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 Procurement

Demand Planning

Manufacturing

Supply Planning

Order Promising & Delivery

Supply Chain Event Management

Supply Chain Portal

Distribution Planning

Warehouse Management

Production Planning

Transportation Execution

Foreign Trade/Legal Services

Transportation Planning Fulfillment Coordination

Supply Chain Performance Management

Collaboration Services

SC Planning Integrated Supply&Production Planning Shelf Life (Production Planning) Forecast Consumption based on DP Char. Extended Demand Prioritization in CTM Extended Order Generation (*)

Supply Chain Integration

SC Execution Multilevel ATP Campaign Planning Order Driven Final Mix & Packaging IPPE based repetitive Manufacturing(**)

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

Integrated S&P Planning – overlay between SNP & PP/DS Bjoern Bernard Shelf Life Enhancements only in PP/DS

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Process Enhancements with SAP APO 3.1 Supply Chain Planning Supply Chain Execution

Supply Chain Design Procurement

Supply Chain Coordination Supply Chain Networking

Demand Planning

Manufacturing

Supply Planning

Order Promising & Delivery

Warehouse Management

Supply Chain Event Management

Supply Chain Portal

Distribution Planning Transportation Execution

Foreign Trade/Legal Services

Transportation Planning Fulfillment Coordination

Supply Chain Performance Management

Collaboration Services

SC Planning Model Consistency Checks Descriptive Characteristics in CTM Mass Maintenance Tools for Master Data

Production Planning

Supply Chain Integration

SC Execution Order Fulfillment with GATP Transportation Management PP/DS with comprehensive integration to R/3 Advanced Block Planning Multi-Line Model Mix Planning (**) Rapid Planning Matrix supporting activities (**)

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

SNP – Model Consistency Check Planning of Scheduling Agreements – integration 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 out as takt-based scheduling. You can enter the backflush data for the production backflush in APO. The backflush data is then posted in the DI System. This procedure is very fast and is therefore ideal for planning high configurable products with a large number of components. Solution based on Discrete Industry system and APO designed for Automotive and High-Tech manufacturing

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

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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

Planning in APO CMP ACT

FLO

liveCache

iPPE

Collective Order

CIF CMP ACT

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

iPPE

2

1

5

(R/3 (R/3ororAPO) APO)

APO 3

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

Model Mix Planning and Sequencing

Backfl ush

7

4 3 APO-PP/DS

iPPE

5

4 BOM Explosion: RPM

Component Requirements

Trigger Backflush Production Tracking

6 Event

PCS Order Headers

Action Handler


Process Steps Create Master Data (iPPE) ... Initialize CIF Interface Create Sales Orders Run Model-Mix Sequencing Explode Requirements in the RPM MM Planning of Components Action Handler Execute Backflush

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Challenges from Engineering to Production

P

C1

C2

C3

C4

Product-Engineering Product-Engineering ACT ACT40 40

ACT ACT31 31

ACT ACT32 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 = number of Takts * Takt time as compared to lead time scheduling lead time = sum of all operation durations


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

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Data and Object Model for iPPE

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

Routings and Activities

ACT

FLO

ACT 40

ACT 31

ACT 32

ACT 20

ACT 10

Factory Layout iPPE

Line 1

Station 1

Station 2

Station 3

Station 4


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Product Variant Structure (PVS): Concept Product structure for highly variant products New structure elements: nodes and variants Multi level hierarchy and multiple usage of the nodes Direct product reference

Product Lifecycle Management (PLM) Consistent data basis for different views of the product Modeling of functional structures (no reference to a material number)

Logistics Basis for efficient material requirements planning (RPM)  SAP AG 2002, Title of Presentation, Speaker Name 11

The goal of the PVS is to provide a redundancy-free description of products or product families that have many variants, as well as a consistent data basis for all enterprise areas that work with the product structure or parts of it. The PVS offers an integrated data model that serves as the basis for an efficient IT management of the product structures. In addition, you can use it to adequately portray the product creation process (with the main focus on Product Data Management) and also production (the main focus being rapid requirements planning – the rapid planning matrix which is executed in the APO system)..

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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


An integrated solution for the Product Data Management (PDM) throughout the supply chain is displayed by the integrated engineering change management (ECM). ECM is a central, integral part of product data management (PDM) in the SAP R/3 System and ensures a complete history of any changes made to product data. The components of ECM are: Master data management (material master records, PVS, Activity Modes) Document management Classification CAD interface Workflow Configuration

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Use of Lines Capacity planning in Repetitive Manufacturing Line Balancing Determination of supply areas for PVS components Demand planning in the Rapid Planning Matrix Backflush


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Calculation of Exact Component Demand 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 logic, exactly when the components will be needed.

