2-2 Specify the menu path and name the indicator for a standard overview with cumulated capacity requirements and available capacities over the entire evaluation period. ______________________________________________________ 1-2-3 Only analyze the pegged requirements in the first period. What sort of pegged requirements are there? _______________________

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LO230 3-29

Exercises Unit: Capacity Evaluation Topic: Detailed Capacity List

At the conclusion of these exercises, you will be able to: • Use the detailed capacity list in the capacity evaluation • Test various selection options • Make changes to the detailed capacity list You are a capacity planner and want to see in an overview the pegged capacities for the work centers for which you are responsible. After seeing an overview, you want to release a production order.

2-1

Call up the detailed capacity list in the capacity evaluation for your work centers T-L## and T-V##. 2-1-1 Describe the menu option for calling up the detailed capacity list directly. _____________________________________________________ 2-1-2 You want to call up the detailed capacity list for 2 special work centers. To do this you need an additional menu option. Restrict the selection of work centers on the dialog box with the entry T-*. Describe the additional menu options. _____________________________________________________

2-2

You want to be able to see which production orders are to be released, and therefore you want to copy the field "Overall order status" into the detailed capacity list after the column for pegged requirements. To ensure that the standard list is not overwritten when saving, you have to first create your own list variant in Customizing. 2-2-1 Copy the list variant SAPDETC0 in Customizing for Capacity Planning (Evaluation). Your detailed list profile should be called ZAPDETC##. Before saving, it is possible to protect this profile from being changed by other users. 2-2-2 Call up the detailed capacity list for your work centers T-L## and T-V## again. Enter a column for the ‘Overall order status’ after the column for pegged requirements. Reduce the column width for the "Overall order status" to 20 and the column width for "Material" to 8 spaces.

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LO230 3-30

Save the changes made to the detailed capacity list in your list variant ZAPDETC##. Note that the subprofile ‘SAPDETF0’ is not changed for the displayed fields. Before saving, overwrite this profile with ZAPDETF##. 2-2-3 Release the production order with the requirements quantity 80 and update the evaluation so that you can see the status change directly in the detailed capacity list. 2-2-4 Look at the detailed capacity list for your work centers T-L## and T-V## again. Switch to the list variant you saved previously to control the detailed capacity list you created.

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LO230 3-31

Exercises Unit: Capacity Evaluation Topic: Creating an Overall Profile

At the conclusion of these exercises, you will be able to: • Define an overall profile with a new entry screen

You are a capacity planner and want to use certain work centers in the entry screen for selection. You therefore create a new initial set and include this in a new overall profile. In addition, you always want to call up this overall profile automatically when you choose Evaluation -> Variable.

3-1

Create for your group an overall profile for a new initial set. You want to see the following entry fields in the initial set when you call up this overall profile: Work center from: Work center to: Capacity cat.: Capacity planner group: Plant: In addition, the work center T-V## should be set as a value. 3-1-1 In the first step create a new basic set Z230-PLZ## for the entry Work center from/to for the field name ARBPL. As descriptive text choose ##-Work center from/to. Take two variables for the entry fields and set the value T-V##. 3-1-2 In the second step create a new multidimension set Z230-EIN## for the complete initial screen. Copy this set using 5kstart1 as a reference. As a descriptive text, choose ##-Work center, CapCat, CapPl. Change the multidimension set for the entry fields according to the defaults and the sequence in 3-1. 3-1-3 Copy the selection profile SAPA010 as a separate profile with the name Z230AUS## and switch the initial set with the multidimension set created in 3-1-2. Choose ##-AUSW as a descriptive text.

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LO230 3-32

3-1-4 Copy the overall profile SAPX912 as a separate profile with the name Z230GES## and swap the selection profile with the profile created in 3-1-3. Choose ##-GES as a descriptive text. 3-1-5 You always want to call up this overall profile automatically when you choose Evaluation → Variable. Maintain your user parameters by entering your overall profile for this parameter. 3-1-6 Describe why requirements are also displayed for the work center T-V##.

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LO230 3-33

Capacity Evaluation Solutions Unit: Capacity Evaluation Topic: Standard Overview

1-1

Look at the capacity loads for your work centers using your capacity planner group 0## in the standard overview. 1-1-1 Logistics → Production → Capacity planning → Evaluation → Work center view → Load 60 days as of today 1-1-2 Specify the menu path that you would use to find this out. Settings → General 1-1-3 Change the settings in such a way that only those periods are displayed with a load greater than 40%. Settings → Evaluations → Standard overview

1-2

Now call up the standard overview for the work center T-M##. 1-2-1 Change the display for the standard overview by defining a period as three days. Settings → Evaluations and radio button Day, period duration 3 1-2-2 Specify the menu path and name the indicator for a standard overview with cumulated capacity requirements and available capacities over the entire evaluation period. Settings → General Cumulated display 1-2-3 Select Period and button Capacity detail/period

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LO230 3-34

Solutions Unit: Capacity Evaluation Topic: Detailed Capacity List

2-1

Call up the detailed capacity list in the capacity evaluation for your work centers T-L## and T-V##. 2-1-1 Describe the menu option for calling up the detailed capacity list directly. Evaluations → Work center view → Orders 2-1-2 You want to call up the detailed capacity list for 2 special work centers. To do this you need an additional menu option. Restrict the selection of work centers on the dialog box with the entry T-*. Describe the additional menu options. Planning → Selection → Work center Once you have specified the restrictions choose Detailed selection

2-2

You want to be able to see which production orders are to be released, and therefore you want to copy the field "Overall order status" into the detailed capacity list after the column for pegged requirements. To ensure that the standard list is not overwritten when saving, you have to first create your own list variant in Customizing. 2-2-1 Copy the list variant SAPDETC0 in Customizing for Capacity Planning (Evaluation). Your detailed list profile should be called ZAPDETC##. Before saving, it is possible to protect this profile from being changed by other users. Tools → Accelerated SAP → Customizing → Edit Project. Button Enterprise IMG. Production → Capacity planning → Evaluation → Lists → Define list variants for capacity detail list. Copy SAPDETC0 into ZAPDETC##.

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LO230 3-35

2-2-2 Call up the detailed capacity list for your work centers T-L## and T-V## again. Enter a column for the ‘Overall order status’ after the column for pegged requirements. Reduce the column width for the "Overall order status" to 20 and the column width for "Material" to 8 spaces. Save the changes made to the detailed capacity list in your list variant ZAPDETC##. Note that the subprofile ‘SAPDETF0’ is not changed for the displayed fields. Before saving, overwrite this profile with ZAPDETF##. Choose Choose fields. Choose Overall order status and transfer it to the list Selected fields. Select Overall order status and place the cursor on the line material. Press Move. Change the column width for the Overall order status and for Material and save this list under your list variant name. Settings→ Capacity detail → Save list variant 2-2-3 Release the production order with the requirements quantity 80 and update the evaluation so that you can see the status change directly in the detailed capacity list. Double-click on the order number and in the order header choose Release and Save. Press Refresh. 2-2-4 Look at the detailed capacity list for your work centers T-L## and T-V## again. Switch to the list variant you saved previously to control the detailed capacity list you created. Call up the capacity detail list again and go to your list variant. Settings→ Capacity detail → Get list variant

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LO230 3-36

Solutions Unit: Capacity Evaluation Topic: Creating an Overall Profile

3-1

Create for your group an overall profile for a new initial set. You want to see the following entry fields in the initial set when you call up this overall profile: 3-1-1 In the first step create a new basic set Z230-PLZ## for the entry Work center from/to for the field name ARBPL. As descriptive text choose ##-Work center from/to. Take two variables for the entry fields and set the value T-V##. Customizing Capacity Planning → Evaluation → Selection set → Define sets. Create set. For the variables, place the cursor in the entry field and press Variable. 3-1-2 In the second step create a new multidimension set Z230-EIN## for the complete initial screen. Copy this set using 5kstart1 as a reference. As a descriptive text, choose ##-Work center, CapCat, CapPl. Change the multidimension set for the entry fields according to the defaults and the sequence in 3-1. Change the copied multidimension set as follows: Substitute the set in line 001 Insert the set 5KKAPARV before line 002 3-1-3 Copy the selection profile SAPA010 as a separate profile with the name Z230AUS## and switch the initial set with the multidimension set created in 3-1-2. Choose ##-AUSW as a descriptive text. Customizing capacity planning → Evaluation → Profiles → Define selection profiles. 3-1-4 Copy the overall profile SAPX912 as a separate profile with the name Z230GES## and swap the selection profile with the profile created in 3-1-3. Choose ##-GES as a descriptive text. Customizing Capacity Planning → Evaluation → Profiles → Define overall profiles.

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LO230 3-37

3-1-5 You always want to call up this overall profile automatically when you choose Evaluation → Variable. Maintain your user parameters by entering your overall profile for this parameter. System → User parameters → Own data. Tab card parameters. Assign the value from your profile to parameter CY7. 3-1-6 Describe why requirements are also displayed for the work center T-V##. The work center was also specified as a value in the basic set.

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LO230 3-38

Capacity Leveling (Part 1)

Contents: z Use of the capacity planning table (tabular form) z Dispatching procedure z Preview of the capacity planning table

© SAP AG 1999

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LO230 4-1

Capacity Leveling (Part 1): Objectives

At the conclusion of this unit you will be able to: z How to use the leveling functions on the

planning tables.

© SAP AG 1999

(C) SAP AG

LO230 4-2

Capacity Evaluation Introduction Overview


Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699


© SAP AG 1999

(C) SAP AG

LO230 4-3

Capacity Leveling (Part 1): Business Scenario

z In your production you want to level the capacity loads at the resources. To do this you compare the capacity requirements with the available capacity using the capacity leveling functions. First capacity leveling should be carried out with the tabular version of the planning table. After simulating several dispatching runs you save the results of your planning and thus fix the capacity requirements for processing in the planned period.

© SAP AG 1999

(C) SAP AG

LO230 4-4


Basic data

Production planning

A Material

PM / PS



Bill of material

10

20

Arbeitsplan Routing TskLst

30

40

50

Scheduling

C1

10 Center 1 20 30

t


Calendar

4

Capacity leveling/-evaluation

t

Available capacity

© SAP AG 1999

Dispatching operations is the main function in capacity planning. Operations are dispatched to fix them at a time when there is sufficient capacity for them to be executed. Depending on whether finite scheduling is to take place, operations can be dispatched based on an unlimited available capacity or existing available capacity. The existing available capacity is equal to the difference between the available capacity maintained in the work center and the capacity requirements already dispatched. If necessary, you can specify a different work center when dispatching.

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LO230 4-5

Capacity Leveling Measures

Increase available capacity

Alternative work center

Date shift

Sequence planning

External processing

Lot reduction / splitting

© SAP AG 1999

There are the following ways to achieve the objectives listed in the preceding slide: y Adjust the available capacity by increasing the standard available capacity for the relevant capacity category or increase the available capacity by inserting an interval of available capacity. y Determine an alternative work center with remaining available capacity, for example by calling up the planning table using a work center hierarchy. y Find a period with sufficient remaining available capacity by dispatching using finite scheduling or manually on the planning table. y Form optimal sequences to reduce setup times. You can only reduce/split the lot size or specify that operations are to be processing externally in the production order.

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LO230 4-6

User Interface for Capacity Leveling

Capacity planning table (tabular) tabular)

Capacity planning table

Work center: Turning capacity: Machine 06.00 05.1998

06.1998

10.00

14.00

18.00

07.1998

Avail. cap. Dispatched Pool Order 100012 Operation 0010 Start 03.05.1998 Order 100014 Operation 0020 Start 15.05.1998 Order 100234 Operation 0030 Start 06.06.1998 Order 100333 Operation 0010 Start 09.05.1998 Order 100456 Operation 0050 Start 01.05.1998

© SAP AG 1999

The capacity planning module offers two interfaces. The main capacity planning module and its various views. y Work center view: You limit the selection for specific work centers. Work centers and capacities are displayed in the planning tables. y Individual capacity view: You limit the selection for specific work centers. You can dispatch operations both to work centers/capacities and to the corresponding individual capacities. y Order view: You limit the selection for specific orders. All the work centers and capacities affected are displayed for one or more orders. Leveling directly from production order maintenance. Depending on the overall profile set for the production controller/order type you branch to one of the two planning tables. If no overall profile has been stored for the production scheduler then the planning table is called up using the overall profile SAPSFCG001.

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LO230 4-7

Capacity Planning Table (Tabular Form) z Period-specific z Aggregate information on available capacity, capacity requirements and capacity load z Distribution of capacity requirements by distribution keys

z Important for shareable capacities

X

Period Avail.cap. Dispatched Pool X

08.1998

09.1998

10.1998

8,0 24,0 16,0 8 33% 2 8,3% 6,5 81,2%

6,5h

Pump

13,0h

Washer

11.1998

12.1998

32,0

16,0

z Display actual capacity load within a period

© SAP AG 1999

There are the following types of display on the capacity planning table (tabular form): y Work center/capacity with available capacity, load, dispatched and pool for several periods y Several work centers/capacities with available capacity and load for several periods The planning table (tabular form) can be called up for the work center view, the individual capacity view and the order view. Available capacities and distributed capacities are displayed. The unit of display for the available capacity and capacity requirements is stored in the evaluation profile. The planning table (tabular form) is divided up into a resource section and a requirements section. The resource section contains the following: name of work center or capacity and capacity category, periods to which operations can be dispatched, capacity requirements from operations that have already been dispatched to a period, capacity requirements from operations that have not yet been dispatched to a period In the requirements section you can display requirements (dispatched and/or not yet dispatched).

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LO230 4-8

Capacity Planning Table

Work centers Work center

00:00

Monday 06:00

12:00

18:00

00:00

Tuesday 06:00

18:00

00:00

Tuesday 06:00

Chart

14100 Lathe 14200 Lathe

Pool Op.

Qty

2010 0010

10

2020 0020

5

2030 0010

10

00:00

Monday 06:00

12:00

Chart

Order

Message line Table section

Diagram section

© SAP AG 1999

- The capacity planning table enables you to carry out detailed planning of capacity requirements continuously over time. - The capacity planning table consists of several charts in which the available capacity (operating time) and the capacity requirements (operation duration) are grouped according to various criteria and can be displayed on the same axis. For example, all the capacity requirements for one order or all the capacity requirements that have been dispatched to one capacity can be grouped together. - Each chart can have its own title bar and is made up of a table section and a diagram section: y The table section contains information for identifying and describing the objects displayed in the diagram section. y The diagram section has a window on the virtual time axis in which the available capacity and the capacity requirements are displayed in graphical form with the start and finish date. This window displays the same section for all the charts. This section can be changed as much as you like by altering the scale.

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LO230 4-9

Dispatching

Available capacity

Capacity load

Pool Order - 1 Order - 2

© SAP AG 1999

Automatic or manual dispatching of orders to times with remaining available capacity. Automatic as well as manual dispatching using planning strategies. Orders with dispatched operations are scheduled using midpoint scheduling.

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LO230 4-10

Dispatching Procedure

Determining the dispatching date - by scheduling or manually by the user Specifying the dispatching sequence - when dispatching several operations at the same time Carrying out checks when dispatching - checking dates and work center Executing finite scheduling Checking results of dispatching - Operation date -

Writing a planning log

Setting the status "dispatched" Executing midpoint scheduling

© SAP AG 1999

The central function of capacity leveling is the dispatching of operations. Operations are dispatched so as to fix them at a point in time when there is sufficient capacity for them to be carried out. If you have set the indicator Finite scheduling in the strategy profile then the system looks for remaining available capacity depending on the planning direction. During dispatching the user can enter another work center, if necessary. The work center may not be locked or marked for deletion. A planning log is written for all planning activities. If errors arise during dispatching then it can be terminated (you can set this in the strategy profile). Midpoint scheduling is dealt with in detail in the unit Capacity leveling part 2.

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LO230 4-11

Types of Dispatching (tabular)

Capacity planning table (tabular)

Select operation

Dispatch manually 1

Select operation, capacity and period

Select operation

Dispatch

Dispatch

2

3

Select operation Manual dispatching by dragging and dropping to desired point in time 4


© SAP AG 1999

This graphic shows the four possible ways of determining the dispatching date. The third way distinguishes between internally processed operations (plant maintenance and networks) and operations that are subdivided into operation segments (production order): internally-processed operations corresponding to the strategies: y earliest / latest start date y depending on distribution keys operations with operation segments always with the latest start date for the operation In the first way you can also change the date, time and work center. The fourth way of dispatching is only possible on the capacity planning table as is dealt with in detail in the unit Capacity leveling part 2. If operations are not to be automatically dispatched on the planning table (tabular form), then you should set the indicator Date entry on dispatching in the strategy profile. In this case a dialog box is displayed for entering the time for the function Dispatch.

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LO230 4-12

Capacity Leveling (part 1): Summary

z In this unit you can dispatch operations to the

capacity planning table (tabular form).

© SAP AG 1999

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LO230 4-13

Capacity Leveling (Part 1) Exercises Unit: Capacity Leveling (Part 1) Topic: Capacity Planning Table (tab.)

At the conclusion of these exercises, you will be able to: • Execute capacity leveling with the capacity planning table (tabular form)

You are a capacity planner and want to simulate capacity leveling for particular work centers using the capacity planning table (tabular form), and only save the finished results.

1-1

Carry out capacity leveling with the capacity planning table (tabular form) for the work centers T-M##, T-V## and T-L##, only for capacity category 002. 1-1-1 Call up the capacity planning table (tabular form) from the work center view and specify your three work centers. Pay particular attention to the selection criteria for the other input fields. 1-1-2 Before you press Continue, save the selection criteria you entered as a variant. Use V-## as a variant name and group ## as the meaning. 1-1-3 Look for the capacity requirements for work center T-V## and switch the view to display just one requirements type. 1-1-4 To see the latest start dates for the capacity requirements in the lower chart switch to a wide screen display for the planning table. 1-1-5 Dispatch the operation with an operation quantity of 120 pieces. 1-1-6 Display only those requirements that have been dispatched. 1-1-7 Display all the requirements again and dispatch another operation 20 with the operation quantity of 100 pieces to work center T-L##. 1-1-8 Look at the planning log and analyze the planning situation at the work center T-L##. 1-1-9 Go from the capacity planning table (tabular version) to the production order and look at the operation status. Now save the results of your simulated planning.

(C) SAP AG

LO230 4-14

1-2

(C) SAP AG

Call up the capacity planning table from the work center view for the work center TV## and compare the planning result with the result saved on the capacity planning table (tabular form).

LO230 4-15

Capacity Leveling (Part 1) Solutions Unit: Capacity Leveling (Part 1) Topic: Capacity Planning Table (tab.)

