SAP APO PPDS for Automotive.pdf

Automotive with DI46C2 (SAP R/3)

IBS Manufacturing, IBU Automotive SAP AG

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Automotive with DI46C2 - 1

New Processes supported by SAP APO 3.1 Supply Chain Planning

Supply Chain Execution Supply Chain Coordination Supply Chain Networking

Supply Chain Design

Proc Pr ocur urem emen entt

Dema De mand nd Plan Planni ning ng

Manu Ma nufa fact ctur uring ing

Suppl Su pply y Plan Planni ning ng

Order Promising & Delivery

Supply Chain Ev Event Ma Management

Supply Chain Portal

Distribution Planning

Warehouse Management

Production Planning

Transportation Execution

Foreign Trade/Legal Services

Transportation Planning Fulfillment Coordination

Supply Chain Pe Performance Management

Collaboration Services

Supply Chain Integration

SC Planning

SC Execution

Integrated Supply&Production Planning

Multilevel ATP

Shelf Life (Production Planning)

Campaign Planning

Forecast Consumption based on DP Char.

Order Driven Final Mix & Packaging

Extended Demand Prioritization in CTM

IPPE based repetitive Manufacturing(**) Manufacturing(**)

Extended Order Generation (*) SC Collaboration Collaborative Management Management of Delivery Schedules (CMDS) (*) process process requires industry solution mySAP Mill Products (**) process requires Industry Industry Solution mySAP Automotive Speaker Name 2  SAP AG 2002, Title of Presentation, Speaker

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Integrated S&P Planning – overlay between SNP & PP/DS PP/DS Bjoern Bernard

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Shelf Life Enhancements only in PP/DS

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Process Enhancements with SAP APO 3.1 Supply Chain Planning

Supply Chain Execution

Supply Chain Design

Proc Pr ocur urem emen entt

Supply Chain Coordination Supply Chain Networking

Dema De mand nd Plan Planni ning ng

Manu Ma nufa fact ctur uring ing

Suppl Su pply y Plan Planni ning ng

Order Promising & Delivery

Distribution Planning

Warehouse Management

Supply Chain Ev Event Ma Management

Supply Chain Portal

Production Planning

Transportation Execution

Foreign Trade/Legal Services

Transportation Planning Fulfillment Coordination

Supply Chain Pe Performance Management

Collaboration Services

Supply Chain Integration

SC Planning

SC Execution

Model Consistency Checks

Order Fulfillment with GATP

Descriptive Characteristics in CTM

Transportation Management

Mass Mainte Maintenance nance Tools Tools for Master Master Data

PP/DS with comprehensive integration to R/3 Advanced Block Planning Planning Multi-Line Model Mix Planning (**) Rapid Planning Matrix supporting activities (**)

(*) process process requires industry solution mySAP Mill Products (**) process requires Industry Solution mySAP Automotive Automotive Speaker Name 3  SAP AG 2002, Title of Presentation, Speaker

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SNP – Model Consist Consistency ency Check

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Planning of Scheduling Scheduling Agreements – integration R/3 R/3 APO



Mass Maintenance Tools for Master Data



Model Consistency Checks

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Repetitive Manufacturing with iPPE

Contents: 

This process describes how to execute Repetitive Manufacturing in APO on the basis of the integrated Product and Process Engineering . Scheduling and material requirement calculation in APO is carried ou t as takt-based takt-based scheduling. scheduling. You can enter the backflush backflush data for the the production production backflus backflush h in APO. APO. The backflush backflush data is then posted in the DI System. This procedure is very fast and is therefore therefore ideal for planning planning high configurable configurable products with a large number of components.