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Production Resources in iPPE Line Net

Line 1 RES1

Line 2 RES2

ACT Head

ACT1 RES1 ACT2 RES2

Li ne

Ba la nc e

ACT3

Line 3 RES3

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

RES3


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New Node Types – DI4.6.C2 ALG

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

Line Net

Part Line Net: • Represents the part (number of) Line nodes within the complete Line Net available. • Technical: Alternative Segment on the Line Net nodes • Collects Line nodes that have to be a part of the specified Line Net. • Can be specified in the production version as a specific production line access object.

Line Area

Line Area • Is an additional structuring of Line nodes which are part of a Line Net. • Has no other function and can not be used in the production version.


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Big Picture

Model Mix Planning

Sequencing

A1 A2

C1

A1 B1 X1

A3

Reservation Planning

A2 B2 A3

X2 X1

B1 C2 B2 C3

C1

X2

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) Sequence or quantity restrictions at characteristic level (variants) Aims: Day and/or shift packages (period segments) Full and even capacity utilization of production line Order sequence in short-term horizon (for example, X days) Precise determination of component requirements (to the hour/minute)

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Model Mix Planning and Sequencing: Result

Sequence

Model Mix

based on takts

based on buckets (Day/Week/Month)

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 line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X

1. Period-oriented planning


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Sales Orders

Production line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X

1. Period-oriented planning


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Sales Orders

Production line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X

1. Period-oriented planning + Quantity restriction  SAP AG 2002, Title of Presentation, Speaker Name 23

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Sales Orders

Production line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X


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Sales Orders

Production line 1

This Week, Day X

Week 1

Week 2

Week 3

Week X


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Sales Orders

Production line 1

Day 1

Day 3

Day 2

Day X

2 . Sequencing


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Sales Orders

Production line 1

Day 1

Day 3

Day 2

Day X

2 . Sequencing


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Restrictions: 1. Not two in a sequence

Production line 1

Day 1

Day 2

2 . Sequencing


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Restrictions: 1. No two in a sequence

Production line 1

Day 1

Day 2

2 . Sequencing


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Production line 1

Day 1

Day 2

2 . Sequencing


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Production line 1

Day 1

Day 2

2 . Sequencing


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Restrictions: a) No two in a sequence

Production line 1

Day 1

Day 2

2 . Sequencing


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Production line 1

b) At least two red cars in sequence

Day 1

Day 2

2 . Sequencing


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Production line 1


Day 1

Day 2

2 . Sequencing


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Production line 1


Day 1

Day 2

2 . Sequencing


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Production line 1


Day 1

Day 2

2 . Sequencing


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Production line 1


Day 1

Day 2

2 . Sequencing


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Sequencing: Restrictions Types of restrictions Quantity (position)

e.g. number of V8 engines <= 200 pieces per day

Spacing

e.g.: max every third engine is US version

K in M

e.g.: three air condition out of five vehicles

Block

e.g.: at least 2 engines for RH-drive vehicles in a row

Even distribution Position

Basic information Created within a planning version

e.g.: active version or simulation version

Assigned to a production line

e.g.: body shop, paint shop, assembly line

Uses characteristics

e.g.: engine type, US version, air condition


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Restrictions Weighting & Validity

Weighting Restrictions are grouped into two categories: Hard

(= ‘0‘)

Soft

(= ‘1, 2, ..., 9‘).

Validity Validity has two categories: Time: interval (e.g from t1, to t2 and from t3 to t4 ... ) Location: assignment to a Line net Line Line segment


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Optimization Algorithms: Procedures - overview 1

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

Linear Program Algorithm Multi-line (daily buckets) Quantity restrictions and transformed spacing Hard and soft weighting of restrictions Due date Finite


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Optimization Algorithms: Procedures - overview 2

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

Percentage Smoothing Heuristic Single line Smoothing on product variant level No restrictions, only capacity Finite

Interface for Customer heuristics


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Procedures Sequencing

Bucket-oriented Model Mix

= Order sequence on lines

= Distribution of orders to lines and to time buckets

Horizon 1 (e.g. 2 days)



Horizon 4 (e.g. 2 month)

(e.g. genetic algorithm)

Procedure II ( e.g. heuristic with restrictions)

Single items

Single items

Quantities per period

Quantities per period

All restrictions

All restrictions

e.g. only quantity and capacity restrictions

only capacity restrictions

Manual Planning / Correction

Procedure I

Procedure III (e.g. equal distribution)