1-1 1-1-1 Call up the capacity planning table (tabular form) from the work center view and specify your three work centers. Pay particular attention to the selection criteria for the other input fields. Leveling → Work center view → Capacity planning table (tabular form). Press the arrow multiple selection to enter your work centers. 1-1-2 Before you press Continue, save the selection criteria you entered as a variant. Use V-## as a variant name and group ## as the meaning. Goto → Variants → Save as variant 1-1-3 Look for the capacity requirements for work center T-V## and switch the view to display just one requirements type. Settings → Change view. Scroll to work center T-V## 1-1-4 To see the latest start dates for the capacity requirements in the lower chart, switch to a wide screen display for the planning table. Settings → Screen type → Wide screen 1-1-6 Display only those requirements that have been dispatched. Settings → Requirements filter → Dispatched requirements 1-1-8 Look at the planning log and analyze the planning situation at the work center T-L##. Button Planning

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LO230 4-16

Available Capacity

Contents: z Options for maintaining available capacity z Factory calendar z Work center hierarchy z Configuration sequence

© SAP AG 1999

(C) SAP AG

LO230 5-1

Available Capacity: Objectives

At the conclusion of this unit you will be able to: z Maintain available capacities z Maintain and assign shift sequences

© SAP AG 1999

(C) SAP AG

LO230 5-2



Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / order


18752

500-300

600001650

100-500

18770

500-300

600001699

Extended planning functions Detailled planning Integration

© SAP AG 1999

(C) SAP AG

LO230 5-3

Available Capacity: Business Scenario

z You have made capacity available in production. This depends on the plant calendar which is definable differently for every work day. Therefore you use intervals at capacities to increase the availability capacity for periods where requirements are high. You can maintain this manually or by using shift sequences.

© SAP AG 1999

(C) SAP AG

LO230 5-4


Basic data

Production planning

A Material

PM / PS



Bill of material

10

20

Arbeitsplan Routing TskLst

30

40

50

Scheduling

C1

10 Center 1 20 30

t


Calendar

4

Capacity evaluation/-leveling

t

Available capacity

© SAP AG 1999

The available capacity is the work that can be done by a capacity at a work center per working day. The available capacity is defined by the start and finish of work, the duration of the breaks, the capacity utilization and the number of machines or persons.

(C) SAP AG

LO230 5-5

Capacities at a Work Center

Work center

Capacity categories

Work center

Pooled capacity Energy Cap.

Scrap Machine Transport

Work center

Labor Storage location

Cap. Machine Labor

© SAP AG 1999

You can allocate as many capacities as you like to a work center. Capacity categories serve to identify capacities belonging to the same category. A capacity category can only be allocated once per work center. You can maintain a separate available capacity for each capacity category. If a capacity is allocated to several work centers then it is a pooled capacity. It must be maintained as a pooled capacity separately before it is allocated to a work center. To calculate capacity requirements formulas must be allocated in the capacity overview. To simplify maintaining capacities you can set up a default capacity in Customizing.

(C) SAP AG

LO230 5-6

Available Capacity at the Work Center

Capacity

Default capacity

Plant: Capacity: Cap.cat.:

1000 ABC 003

Default values for every capacity category For example: 001

Reference available cap. Work center Capacity cat.: Capacity:

003 ABC

Capacity cat.:

001

Capacity cat.: Capacity:

002 Group

Pooled capacity Plant: 1000

Capacity: Group

Capacity cat.: 002

© SAP AG 1999

The reference indicator is set for the available capacity of a pooled capacity in the work center and so cannot be changed there. The available capacity of an external capacity as well as that of a default capacity is copied to a capacity category at a work center and can be changed. However, an external capacity can also be referenced.

(C) SAP AG

LO230 5-7

From Work Time to Operating Time Number of hours

Time:

Work time: 7:00 - 16:30

Data at Work start work center Work finish

Break times

Technical and organizational disruptions

Work time: minus breaks

Work center

Productive work time

Operating time Efficiency per shift rate

Productive operating time

Work center Operating time per capacity category

X

Number of individual capacities

© SAP AG 1999

The basic work time (start of work until end of work) at a work center is reduced by break times and organizational disruptions. The work time minus the break times is stored in the work center as the operating time per shift. Technical and organizational disruptions are reflected in the efficiency rate.

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LO230 5-8

Maintaining Available Capacity using Shift Sequences

Day 1

Day 2

...

Day 5

Shift definition Shift 1

Shift 1

Shift 1

Start of work ...

End of work

Shift sequence

Breaks Shift 2

Shift 2

Shift 3

Shift 3

Shift 2

Labor

© SAP AG 1999

Shift sequences and shift definitions can be used to maintain available capacity in detail for every capacity category, but only by using intervals of available capacity. Shift sequences and shift definitions can be created and selected for specific parts of Customizing using the Grouping key. In a shift sequence you can define work start, work finish and break times for all work centers. In shift sequences the specific sequence of shift definitions is maintained for all work centers. You can automatically change available capacities that have shift definitions by changing the shift definition.

(C) SAP AG

LO230 5-9

Available Capacity in the Work Center

h

Interval 1

Not a work day according to factory caledar

Standard available capacity Time

h Interval 1

Interval 2

Interval 3

Time from

Cycle duration

to

Interval duration © SAP AG 1999

An interval of available capacity has a temporal validity. By adding an interval for a particular period (date from/to) the standard available capacity for this period is overwritten by a second interval. If this second interval is deleted again then the following interval is brought forward to the date of the interval that has been deleted.

(C) SAP AG

LO230 5-10

Available Capacity/Maintenance Variants

Standard available capacity

Interval without shift sequence

Interval with shift sequence

Shifts not possible !

Shifts possible !

Shifts useful !

Screen

:

Capacity header

Interval of available capacity

Interval of available capacity

Version

:

Blank

automatic 01..... Activate !

automatic 01..... Activate !

Breaks

:

Globally per work day

Globally per shift

In detail per shift

Validity

:

Work days according to factory calendar

from/to (any specification of work days)

from/to (any specification of work days)

Central maintenance

:

Reference capacity

Reference capacity

Reference capacity, shift sequence

Interval cycle

:

1 Work day

1 or 7 work days

automatically = 7 W D

© SAP AG 1999

You can maintain the available capacity in various ways. You can interrupt the validity of the available capacity (standard available capacity) by using an interval of available capacity with a limited validity period. You can maintain intervals of available capacity using shift sequences.

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LO230 5-11

Maintaining and Assigning Factory Calendar

1.

Maintaining holidays

2.

Maintaining holiday calendar

3.

Maintaining factory calendar

4.

Assigning factory calendar

Definition holiday 1

Definition holiday 2

...

Definition holiday n

Definition Holiday calendar ID: 08 holiday 1 ... holiday n

Definition Factory calendar ID: 01 Holiday calendar ID 08 Definition plant-/holidays per week Special rules

Plant 1000

Work center/capacity

© SAP AG 1999

Capacities at work centers only have available capacity on work days. To calculate the available capacity a plant calendar must be maintained that clearly defines the work days. Plant calendars are maintained in Customizing and one can be assigned to a plant or to any particular capacity if it is different from that of the plant.

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LO230 5-12

Work Center Hierarchy

Manufacturing

Turning Lathe machines in company

Manufacturing plant 1

Lathe shop

Paint shop

Capacity

Milling shop

Machine t

Lathe machine in plant 2

Lathe machine in laboratory

Machine t

Machine t

Capacity

Capacity

Capacity Machine t

Capacity

Lathe machines

Capacity

NClathe machine

Lathe machines in plant 1

Machine t

Machine t

© SAP AG 1999

You can place work centers in work center hierarchies. You can have as many work center hierarchies as you wish. Work center hierarchies serve to cumulate available capacities and capacity requirements in capacity planning. A work center can be assigned to several hierarchies. On this slide lathe machines are assigned to a hierarchy called manufacturing and to a hierarchy called turning.

(C) SAP AG

LO230 5-13

Configuration Sequence Capacitiy Planning (2)

M Maintaining and cumulating available capacity K K

Creating work center hierarchy Setting up requirements distribution

D Profiles for capacity evaluations D Profiles for capacity leveling / extended evaluations

© SAP AG 1999

A prerequisite for maintaining available capacity is that capacity categories must be created in Customizing. Labor capacity categories must be defined as such. To facilitate maintaining available capacity at work centers you can create a default work capacity for each plant and capacity category. To cumulate available capacities at a hierarchy work center there must be a period pattern key. Legend: M = Mandatory action (Mandatory) O = Optional action (Optional) D = Action performed by default setting

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LO230 5-14

Shift Sequences and Shifts

MAS

PER

Shift sequence Shift grouping

Reserved area for PP application 51 to 99

Shift

1 2 3

Shift definition per day

1

2

3

4

5

6

7

Shift definition Validity period, -rules (HR) Start of work/-finish Work break schedule

Work break schedule Start/finish of break Duration of break, according to number of hours © SAP AG 1999

The tables used for the management of shift sequences, shift definitions and work break schedules are also used in the application HR. Breaks are represented using work break schedules and are used in shift definitions. The argument shift grouping is used to distinguish between table entries for the applications PP and HR. The groupings 51 .... 99 have been defined for PP.

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LO230 5-15

Available Capacity: Summary

z This unit has shown you how to maintain

available capacities at work centers and how to use work center hierarchies.

© SAP AG 1999

(C) SAP AG

LO230 5-16

Available Capacity Exercises Unit: Available Capacity Topic: Maintain Available Capacity

At the conclusion of these exercises, you will be able to: • Maintain a work center with available capacity.

You require a new work center in your organization and want to maintain the available capacity for a capacity category Machine and a capacity category Person at the work center.

1-1

Create a work center for pre-assembly with the following data: Plant:

1000

Work center number:

V##

Work center category:

0001

Work center description: Assembly-## Person responsible:

0##

1-1-1 When you create the work center with the capacity category 0001, copy the default values for task list usage, standard value key, control key, and the data for cost center assignment. Save the work center. 1-1-2 Change the work center and for both capacity categories replace the planner group with your capacity planner responsible (0##). 1-1-3 Maintain an available capacity that deviates from the standard available capacity for capacity category 001 for the coming two weeks. There should be two shifts from Monday to Thursday. On Friday, there should be a shift from 8:00 – 16:00, with a 1 hour break. Do not use a shift sequence for this interval of available capacity. For the available capacity from Monday to Thursday use the possible entries function for the shift definitions. Analyze the available capacity profile for the capacity category 001.

(C) SAP AG

LO230 5-17

Assign your work center to the work center hierarchy T-V in the plant 1000. The superior work center is T-VH. Look at the hierarchy as a structure and as a graphic.

(C) SAP AG

LO230 5-18

Exercises Unit: Available Capacity Topic: System Settings

At the conclusion of these exercises, you will be able to: • Create a capacity category • Create and use a shift sequence

For some of the work centers in your organization, the same capacity is not available on each working day. You therefore maintain for these work centers a special available capacity that you can use for the available capacity maintenance for all capacity categories.

2-1

Maintain a new capacity category for the category Person. The key for the capacity category is P##, and as description you use the group ##.

2-2

Create a shift sequence for the grouping 52 with the shift schedule PA1. The grouping 52 and the shift schedule PA1 were already created during the course. 2-2-1 First maintain a shift definition for an early and a late shift with the following data: Early shift valid from today until 9999 with the following key: ##F Text: 1. shift ##

Start: 05:00

Finish: 13:00

Late shift valid from today until 9999 with the following key: ##S Text: 2. shift ##

Start: 13:00

Finish: 21:00

2-2-2 Create a shift sequence with the description PR##. For Monday until Saturday, use the early shift created in exercise 2-2-1, and for Monday until Friday, the late shift. 2-2-3 Enter a pooled capacity for the capacity category P## from exercise 2-1. The description should be VOR##, and the text Person responsible for setup ##. This pooled capacity is in Germany (Baden-Württemberg) and work should take place 6 days a week. The base unit of measure is hours. The start time is 7.00, and finish is 16.00. The utilization rate is 90% and there are 2 employees available. Instead of the work time in the standard available capacity, you (C) SAP AG

LO230 5-19

assign this pooled capacity an interval for the next two years using the shift sequence from exercise 2-2-2. 2-2-4 As an additional available capacity, you assign the work center V## the pooled capacity VOR##.

(C) SAP AG

LO230 5-20

Available Capacity Solutions Unit: Available Capacity Topic: Maintain Available Capacity

1-1 1-1-1 Use the default values when creating the work center with the work center category 0001. Save the work center. Logistics → Production → Master data → Work centers → Work center → Create. Call up all the detail screens using the Next screen button. 1-1-2 Change the work center and for both capacity categories replace the planner group with your capacity planner responsible (0##). Work center → Change. Capacities button. Overwrite the capacity planner group for every capacity category in the header data. 1-1-3 Maintain an available capacity that deviates from the standard available capacity for capacity category 001 for the coming two weeks. Intervals button. Insert Button. Cycle duration 7 and number of shifts 2 1-1-4 Assign your work center to the work center hierarchy T-V in the plant 1000. Goto → Hierarchy → Sequences Edit → New entries Goto → Hierarchy → Structure Graphic button

(C) SAP AG

LO230 5-21

Solutions Unit: Available Capacity Topic: System Settings

2-1

Maintain a new capacity category for the category Person. Customizing: Production → Basic data → Work center → Capacity planning → Define capacity category New entries Set indicator CapCatPer

2-2

Create a shift sequence for the grouping 52 with the shift schedule PA1. Customizing: Work center → Capacity planning → Available capacity → Define shift sequence Select grouping 52 and select Shift definitions 2-2-2 Enter a pooled capacity for the capacity category P## from exercise 2-1. Area menu Work center: Capacity → Create Pooled capacity indicator Grouping 52 Choose the factory calendar ID W6 2-2-4 As an additional available capacity, you assign the work center V## the pooled capacity VOR##. Work center → Change. Capacities button Create capacity Button Enter the capacity category P## and the pooled capacity VOR##.

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LO230 5-22

Capacity Requirements and Reduction

Contents: z Views of capacity requirements z Formulas z Ways of reducing the load

© SAP AG 1999

(C) SAP AG

LO230 6-1

Capacity Requirements and Reduction: Objectives

At the conclusion of this unit you know how to: z Call up the capacity requirements for the various pegged requirements. z Reduce or delete capacity requirements.

© SAP AG 1999

(C) SAP AG

LO230 6-2



Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2

Available capacity

Capacity reqmts / -reduction Arbeitsplätze Jun' 98 Material

Scheduling

Jul' 98

Auftrag / order


18752

500-300

600001650

100-500

18770

500-300

600001699


© SAP AG 1999

(C) SAP AG

LO230 6-3

Business Scenario

z You want to generate capacity requirements for the various planning levels in your company (SOP, MRP, SFC, ..). You want to calculate them using the various scheduling instruments and with the appropriate formulas for the capacities affected. Once the operation has been processed you want to confirm the work done to reduce the capacity requirements. For orders that do not have to be executed the capacity requirements automatically deleted by the cancelling order.

© SAP AG 1999

(C) SAP AG

LO230 6-4


Basic data

Production planning

A Material

PM / PS



Bill of material

10

20


30

40

50

Scheduling

C1

10 Center 1 20 30

t


Calendar

4

Capacity evaluation/evaluation/-leveling

t

Available capacity

© SAP AG 1999

The capacity requirements are the work that arises at a capacity at a specific point in time because of the individual orders. The capacity requirements are generated by lead time scheduling. The following pegged requirements are dealt with in the course: y SOP order y Simulated requirements for long-term planning y Planned order y Production order y Run schedule header Other pegged requirements include networks, inspection orders, maintenance orders and process orders. These capacity requirements are dealt with in the relevant applications.

(C) SAP AG

LO230 6-5

Planning Levels

SOP

MRP / MPS

Rough-cut planning REM

Production-rate planning SFC

Detailed planning

© SAP AG 1999

Capacity requirements can be generated for the various scheduling levels in different applications, that is, on different planning levels. The capacity requirements that have been generated for a product in an application at a particular point in time as a result of detailed-, production rate- and rough-cut scheduling exist in the system in parallel. You can look at the capacity requirements separately on every level. When a planned order is converted to a production order the production order is rescheduled and the planned order is deleted. The capacity requirements for rough-cut planning and rate-based planning are in this case copied to the production orders. Rough-cut planning is a long-term, aggregate planning. It is period-oriented and uses rough-cut planning profiles. Production-rate planning is appropriate for medium-term, period-oriented planning and uses a rate routing. Detailed planning is appropriate for the short-term and uses a routing which means that you can plan is for specific points in time.

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LO230 6-6

Determining Capacity Requirements

Work center z Formula key z Formula constants

Operation z Standard values

Setup time Processing time z Teardown time z Number of splits z Control key z z

Formula

Setup

Processing Teardown

Capacity requirements © SAP AG 1999

To determine capacity requirements, capacity requirements records are written for every operation and every capacity. Every capacity requirements record contains the dates and the requirements for setup, processing and teardown.

(C) SAP AG

LO230 6-7

Formulas

Execution time

Costing

z Setup z Processing

z Setup z Machine

z Teardown z Work (PS)

z Labor z Work (PS)

Formulas z Command lines (ABAP) z Generate z Scheduling (Y/N)

Capacity requirements (per capacity category) z Setup z Processing z Teardown

z Capacity reqmts z Costing

(Y/N) (Y/N)

PRT

z PRT z Required quantity z Usage value

z Work (PS)

© SAP AG 1999

Every capacity at the work center can be assigned formulas for calculating the capacity requirements. The formulas can be used for various functions (capacity requirements, scheduling, costing). "Generate" controls the immediate code generation for the formula. If no generation takes place in formula maintenance then it is generated at the time of execution. A formula can consist of a maximum of 3 lines with the following operation: +, -, *, /, SIN, COS, DIV, MOD, SQRT, EXP, LOG. The units of measure are converted automatically.

(C) SAP AG

LO230 6-8

Link between Formula and Standard Values

Standard value keys

Other origin z General operation values

V1

V2

e.g. no. of splits, lot size z User fields from operation z Work center constant z Values from PRT

...

Formula parameters Setup Setup

F1

Machine Machine

F2

Labor Labor

F3

Teardown Teardown

The formula definition F3 is missing the parameter for teardown.

... ...

...

Formula definition © SAP AG 1999

The formula definitions for calculating the execution time and the capacity requirements are stored in the work center. The formulas themselves are stored in Customizing as formula definitions. The parameters used in the formula definitions must first be maintained in Customizing as formula parameters. The standard value key defines the entry fields for the standard values in the operation. The standard values entered in these fields are used to calculate the execution time and the capacity requirements.

(C) SAP AG

LO230 6-9

Setting up a Formula

Formula parameters z Parameter ID z Parameter origin

z General operation value z Work center constant

Parameter attributes z z z z z

Origins

(short/long) Keyword (T006) Dimension Standard value (fixed) UMeas stnd value (operation) Field name

z Standard value from operation z User field from operation z Value from PRT assignment z PRT constant z General formula constant

Formula definition z Define z Generate z Test

(CR04)

© SAP AG 1999

The parameters are distinguished by their origin. You can define the following origins for a parameter in Customizing: y General operation value: The parameter is assigned a field directly from the general operation data. The value of this field goes into the formula. Typical fields are lot size, basis quantity, number of splits and the number of employees. y Work center constant: The parameter is assigned a fixed value in the work center and this value goes into the formula. y Standard value: A standard value is assigned to the parameter that goes into the formula. The assignment is by means of the standard value key. y User field from operation: The parameter is assigned a user-specific data field for the operation. y Value from PRT assignment: This may involve both the quantity and the usage value of the PRT. This parameter can only be used for formulas in the context of PRT management. y PRT constant: The parameter is assigned a fixed value in the PRT master. y General formula constant: This parameter can be assigned a value that is then copied to the application.