Soluti Solution on based based on Discr Discrete ete Indust Industry ry system system and and APO APO design designed ed for Automot Automotive ive and HighHigh-Tech Tech manufa manufactu cturin ring g

Speaker Name 4  SAP AG 2002, Title of Presentation, Speaker

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Unit Objectives

At the conclusion of this unit, you should be able to: 

Understand the Automotive Manufacturing scenario based on Discrete Industry system (DI46C2) and SAP APO 3.1



Have a basic knowledge about the principles of the SAP APO functions used in this scenario



Have the awareness about the business processes where it’s recommended to use such a scenario


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SAP APO and SAP R/3 in Automotive System Rapid Planning Matrix

Planni Planning ng in APO CMP ACT

FLO

liveCache liveCache

iPPE

Collective Order

CIF CMP ACT

Execut Execution ion in R/3

FLO

iPPE


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Automotive Functions in SAP APO: Planning Process

R/3-DI

SD

Postings (MM/IM)

PP/MRP

Customer Customer requirements requirements 04/15/00 -20 units 04/15/00 04/15/0 0-15 - 20 units 04/16/00 units 04/16/00 04/16/0 0 - 15 units ... ...

iPPE

2

1

5

(R/3 (R/3 or APO) APO) (R/3 (R/ 3 or APO APO))

APO 3

MM MMDelivery Delivery Schedules Schedules 04/15/00 - 200 pcs 04/15/00 - 200 pcs 04/16/00 - 150 pcs 04/16/00 ... - 150 pcs ...

Model Mix Planning and Sequencing

Backfl

7

ush

4 3 APO-PP/DS

iPPE

5

4

Trigger Backflush Production Tracking

BOM Explosion: RPM

Component Requirements

6 Event

PCS Order Headers

Action Handler




Process Steps 

Create Master Data (iPPE) ... Initialize Initialize CIF Interface



Create Sales Orders



Run Model-Mix Sequencing

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Explode Requirements in the RPM



MM Planning of Components



Action Handler



Execute Backflush

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Challenges Chall enges from from Engin Engineerin eering g to Production Production

P

C1

C2

C3

C4

Product-Engineering Product-Engineering ACT ACT40 40

ACT ACT 31 31

ACT ACT 32 32

Process-Engineering Process-Engineering

ACT ACT20 20

Line 1

ACT ACT10 10

Production Production Station 1

Station 2

Station 3

Station 4

„Time-to-Market”

„Time-to-Customer”


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Takt-based Scheduling

Line

Station 1 Takt-based Scheduling

Takt time

Station 2 Takt time

Station 3 Takt time

very fast, since

lead time = numbe numberr of Takt Takts s * Takt time as compar compared ed to lead lead time sche schedulin duling g lead time = sum of all opera operation tion dura durations tions


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

With takt scheduling the lead time equals the number of takts multiplied multiplied by the takt time. The system does not calculate the lead time based on the duration duration of single operations. operations. Thus, scheduling enables enables you to execute high volume scenarios with short system response time. Note: Takt = Tact

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Data and Object Model for iPPE

Product Variant Structure ... and relationships between all objects CMP

Routings and Activities

ACT

F LO

ACT 40

ACT 31

ACT 32

ACT 20

ACT 10

Factory Layout Line 1

Station 1

Station 2

iPPE Station 3

Station 4


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Automotive with DI46C2 - 10 10

Product Variant Structure (PVS): Concept Product structure for highly variant products 

New structure elements: nodes and variants

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Multi level hierarchy and multiple usage of the nodes

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Direct product reference

Product Lifecycle Management (PLM) 

Consistent data basis for different views of the product

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Modeling of functional structures (no reference to a material number)

Logistics 

Basis for efficient material requirements planning (RPM)


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The goal of the PVS is to provide a redundancy-free description of products or product families that have many variants, as well as a consistent data basis for all enterprise enterprise areas that work with the product structure or parts of it.



The PVS offers an integrated data model that serves as the basis basis for an efficient IT management of the product structures. structures. In addition, addition, you can use it to adequately adequately portray the product product creation process process (with the main focus on Product Data Management) and also production (the main focus being rapid requirements planning – the rapid planning planning matrix which is executed in the APO system).. system)..

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Engineering Change Management as part of the iPPE

Material

Master Data Variant Configuration Document Management W O R K F L O W

Classification

Engineering Change Management

CAD Interface


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An integrated solution for the Product Data Management (PDM) throughout the supply chain is displayed by the integrated engineering change management (ECM).

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ECM is a central, integral part of product data management management (PDM) in the SAP R/3 System and ensures a complete history of any changes made to product data.