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Sequencing: Interactive planning

Restrictions

Planned Orders

Unscheduled Orders


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Model Mix Planning and Sequencing in SAP APO 3.1

Model Mix Planning and Sequencing in SAP APO 3.1


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Line Net

assembly line I

A typical example for a line net of an OEM is

C1

A1 buffer

A2

B1

X1 B2

C3

A3 group of alternative lines

planning segment

assembly line II

C2

X2

F1 D1

Y1

E1

Y2 F2

planning segment


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Partial Line Nets

In general the products are not buildable on the whole linenet. Therefore one defines partial line nets and then assigns the products to the partial line nets by their production versions.

C1

A1 B1 A2

X1

X2 B2

A3

C2 C3


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Capacities and Restrictions The planning is based on the following assumptions : max 25 sedan per day

...

...

A1 12 PCS / H

A2

X1

...

C1

B1

max 2 in 4 air conditioning ...

max 15 RED per. day ..

min distance 1 ... for convertibles

C2

X2

B2

1 PCS / 10 MIN

C3

A3

1. Each line has a capacity profile. 2. One can assign spacing restrictions to the lines. 3. One can assign quantity restrictions to the lines or the groups of alternative lines.


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Conversion

The capacity profiles and the spacing restrictions are converted into quantity restrictions, for example

C1

A1 B1 A2

X1

X2

C2

A3. C2.

capacity: min distance 1 for convertibles * 16 PCS / shift

=

shift duration 8 H / shift

=

capacity: 20 PCS / shift

=

Rate 1 PCS / 10 MIN

*

max 8 convertibles per shift

max 48 PCS per shift

B2 A3

C3

max 2 in 4

C3. air conditioning *

max 10 air cond. per shift


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... . . .

Paths through the Line Net

A3

Based on this decomposition a restriction can be assigned to several paths (although it‘s basically assigned to just one line).

A3

A3

Furthermore certain products can only run on certain paths depending on the production version.

A3

X1

X1

X1

X1

B1

B1

B1

B2

. . . ...

The line net is decomposed into the possible paths. For simplicity not all paths are shown in the sketch.

X2

X2

X2

X2

C1

C2

C3 C1

max 2 in 4 air cond.

no red colour


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... . . .

The Planning

A linear program will now assign the orders to the paths while respecting the restrictions and production versions. A3

A3

A3

X1

X1

X1

B1

B1

B1

B2

X2

X2

X2

X2

C1

C2

C3 C1

. . . ...

A3

X1


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The Result

The model mix plan is obtained by adding the paths‘ loads segment by segment :

C1

A1 B1 A2

C2 B2

A3

C3


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From Buckets to Positions At a certain point one has to create a sequence out of the bucket orders (bucket size can be shift or day). Since one has already considered aggregated spacing restrictions in the model mix planning it should basically be possible to obtain a feasible sequence out of the bucket orders.

The sequence is built in the planning segment and will later on also be manipulated there. The result is propagated to the other segments.

C1

A1 B1 A2

X1

X2

C2

B2 C3

A3 Planning segment

Gap: Since the sequence is built on the planning segment and simply propagated without any further re-sequencing in the buffers, only restrictions from the planning segment will be taken into account during this process.


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Line Switch

Due to unplanned down times or problems with the supply to line there can be the need to change the path of an order.

Obviously only those lines can be chosen which belong to the partial linenet in the production version.

C1

A1 B1 A2

X1

X2

C2

B2

Assume there are problems on line A2 and C2. Therefore the paths of the green car has to be changed.

A3

C3


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Rapid Planning Matrix (RPM)

Rapid Planning Matrix (RPM)


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Alternatives in Requirements Planning 1. Rapid Planning Matrix (explosion type=4) APO liveCache liveCache

Optimized for high volume scenarios

2. Order Network iPPE RTO (explosion type=3)

3. MRP (PVS)

R/3

R/3

APO liveCache liveCache

Optimized for real time planning

4. MRP (BOM)

PVS Explosion

BoM Explosion


There are several options for planning products. Depending upon the need for various functions, like rapid planning, highly configurable products, or integration back to standard R/3 functions a customer may choose a combination of these planning options. For example, the higher level more expensive parts can be planned within APO and the lower level or consumption based materials can be planned in the R/3 system.