(C) SAP AG

LO230 6-10

Examples of Formulas

Formula parameters

Formula for periodic setup

SAP_01 SAP_02 SAP_03 SAP_08 SAP_09 SAP_11 SAP_04 SAP_05 SAP_xx

Operation value setup Operation value machine Operation value labor Base quantity Operation value Operation splits Var.standard value 1 (teardown) Var.standard value 2 (per.setup) Setup branch

SAP_02 x SAP_09 + SAP_05 x ((SAP_09-1) / SAP_xx) SAP_08

© SAP AG 1999

Please note: The operation value must have the same dimension as the setup branch.

(C) SAP AG

LO230 6-11

Unit T T T Q Q Q T T Q

Capacity Reduction

Manual entry

BDE data transfer

Order confirmation Order status

Set status Lock Technically close Deletion flag

Op. 10 20 30 . . .

Confirmation data Individual confirmation Collective confirmation

Type of confirmation Standard confirmation Milestone confirmation Summary confirmation

© SAP AG 1999

Capacity requirements are reduced or deleted by order confirmation, setting one of the statuses "Lock" or "Technically complete" or settings the deletion indicator. The following confirmations lead to a change in the capacity requirements: y Confirming quantities y Confirming forecast standard values y Confirming to another work center

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LO230 6-12

Determining Remaining Capacity Requirements

Planned quantity Actual quantity 150 pieces 100 Stück

Standard value

Forecast value for work done

OR

Forecast standard value

Formulas per capacity category KBED = Setup + Lot size x Maschine time Remaining capacity requirements 50 pieces x 0.1hours / piece = 5 hours

© SAP AG 1999

Remaining capacities are determined using a corrected standard value. The remaining standard value for setup is set to zero after the first confirmation. The remaining standard value for teardown is set to zero with the final confirmation. All other remaining capacities can only be deleted by setting the remaining quantity to zero or the forecast quantity to zero.

(C) SAP AG

LO230 6-13

Capacity Requirements and Reduction: Summary

z This unit dealt with the capacity requirements

for the various pegged requirements and the capacity reduction.

© SAP AG 1999

(C) SAP AG

LO230 6-14

Capacity Requirements and Reduction Exercises Unit: Capacity Requirements and Reduction Topic: Create Formula

At the conclusion of these exercises, you will be able to: • Create a formula for a 50% reduction of capacity requirements. • Test the formulas you created In your organization, the people responsible for setup represent a bottleneck in some areas. You therefore want to determine the capacity requirements as a percentage of productive processing time for the work done by those responsible for setup.

1-1

Create a formula for a 50% reduction of capacity requirements. 1-1-1 Define a new formula parameter LO## with the origin General formula constant and maintain the attributes as follows: Keyword: Percentage (in both lines) Dimension:

AAAADL (no dimension)

Standard value:

0,5

Standard value unit:

%

1-1-2 Maintain a formula definition for a 50% reduction of the labor requirements with the formula key FO##. To simplify creating a formula, you can copy a similar formula definition and change it.

1-1-3 Maintain this formula definition in the capacity overview for the capacity category P## in the work center V## in the field Processing formula. 1-1-4 Check the formulas for the capacity category with the function Test formula.

(C) SAP AG

LO230 6-15

Exercises Unit: Capacity Requirements and Reduction Topic: Capacity Requirements and Reduction

At the conclusion of these exercises, you will be able to: • Execute capacity requirement reduction by confirming to another work center or by locking an order.

To achieve exact capacity planning in your organization, you want to confirm the work done. If the work center to which the load was assigned for processing is not available due to machine breakdown, you can confirm the work done at the alternative work center. The confirmation of work done and the cancellation of the capacity requirements that are no longer required leads to a reduction in the capacity requirements determined. 2-1

Call up the capacity planning table using the work center T-M##. Create a production order with the order type PP01 for material T-F2## with a quantity of 500 pieces and a delivery date of four weeks in the future. Save the planning.

2-2

Look at the capacity loads at the work centers with overloads in the whole of your area of responsibility. 2-2-1 What options do you have to solve this problem? Write down the better option first. _____________________________________________________ _____________________________________________________ 2-2-2 Which work centers have an overload? Make a note of the work centers with the highest load first. __________

(C) SAP AG

LO230 6-16

__________

__________

__________

2-3

In exercise 2-2-2, you found out which work center has the greatest load. Only look at the capacity requirements for the first period with a load for this work center on the capacity planning table (tabular form) and describe how you could level this overload, particularly on the planning table. ___________________________________________________________ ___________________________________________________________ ___________________________________________________________ ___________________________________________________________

2-4

From which capacity planning instrument can you confirm operations? ___________________________________________________________

2-5

(C) SAP AG

You achieved a result in exercise 2-4 and want the overload in the work center T-M## to be processed by another work center. Confirm the operation with the operation quantity 80 at work center T-V## and look at the changed capacity requirements at the work center T-M##.

LO230 6-17

Capacity Requirements and Reduction Solutions Unit: Capacity Requirements and Reduction Topic: Create Formula

1-1

Create a formula for a 50% reduction of capacity requirements. Customizing: Work center → Capacity planning → Work center formulas → Define formula parameters for work centers 1-1-2 Maintain a formula definition for a 50% reduction of the labor requirements with the formula key FO##. Customizing: Work center → Capacity planning → Work center formulas → Define formulas for work centers Copy the formula SAP007 The formula for the formula key FO## is: ( SAP_03 x SAP_09 / SAP_08 ) x 50 / 100

(C) SAP AG

LO230 6-18

Solutions Unit: Capacity Requirements and Reduction Topic: Capacity Requirements and Reduction

2-1

Create a production order with the planning table (tabular). Leveling → Work center view → Capacity planning table (tabular form). Goto → Order → Create

2-2

Look at the capacity loads at the work centers with overloads in the whole of your area of responsibility. 2-2-1 Capacity evaluation for capacity planner 0##Capacity planning table (tabular form) for planner group 2-2-2 Evaluation → Work center view → Overload T-M##

2-3

In exercise 2-2-2, you found out which work center has the greatest load. Only look at the capacity requirements for the first period with a load for this work center on the capacity planning table (tabular form) and describe how you could level this overload, particularly on the planning table. Call up the planning table (tabular form) for the work center T-M##. Deactivate all periods by choosing Edit → Period → Deactivate all per., and only activate the first period by double-clicking on it. Change order quantity or reschedule order. Dispatch operation to a period with remaining available capacity. Dispatch operation to another work center (this work center must also have been selected).

2-4

(C) SAP AG

Capacity evaluation - Detailed capacity list

LO230 6-19

2-5

Confirm the operation with the operation quantity 80 at work center T-V## and look at the changed capacity requirements at the work center T-M##. Select line and Environment → Confirmations → Enter data Actual data button The capacity requirement for this operation at the work center T-M## has been deleted.

(C) SAP AG

LO230 6-20

Scheduling

Contents: z Scheduling types z Distribution

© SAP AG 1999

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LO230 7-1

Scheduling: Objectives

At the conclusion of the unit you should understand: z The main elements of the lead time with the origin of the data. z The capacity requirements are displayed and distributed along the time scale.

© SAP AG 1999

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LO230 7-2



Capacity Evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29

Capacity Leveling (part 1)

1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699


© SAP AG 1999

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LO230 7-3

Scheduling: Business Scenario

z You want to reschedule orders in your company because of the capacity overload and therefore need to find out about the time elements in the order and the scheduling types. Since in the capacity evaluation and on the capacity planning table (tabular form) the capacity requirements are displayed in periods you need to know about distributing capacity requirements using the lead time.

© SAP AG 1999

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LO230 7-4

Work Center and Lead Time Scheduling

Basic data PP Routing

Work center

10

Default values

Costing data

Operating time

10

20

30

40

Available capacity

Lead time scheduling

23 22 21

20

Capacity planning

30

Order dates

© SAP AG 1999

Lead time scheduling is carried out for various order categories (planned order, production order, inspection plan, maintenance task lists). Lead time scheduling determines order dates and calculates capacity requirements. The capacity requirements calculated in lead time scheduling along with the available capacity in the work center serve as a basis for capacity planning.

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LO230 7-5

Lead Time Scheduling - Basics

Planned orders

10 PS

20

Routing

30

SS

SF

PF

Production orders

10 BS

SS

20

Routing

30 SF

BF

© SAP AG 1999

Lead time scheduling for planned orders always takes place in connection with the calculation of basic order dates. If you execute the planning run with lead time scheduling this happens automatically. In lead time scheduling the scheduled dates are calculated for the order (production dates). Lead time scheduling for production orders is always carried out using a routing. The scheduled dates are not transferred from the planned order to the production order.

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LO230 7-6

Scheduling / Time Elements in an Order

Float before Op. Op. Op. Op. ........ Op. Float after GRPick/pack Load time Transit time production 0010 0020 0030 0040 0099 production Proc.time time PS

SS

Setup Processing Teardown time time time

Queue time ES

SF

LS

AD

LD

GI

DDD

Transport time LF

Order dates PS SS SF PF AD LD GI DDD

Wait time

PF

Operation dates

Planned start Scheduled start Scheduled finish Planned finish Anticipated availability date Load date Goods issue date Desired delivery date

ES Earliest start LS Latest start LF Latest finish

Time concepts Lead time or order or operation Float times for orders Lead time for operation Interoperation times Processing times in sales and distribution

© SAP AG 1999

The two order floats serve different purposes: Float before production date shift, capacity planning Float after productionallow for disruptions The order floats can be predefined in Customizing and in the material master (scheduling margin key). The duration of an operation is made up of a maximum of five time elements: y Queue time y Setup time, processing time, teardown time y Process-specific wait time The duration of the move time lies between two operations but it is assigned to the preceding operation. The material requirements are scheduled to the earliest start date (changeable in Customizing). The capacity requirements can be displayed at the earliest or at the latest dates.

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LO230 7-7

Scheduling Types

Scheduling types Starting from 1

Forward scheduling

Order start date

2

Backward scheduling

Order finish date

3

Scheduling to the day

Day as basic start

4

Only capacity requirements

No scheduling

Basic dates exact to the hour

Production-, process order

Special types Today scheduling

As of current date

Midpoint scheduling

As of operation

Finite scheduling

With available capacity check

© SAP AG 1999

Scheduling types (forwards, backwards) are assigned to the appropriate order types as default values. Today scheduling is automatically triggered for orders with a start date in the past. Midpoint scheduling is used in capacity planning and automatically executed for orders with dispatched operations. Finite scheduling takes into account the available capacity at the individual work centers. With the scheduling type Only capacity requirements the dates of the operations are drawn from the basic dates and the capacity requirements are calculated for these dates. As of Release 4.0 basic dates with the time can be determined for process orders and production orders.

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LO230 7-8

Today Scheduling

Order not started Today’s date

10 PS

20

30

SS

SF

10 PS

SS

PF

20

30 SF

PF

© SAP AG 1999

For a scheduling result with a start date in the past the system automatically carries out scheduling again with the scheduling direction ”forwards” and the current date. When it does this the system carries out reduction measures contained in the reduction strategies specified in the operations. The reducible time elements along with the reduction strategy and the sequence are defined in Customizing for each order type and planner group. Reduction options: y Queue time to minimum queue time y Processing time using the settings for optional splitting and overlapping y Move time to minimum move time y Float before and after production as a percentage

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LO230 7-9

Scheduling / Performance Efficiency Machine time 4h

Standard values op. 14400 sec

Conversion Conversion to to ’seconds' ’seconds' 100%

Perform. Perform. effic. effic. per. per. act. act. type type 14400 sec

14400 (4h)

New standard value Formula Formula from from work work center center

Mach x Lot / Base quantity

Time Time factor factor

Work time (8h) / prod. op. time. (6,3h)

Ideal execution time

= 1,27 Ideal exe.tm. X time factor

Duration on time axis = 5,08h

© SAP AG 1999

To get from the standard values in an operation to the execution time various arithmetical operations are carried out. The standard values are first converted to the unit of time ”seconds” and adjusted using the performance efficiency rate. The ideal execution time is calculated using a formula key from the work center. The ideal execution time is adjusted using the internally calculated time factor which is determined by the efficiency rate and the break times.

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LO230 7-10

Correction of Execution Time

'Ideal' execution time 4 h

8.00

9.00

10.00

11.00

12.00

13.00

14.00

False False

15.00

16.00

Work finish

Work start

“Dispatched” execution time: 5,08 h

8.00

9.00

10.00

11.00

12.00

13.00

14.00

Correct Correct

15.00

16.00

Work finish

Work start

© SAP AG 1999

The ideal execution time cannot generally be achieved in business practice since breaks and disruptions interrupt work. With lead time scheduling the execution time is adjusted to take account of these facts.

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LO230 7-11

Distribution of Capacity Requirements

Capacity evaluation Capacity distribution

Distribution strategy

Distribution function

Dates: Distribution at earliest or latest date

Distribution pattern Duration [%]

Type: Distribution by function or discrete (point in time)

Distribution pattern Requirements [%]

Basis of distribution: Factory calendar Gregorian calendar Operating time © SAP AG 1999

Capacity requirements are saved for each operation (order) and capacity category on the databank (KBED). For display purposes the capacity requirements can be split up as you like using distribution functions. Capacity requirements is only used for the display per period. Orders only determine the duration and capacity requirements of operations. The distribution takes place using a distribution key for every capacity category. The distribution strategy defines the dates, type and basis of a distribution. The distribution function consists of a series of basic values each of which contains a percentage time value and a percentage requirements value.

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LO230 7-12

Distribution Basis Gregorian calendar Mo

Tu We Th

0%

30%

Fr

Sa So Mo Tu

50%

80%

We Th 100%

Factory calendar Not a work day

Mo

Tu We Th

0%

30%

Fr Sa So Mo 50%

Tu We Th

50%

80%

Fr 100%

Operating time Mo Tu We Th Fr Sa So Mo Tu We Th Fr 6h 8h 8h 12h 8h 8h 12h 12h 12h 0%

30%

50%

80%

© SAP AG 1999

The points in time can be determined for the percentage duration using the gregorian calendar, the factory calendar or the operating time using the distribution basis. You can only dispatch exact to the hour using the operating time. In the distribution example using the operating time it is assumed that the requirements are 100 hours. Thus 30% of the requirements are distributed on Thursday after 8 hours of operating time that day.

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LO230 7-13

Scheduling: Summary

z In this unit you have learnt about the basic elements and effects of scheduling.

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LO230 7-14

Scheduling Exercises Unit: Scheduling Topic: Capacity Distribution

At the conclusion of these exercises, you will be able to: • Explain the scheduling of capacity requirements and capacity distribution.

1-1

Change the following scheduling data in your work center V##: Location group:

1-2

0003

Normal queue time:

12h

Minimum queue time:

3h

Call up the capacity planning table for the work centers T-V## and V## and go to the production order with the requirements quantity 80 pieces. 1-2-1 Look at the results of scheduling for the production order in an object overview (Goto → Object overview, time segments). Make a note of the values for queue time and processing time in operation 20. Queue time___________ Processing time___________ 1-2-2 Dispatch the operation to the work center V## instead of to the work center TV##. Select the planning strategy Date entry on dispatching and deselect Finite scheduling. 1-2-3 Analyze the planning log and look for the dispatched requirements. What has happened to the requirements? Try to find the requirements by using a smaller scale and compare the results on the planning table with the scheduling results in the object overview in the production order. Describe why the duration for processing is not displayed. _____________________________________________________ 1-2-4 Save the results of planning.

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LO230 7-15

1-3

Call up the capacity planning table (tabular form) for the work centers T-V## and V##. 1-3-1 First look at the requirements for the work center V##. Why have these requirements not been distributed? _____________________________________________________ 1-3-2 Now look at the requirements for the work center T-V## and explain the distribution. Determine which distribution key was used and cross out the incorrect origin. According to the distribution key in the capacity overview in the work center or in the evaluation profile.

1-4

True or false: 1-4-1 In the capacity evaluation, the requirements are not distributed using a distribution key. 1-4-2 The distribution key can be changed in the capacity evaluation and displayed immediately using the Refresh function. 1-4-3 The distribution key is important for the capacity planning table.

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LO230 7-16

Scheduling Solutions Unit: Scheduling Topic: Capacity Distribution

1-2

Call up the capacity planning table for the work centers T-V## and V## and go to the production order with the requirements quantity 80 pieces. 1-2-1 Look at the results of scheduling for the production order in an object overview (Goto → Object overview, time segments). Make a note of the values for queue time and processing time in operation 20. Queue time: 0 minutes

Processing time: 2000 minutes

1-2-3 Analyze the planning log and look for the dispatched requirements. The formula at the work center V## needs a standard value for machine for scheduling and the operation only provides a standard value for labor. 1-3

Call up the capacity planning table (tabular form) for the work centers T-V## and V##. 1-3-1 Select order, Extras → Evaluation → Cap. distribution Requirements are distributed over the duration, but no duration could be calculated for processing. 1-3-2 Now look at the requirements for the work center T-V## and explain the distribution. Determine which distribution key was used and cross out the incorrect origin. According to the distribution key in the evaluation profile.

1-4

True or false: 1-4-1 False 1-4-2 True 1-4-3 False

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LO230 7-17

Capacity Leveling (Part 2)

Contents: z Types of dispatching z Dispatching procedure z Dispatching strategies z System settings z Cumulation using work center hierarchy

© SAP AG 1999

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LO230 8-1

Capacity Leveling (Part 2): Unit Objectives

At the conclusion of this unit you will know: z How capacity leveling is carried out (mainly with the capacity planning table). z How to change profile settings or create new profiles.

© SAP AG 1999

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LO230 8-2

Overview Diagram (8) Introduction Overview


Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Auftrag / Order

100-500

18752

500-300

600001650

100-500

18770

500-300

600001699

Scheduling

Jul' 98

Capacity leveling (part 2) Extended planning functions Detailed planning Integration

© SAP AG 1999

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LO230 8-3

Business Scenario

z In your production process you want to level the capacity loads on the resources. You need to carry out capacity leveling with the capacity planning table using various planning strategies.

© SAP AG 1999

(C) SAP AG

LO230 8-4


Basic data

Production planning

A Material

PM / PS



Bill of material

10

20


30

40

50

Scheduling

C1

10 Center 1 20 30

t


Calendar

4

Capacity evaluation/ evaluation/-leveling

t

Available capacity

© SAP AG 1999

With the help of R/3 basic data such as Material Masters, work plans and work centers, as well as planned orders and production orders, a database is created, which can show the available capacity and the capacity required. Available capacity indicates which activity produces a capacity each day. A capacity is always assigned to at least one work center. Capacity requirements shows how much capacity the individual orders need at a certain point in time. Capacity requirements are determined during lead time scheduling. In Capacity evaluation, these requirements can now be compared with the available capacity. In Capacity levelling, orders can be shared out to avoid overloading. This way it is possible to leverage the suitable resources or to plan optimal scheduling with sort criteria.

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LO230 8-5

Capacity Planning Table

Work centers Work center

00:00

Monday 06:00

12:00

18:00

00:00

Tuesday 06:00

18:00

00:00

Tuesday 06:00

Chart


Pool Op.