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The components of ECM are: 

Master data management (material master records, PVS, Activity Modes)

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Document management



Classification



CAD interface



Workflow



Configuration

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Use Us e of Li Line nes s Capacity planning Capacity planning in Repetitive Repetitive Manufacturing Line Balancing Determination of supply areas for PVS compo component nents s Demand pla Demand planni nning ng in the Rap Rapid id Planni Pla nning ng Mat Matrix rix Backflush


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Calculatio Calcu lation n of Exact Componen Componentt Demand times times

Line 1

Station 1

Station 2

Takt time

ACT ACT 11

Station 3

Takt time

Takt time

ACT ACT 22 ACT ACT 33

C1 C1

C2 C2

Station 4

C3 C3

Takt time

ACT ACT 44

ACT ACT 55

C4 C4

C5 C5

C1 Requirement:

C2 & C3 Requirements:

C4 Requirement:

C5 Requirement:

Order Start

Order Start + 1 Takt

Order Start + 2 Takts

Order Start + 3 Takts




Because each component is assigned to a specific activity and the activity is assigned to a line (via the line balance) we can know, based on the simple takt scheduling scheduling logic, logic, exactly when the components components will be needed.

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Prod Pr oduc ucti tion on Re Resou sourc rces es in iPPE iPPE Line Net

Line 1 RES1

Line 2 RES2

Line 3 RES3

ACT Head

ACT1 RES1 ACT2 RES2

L i n e B a l a n c e

ACT3

The same resource can be be assign assigned ed to activities activities and line objects. This is either either the the Human Human Resources or the Production Resource.

RES3


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New Node Node Types Types – DI4 DI4.6. .6.C2 C2 ALG

Alternative Line Group (ALG): • Contains alternatives, under which Line nodes can be assigned. Only one one Line node can can be assigned per alternative alternative (for use with orde orderr activities). activities). • Are assign assigned ed directl directly y underne underneath ath the the Line Net Net or can repre represent sent a Line Line structure struc ture (acce (access) ss) itself. Relationsh onships ips can exist at Line Line leve levell or Altern Alternate ate Line Group level level.. • Relati

Line Net

Part Line Net: Represents the part (numbe (numberr of) Line nodes nodes within within the complete complete Line Net Net • Represents available. • Technical: Alternative Alternative Segment on the Line Net nodes nodes • Col Collec lects ts Lin Line e nodes nodes that that have have to be a part part of the spe specif cified ied Lin Line e Net. Net. • Can be specifie specified d in the production production versio version n as a specific specific production production line access object.

Line Area Line Area

• Is an additiona additionall structuring structuring of Line nodes nodes which which are part part of a Line Net. Net. • Has no other other function and can not be used used in the production production version version.. Speaker Name 16  SAP AG 2002, Title of Presentation, Speaker

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Model Mix Planning and Sequencing


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Big Picture

Model Mix Planning

Sequencing

A1

A2

C1

A1 B1 X1

A3

Reservation Planning

A2 B2 A3

X X2 1

C1

B1 C2 X2 B2 C3

C2

C3

Re-Sequencing


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Model-Mix Planning: Situation

Orders

Line network

Restrictions

Quantity Distance X in Y

Objective

Block Equal distribution Position

Business value

Generation of a feasible and optimal plan for configurable products with high volume

Balanced usage of production resources Early identification of potential bottlenecks

Adherence to promised delivery date

Reliable delivery date leads to increased customer satisfaction


Purpose: Determine the sequence of orders on line segments and determine the start and end date of the orders, so that specific goals can be pursued under consideration of certain restrictions. Constraints: 

Production of variants or configurable products in model-mix



Production on lines with restricted production rates (finite capacity)

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Sequence or quantity restrictions at characteristic level (variants)

Aims: 

Day and/or shift packages (period segments)

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Full and even capacity utilization utilization of production line

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Order sequence in short-term horizon (for example, X days)



Precise determination of component requirements (to the hour/minute)

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Model Mix Mix Planning Planning and Sequencin Sequencing: g: Result Result

Sequence

Model Mix

based based on takts takts

based based on buckets buckets (Day/Week (Day/Week/Mon /Month) th)

3

3

4

4

3

3

now

future

X days from today


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Example: Model Mix Planning (1) Model Mix

Sales Orders

Production Production line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X

1. Period-oriented planning


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Example: Model Mix Planning (2) Model Mix

Sales Orders

Production Production line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X

1. Period-oriented planning


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SAP APO PPDS for Automotive.pdf

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