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Classic MRP: Performance Bottlenecks Maximum bill of material contains 40,000 components 30,000 individual customer orders Storage on a relational database means movement of 60 Gigabyte of data Explosion of maximum BOM order by order means more than one Billion checks of effectivity-parameters and selection conditions

Solution: Keep Data in RAM in optimized form liveCache main memory database Matrix form for data storage, object oriented access simultaneous BOM explosion for all orders -> RPM (Rapid Planning Matrix) liveCache


Maximum BoM has 40,000 components including all historical changes Exploded customer order has 2,000 components of the maximum BoM selected results in storage of 60 Gigabyte dependent requirements in R/3-MRP in database in relational form need to write and read that amount of data during an MRP-run Explosion must look at all historical changes at a component variant 1.2 billion checks of effecitivity parameters in the worst case 1.2 billion checks of selection conditions LiveCache storage in RAM instead of disk forces optimized form (little memory usage): matrix representation matrix representation allows simultaneous explosion of all orders instead of order by order RPM is the name of this new algorithm

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Contents of Logical Matrix

1 Assy View

2

Orders

Data of assembly orders Order Order Order Order Order Order 01 02 03 04 05 06

Components Mat A Mat B Mat C Mat D

Bumpers green Bumpers white Bumpers red Navigation Advisor GPS Engine 2.5 Disk

3

x x

x x x

x x x

x x x

x x x x

x x x

BOM-Explosion - interpretation of effectivity - interpretation of dependencies


The first step is to convert the assembly view of the PVS into a flat list of the master data material number, quantity, selection condition, effectivity parameters Second step is to include the assembly orders: due date quantity configuration Third step explode the BoM for the orders a ‚cross‘ means: component selected for order one cell in the matrix = one bit 30,000 orders, 40,000 components about 350 Megabytes

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Functions Using Logical Matrix I

Reading and Interpreting Columns Component list for selected order

Data of assembly orders

Backflush

Order Order Order Order Order Order 01 02 03 04 05 06

Sequenced JIT calls Sequencing Bumpers green Bumpers white Bumpers red Navigation Advisor GPS Engine 2.5 Disk

x x

x x x

x x x

x x x

x x x x

x x x

...

.. .. .. .. .. ..

Access to component list via Logical Matrix ‘From the top’  SAP AG 2002, Title of Presentation, Speaker Name 58

Write: MRP

(daily)

Backflush (every two minutes) Impulse

(update dates every two minutes)

Read: All functions which need: - BOM of the order - Component requirements Examples: Component MRP, Backflush, Delivery schedules...

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Functions Using Logical Matrix II

Reading and Interpreting Rows Reporting Stock/requirements list

Data of assembly orders

Coverage calculation


Delivery scheduling Pull-list

x x

Bumpers green

‘From the Left’ Aggregation to time buckets

Bumpers white Bumpers red Navigation Advisor GPS Engine 2.5 Disk

x x x Day 1

Component

Day 1 Day 2

1 1 3

Bump red GPS Disk

...

0 3 3

x x x

x x x

x x x x

x x x

...

.. .. .. .. .. ..

Day 2 Aggregation in customized time buckets: • Hour • Shift • Daily • ...


Time buckets are created for component requirements Requirements from Matrix Time buckets are input for MRP requirements In APO: As APO orders (e.g. purchase orders) In R/3: As delivery schedules (daily requirements only) Size of time bucket is variable Short term horizon with more precise than long term horizon

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Integration of Line Design Information

Line Design

RP 3 RP 2 RP 2

A6

A5

A4

A3

start times • body • paint • assembly

A2

A1

Matrix Order RP 1 RP 1

K1,

RP1,

∆T = 0

X

X

X

X

X

X

K2,

RP1,

∆T = 10

X

X

X

X

X

X

K3,

RP2,

∆T = 20

X

X

X

X

X

X

K4,

RP2 ,

∆T = 20

X

X

X

X

X

X

K5,

RP3 ,

∆T = 30

X

X

X

X

X

X

K6,

RP4 ,

∆T = 40

X

X

X

X

X

X

RP1, RP2, RP3: Reporting points per line defined in Line design  SAP AG 2002, Title of Presentation, Speaker Name 60

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Scheduling Components using Line Design

Subdaily on Supply Area Level ACT 1

C1

Matrix Order

C2

RP 2

RP RP 2 1

C1, T1, ∆T = 0

+

+

+

C2, T 2 ∆T = 10

+

+

+

+

+

X

C3, T 2, ∆T = 20

+

+

+

X

X

X

C4, T3 ∆T = 20

+

+

C5, T4 ,∆T = 30

+ X

X

X

X

X

C... T ...