Qty

2010 0010

10

2020 0020

5

2030 0010

10

00:00

Monday 06:00

12:00

Chart

Order


Diagram section

© SAP AG 1999

- The capacity planning table enables you to carry out detailed planning of capacity requirements continuously over time. - The capacity planning table consists of several charts in which the available capacity (operating time) and the capacity requirements (operation duration) are grouped according to various criteria and can be displayed on the same axis. For example, all the capacity requirements for one order or all the capacity requirements that have been dispatched to one capacity can be grouped together. - Each chart can have its own title bar and is made up of a table section and a diagram section: y The table section contains information for identifying and describing the objects displayed in the diagram section. y The diagram section has a window on the virtual time axis in which the available capacity and the capacity requirements are displayed in graphical form with the start and finish date. This window displays the same section for all the charts. This section can be changed as much as you like by altering the scale.

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LO230 8-6

Types of Dispatching (Graphical)


Select operation Manual dispatching using Drag and Drop to desired point in time 4

Select operation

Select operation, capacity and period

Dispatch

Dispatch

3

2

Select operation Dispatch manually 1

Capacity planning table (tab.)

© SAP AG 1999

This graphic represents the ways of determining the dispatching date. To specify that operations are not to be dispatched automatically on the planning tables, set the indicator Date entry on dispatching in the strategy profile. When this indicator is set then when you execute the function Dispatch the system displays a dialog box where you specify the dispatching date.

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LO230 8-7

Dispatching Operations

1

Specify operations to be dispatched

2

Specify dispatching dates

3

Sort operations (sequence)

4

Setup time optimization

5

Finite scheduling

6

Operation date check

7

Midpoint scheduling

© SAP AG 1999

The dispatching dates are the start dates for the search for remaining available capacity in finite scheduling. You can specify them in several ways: y Manual entry y Using the scheduled operation dates (lead time scheduling of production order) y Drag and drop with the mouse Finite scheduling is a special type of lead time scheduling with an availability check. Finite scheduling is only carried out for operations whose work centers have the indicator Relevant for finite scheduling. Midpoint scheduling can be executed either during the simulation or on saving.

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LO230 8-8

Planning Details at the Work Center / Capacity

Shareable capacity Available capacity not shareable Op. 3 Op. 1

Overload factor

Overload factor Available capacity

Op. 2

Available capacity shareable Op. 2 Op. 1

z Indicator: Relevant for finite scheduling

© SAP AG 1999

You can maintain further planning details for capacity planning for each capacity category. Indicator: Relevant for finite scheduling. If this indicator is set the system checks the current dispatched load when searching for remaining available capacity. The indicator Can be used by several operations allows a multiple commitment when dispatching operations to a capacity. With a non-shareable capacity only one operation can be dispatched at any point in time. That means that the available capacity of another individual capacity is not taken into account for this capacity category. The overload factor increases the available capacity by this percentage on the capacity planning table (tabular form).

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LO230 8-9

Lead Time Scheduling - Finite Scheduling

Lead time scheduling

23 22 21 Order dates

Unlimited available capacity! Capacity requirements Finite scheduling

23 Finite available capacity! Changed operation dates and times

© SAP AG 1999

Lead time scheduling uses an unlimited available capacity to determine the dates for the capacity requirements. In contrast to lead time scheduling where the system does not take into account the load situation of the relevant work centers, finite scheduling schedules the operations taking into account the current load situation generated by operations dispatched to work centers.

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LO230 8-10

Finite Scheduling

Prerequisites and procedure Work center / capacity Ind.: Relevant for finite scheduling

Strategy profile Ind.: Finite scheduling on / off Search direction forward / backward

Overload factor for permissible overload Can be used by several operations

Time profile Search period for remaining available capacity

Sufficient available capacity at relevant date?

Shift operation to date without capacity problems © SAP AG 1999

When dispatching operations using finite scheduling, the system takes into account the current capacity loads of the capacities. In finite scheduling only those capacities are taken into account for which the indicator Relevant to finite scheduling has been set. By not setting this indicator a capacity with sufficient available capacity can be excluded from finite scheduling. Conflicts that arise between the operation dispatched and other operations in the order that have been dispatched and/or with the order itself, do not lead to an automatic correction of dispatching. For every operation to be dispatched the system checks whether there is remaining available capacity for it at the date determined. If the operation has suboperations relevant to scheduling then the system also looks for available capacity for these. If there is sufficient available capacity then the system dispatches the operation. If there is not sufficient capacity then the system shifts the operation to a date when it can be processed without any capacity problems. You can specify the search direction in the strategy profile using the indicator Planning direction forwards. The period for the search for remaining available capacity is specified in the time profile in the section Planning period.

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LO230 8-11

Rescheduling / Deallocating

Rescheduling

Dispatched

Pool

Deallocating

Dispatched

Pool

© SAP AG 1999

You can reschedule operations that have already been dispatched by specifying a different date and/or a different work center. In the case of specifying another work center this work center must have been selected when calling up the planning table. When deallocating operations the current dispatching date and the status Dispatched are reversed. The order is rescheduled. The system can close gaps that arise when operations are rescheduled or deallocated. It does this by shifting operations according to the key Close gaps in the strategy profile. Changing the order quantity automatically leads to the operation being deallocated. On the capacity planning table material availability checks can be carried out for production orders using ATP logic. The system checks the availability of components at order level, that is for all operations in the production order for the requirements dates. Operations with missing parts are highlighted. The result of the availability check can be analysed in the planning log.

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LO230 8-12

Midpoint Scheduling I

1. Example: A dispatched operation Before dispatching 10

PS

20

30

SS

SF

PF

Dispatch operation 20

Forward and backward scheduling

10

SS

20

30

SF

© SAP AG 1999

The example shows the dispatching of an operation. Midpoint scheduling is always executed when at least one operation is dispatched. With midpoint scheduling the order is not scheduled starting from the basic start or basic finish date.

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LO230 8-13

Midpoint Scheduling II

2. Example: Dispatching a second operation Before dispatching 10

BS

20

30

40

50

SF

SS

BF

Dispatch operation 50

Backwards

10

20

10

20

30

40

50

Lead time scheduling Forwards

30

40

50

© SAP AG 1999

The example shows the dispatching of a second operation in an order. If only one operation is dispatched then all the operations that precede it are scheduled backwards and all the operations that follow it are scheduled forwards. If more than one operation was dispatched then the scheduling direction between the two dispatched operations depends on the scheduling direction that was selected during lead time scheduling. If a subsequent operation is completed during a previous fixed operation, then you will be notified of the duplication in the planning records

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LO230 8-14

Structure of a Profile (Leveling)

Overall Overall profile profile

Control Control profile profile

Evaluation Evaluation profile profile

Strategy profile

Period profile

Profile cap.plan.table

Time profile

List List profile profile

Profil cap.plan.tab.(tab.)

Selection Selection profile profile

Filter Filter set set

Object Object set set

Reqmts Reqmts grouping grouping

Selection Selection key key

© SAP AG 1999

The overall profile contains subprofiles with settings that fit together; there are seven profiles for the capacity planning table and eight profiles for the capacity planning table (tabular form). The control profile specifies the type of presentation and the layout of the data. There are also indicators for restricted planning, setup time optimization and actions to start jobs. In the options profile you can specify the work center hierarchy name for cumulating available capacity and capacity requirements and you can specify the distribution key. The strategy profile specifies the planning strategies for dispatching and rescheduling. The time profile specifies the period for which capacity requirements are read from the database. The list profile specifies the layout of the standard overview and the detailed capacity list. The selection profile specifies which sets are used to determine the layout of the various selection screens. When calling up the overall profile for leveling with the capacity planning table the system also uses the profile for the capacity planning table. When calling up the overall profile for leveling with the capacity planning table (tabular form) the system also uses the profile for the capacity planning table (tabular form) and the period profile. The period profile specifies the periods in which the loads appear. For example, a period can represent a day, a week, several days or several weeks.

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LO230 8-15

Dispatching to Freely-Definable Period split

z Specification of period split for dispatching on capacity planning table using following indicators:

1 = daily split, 2 = shift split, 3 = hourly split

z Specification of point in split from which the system starts its search for remaining available capacity. z Specification of point in split as start time or finish time of operation, depending on planning direction, z Specification that an operation is to be dispatched within a period split

© SAP AG 1999

If it is necessary that the start times of operations should always be at the start of a shift or that operations should only be dispatched to a shift if they can be completed in the shift then you should use a period split to carry out dispatching. If you want to use this function, select a period split in the strategy profile (for example, a shift split) and specify the conditions for dispatching using the following indicators: y Start search in period split - The search starts at the first point in the split in the planning direction and the search is carried out in the planning direction. y Always adhere to period split - Specifies that either the start dates or the finish dates of operations should always be on points in the period split. y Operation completely in period split - Specifies that the start time and finish time of an operation must lie within a split interval.

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LO230 8-16

Enhanced Handling Functions 1

z Positioning on the time axis z Selecting and moving groups of operations z Changing the scale z Planning - information functions

© SAP AG 1999

To position the graphical object at the start of the time axis, choose Edit - Position on time axis. With the first graphical object the time axis is positioned such that the first graphical object in a selected line appears at the left-hand edge of the diagram. To dispatch operations on the capacity planning table the objects must be selected. You have the following options: y Select by clicking with the Shift button y Select by dragging a frame around the operations y Select all objects on a line or in a chart by choosing: Edit - Select - For line or For chart. y Select operations that have certain properties in common by using a selection key and choosing Edit Select - Objects belonging together To change the scale of the time axis in the capacity planning table online choose: Settings - Scale. You can choose between several predefined scales and a variable scale. To call up a dialog box displaying data on the work center choose: Extras - Planning info system.

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LO230 8-17

Strategy Profile

Overall profile

z Planning direction z Dispatching at earliest point in time z Finite scheduling yes/no z Overall capacity load

Strategy profile

z Insert operation / Close gaps z Date entry when dispatching z Cancel dispatching due to error z Dispatch. sequence z Using order-/operation floats z Treatment of queue time z Dispatch internal production z Operation date check z Midpoint scheduling yes/no

© SAP AG 1999

The strategy profile is part of the overall profile for capacity planning and defines the parameters for an individual planning strategy. Different strategies profiles reflect different planning goals. You can switch profile interactively during planning. If the indicator Cancel dispatching due to error is set then dispatching is cancelled if errors are detected when the system checks the operation and order dates.

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LO230 8-18

Planning Direction

Forwards

Backwards

© SAP AG 1999

The planning direction determines the search direction for remaining available capacity. With automatic dispatching the system searches in the future for a possible dispatching date within the planning period. The indicator Change planning direction has the effect that the system changes planning direction when searching for remaining available capacity if it does not find any in the planning period in the planning direction. If this indicator is not set then dispatching occurs in the past.

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LO230 8-19

Dispatching at the Earliest Time

© SAP AG 1999

When the system dispatches operations at the earliest point in time it does not take into account the scheduled dates of the operation. By combining this planning strategy with the setting "Plan. direction forwards" you can achieve a commitment without any gaps.

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LO230 8-20

Planning Strategy: Strategy Profile

Planning table (tab.) Backlog

Planning table Today line

Inserting an operation

Available capacity

Planning period

Closing gaps

committed capacity

© SAP AG 1999

Overloads in individual periods can only be taken into account in the capacity planning table (tabular form). You can specify that when the system searches for a period with remaining available capacity that the capacity overloads (for example, because of backlogs) in other periods within the planning period are to be taken into account. For example, for a planning period with two periods where one has a 200% overload, no capacity requirements can be dispatched to the following period. Operations can be inserted in an already existing capacity commitment in the capacity planning table. The operations that have already been dispatched are shifted according to the planning direction without changing the sequence. The capacity must not allow a multiple commitment. The function Close gaps is used when an operation is deallocated or rescheduled. Depending on the planning direction indicator in the strategy profile the operations that follow or precede the operation rescheduled or deallocated are rescheduled (shifted) to close the gap that has arisen. You can define the direction and period concerned in the strategy profile. Thus this rescheduling either finished at the next gap or at the end of the planning period. You can achieve a commitment without gaps by using the function "Dispatch at earliest point in time".

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LO230 8-21

Treatment of Queue Time

Float before production 10

BS

30

40

Operation date check

X

Use operation float 10

20

30

40

SS

Float after production

50

SS

X

BS

20

Queue time = Operation float

SF

BF

SF

BF

50

Dispatching period

© SAP AG 1999

To specify that the system is to check the operation dates and use the queue time you must set the following indicators in the strategy profile: Operation date check Use operation float. That means that the operation can only be moved within the earliest and latest dates (queue time). The queue time is calculated according to the settings in the strategy profile.

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LO230 8-22

Use of Order Floats / Operation Floats

X

Use operation float

X

Use float before production 10

BS

20

30

40

50

SS

SF

BF

SF

BF

Dispatching period X

Use operation float

X

Use float before production

X

Use float after production 10

BS

20

30

40

SS

50

Dispatching period © SAP AG 1999

To check the operation dates and use all the order floats the following indicators must be set in the strategy profile: Operation date check Use operation float. This means that the operation can only be shifted within the earliest and latest dates. The queue time is calculated according to the settings in the strategy profile. Indicator: Use float before production Indicator: Use float after production The time periods are extended by the duration of the order and operation floats.

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LO230 8-23

Various Functions

Display / maintenance

Auftragskopf

Arb eitsvorgänge

Materialkompon enten

Fertigungshilfsmittel

Kosten

Plan Soll Ist

20

100 50

Material Management Work center

t

t

Capacity

Order

Various functions

Stock-/ reqmts list

Personnel data

Display

Inspection lot Stock/reqmts list

© SAP AG 1999

With the functions in the upper section of the slide the simulated changes are based on the current data that have arisen during the simulation. With the functions in the lower section of the slide the data is read from the database without taking into account the current planning situation on the planning table.

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LO230 8-24

Configuration Sequence Capacity Planning (3)

M K K D

Maintaining and cumulating available capacity Creating a work center hierarchy Defining distribution of requirements Profiles for capacity evaluations

D Profiles for capacity leveling

© SAP AG 1999

Legend: M = Mandatory action O = Optional action D = Action executed by default setting

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LO230 8-25

Capacity Leveling - Overall Profile

Overall profile Control profile Selection profile Time profile Option profile Strategy profile Period profile Profile for plan. table (tab.) Profile for planning table List profile © SAP AG 1999

When you call up capacity leveling and capacity evaluations all the necessary settings are taken from an overall profile. This overall profile can be one provided by SAP or a user-specific profile. For capacity leveling the relevant overall profiles are tied to a menu option but you can access them using the appropriate user parameters (see next slide). If an overall profile is called up for a capacity planning table then the profile for the capacity planning table (tabular form) and the period profile are not needed. If an overall profile has been called up for a capacity planning table (tabular form) the profile for the capacity planning table is not needed.

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LO230 8-26

Standard Overall Profiles for Capacity Leveling

Leveling Work center view Individual capacity view Order view

Cap.plan.table

Cap.plan.table (tab.)

SAPSFCG001 (CYA)

SAPSFCG002 (CYB)

SAPSFCG005 (CYH)

SAPSFCG006

SAPSFCG004 (CYM)

SAPSFCG003 (CYE)

Variable access Project views

(CYI)

CYG

CYG SAPPS_G002 (CYN)

SAPPS_G001

SAPPM_G006

SAPPM_G005 (CYP)

(CYF)

Plant maintenance Work center view Individual capacity view

(CYO)

SAPPM_G002 (CYK)

SAPPM_G001 (CYD)

© SAP AG 1999

The values in brackets specify the relevant user parameters where you can predefine a profile.

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LO230 8-27

Control Profile

Overall profile

Presentation:

Control profile

Planning table: tabular/graphical

Presentation type: Per period or continuously through time Change mode:

Lock objects when reading KBED or in change mode

GUI status:

Controls structure of menu in display- / change status

Sort:

Sort table section immediately after every change

© SAP AG 1999

The control profile contains settings such as the type of presentation, whether the tabular or graphical version of the planning table is to be used or only lists. With the presentation you define the type of display for your data within capacity leveling. You can choose between the two types of planning table and the list display. You use the layout type to specify whether the capacity requirements or available capacity data is to be displayed per period or continuously through time. The display per period is used for data for example in the capacity planning table (tabular form) or in the planning tableau. The data is display continously through time on the capacity planning table. If the indicator change mode is set then capacity leveling is called up in change mode and you can make changes to objects. In this case objects can be locked when they are read from the database by setting the indicator Lock all. If the indicator is not set then capacity leveling is called up in change mode. The indicator Always sort specifies that the lines in the planning table after sorted after every change (for example, once a requirement has been deallocated). If the indicator is not set then new lines in the planning table are added to the end of existing ones.

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LO230 8-28

Selection Profile Overall profile

Other controls:

Selection profile

Hierarchy explosion Planning individual capacities permitted Version of available capacity

Object set:

Control reading KBED for objects (work center, order...)

Filter set:

Filter for fields of KBED object data read

Requirements grouping: Grouping of requirements into requirements groups Scheduling level:

Selection of KBED records according to detailed, production rate- and rough-cut planning - scheduling and specification of order categories (Note scheduling levels table TCX00)

© SAP AG 1999

In the selection profile you make specifications for selecting, filtering and grouping data relevant to capacity leveling. The object- and filter sets define the selection screens for accessing capacity leveling from the capacity planning menu. An object set contains criteria and default values such as fixed values according to which objects relevant to capacity leveling are selected. A filter set contains criteria and default values such as fixed values according to which the requirements belonging to the objects selected can be filtered. The requirements grouping specifies according to which point of view the requirements are to be grouped on the relevant planning table. They control the correct selection of capacity requirements for the charts in the planning table. In the selection profile you can also specify which requirements for which scheduling level (detailed-, production rate- or rough-cut scheduling) and for which order category are to be read by the system. You can then process these capacity requirements. Note: Sets in capacity planning must be imported from the delivery client into the work client using the report SETIMP00.

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LO230 8-29

Planning- (Scheduling) Levels RoughRough-cut planning Long-term Aggregate Bottleneck resources Periodic planning

Rough-cut planning profile Rough-cut scheduling

Routing Planning recipe

SOP order ProductionProduction-rate plan. Medium-term Bottleneck resources Period-oriented

Rate routing Production-rate scheduling

Routing Master recipe

Run schedule quantity Detailed planning Short-term Indiv.capacities/ persons Planning to specific points in time © SAP AG 1999

Routing Rate routing Master recipe Finite scheduling Production- / process order

In capacity planning there are three different planning levels. The capacity requirements on the planning levels each have their own capacity requirements ID. In the individual capacity planning applications (PP-SOP, master production scheduling, repetitive manufacturing, shop floor control) the capacity evaluations are firmly defined for a specific level. Detailed scheduling is generally carried out for production orders.

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LO230 8-30

Time Profile

Overall profile

Arbeitsplatz/Kap.art

Time profile

14100/001

Drehmaschine

Periode

2.1996

3.19964.1996 5.1996

6.1996

Kapa.angebot Eingeplant

24,0 8 33,3%

8,0

10,0

Vorrat

2

6,5

8,3%

7,0 81,2

12,0

13,0 185,7%

Bedarfe Ges.Bed. 6,5 h 13,0 h

Material Welle 1 Welle 2

Menge

Eh

Auftrag

Vrg.

Beschreibung

20 35

St. St.

0001891 0001953

0010 0030

Drehen Feindrehen

Database read period

Evaluation period

Planning period

© SAP AG 1999

The time profile defines the following time periods: the database read period, the evaluation period and the planning period. All the time periods are defined relative to the current planning date (positive / negative). Various types of date entry are possible. All the requirements are read that lie partly or wholly in the database read period. The evaluation period must be less than or equal to the database read period and reflects the range of capacity requirements records (KBED records) that have been read. The planning period represents the range of the KBED records to be dispatched and must be less than or equal to the evaluation period. The date for dispatching the backlog is a date to which all capacity requirements records are dispatched that are at this time in backlog. This provides an overview of the operations that have been delayed. It is used for the capacity planning table (tabular form), that is for the display per period.

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LO230 8-31

Evaluation Profile

Overall profile

Evaluation profile

Unit of measure:

Unit for available capacity and capacity requirements

Distribution function:

Control distribution of KBED

Cumulation of available Cumulation of available capacity using individual capacities in a work center hierarchy capacity: © SAP AG 1999

The evaluation profile contains settings that are important for evaluating data.

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LO230 8-32

List Profile

Overall profile

List profile

Subprofiles define the layout of the detailed capacity list Profile for capacity requirements list Percentage value display Descending sort List width Column width

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The list profile defines the layout of the detailed capacity list. In the overall list profile you can also specify subprofiles for defining the fields to be displayed on the detailed capacity list. These subprofiles also define the sequence in which the fields are to be displayed. The profile for the capacity requirements list defines how the fields in the list are displayed. You can specify a profile for the standard overview and for the detailed capacity list and define one of them as the default option.

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LO230 8-33

Profile for Capacity Planning Table (tab.)

Overall profile

Profile for cap. planning table

Planning table layout Reqmts to be displayed

(all, dispatched, not dispatched)

Screen width Formula to calculate remaining available capacity Start time for dispatching when rescheduling

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The profile for the capacity planning table (tabular form) specifies, for example, which requirements are displayed in which charts as well as the type of requirements to be displayed. The layout of the planning table is dealt with in the next unit. You specify what type of requirements you want to display using the key "Rqts to be displayed". You can choose between requirements generated by dispatched operations and those generated by operations not yet dispatched. You can use the indicator Ind. width to control how wide the screen is that is displayed on the capacity planning table (tabular form). You can use the field Formula rem. av. cap. to specify the formula used to calculate the remaining available capacity. You can use the indicator Dispatch time to specify the time when the operation is dispatched when it is rescheduled on the capacity planning table. The system proposes this time when an operation is rescheduled.

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LO230 8-34

Period Profile

Overall profile

Period profile

Period type:

Unit of measure of period (day, posting period, MRP calendar...)

Period duration:

Period duration

Planning calendar ID:

MRP calendar

for example 7

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The period profile contains settings that are relevant to period-related displays. These settings include the period type and the period duration. You use these two entries to specify the period split for your evaluation period. You can also specify a planning calendar in the period profile. This allows you to define period lengths flexibly. The period profile is only necessary if you want to see the capacity planning table with a display per period. In this case you must have defined a display per period in the control profile.

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LO230 8-35

Profile for Capacity Planning Table

Overall profile

Chart sequence (max. 8 windows) Table section Layout ID

Profile for cap. planning table

Line representation selection in table section

Diagram section Scale / time scale Graphical object selection Representation profile Histograms

Graphics profile

© SAP AG 1999

The profile for the capacity planning table contains settings that define the structure and layout of the capacity planning table. The capacity planning table should be used with the standard setting provided. Every chart is a horizonal window within the planning table. If not all of the charts fit in the screen then you can scroll through the chart sequence. Every chart contains a table section and a diagram section. You can define the display for the material stock curve in the section Histogram. For example, you can define the color and width of the line for the chart to be displayed.

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LO230 8-36

Check Report / Overall Profile

Overall profile Control profile Selection profile Time profile Evaluation profile Strategy profile Period profile Profile cap.plan.table (tab.) Profile cap.plan.table List profile © SAP AG 1999

The overall profile can be a standard profile provided by SAP or a user-specific profile and consists of a series of individual profiles. Since Customizing for the overall profile for capacity leveling is very complex errors frequently arise when changes are made or new profiles created. The check report is a simple tool that analyzes an overall profile for errors. The check report lists the profiles in the overall profile on the screen. The system highlights profiles with errors. By double-clicking on a selected profile the profile hierarchy is exploded and possible errors displayed. The long text for the error message specifies how to remove the error and refers to the relevant transactions in Customizing. You can call up the check report with the transaction CMCH or in the capacity planning table with the menu options Settings -> Display profiles. By calling up the check report with the transaction CMCH and the menu options Edit -> Assign colors you can highlight errors in objects affected (for example, missing parts in the ATP check).

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LO230 8-37

Requirements Grouping

Group

Description

Set

1

KAKO/KBED (dispatched)

5KSAPGR1

2

AFKO/KBED (not dispatched)

5KSAPGB5

3

PLAF/KBED (not dispatched)

5KSAPGB9

4

PLAF/KBED (initial status)

5KSAPGB6

© SAP AG 1999

The requirements grouping specifies which objects are to appear on the planning table. A requirements grouping generally consists of several groups that are maintained as a multidimension set. Every group contains a particular combination (production orders, planned orders) of capacity requirements as well as filter criteria. These groups are assigned to the individual charts in the planning table. Typical charts in the planning table include work centers, orders (pool), order (dispatched).

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LO230 8-38

Requirements Grouping - Example Group

Group

Set

Description

Field

Value

1

5KARBPL

Work center w/o value

ARBPL

-

2

5KKAPIE_INI

KAPIE initial

KAPIE

0

3

5KKAPAR

Cap.cat. w/o value

KAPAR

-

4

5KKBEDSELAVE

KBED dispatched

KBEDS

SAP001

5

5KCANUMFI

CANUMF w/o value

CANUMF

0

© SAP AG 1999

The example group has been created as a multidimension set 5KSAPGR1 with 5 basic sets. The first three lines have the following effects: They calculate capacity requirements for all selected work centers (ARBPL) and all their capacity categories (KAPAR) that are not individual capacities (KAPIE). Groups 1 and 3 generate a new line for every capacity requirement calculated since they do not have a value.

Group 2, since it has a value, only filters the display for main capacities. Groups 4 and 5 mean: Assign to this group all capacity requirements (KBEDS), that are dispatched (selection profile SAP001) but not split (CANUMF = counter for leading capacity requirements record).

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LO230 8-39

Cumulation of Available Capacity / Capacity Requirements Plant

Manufacturing

Assembly

Engineering

Lathe shop 18 h

t Transport t

Capacity

10h

Maschine t Labor

Center 1

8h

t

Work center group 1

t

Capacity

Capacity

Maschine t Labor

2h

Transport t

Center 2

4h

Labor

10 h

Capacity

8h

10h

t

Center 3

Labor

t

Capacity

Maschine t Labor

3h

Capacity

Capacity

16h

6h

Work center group 2

1h

6h

Maschine t Labor

t Transport t

Center 4

© SAP AG 1999

Available capacity can be cumulated for a specific capacity category, statistically or dynamically over several hierarchy levels. The available capacity can be cumulated dynamically during capacity planning.

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LO230 8-40

Cumulation of Available Capacity using Period Split

Period split key XYZ Segment 1

Segment 2

Segment 1

7 periods of 1 day

3 periods of 7 days

1 periods of 1 month

Cumulated available capacity for one capacity category

A B © SAP AG 1999

Available capacity can be cumulated for a specific capacity category for a specific period. It can be cumulated statically or dynamically over as many hierarchy levels as you like. The dynamic cumulation of available capacity takes place during capacity planning. You must carry out a static cumulation of available capacity when maintaining work centers or capacities. You can use a period split key to define time intervals for cumulating the available capacity to a superior work center. The period split key determines the degree of detail of the cumulation of available capacity and thus capacity planning. The period split key is only used for static cumulation (that is, in the work center). The period split key is defined in Customizing Work center -> Capacity planning -> Available capacity. The cumulation of capacity requirements and available capacity is only relevant for the display per period (capacity evaluation, capacity planning table (tabular form).

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LO230 8-41

Capacity Leveling (Part 2): Summary

z This unit dealt with capacity leveling on the capacity planning table with various planning strategies, with creating an overall profile and cumulating available capacity and capacity requirements.

© SAP AG 1999

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LO230 8-42

Capacity Leveling (Part 2) Exercises Unit: Capacity Leveling (Part 2) Topic: Capacity planning table

At the conclusion of these exercises, you will be able to: • Execute capacity leveling with capacity planning table • Reschedule operations

1-1

Execute capacity leveling using the capacity planning table. 1-1-1 Call up the capacity planning table with the variant you have saved V-##. You have created this variant for 3 work centers in the unit for capacity leveling part 1. 1-1-2 You have carried out dispatching twice in this unit using the capacity planning table (tabular form): once automatically to the work center T-V## and once manually to another work center T-L##. Find out about these work centers using the capacity planning table. 1-1-3 Go to the production order for the work center T-V##. What status does this operation have? 1-1-4 Look for the dispatched operation at the work center T-L##. To do this, use the hourly period split. 1-1-5 Do you remember why the duration of processing is not displayed for this operation? Are there capacity requirements for this operation's processing time? 1-1-6 If you have answered question 1-1-5 with yes, state where these requirements can be displayed. _____________________________________________________

1-2

Now dispatch a further operation to the work center T-L## with an operation quantity of 100. Use the weekly period split again. 1-2-1 Make a note of the following dates in the order for the operation dispatched: Order: Basic start ______________ Basic finish ______________ Operation 30: Start ______________ Finish _______________ 1-2-2 Shift your operation on the capacity planning table two weeks into the future. Look for the dates in the order and make a note of the order dates. Basic start: ________ Basic finish: ________

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LO230 8-43

1-2-3 Reschedule the production order with a finish date that is one week later. 1-2-4 Explain what happened to the dates. _____________________________________________________ 1-2-5 Increase the total quantity for this production order to 110 pieces and go back to the planning table. 1-2-6 What has happened to the operation? ____________________ 1-2-7 Explain why. ________________________________ _____________________________________________________ 1-2-8 Save the results of your simulation on the planning table.

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LO230 8-44

Exercises Unit: Capacity Leveling (Part 2) Topic: Planning Strategies

At the conclusion of these exercises, you will be able to: • Create a commitment without any gaps.

2-1

Create a commitment without any gaps using the capacity planning table, Work center view at the work center T-E## and the capacity category 002. 2-1-1 Select four operations and dispatch them using the planning strategy Dispatch at earliest possible time. 2-1-2 Why must this planning strategy be used? _____________________________________________________ 2-1-3 Now deallocate the second operation and make sure that the work center still has a commitment without any gaps.

2-2

You want to make sure that when another operation is dispatched, this operation is dispatched to a date, ensuring that the basic order dates are not changed. 2-2-1 In the following list, only select the dispatching strategies that guarantee this condition. Date entry when dispatching Finite scheduling Midpoint scheduling Cancel dispatching due to error Use operation float Use float before production Use float after production Planning direction forwards Operation date check Change planning direction

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LO230 8-45

2-2-2 With which strategies must the strategy Planning direction forwards be deselected? _____________________________ _____________________________________________________ 2-2-3 Do not save the planning table.

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LO230 8-46

Exercises Unit: Capacity Leveling (Part 2) Topic: Creating an Overall Profile

At the conclusion of these exercises, you will be able to: • Create a work center hierarchy and use it for leveling • Create an overall profile for leveling • Analyze errors with the check report In order to carry out accurate capacity planning in a production area, you want to create a work center hierarchy and level the capacity requirements as well as the available capacity for the subordinate work centers by calling up the planning table.

3-1

Create a work center hierarchy with the name H-## in plant 1000. The hierarchy should have the following structure: Hierarchy name: H-## erarchy work center: KS## T-V##

V##

T-M##

3-1-1 First create a work center with the name KS## and the description Area-## as a capacity collector for the work center category 0004. When you create the hierarchy work center make sure that you only maintain the basic data and all of the capacity categories. 3-1-2 Create the hierarchy with the name H-## and the description Group-##. 3-1-3 Assign to this hierarchy the four work centers according to the pattern above. Use the person responsible for your group as a selection criterion.

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LO230 8-47

3-2

Create your own overall profile with the name Z##SFCG... to call up the planning table for your hierarchy. Use as a reference the overall profile that you find by choosing Leveling → Work center view for the work center V##. Note: Choose the appropriate planning table. 3-2-1 Copy the overall profile you have found and call it Z##SFCG... using the check report. 3-2-2 Change the selection profile copied by setting the indicator for the hierarchy explosion. 3-2-3 Change the evaluation profile you have copied in such a way that you can read the current capacity requirements and current available capacity of your work center hierarchy. 3-2-4 Call up the planning table with the overall profile you have created for the work center KS## and look at the result.

3-3

You want to deallocate a planned order after it has been dispatched in simulation and you discover that the planned order can no longer be found on the planning table. Therefore you call up the check report and analyze the error. 3-3-1 Create a planned order with capacity requirements for the material T-F2## with 100 pieces as a stock order with a delivery date in four weeks. 3-3-2 Copy an overall profile with the name Z##SFCG011 using the check report and the overall profile ZPPSFCG011. 3-3-3 Call up the planning table with the overall profile Z##SFCG011 for your work center T-P## and simulate the dispatching of the planned order. 3-3-4 Now deallocate the planned order and look at the deallocated capacity requirements. What has happened? Refer to the help for the status row. 3-3-5 Analyze the error using the check report and try to remove it.

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LO230 8-48

Capacity Leveling (Part 2) Solutions Unit: Capacity Leveling (Part 2) Topic: Capacity Planning Table

1-1

Execute capacity leveling using the capacity planning table. 1-1-3 Created, dispatched 1-1-5 Yes 1-1-6 If you have answered question 1-1-5 with yes, state where these requirements can be displayed. In the capacity evaluation and on the capacity planning table (tabular form)

1-2 1-2-3 Reschedule the production order with a finish date that is one week later. Select operation and press the Change order button. Change the basic finish date Order → Functions → Schedule 1-2-4 Explain what happened to the dates. Midpoint scheduling was carried out on the basis of the dispatched operation. 1-2-6 The operation was deallocated. 1-2-7 Explain why. Lead time scheduling was triggered with the new order quantity.

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LO230 8-49

Solutions Unit: Capacity Leveling (Part 2) Topic: Planning Strategies

2-1-2 Otherwise it would be dispatched according to the scheduled dates. 2-1-3 Now deallocate the second operation and make sure that the work center still has a commitment without any gaps. Strategy profile: Indicator: Close gaps to end of planning period 2-2-1 In the following list, only select the dispatching strategies that guarantee this condition. X Finite Scheduling X Cancel dispatching due to error X Use operation float (not with planning direction forwards) X Use operation float (not with planning direction forwards) X Use float after production X Planning direction forwards (if float after production) X Operation date check X Change planning direction (after all floats have been set)

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LO230 8-50

Solutions Unit: Capacity Leveling (Part 2) Topic: Creating an Overall Profile

3-2 3-2-1 Copy the overall profile you have found and call it Z##SFCG... using the check report. Customizing capacity leveling → Define overall profile Copy the overall profile SAPSFCG002 with the button Check and the button Copy overall profile 3-2-2 Change the selection profile copied by setting the indicator for the hierarchy explosion. Double-click on the profile number 3-2-3 Change the evaluation profile you have copied in such a way that you can read the current capacity requirements and current available capacity of your work center hierarchy. Double-click on the profile number Plant 1000, hierarchy name H-## Select the indicators Cumulation of requirements and Dynamic capacity cumulation. 3-2-4 Call up the planning table with the overall profile you have created for the work center KS## and look at the result. Leveling → Variable → Dialog Overall profile Z##SFCG002 Work center KS## 3-3 3-3-1 Create a planned order with capacity requirements for the material T-F2## with 100 pieces as a stock order with a delivery date in four weeks. Logistics → Production → MRP → Planned order → Create Planned order profile LA Schedule the planned order by choosing Edit → Schedule (C) SAP AG

LO230 8-51

3-3-4 Now deallocate the planned order and look at the deallocated capacity requirements. What has happened? Refer to the help for the status row. The planned order is given an internal status Not dispatched and therefore the group 5 is missing in the grouping in the chart.

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LO230 8-52

Extended Planning Functions

Contents: z Sequencing z Other functions z Temporary saving results of planning z Mass processing z Capacity planning with production versions

© SAP AG 1999

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LO230 9-1

Extended Planning Functions: Unit Objectives

By the end of this unit you will understand: z How special planning functions are dealt with on the two types of planning table.

© SAP AG 1999

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LO230 9-2



Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699


© SAP AG 1999

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LO230 9-3

Business Scenario

z In your production there are work centers that are overloaded with capacity requirements. Thus you use the following methods to try to adhere to your delivery dates: generating an optimal despatching sequence, mass despatching and production versions to process requirements at alternative work centers.

© SAP AG 1999

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LO230 9-4

Sequencing 1

1

2

3

4

Finite scheduling 1 2 3

Sort operations

4

2 4 1 3 © SAP AG 1999

You define the dispatching sequence for the selected operations using the sequencing key in the field Dispatching sequence. The operations must either have the same start dates or the indicator Dispatch at earliest start date must be set in the strategy profile. Once sequencing and dispatching have taken place the setup standard values are only reduced if the relevant strategy is set in the strategy profile. You can also use other sort criteria by assigning sequence numbers in the order header (planned order and production order).

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LO230 9-5

Sequencing 2

Dispatch

Deallocate

Order

Capacity

Operation

Dispatched June 98

Center

Work center descr.

1906

Paint 1

July 98

CW 26

CW 27

60Min 1 / 10 1 / 10

Center

SK

600001540

1906

1

50

600001650

1906

1

50

600001666

1906

1

30

1000

1

10

1

10

1 Min

1000

1

10

1

20

10 Min

1000

1

10

1

30

5 Min

10

1

50

25 Min

15Min 1 / 40

1000

1

20

1

50

5 Min

1000

1

30

1

50

15 Min

1000

1

50

1

20

20 Min

1000

1

50

1

30

12 Min

1000

1

50

1

40

8 Min

1000

1

50

1

-

25Min

1 / 50

12Min 1 / 30 1 / 50 20Min 1 / 20 1 / 20

SG

STD

1

5Min

1 / 50 8

Pool Order

SG SSG

1000

30Min 1 / 20

June 98

PSG

CW 29

1 / 30

Best time for setup

PG

CW 28

5Min

1 / 30 15Min

Plant

30 Min

July 98

CW 26

CW 27

CW 28

CW 29

PG

1 / 50

PSG SG SSG STD

Predecessor group (setup group category) Predecessor subgroup (setup group key) Successor group Successor subgroup Standard value

© SAP AG 1999

With sequencing the setup time of an operation that is to be processed at a work center can depend on which operation was processed previously at the work center. Thus the setup time depends on the setup state of the work center. The following functions that automatically take into account the setup state of the work center are available on the capacity planning table: y Adjusting setup times of dispatched operations y Dispatching operations at the best time for setup (see slide for example ) y Dispatching operations in a sequence with minimum setup time (see next slide for example) To calculate the setup time of an operation these planning functions do not use the setup standard value from the operation but instead an appropriate setup standard value from the setup matrix. The setup matrix shows how the setup standard value depends on the setup state of the work center. The setup state of a work center is defined in the setup matrix by the setup group category and the setup group key that are stored in the operation. The transition between two setup states is defined in terms of the setup group categories and the setup group keys of two operations that are processed at the work center one after the other. The setup standard value saved for a transition is assigned to the following operation.

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LO230 9-6

Sequencing 3

Dispatch

Deallocate

Order

Capacity

Operation

PG

PSG

SG SSG

STD

1

10

1

10

0 Min

1

10

1

20

10 Min

1

10

1

30

15 Min

1

10

1

40

20 Min

1

20

1

10

30 Min

1

20

1

20

0 Min

1

20

1

30

10 Min

1

20

1

40

15 Min

1

30

1

10

40 Min

1

30

1

20

30 Min

1

30

1

30

0 Min

1

30

1

40

10 Min

1

40

1

10

50 Min

1

40

1

20

40 Min

1

40

1

30

30 Min

Dispatched CW 26

Center

Work center descr.

1906

Lack 1

CW 27

Friday

Monday

15Min 1 / 10

0Min

1 / 10

Tuesday

10Min 1 / 20

Wednesday

15Min 1 / 40

Pool CW 26

Center

Order

SG

SK

600001540

1906

1

20

600001650

1906

1

10

600001666

1906

1

10

600001750

1906

1

40

CW 27

Friday

Monday

15Min 1 / 20 15Min 1 / 10 15Min 1 / 10 15Min 1 / 40

Tuesday

Wednesday

© SAP AG 1999

In this example the dispatching sequence is determined by the setup optimization function instead of by the sequencing key. In setup time optimization the standard value for setup is changed. This has the effect that the values for the duration and capacity requirements are recalculated using the formulas. The setup group key and setup group category are a prerequisite both for setup time optimization and for the sort sequence. A field Initial setup state has been integrated into the strategy profile. This field allows you to maintain a predecessor operation for the first operation to be dispatched so that a setup time adjustment can be executed. Operations are also deemed predecessor operations if they lie outside the planning period but within the evaluation period.

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LO230 9-7

User Exits Changes to operations Change options

Function Dispatch Reschedule Deallocate Update

Dates Standard values Work centers Sequence numbers of operation of orders

Sort selected operations

User-specific sort (function) module Dispatchin

ns g operatio

© SAP AG 1999

The user exit is an interface predefined by SAP. You can use the user exit to make customer enhancements without making changes to original SAP objects. The enhancement concept is dealt with in the course BC425. You access the user exit for changing operation data (CY190001) from the planning table with the menu options "Function - User". You can only access one user exit to sort capacity requirements (CYPP0001) using the interface defined in the program. If a user exit has been activated for the sort sequence then the sequence key is ignored. You can automatically fix time periods for dispatching on the capacity planning table using the enhancement (CY040001). In the table sections of the planning tables you can use the enhancement (CYPP0002) to fill the text fields with any user-specific data you like.

(C) SAP AG

LO230 9-8

Additional Functions 1

z Changing time periods z Generating a shift split z Hiding break times z Inserting date markers z Displaying multiple commitments

© SAP AG 1999

To change the time periods on the initial screen, choose Time profile. On the capacity planning table you can change the evaluation period and the planning period. On the capacity planning table (tabular form) you can also change the database read period. You can display the shift calendar for a capacity on the capacity planning table. You can define the properties of the shift split and the time fence belonging to it in Customizing for capacity leveling under Define time scale profile. You can specify that the system is to hide non-work periods that are common to all capacities when the capacity planning table is called up. You specify this in Customizing under Define time scale by setting the indicator Hide NW periods. To aid orientation you can insert date markers in the diagram section of the capacity planning table. In Customizing for the capacity planning table under Define chart sequence you must enter a color category in the chart position. In Customizing for capacity leveling under Define chart sequence you can specify that multiple commitments are automatically displayed in the capacity planning table.

(C) SAP AG

LO230 9-9

Additional Functions 2

z Creating an order z Copying data from other structures z Maintenance times of capacities

© SAP AG 1999

You can create a production order in both types of planning table. The order is scheduled automatically and you automatically branch back to the planning table to dispatch orders. On the capacity planning table you can copy data from other structures to production orders and maintenance orders. For example, you can copy material data from the structure MARA in the capacity planning table (tabular form) and in the capacity planning table (table section) using the sort layout key. If a work center is being maintained then the capacity at the work center carrying out the maintenance is not available at this time. This capacity is assigned an unchangeable commitment. To do this you must make the appropriate entry for the state of the machine in the maintenance order.

(C) SAP AG

LO230 9-10

Material Stock Curves

Dispatch

Deallocate

Capacity

Order

Operation

Work Centers June 97 W. Cntr Description 1310

Assembly I

Cap

July 97

CW 26

CW 27

CW 28

CW 29

2

Work centers June 97 Material 100-500

Order

July 97

CW 26

CW 27

CW 28

CW 29

18752

Material stock

© SAP AG 1999

You can hide and show a chart with material stock curves for the materials to be produced on the capacity planning table. These curves are not automatically updated but updating can be triggered if order data has been changed. The stock receipts are displayed in a daily period split for the material selected. The material is only displayed as a receipt once the last operation in the order has been processed. You can specify the type of stock curve in Customizing (available stock, safety stock, day's supply). The overall profiles SAPSFCG001 and SAPSFCG004 are equipped with this function. Prerequisites in Customizing: y In Define profile for capacity planning table you must specify the axis- and curve representation selection. y In Define requirements grouping you must define a grouping with the usage “1” = material stock curve. y In Define layout you must maintain for the material stock curves a further chart with an appropriate grouping and sort. y In Define chart chart sequence you must maintain a chart position for the other chart and activate Use as histogram.

(C) SAP AG

LO230 9-11

Planning in Non-Work Periods / Fixing

Dispatch

Deallocate

Order

Capacity

Operation

Work Centers June 97 W. Cntrs

Description

July 97

Cap CW 26

1310

Assembly I

1320

Assembly II

2

CW 28

CW 27

CW 29

Company holiday

Planning period fixed

Work centers June 97 Material

Order

100-500

18752

500-300

600001650

CW 26

July 97 CW 27

CW 28

CW 29

© SAP AG 1999

Planning in non-work periods is especially useful for plant maintenance. With this function you can dispatch operations to non-work periods without first changing the available capacities in the work centers. The indicator Planning in non-work periods determines that during dispatching the system ignores the calendar, operating times and available capacities. Then a full 24 hours are available for the available capacity. You can fix planning intervals on the capacity planning table. You can no longer change planning in these time intervals. You cannot deallocate or reschedule operations in these periods and new operations cannot be dispatched to them.

(C) SAP AG

LO230 9-12

Temporarily Saving Results of Planning

Leveling Variable Own overall profile SAPSFCG016 Only on capacity planning table (graphical)

Reading the most important order data No locking of orders when reading

Restricted planning functions No changing of orders No changing of available capacity No planning of individual capacities

© SAP AG 1999

You can temporarily save planning results without automatically leaving the planning table by calling up the capacity planning table with the overall profile SAPSFCG016. You can see information on the result in a saving log. Conditions: In the control profile the indicator Restrict. plan must be set and the GUI-status, change status SAPPLT05, for the pull-down menu. Midpoint scheduling should be turned on to update the planning table. Otherwise an inconsistency will arise when temporarily saving because the orders will have been rescheduled.

(C) SAP AG

LO230 9-13

Mass Processing

Work Centers CW 26 1310

Order 4711 Order 4725 Order ........ . . .

CW 27

CW 28

CW 29

CW 28

CW 29

Assembly

Work Centers CW 26

CW 27

18752

JO

B

100-500

Mass dispatching online / batch

© SAP AG 1999

Mass processing in production planning and control can be used anywhere where large amounts of data is being processed. The main use if with automatic dispatching and deallocating of operations for preselected work centers in batch. For example, you can specify that for specific work centers at the start of each week the pool of orders is automatically dispatched. Mass dispatching can affect the following profiles by calling up the overall proflile: y Selection profile y Strategy profile y Time profile Requirement grouping and planning are of no significance to individual cpacities.

(C) SAP AG

LO230 9-14

Capacity Planning with Production Versions

Material master (MRP 4) Version 1

Version 2

Dispatched Center

Description

Cap.

Ctr A

Assembly I

2

Ctr B

Assembly II

2

Ctr C

Assembly III

2

CW 26

CW 27

CW 28

CW 29

CW 27

CW 28

CW 29

Version 3

Center A

Center B

Center C

Routing group 1/1

Routing group 1/2

Routing group 1/3

Op. 10 Ctr 1020

Op. 10 Ctr 1020

Op. 10 Ctr 1020

Op. 20 Ctr A

Op. 20 Ctr B

Op. 20 Ctr C

Op. 30 Ctr 1022

Op. 30 Ctr 1022

Op. 30 Ctr 1022

Pool Material Order

Center

100-500

18752

Center A

100-500 18767

Center B

100-500 18752

Center B

CW 26

NEW in pool

Customizing - strategy profile Indicator Reschedule with production version Dispatching function Change production version on error

© SAP AG 1999

If it is necessary to process an operation at another work center because of insufficient capacity in a planning period, then a different work process is usually necessary. Not only does the work center change but also data concerning times. If the operations to be dispatched involve planned orders then you can read in the routing again and schedule it again. A condition is that production versions with alternative routings and production lines must be maintained in the material master. These production lines must also be used in the routing. In Customizing the indicator Rescheduling with production versions must be set. With manual rescheduling to a bottleneck work center the new version is read in, scheduled and dispatched. With the dispatching function Change production version on error the next production version is copied to the planned order with automatic dispatching and manual dispatching. The planned order is scheduled again but not dispatched. With the strategy indicator Terminate when rescheduling with production version the system ensures that an operation that is meant for a bottleneck work center can only be dispatched manually to a bottleneck work center of another version. Note: When the planning table is called up using the work center view only the work centers previously selected are displayed. If the operations that were scheduled again using the planned order are to be displayed on the planning table then these work centers should be selected when you call up the planning table.

(C) SAP AG

LO230 9-15

Notes on Documentation

z Changing the color of graphical objects

Useful notes → Color of graphical objects

z Changing size of display of data on the planning table

Useful notes → Change display area

z Copying and changing overall profiles

Call up overall profile and use pushbutton CHECK

© SAP AG 1999

(C) SAP AG

LO230 9-16

Extended Planning Functions: Summary

z You now know about extended planning functions in capacity planning. z You know how to change colors of graphical objects on the capacity planning table.

© SAP AG 1999

(C) SAP AG

LO230 9-17

Extended Planning Functions Exercises Unit: Extended Planning Functions Topic: Sequencing

At the conclusion of these exercises, you will be able to: • Dispatch an operation at the best time for setup • Dispatch operations using setup time optimization.

In order to achieve optimal use of your resources, you want to reduce setup times using appropriate dispatching sequences. You therefore create a setup time matrix and create setup group categories and setup group keys to optimize dispatching using planning strategies.

1-1

Carry out sequencing for the work center T-L##. You want to dispatch an operation to already dispatched operations, and at the best time for setup. 1-1-1 Create a production order for the material T-F1## with a quantity of 150 pieces, starting in 2 weeks. 1-1-2 Call up the capacity planning table for the work center T-L## and the capacity category 001 using the menu option Variable with the overall profile SAPSFCG014. Look at the setup group category and setup group key for operation 30. 1-1-3 Use the strategy Dispatch at earliest possible time to dispatch the operations with an operation quantity of 80, 120, 130 and 150. 1-1-4 Now dispatch the operation with the operation quantity 500 using the strategy Dispatch at best time for setup and not Dispatch at earliest point in time. 1-1-5 Leave the planning table without saving.

1-2

Carry out sequencing for the work center T-L##. You want to dispatch several operations using setup time optimization. 1-2-1 Call up the capacity planning table for the work center T-L## and the capacity category 001 using the menu option Variable with the overall profile SAPSFCG014. 1-2-2 Make a note of the order number and the setup times for an operation with a setup group key 20, and for another with a setup group key 40.

(C) SAP AG

LO230 9-18

Order no. _________ Setup time _____ Order no._________ Setup time ____ 1-2-3 Dispatch all the operations using the strategy Setup time optimization. 1-2-4 Analyze the adjusted setup times. 1-2-5 Compare the result with the setup matrix in Customizing. 1-2-6 Leave the planning table without saving.

(C) SAP AG

LO230 9-19

Exercises Unit: Extended Planning Functions Topic: Other Functions

At the conclusion of these exercises, you will be able to: • Select the graphical objects that belong together • Display material stock curves • Save the planning results temporarily

2-1

Call up the capacity planning table with Leveling -> Work center view for the work center T-P##. 2-1-1 Select all the operations for material T-F2##. 2-1-2 Select all the operations in the chart. 2-1-3 What is the difference? ___________________________________________________________

2-2

Now dispatch the selection operations in the chart and analyze the material stock for material T-F2##.

2-3

Shift an operation into the past and update the material stock curve. Leave the planning table without saving it.

2-4

You want to temporarily save the results of planning without having to call up the planning table again. Call up the planning table with the overall profile SAPSFCG016. Dispatch some operations from the area you are responsible for and temporarily save the simulation results up to that point.

(C) SAP AG

LO230 9-20

Exercises Unit: Extended Planning Functions Topic: Mass Dispatching

At the conclusion of these exercises, you will be able to: • Dispatch or deallocate operations in the background

In your company the capacity requirements are very high and you therefore want to dispatch or deallocate your requirements at specific points in time.

3-1

You want to define the control parameters for deallocating operations at the work centers T-P## and T-V##. To do this, call up capacity planning by choosing Leveling > Variable. Enter the name CRP-A## in the field Job name. Mass dispatching should be executed using the overall profile SAPSFCG001.

3-2

After saving the parameters, you now want to define the batch job for dispatching. (The indicator Redefine selection must be empty, and the overall profile is set) 3-2-1 Now create a variant CRP-VA## and link this to the job name. The variant should be called GR##-deallocate. The variant links the job name with a report for executing mass processing. If a variant is already assigned to a job name, then this job name is also copied over. 3-2-2 Select the variant you have saved for dispatching. 3-2-3 Define the parameters as follows: Date Time 2 minutes later Dispatch once

(C) SAP AG

LO230 9-21

3-2-4 Look at the progress of the job.

Additional exercise, if you have sufficient time. 3-3

(C) SAP AG

You now want to dispatch all the operations for the work center T-P## using mass processing. To do this, create the relevant parameters and variants. Use the job name CRP-E##, and the variant CRP-VE##.

LO230 9-22

(C) SAP AG

LO230 9-23

Exercises Unit: Extended Planning Functions Topic: Production Versions

At the conclusion of these exercises, you will be able to: • Dispatch and reschedule operations using production versions

In your company, you are often forced to use alternative resources for some of the bottleneck work centers. This changes the processing procedure and also the standard times. Therefore, you prepare alternative work processes in the form of production versions to manufacture these products. A planning strategy then accesses these versions when dispatching operations to a work center that does not have remaining available capacity. 4-1

You need scheduled planned orders to carry out capacity planning with production versions. Look at the material T-F2## in the stock-/requirements list and try to get an overview of the planning situation. 4-1-1 First set all production orders to technically complete. 4-1-2 Carry out an MRP run with lead time scheduling for planned independent requirements, and look at the planning result.

4-2

Look at the material master and make a note of the critical work centers for your production versions. Also note that every production version has its own routing which contains the adjusted processing procedure and the adjusted standard values. Look at these routings. 4-2-1 Look at the material master for the material T-F2## and complete the following table: Version

Work center

Task list groupTskLstCounter

1

______

__________

3

2

______

__________

4

3

______

__________

5

4-2-2 Use the task list groups and task list counters from exercise 4-2-1 to give yourself an overview of your routings for material T-F2##. (C) SAP AG

LO230 9-24

4-2-3 Define your work center T-V## in such a way that the operations can be dispatched without any gaps. 4-3

For dispatching, call up the overall profile T-G001 for the work centers specified in exercise 4-2-1 for the capacity category 002. Save this selection as variant FV-GR## with the description Production version-##. 4-3-1 First dispatch the operations for the planned order with the order quantity 100 by choosing the functions Edit → Select → Selection. 4-3-2 Shift the dispatched operation to the work center T-V## to two weeks before the end of the planning period. 4-3-3 Select two more operations from the pool and dispatch these as well. Then look at the dispatching log. 4-3-4 Dispatch another operation and look at the planning results on the planning table. Also look at the planning log.

(C) SAP AG

LO230 9-25

Extended Planning Functions Solutions Unit: Extended Planning Functions Topic: Sequencing

1-2

Carry out sequencing for the work center T-L##. You want to dispatch several operations using setup time optimization. 1-2-4 Analyze the adjusted setup times. Functions → Adjust setup time → Manual 1-2-5 Compare the result with the setup matrix in Customizing. Customizing: Capacity planning → Master data → Routing data → Define setup matrix

(C) SAP AG

LO230 9-26

Solutions Unit: Extended Planning Functions Topic: Other Functions

2-1

Call up the capacity planning table with Leveling -> Work center view for the work center T-P##. 2-1-1 Select all the operations for material T-F2##. Select an operation for material T-F2##. Edit → Select → Objects that belong together 2-1-3 In 2-1-1, the operation for material T-F1## was not selected.

2-2

Now dispatch the selection operations in the chart and analyze the material stock for material T-F2##. Extras → Material stock → Show

(C) SAP AG

LO230 9-27

Solutions Unit: Extended Planning Functions Topic: Mass Dispatching

3-1

You want to define the control parameters for deallocating operations at the work centers T-P## and T-V##. Capacity planning → Leveling → Variable → Background → Execute Parameters for mass processing Overall profile: SAPSFCG001 Redefine selection: Set indicator Action: Deallocate Call up function: Save parameters Execute button Specify work centers Continue button

3-2

After saving the parameters, you now want to define the batch job for dispatching. (The indicator Redefine selection must be empty, and the overall profile is set) Back twice Capacity planning → Leveling → Variable → Background → Execute Enter your job name CRP-A## and the overall profile SAPSFCG001. Call up function: Dispatch background job Execute 3-2-1 Now create a variant CRP-VA## and link this to the job name. Create variant and Continue Enter CRP-VA## and Create Specify the job name CRP-A## Continue Meaning: GR##-Deallocate Save

(C) SAP AG

LO230 9-28

3-2-2 Select the variant you have saved for dispatching. Back Place cursor on the variant and press Dispatch 3-2-4 Look at the progress of the job. Display scheduling button

(C) SAP AG

LO230 9-29

Solutions Unit: Extended Planning Functions Topic: Production Versions

4-1

You need scheduled planned orders to carry out capacity planning with production versions. Look at the material T-F2## in the stock-/requirements list and try to get an overview of the planning situation. Production control → Control → Stock-/reqmts list 4-1-1 First set all production orders to technically complete. Production control → Control → Mass processing Material number T-F2## Action Complete technically Technical data without the indicator for Test run Execute button 4-1-2 Carry out an MRP run with lead time scheduling for planned independent requirements, and look at the planning result. MRP → MRP → Sng.item sng.-level For material T-F2## with indicator 2 in the Scheduling field Process control parameters with Display result indicator Save button

4-2

Look at the material master and make a note of the critical work centers for your production versions. Logistics → Production → Master data → Material master → Material → Display → Display current status View MRP 4 Versions button Cursor on a version and Detail button to make a note of the work center in the Production line field and the group with the group counter. Next version button 4-2-2 Use the task list groups and task list counters from exercise 4-2-1 to give yourself an overview of your routings for material T-F2##.

(C) SAP AG

LO230 9-30

Logistics → Production → Master data → Routings → Routings → Routing → Display Specify the material number T-F2## and plant 1000 Goto object overview Overview variant 000000000001 4-2-3 Define your work center T-V## in such a way that the operations can be dispatched without any gaps. In the capacity header, it should not be possible to use the capacity type for several operations. 4-3 4-3-1 First dispatch the operations for the planned order with the order quantity 100. Select a line with an operation for a planned order with the quantity 100 pieces. Edit → Select → Selection Only select order Edit → Select → Objects that belong together Dispatch button

(C) SAP AG

LO230 9-31

Detailed Planning

Contents: z Allocation of individual capacities and persons z Qualifications z Splitting and allocating

© SAP AG 1999

(C) SAP AG

LO230 10-1

Detailed Planning: Unit Objective

At the end of this unit you will be able to: z Explain capacity planning for individual machines and persons. z Maintain the master data required for individual capacities and persons. z Select employees qualified to carry out a specific operation. z Define data required in HR to create qualifications and requirements profiles. z Use split categories and make selections using a hitlist. z Confirm splits. © SAP AG 1999

(C) SAP AG

LO230 10-2



Capacity evaluation


Jul' 98

W 26

W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699

Extended planning functions

Detailed planning Integration

© SAP AG 1999

(C) SAP AG

LO230 10-3

Detailed Planning: Business Scenario

z Because of the continually growing competition and the market’s demands regarding quality, it is necessary to carry out planning in more detail. Therefore you must dispatch the capacity requirements of the incoming orders to individual machines or the appropriate persons.

© SAP AG 1999

(C) SAP AG

LO230 10-4

Application Criteria for Splits

z Planning of individual capacities and persons z Planning beneath the normal operation level (capacity requirements) z Planning in more detail than work centers or capacities z Splitting capacity requirements for the purpose of assigning work to machines or for planning human resources in the short term z Use at the level of production control and in the applications that also use human resources (PD, PM, PS)

© SAP AG 1999

A split is a partial capacity requirement that must be assigned to an individual capacity. The creation of individual capacities in defined in Customizing by the capacity category. Splitting involves the splitting of quantities or standard values.

(C) SAP AG

LO230 10-5

Levels of Detail

Plant 1000 Cost center 4210 ... Machine group 1901

Cost center 4220 Machine group 1904

...

Machine group 1113

Capacity category machine Pooled capacity setup Person A Person B ...

Individual machine - 1 Individual machine - 2 ... Capacity category Person Person 1 Person 2 ...

© SAP AG 1999

Detailed planning of resources and commitments up until now required maintaining a machine or an employee as a work center. By subdividing the capacities at a work center into individual capacities the work involved in maintaining them is significantly reduced. If no available capacity has been maintained for the individual capacities then the available capacity of the main capacity is used. Any number of people from the Personnel System or other individual capacities can be assigned to every capacity when maintaining work centers and pooled capacities. The corresponding requirements can be assigned and dispatched on either of the planning tables.

(C) SAP AG

LO230 10-6

Capacity Assignments

Capacity category: Labor

Capacity category: Not labor

Position Individual capacity Qualification

Person

Checks made against HR - tables © SAP AG 1999

These four elements can be assigned to the capacity. The possible assignments depend on the capacity category. You can only maintain links to persons, qualifications and positions if the SAP Human Resources (HR) module has been implemented. These assignments can also be made to the work center header. Assigning individual capacities to a capacity allows you to carry out more detailed planning within capacity planning. This assignment allows you to divide up the capacities for example into individual machines for which available capacities can also be maintained. Linking persons with the capacity allows you to specify individual employees who are selected to work at this capacity. The assigned persons must already exist in the human resources system. Assigning a qualification to a capacity guarantees that a person will be selected to work at this capacity who has appropriate qualifications. You specify which qualifications are required for someone to work at the capacity. If the capacity is assigned to a requirements profile then the qualification is determined by the requirements profile.

(C) SAP AG

LO230 10-7

Qualifications - Objectives

z Search for people,

who can carry out an operation

who can work at a specific work center

who are in a position to carry out a particular job

z Direct assignment of operation to a person

© SAP AG 1999

In addition to purely manual assignment of individual capacities you can also select personnel with the right qualifications on the basis of qualification specifications resulting from data entered in the: y work center, y work center capacity and y operation. You can maintain these qualifications or requirements profiles in the personnel system. You can also save positions in the operation (the former serve as the bearers of qualifications). All the data is linked when selecting a suitable person.

(C) SAP AG

LO230 10-8

Qualifications - Abilities Required

Routing / order

Work center

Capacity

10 20 30 Requirements profiles, job or position

Requirements profiles, qualifications

Requirements profiles, qualifications

© SAP AG 1999

In the routing and in the order you can attach requirements profiles, a job and a position to an operation. You can assign requirements profiles and qualifications (with characteristics) to work centers and capacities.

(C) SAP AG

LO230 10-9

Qualifications - Assignments

Person Mr. Mr. Smith

Requirements profile Position Maschine operator A1

NC Programming experience

Qualifications/ requirements

At least 3 years in the machining room Certified with QM deparment Experience in drilling Experience in lathing Knowledge of English

© SAP AG 1999

You define a requirements profile in the HR System. To work with the profile it must be linked with one or more qualifications. You can assign a characteristic to every qualification. An HR work center must be created if requirements profiles are to be assigned in work center maintenance. This is not necessary with an assignment to a capacity with the category "labor". Labor can also be assigned to positions.

(C) SAP AG

LO230 10-10

Requirements Profiles

Required Qualifications

Requirements profile

Safety note

SAP course

NC prog. experience

Assignments

Operation

Profile A

Work center

Capacity

© SAP AG 1999

When you maintain work centers or capacities you can assign more that one object from the PD system. However, since this close connection does not exist for operations, you cannot assign more than one PD object to an operation. Another way of assigning multiple qualifications (requirements) to an operation consists in using jobs and positions or the new object, the ”requirements profile”. As always, you define a requirements profile as an object in the PD system. To work with the profile, it must be linked to one or more qualifications. You can assign a characteristic and a priority to each qualification. You can use requirements profiles with work centers and with capacities. It is up to the user whether he wants to assign only qualifications or only requirements profiles or both.

(C) SAP AG

LO230 10-11

Splitting and Allocating

Work center / capacity

Capacity: Machine

Capacity: Labor

Assign Capacity requirements: Machine

Capacity requirements: Labor

© SAP AG 1999

You can assign any number of individual capacities or persons from the personnel system (PD) to each capacity in work center maintenance. If no available capacity has been maintained in an individual capacity then the available capacity is calculated using the operating time of the main capacity. Capacity requirements can be assigned either partly or wholly to individual capacities. Finite scheduling is not possible for individual capacities. You can assign all of the capacity requirements to people or individual capacities using the ”drag and drop” function. You do this on one of the two planning tables from the individual capacity view.

(C) SAP AG

LO230 10-12

Ranking List

Person

Requirements profile

Qualification with characteristic ( X )

Qualification with characteristic ( # )

Welding exam Knowledge of English Fitter

5 7 3

5 6 3

Welding exam Knowledge of English Fitter

Profile comparison Characteristic Welding exam Knowledge of English Fitter Foreman

0

1

2

3

4

5

6

7

#

x

8

9

x x #

© SAP AG 1999

The ranking list is the result of comparing the qualifications in the operation, the work center and the capacity on the one hand with the abilities of the individual employees on the other hand. The system compared the required qualifications of the operation, the work center and capacity with the abilities of the employee. The result is a so-called "ranking list". You can select an employee from this list to assign the capacity requirements to him.

(C) SAP AG

LO230 10-13

Types of Split

Quantity split or duration split Different capacities

Different times

50

100

50

50

50

Standard values split or work split

10 h labor time for 100 pieces

5 h labor time 5 h labor time

Different capacities work on the same lot or the same job at the same time but carry out partial jobs.

© SAP AG 1999

There are several types of splits available. The data that is used to define splits depends on the type of operation (operations with work elements or internally processed operations). In the case of operations with work elements (SFC) you can split either the quantity or the standard values of the capacity requirements (or both if this makes sense). In the case of internally processed operations (PS, PM, PP-PI) you can split the work or the duration. Splitting the quantity corresponds to splitting the duration and splitting the standard values corresponds to splitting the work. It makes sense to split the quantity if parts of the task are to be carried out either by two or more individual capacities at the same time or by one or more individual capacities at different times and there are gaps between them. If an operation can be split into two or more partial tasks that can be executed by different individual capacities at the same time and for the whole quantity then it makes sense to use the standard value split. In very specific cases it can be useful to split both the quantity and the standard values. This is also possible.

(C) SAP AG

LO230 10-14

Confirmation of Splits

z The confirmation of an individual split is identified by its confirmation number. z Summary confirmation are possible with percentage values. z Capacity requirements for operation can be reduced when splits are confirmed (Customizing).

© SAP AG 1999

A summary confirmation can only be carried out for splits that have not been partially or finally confirmed. The capacity requirements for the splits that were not partly or finally confirmed are reduced when the operation is finally confirmed. For example, that is possible in the case of splits with very small requirements where a confirmation would mean too much work. If the requirements for the operation are only partly distributed over splits then the split requirements are reduced when the split is confirmed. The remaining requirements that were not distributed to splits are only reduced when the operation is confirmed.

(C) SAP AG

LO230 10-15

Detailed Planning: Summary

z In this unit detailed planning was explained

by linking individual capacities with the main capacity.

© SAP AG 1999

(C) SAP AG

LO230 10-16

Detailed Planning Exercises Unit: Detailed Planning Topic: Assigning Individual Capacities

At the conclusion of these exercises, you will be able to: • Assign individual capacities to a work center • Assign people and qualifications to a work center

The capacity planners in plant 1000 must assign specific machines and/or persons to specific operations in contrast to other plants that only have to assign work at work center level. Test this functionality by first assigning the three machines to the machine work center. Assign the two people who are to prepare the parts to be processed to the appropriate labor work center. 1-1

Assigning individual capacities to a work center. 1-1-1 Assign to the work center T-L## the three following individual capacities: L1## (machine 1) to L3## (machine 3). Assign these individual capacities to the machine capacity category. 1-1-2 Change the standard available capacity from L1## and L2## as follows: The day should begin at 5:00 and finish at 14:00. The break for each machine lasts 1 hour. L3## has the same hours as the standard available capacity of this capacity category. 1-1-3 Save the changes to the work center.

1-2

Assigning people and qualifications to a work center. 1-2-1 Assign Manfred Weinig and Udo Schüttler to the labor capacity at work center T-M##. Note: Use the standard matchcode. Check the persons assigned. 1-2-2 To work at the work center certain technical knowledge is required. Maintain the following qualifications with the characteristics:

(C) SAP AG

LO230 10-17

Qualification

Characteristic

Business Process Technology

Good

Knowledge of materials Very good Quality management

Very good

As a help tool, use the structure search. 1-2-3 Save the changes to the work center.

(C) SAP AG

LO230 10-18

Exercises Unit: Detailed Planning Topic: Allocating and Dispatching Splits

At the conclusion of these exercises, you will be able to: • Assign capacity requirements to machines or people using the capacity planning table

The person responsible for the machine must define the order operations as specific machines and people, for which and for whom he is responsible. First he wants to allocate or split the work among the machines and persons before he dispatches the operations. When the work is ready, he would dispatch the operations to the work center on the basis of these splits. 2-1

Creating a production order for splitting. 2-1-1 Create a production order for the material T-F2## with the order category PP01 in plant 1000. Order 100 pieces, scheduled forwards as of next Monday. 2-1-2 Once the availability check is complete, release the order and save it. Make a note of the order number: ______________________

2-2

Allocating and dispatching with persons on the capacity planning table. 2-2-1 Start capacity leveling for individual capacities (machines 1 to 3) for the work center T-L## in plant 1000 for the capacity category 001. 2-2-2 Select the production order from exercise 2-1 from the pool of orders for the orders to be dispatched. Split the operations and allocate it to the appropriate machines. Every machine should process the whole operation quantity but with different standard values: Machine 1 = 2 minutes, machine 2 = 2 minutes and machine 3 = 1 minute. 2-2-3 What are the two changes on the planning table with respect to the order that you have just split? _____________________________________________________ _____________________________________________________

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LO230 10-19

2-2-4 Dispatch the splits and save the changes on the planning table. 2-3

Allocating and dispatching with persons on the capacity planning table. 2-3-1 Start capacity leveling for the individual capacities at the work center T-M## in plant 1000 for the capacity category 002. 2-3-2 Select the production order (from exercise 2-1) from the pool of orders to be dispatched. Split the operation and allocate the most suitable employee a quantity of 60 and the other employee a quantity of 40. Dispatch the splits and save the changes made on the planning table. 2-3-3 Save the changes made to the planning table.

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LO230 10-20

Detailed Planning Solutions Unit: Detailed Planning Topic: Assigning Individual Capacities

1-1

Assigning individual capacities to a work center. 1-1-1 Assign three individual capacities to work center T-L##. Logistics → Production → Master data → Work centers → Work center → Change Select Capacities for the capacity category Machine (001), and select Capacity header. Choose Goto → Indiv.capacities 1-1-2 Change the standard available capacity from L1## and L2##. Double-click on L1##. Define the standard available capacity.

1-2

Assigning people and qualifications to a work center. Logistics → Production → Master data → Work centers → Work center → Change Select Capacities for the labor capacity category (002), and select Capacity header. Select Goto → HR assignment. Double-click on the person and enter the last name in the dialog box. Copy Expand person

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LO230 10-21

1-2-2 To work at the work center, certain technical knowledge is required. Maintain the following qualifications with the characteristics Back to the capacity header Choose Goto → HR assignment. Click on the button Qualifications and then Create. Expand Technical knowledge general Select the qualifications Copy Evaluate the characteristics using the entry help.

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LO230 10-22

Solutions Unit: Detailed Planning Topic: Allocating and Dispatching Splits

2-1

Creating a production order for splitting. Logistics → Production → Production control → Order → Create → With material Scheduling category 1 2-1-2 Once the availability check is complete, release the order and save it. Order → Functions → Release

2-2

Allocating and dispatching with persons on the capacity planning table. 2-2-1 Start capacity leveling for individual capacities (machines 1 to 3) for the work center T-L## in plant 1000 for the capacity category 001. Logistics → Production → Capacity planning → Leveling → Individual capacity view → Capacity planning table 2-2-2 Select the production order from exercise 2-1 from the pool of orders for the orders to be dispatched. Split the operation and allocate it to the appropriate machines. Select the operation Split/allocate Assign machines and split quantity Standard values button Change the standard values for the machine to 2, 2, 1 Enter 2-2-3 The splits are displayed in the chart Splits (not dispatched). In addition, the requirements were divided up amongst the machines.

2-3

Allocating and dispatching with persons on the capacity planning table. Logistics → Production → Capacity planning → Leveling → Individual capacity view → Capacity planning table

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LO230 10-23

2-3-2 Split the operation and allocate the most suitable employee a quantity of 60 and the other employee a quantity of 40. Select the production order (from exercise 2-1) from the pool of orders to be dispatched. Split/allocate button Ranking list – (percentage) Select suitable person for quantity 60 – Assign the second employee the quantity 40. Set the Dispatch (D) indicator for both split records.

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LO230 10-24

Integration

Contents: z Planning levels z Capacity planning integrated with:

Sales and Distribution

Sales and Operations Planning (SOP)

MPS/MRP

Long-Term Planning

Repetitive Manufacturing

Shop Floor Control

© SAP AG 1999

(C) SAP AG

LO230 11-1

Integration: Unit Objectives 1

By the end of the unit you will understand: z The overall integration of capacity

planning on different planning levels z The integration types in capacity planning z Profiles that are used for the various

planning levels z The integration of Sales and Distribution

with capacity planning z Rough-cut planning in SOP

© SAP AG 1999

(C) SAP AG

LO230 11-2

Integration: Unit Objectives 2

z Using capacity planning in MRP/MPS z Capacity planning in long-term planning z Capacity leveling in repetitive manufacturing z Shop floor control functions that are relevant to

capacity planning (production orders, operations).

© SAP AG 1999

(C) SAP AG

LO230 11-3



Capacity evaluation


W 26

Jul' 98 W 27

W 28

W 29

W 28

W 29


1310 1320

Mont. 1

1330

Mont. 2


Material

Scheduling

Jul' 98

Auftrag / Order


18752

500-300

600001650

100-500

18770

500-300

600001699

Extended planning functions Detailed planning

Integration © SAP AG 1999

(C) SAP AG

LO230 11-4

Integration: Business Scenario

z You want to plan the resources for the future for your company. For this purpose you need the capacity requirements, for example, already at the planning stage. This is possible when you, while creating a sales plan, calculate the capacity requirements in the individual production areas with a rough-cut planning profile. You can pass these requirements along the whole process chain and thus recognize your capacity load in each planning phase.

© SAP AG 1999

(C) SAP AG

LO230 11-5

Integration of Capacity Planning (2)

PP SOP PP MPS PP MRP PP REM

SD PM

Capacity Planning PP SFC

PM Service

PS

PD PP PI

© SAP AG 1999

The integration with the following functions is dealt with in this unit: y Sales and Distribution y Sales and Operation Planning (SOP) y MPS/MRP y Long-term planning y Repetitive manufacturing y Shop floor control The integration with other functions is dealt with in the relevant courses.

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LO230 11-6

CRP Along the Process Chain

Long-term planning LTP

Capacity planning

Sales and Operations Planning

SOP

Planned independent requirements Master production scheduling

MPS

Material requirements planning

MRP

Production order/ run schedule headers Shop floor control

SFC/REM

© SAP AG 1999

Sales and Operations Planning No detailed planning involving exploding bill of material and scheduling routing Rough-cut scheduling Master Product Scheduling Separate planning run only for master schedule items without further planning of the bill of material structure Scheduling: Rough-cut, - production-rate Material Requirements Planning Planning run with complete planning of bill of material structure Scheduling: Production-rate, - detailed Shop Floor Control Conversion of planning data from material requirements planning into concrete production orders Detailed scheduling Repetitive Manufacturing For the continuous production of a product that remains the same over a long perio Detailed scheduling Long-Term Planning To simulate several versions of the production plan

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LO230 11-7

Planning Phases MRP Including sales orders

SOP / MPS

Start

Sales plan

Material requirements planning Scheduling Changing planned dates

Demand program

Capacity planning

Master plan Capacity leveling Scheduling

Detailed

Production-rate

Rough-cut

SFC Creating production orders Scheduling Releasing production orders Order execution Confirmation

© SAP AG 1999

Scheduling and the calculation of capacity requirements can take place on different levels depending on the application area: y rough-cut scheduling y production-rate scheduling y detailed scheduling

(C) SAP AG

LO230 11-8

Integrated Planning Levels

SOP

MRP / MPS

Rough-cut planning

REM

Producton-rate planning SFC

Detailed planning

© SAP AG 1999

Capacity requirements are always attached to an order. If there are several capacity requirements for a material from various planning levels they are copied when the planned order is converted to the production order. Rough-cut planning y Long-term, aggregate y Bottleneck resources y Planning in periods with rough-cut planning profiles Production-rate planning y Medium-term y Bottleneck resources y Period-related with rate routing Detailed planning y Short-term y Individual capacity/labor y Planning to exact points in time with routing

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LO230 11-9

Simultaneous Use of Different Planning Levels

Production line Productionrate scheduling

Run schedule header Inspection work center

Detailed scheduling

Production order Work center Work center 1 2

Work center 3

Work center 4

© SAP AG 1999

Repetitive manufacturing and discrete manufacturing can take place in the same plant. In this example, run schedule headers and production orders are used with the same plant maintenance work center. The production orders and plant maintenance work centers use detailed scheduling. Repetitive manufacturing uses production-rate scheduling.

(C) SAP AG

LO230 11-10

Overall Profiles in the Applications

Overall profiles

z SOP

Special planning table (tabular)

SAPSOPG001

z MPS/MRP

Planning table (graphical) Capacity situation (tabular)

SAPMPSG010 SAPMPS G011 SAPMPS G001 SAPMPSG002 SAPMPSG003 SAPMPSG014 SAPCRPG001 SAPCRPG0 02

z SFC

Planning table (graphical) Planning table (tabular)

z REM

Special planning table (tabular) Planning table (graphical)

© SAP AG 1999

The table only contains a selection of the most important profiles.

(C) SAP AG

LO230 11-11

SAPSFCG001 SAPSFCG0 02 SAPMPSG004 SAPMPSG0 05

Integration Types

Application-specific planning table

Planning application

Cap.plan.table

Capacity planning module

Integration type 1

SOP/ MPS/ MRP/ REM

Integration type 2

MPS/ MRP/ REM/ SFC/ SD/ PS / PD

Integration type 3

SFC/ PS/ PM/ PP-PI

Calling up capacity planning using menu

Feedback 1, 2, 3 © SAP AG 1999

Integration type 1 The capacity planning mode is used by the applications as a source of capacity planning data. Integration type 2 The capacity planning module and the planning tables are called up by an application. Integration type 3 The capacity planning module and the planning tables are configured as a separate system for a special view.

(C) SAP AG

LO230 11-12

Cap.plan.table (tab.)

Integration: Sales and Distribution (SD)

Sales order

Production order

Planned order

Network

Capacity planning

© SAP AG 1999

Once a sales order has been created a production order, a planned order or a network can be generated automatically. The planning table can be called up directly from these orders in display mode. Changed data is then copied back to the sales order. Integration type 2

(C) SAP AG

LO230 11-13

Integration: Sales and Operations Planning Planning Table (SOP)

Material

5/99

6/99

7/99

8/99

9/99

5/99

6/99

7/99

8/99

9/99

Sales Production Stock

Resources Resource 1 Avail. cap. Cap. load Cap. reqmts Resource 2 Avail. cap. © SAP AG 1999

SOP uses the two-part tabular version of the planning table for capacity leveling. In the upper section you can enter the following data for a material or for a product group for specific periods: y Planned sales y Planned production quantity y Warehouse stock and target stock The capacity requirements are generated by the planned figures that are entered in the line for production (the so-called requirements entry line). The lower section displays the capacity requirements from Sales and Operations Planning and the available capacities of the work centers where the material or product group is to be manufactured and its load. Only SOP requirements are displayed on this planning table. Integration type 1

(C) SAP AG

LO230 11-14

Integration: MRP/MPS

Capacity situation for the material Stock-/ reqmts list

Planning table graphic Capacity situation for the order

Capacity check Planned order Capacity leveling

Capacity leveling for the material Interactive planning

Planning table graphic Capacity leveling for the order

© SAP AG 1999

In MRP/MPS two lists are displayed on which the planning periods are shown on a vertical axis: y Capacity leveling - to carry out leveling with changes y Capacity situation - only display data The capacity situation or capacity leveling can be called up for all planned orders for a material or for just one planned order. The following data is displayed for a work center per period: y Available capacity of work center in a period y Overall capacity load of work center resulting from all planned orders and production orders in a period. y Capacity requirements generated by the material for which planning was carried out in a period. By changing the order quantity and the basic order date, it is possible to reduce overloads and underloads for the work center in question.

(C) SAP AG

LO230 11-15

Integration: Long-term Planning 1

Independent of operative planning

Comparison with operative planning

Several parallel scenarios

Planning for all MRP levels

Long-term planning

Reporting as for operative planning

Bill of material for operative planning

Routing for operative planning

Master data for operative planning

© SAP AG 1999

Long-term planning gives you an overview of plans for production and procurement. You can use the simulated planning run to plan several versions of the production plan and check the results using special evaluations. The planning run and the evaluations in long-term planning are separate from the tools in MRP because long-term planning runs in simulation. Entries are written in a special planning file for long-term planning as are simulated capacity requirements for long-term planning. The description of the capacity planning functions in MRP is also valid for long-term planning. The result of long-term planning are the simulated planned orders at the level of the final material for the long-term planning version of the production program. Separate requirements lists are generated for long-term planning. In the long-term planning menu the stock-/requirements list is also available as is the planning situation for capacity planning. To compare the results of long-term planning with operative planning you can call up a comparison function from all the evaluations. The operative plan for a specific material can be compared directly.

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LO230 11-16

Integration: Long-term Planning 2

Simulated planned independent requirements

MRP/MPS

Simulated orders

Simulated dependent requirements

Simulated capacity planning

© SAP AG 1999

The following steps are necessary for long-term planning: Create the long-term planning scenario. The scenario defines the planned independent requirements versions that are used in the simulation, the assigned plants and the capacity version for scheduling. Create the simulated planned independent requirements. Run single-/multi-level long-term planning. Look at the results of long-term planning in capacity planning.

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LO230 11-17

Available Capacity and Requirements Versions

Sales and Operations Planning

Planned independent requirements transfer

change

Version 2

copy Version 03 Version 02

Available capacity version 1

Version 01

Simulated requirements © SAP AG 1999

You can create and maintain simulated independent requirements by copying them from other independent requirements or you can maintain them manually. You can assign several versions of independent requirements to a planning scenario.

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LO230 11-18

Integration: Repetitive Manufacturing (REM)

Production line view Capacity situation per period for production line selected The manufactured quantity per period for each material made on the production line

Material view Overall supply and demand in relation to material selected Capacity situation per period in relation to production line selected Production quantity per period for the corresponding production lines

© SAP AG 1999

Within repetitive manufacturing you can execute capacity planning from the point of view of the production line or the material. The tabular version of the planning table for repetitive manufacturing consists of two parts: The Aggregate Information is displayed in the upper section. The following data is displayed for the planning object: y Name of the production line y Available capacity of the production line y Total capacity requirements for the production line y The percentage capacity load resulting from the capacity requirements or the capacity requirements for run schedule headers that are processed on this line. In the section Detailed Information you can specify the quantities per period over a specific period of examination. From the quantities that you enter in the section Details on the Line per material per period the system calculates the capacity requirements and the load of the production line. Thus the quantities can be adjusted to the available capacities.

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LO230 11-19

Repetitive Manufacturing with Production Versions

P1

Material master Production version 1

X1 Production version 2

Production version 3

W3

R2

K1

N1

Bill of material

Routing Operation 1

Operation 2

Work center

© SAP AG 1999

A material can have several bills of material (BOMs) that determine the components for production. The production process can also be described in different routings. The data on the various methods used to manufacture the material are saved in the so-called production versions that are assigned to the material. Thus a production version can comprise the following data: y Alternative BOM and BOM usage for the BOM explosion y Task list type, group and group counter for the assignment of task lists (routings) y Lot size restrictions and validity period y Production line and storage location A material can have one or more production versions. Data on individual production versions are located at plant level. You can define the production versions as you like; however, every number must be unambiguous. You can use production versions to deal with the following situations: y Manufacture with various resources (for example, two different production lines) y Manufacture with various processes (for example, different routings) y Individual production quantities can be assigned to different production versions, for example to achieve a uniform utilization of the various alternative production lines.

(C) SAP AG

LO230 11-20

Integration: Shop Floor Control (SFC)

Create or change a production order

with Capacity planning profile

Work center view Individual capacity view Capacity planning menu

with

Order view

entry

© SAP AG 1999

Leveling of capacities directly during order maintenance Calling up capacity planning by selecting a role-specific view, such as the capacity planner or MRP controller Integration type 2 for calling up the planning table from order maintenance Integration type 3 for calling up the planning table using the menu When the order lot is changed the dispatched requirement is automatically deallocated but not when the order dates are changed.

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LO230 11-21

Integration: Unit Summary

z This unit explains the integration of capacity planning along the process chain.

© SAP AG 1999

(C) SAP AG

LO230 11-22

Integration Exercises Unit: Integration Topic: Rough-Cut Planning At the conclusion of these exercises, you will be able to: • Create a rough-cut plan for a product group, taking into account the available capacity

The planners for the pump product group must review the roughcut capacity plan before the production is approved. After the rough-cut plan is approved, the planners will disaggregate the plan to the individual materials and transfer the resulting independent requirements to demand management, ready for MPS/MRP processing. 1-1

Perform rough-cut planning. 1-1-1 Plan for product group. 1-1-2 Create an inactive plan for product group PG-100 with version 1##. Change descriptive text to Version-##. 1-1-3 Create a sales plan for PG-100 for 5 months, starting in the third period. Sales are 100 units per month. 1-1-4 Save your plan.

1-2

Display a rough-cut capacity profile. 1-2-1 Display the rough-cut planning profile for the product group PG-100 in plant 1000, and list the following values: Work center _________________ Time span _________________ Base quantity _________________ Usage _________________ Status _________________ Lot size

_________________

1-2-2 Look at the capacity situation for Sales and Operations Planning for the product group PG-100.

(C) SAP AG

LO230 11-23

Select [inactive version 1##] Look at the capacity situation. 1-2-3 Change the sales plan (and the production plan) in such a way that it corresponds to the available capacity. Then create the production plan again.

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LO230 11-24

Exercises Unit: Integration Topic: Repetitive Manufacturing

At the conclusion of these exercises, you will be able to: • Execute capacity leveling for repetitive manufacturing

The person responsible for the production line must dispatch work every week to production line 2 in plant 1200. Run schedule headers have been created for all the materials. The person responsible must check the run schedule header, the rate routing and the data for the production version.

2-1

Check the master data for repetitive manufacturing. 2-1-1 Look at the production versions in the material master for R-1000 in plant 1200. Make a note of the task list type and what this task list type means. _____________________________________________ 2-1-2 Look at the rate routings for material R-1000. Make a list of the task list groups and production lines that are that are used in this routing. Also look at the base quantity. ______________ _____________ ____________ ______________

_____________

____________

2-1-3 Look for a valid run schedule header for material R-1000 for production line 2. List the start and end validity dates.

2-2

(C) SAP AG

Validity start

_________________

Validity finish

_________________

Carry out capacity leveling on the planning table for LINE 2 in plant 1200. Set the indicator Capacity Planning and make a note of the correct scheduling type.

LO230 11-25

Note that generally only one capacity planner is responsible for a line. Therefore, save the results of your planning in this exercise.

2-2-1 Specify for the next week a quantity of 50 pieces for the material R-1000 for every working day. How big is the load for this line on these working days? ____________________________ 2-2-2 You want to maximize the load on this line and therefore increase the quantity on the first day of the week for this line. 2-2-3 On the second day of the week, you try to increase the load on the line by using other materials. 2-3

Call up capacity leveling with the capacity planning table and dispatch the requirements for Monday.

2-4

Only display the dispatched requirements on the planning table.

Do NOT save the planning table.

(C) SAP AG

LO230 11-26

Integration Solutions Unit: Integration Topic: Rough-Cut Planning

1-1

Execute rough-cut planning. 1-1-1 Plan for product group. Logistics → Production → Sales and Operations Planning → Planning → For product group → Create 1-1-2 Create an inactive plan for product group PG-100 with version 1##. Change descriptive text to Version-##. Product group: PG-100 Plant: 1000 Enter Version: 1## Version name: Version-## 1-1-3 Create a sales plan for PG-100 for 5 months, starting in the third period. Sales are 100 units per month. Edit → Create product. plan → Synchronous to sales

1-2

Display a rough-cut capacity profile. 1-2-1 Display the rough-cut planning profile for the product group PG-100 in plant 1000. Logistics → Production → SOP → Tools → Rough-cut plng profl. → Display Product group: PG-100 Plant: 1000 Execute Work center: 1310 Profile header button Time split: 5 working days Base quantity: 1 Usage: Universal Status: Released general Lot size: 1 to 3.450.000

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LO230 11-27

1-2-2 Look at the capacity situation for Sales and Operations Planning for the product group PG-100. Logistics → Production → Sales and Operations Planning → Planning → For product group → Create Inactive version button Select version 1## Enter Views → Capacity situation → Rough-cut planning → Show 1-2-3 Change the sales plan (and the production plan) in such a way that it corresponds to the available capacity. Then create the production plan again. Edit → Create product. plan → Synchronous to sales

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LO230 11-28

Solutions Unit: Integration Topic: Repetitive Manufacturing

2-1

Check the master data for repetitive manufacturing. 2-1-1 Look at the production versions in the material master for R-1000 in plant 1200. Logistics → Production → Master data → Material master → Material → Display → Display current status Material: R-1000 Enter Select MRP 4 Enter Plant: 1200 Enter (on the screen MRP 4) Button: Versions Detail button for the versions Task list type R. It is a rate routing. 2-1-2 Look at the rate routings for material R-1000. Logistics → Production → Master data → Routings → Routings → Rate routings → Display Material: R-1000 Plant: 1200 Enter Task list counter 1, Line 1, Base quantity 12 Task list counter 2, Line 2, Base quantity 15

2-1-3 Look for a valid run schedule header for material R-1000 for production line 2. Logistics → Production → Repetitive manufacturing → Master data → Run schedule header → Display Plant: 1200 Material number: R-1000 (C) SAP AG

LO230 11-29

Enter Start and finish validity dates: 05/12/95 until 12/31/xx 2-2

Carry out capacity leveling on the planning table for LINE 2 in plant 1200. Logistics → Production → Repetitive manufacturing → Planning → Planning table → Change mode MRP area and plant: 1200 Select production line Production line: LINE 2 Select the tab page Scheduling Indicator: Select Capacity planning Rate-based planning button Enter twice

2-3

Call up capacity leveling with the capacity planning table and dispatch the requirements for Monday. Capacity planning → Configure graphic

(C) SAP AG

LO230 11-30

Appendix

Contents: z This section contains additional material that can be used for reference purposes. z This material is not included as part of the standard course. z It could, therefore, be the case that this material is not dealt with during the course.

© SAP AG 1999

(C) SAP AG

LO230 12-1

Change Mode and GUI Status

Type of presentation

Planning table (tabular)

Planning table (graphical)

Status for change mode

Status for display mode

Cap. planning table

Type of presentation

Change

Status for change mode

Display

Status for display mode

Cap. planning table (tab.)

© SAP AG 1999

GUI status for display mode: You use this GUI status to define the menu structure for both types of planning table for the display mode. If you do not maintain the GUI status for the display mode the GUI status predefined in the system by SAP is used. GUI status for change mode: You use this GUI status to define the menu structure for both types of planning table for the change mode. If you do not maintain the GUI status for the change mode the GUI status predefined in the system by SAP is used.

(C) SAP AG

LO230 12-2

Layout of the Planning Table

Layout ID Chart 1

Work centers Monday 00:00 06:00

Work centers

Group 1

Sort key or sort-layout keys

Group 2

Tuesday 12:00

18:00

00:00

18:00

00:00

06:00


Orders Order. Op. Qty

Group 3

Group 4

Sort-layout keys

Sort-layout keys

2010

0010 10

2020

0020

2030

0010 10

Monday 00:00

06:00

Tuesday 12:00

06:00 Chart

Chart 2

5


Diagram section

Reqmts grouping © SAP AG 1999

The correct requirements grouping must be maintained for every chart otherwise the capacity requirements are not displayed in that chart. A sort-layout key must be defined for every order type, planned order and production order. These sortlayout keys are grouped together as a sort key.

(C) SAP AG

LO230 12-3

Chart Sequence

Chart

Work centers

z 1 - 8 charts z Each chart contains:

Pool

Title (language-dependent)

Color definition

Form

Chart


Height

Global calendar and calendar color

Time scale for every section of the time scale

Table heading incl. color and form definition

Diagram section

© SAP AG 1999

Every chart is a horizontal window within the planning table. If not all the charts fit into the screen then you can scroll along the chart sequence. Every chart contains a table section and a diagram section. The title, table heading and time scale are optional.

(C) SAP AG

LO230 12-4

Chart Sequence (cont.)

z

Graphics profile

Chart group

Form category z Form definition field definition

Color group

Color category z Color definition

Chart

Form group

Chart sequence

Chart category z Color definition

z

Chart category

Title

Form category

Color category

Table section

Form category

Color category

Diagram section

Graphical element group

Time scale profile

Options profile

Color category calendar

Color category time-now line

© SAP AG 1999

The chart group in the graphics profile contains all the settings that are needed to generate the structure of the planning table in the individual charts. It consists of several chart categories, such as 00 for the capacity planning table standard and 01 for the histogram. In the chart sequence a special assignement is made for every chart based on the settings in the graphics profile. You can specify the display of the visible sections of the chart, the colors and fonts using the chart category in Customizing. The graphics profile consists of the chart group, the form group, the color group, the options profile and the graphical element group. The graphical element group contains the forms such as lines, rectangles, triangles and symbols along with their colors. In the options profile you make specifications concerning the window, the processing mode and the colors.

(C) SAP AG

LO230 12-5

Actual Capacity Requirements

Capacity category Machine

Actual capacity requirements

Activity Setup time

11 10 9

12

1 2 3

8

4 7 6

Setup

5

Process Tear down

Capacity category Personnel

Actual capacity requirements

Activity Processing time

Activity Tear down time

11 10 9

12

1 2 3

8

4 7 6

11 10

12

5

1 2 3

8

4 7 6

Setup

5

Process Tear down

Activity Personnel time

11 10 9

12

1 2 3

8

4 7 6

5

© SAP AG 1999

The actual capacity requirement is the capacity requirement of a work order that has been torn down since the start of the order processing, or since the last confirmation. In the extended evaluation you can display the actual capacity requirements, as well as the target capacity requirements or remaining capacity requirements. z Activities in which every actual capacity requirement is evaluated. z Quantities, in which the formulas for determining the appropriate capacity requirements are used. You must have entered these formulas on the capacity tab page. Example: Assigning activities to actual capacity requirements z You have two capacity categories at your work center (for example: machine and personnel). Four activities are confirmed (for example: setup time, processing time, tear down time, and personnel time) for operations carried out at your work center. z You want the actual capacity requirements setup (or tear down) to be equated to the setup time activity (or tear down time). The actual capacity requirement processing will z be equated for the capacity category ‘machine’ in the ‘processing time’ activity z be equated for the capacity category ‘personnel’ in the ‘personnel time’ activity The assignment of activities and actual capacity requirements, which you must carry out, is shown in the diagram.

(C) SAP AG

LO230 12-6

LO230 - Capacity Planning

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