X X

X

X

X

X

Takt 3

ACT 5

C5

+

+

X

A6

RP 3

C4

A4

A3

ACT 4

A2

C3

start times • body • paint • assembly A1

Line Design

A5

ACT 2 ACT 3 Takt 2

Prod

uctio

n

Takt 1

RP 1

+

X


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X

Rapid Planning Matrix (RPM) in SAP APO 3.1

Rapid Planning Matrix in SAP APO 3.1


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RPM - Activity Matrix

Planning production activities per order (analogous to components) Necessary information from the iPPE routing

Install Xenon light Fit air conditioning Fit navigation system Fit child‘s seat Polish wheel rims Check oil


x x

x x x

x x x

x x x

x x x x

x x x

Integration: Backflush (Posting all activities performed, capacity reduction) Controlling (Value of all activities per vehicle, resource capacity) Model-mix (Material matching of necessary activities against resources)


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Activity Matrix: Calculation of Actual Resource Requirements in Sequencing Challenge: Optimization of utilization of stations when manufacturing variants New: The Activity Matrix allows the calcualtion of actual resource requirements per station Aggregation of all activities which are carried out at a station Matching of actual working hours with working hours available Production scheduler can adjust resource availability to requirements


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

A1

C1 B1

A2

C2


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Activity Matrix: Integration with Action Handler Mixed Order Some components are in the matrix, some are in the APO order network Components can be dynamically moved from the matrix into the order network (with firming etc.) Unrestricted pegging for important components Example: Vehicle passes tracking point Components for line segment have to be fixed (until backflush), and shop floor papers are printed Vehicle is produced according to shop floor papers Technique: Components are moved from the matrix to a order network Mixed order: Some components are stored in the matrix, other are stored in order networks Additional functions: Specific components for MTO can always be planned in order networks in order to ensure full traceability via the pegging function

A1

C1 B1

A2

C2


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Manufacturing Execution: Action Handler

Production Action Handler


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Overview

Actions to do

Production Tracking

Tracking point ‘1’

Trigger JIT for a component


Event

Backflush Backflush Backflush


Event

Event

Production Control System / Assembly Control System Line Line

Station Station 11

Station Station 22

Station Station 33


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Action Handler & SAP Business Workflow SAP APO Action Action Handler Handler

Tracking Tracking evaluation evaluation

Actions Event Event Manager Manager

Triggers Get Sequence

Analyse Analyse event event and and dispatch dispatch to to action action

Trackin gpoint with event and action informations

Feedback

Warehouse pull Customer Function Module

Realtime Realtime

Delayed Delayed (FIFO (FIFO Queue) Queue)

Trackinginformation Insert & Update

RFC with Tracking point & order & Customer data

Server

Tracking point ‚S01‘

Tracking point ‚S02‘

Event Client

Line Line

Event

Production Control System / Assembly Control System Station Station 11

Station Station 22

Station Station 33

Station Station nn


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Action Handler Standard Actions Save Tracking data Business Add-Ins to insert additional customer data into standard tables with customer includes.

Order Modify Adjust order start time (example vehicle leaves Paint Shop) Change activity status

Backflush


PBS = painted body storage (buffer after paint shop) Prerequisite for WIP-counting (supply area inventory): action handler provides the actual sequence!!!

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Interaction of Action Handler and Backflush

ACT 1

C1

ACT 2

C2

ACT 3

Pro

du c

tion

RP 1

Goods Issue

C3

ACT 4

Load Reduction. C4

RP 2

Event X ACT 5

C5


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Manufacturing Execution: Backflush

Production Confirmation (Backflush)  SAP AG 2002, Title of Presentation, Speaker Name 72

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Overview Solution for high-volume scenarios Usage of Rapid Planning Matrix (RPM) Work in Process (WIP) calculation Sales order specific cost estimate at GR posting Aggregated and parallel GI posting Capacity reduction at reporting point backflush


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Process Overview

APO

CIF

Automotive System

Buffer

Scenario without RPM

RPM scenario

Postings (MM/IM)


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Prerequisites from a Backflush View

APO

Automotive System

Orders

CIF

iPPE

Sales Orders

Product Master

CIF

iPPE

Sales Orders

Product Cost Collector

CIF

Production Versions

CIF

Material Master

Production Versions


Create iPPE Create production version and maintain iPPE data production version used to determine cost collector Enter REM profile in material master Movement types, batch and stock determination Determine in material master of components whether GI is posted synchronously or asynchronously Create classes und characteristics Create sales orders and assign characteristic values Create product cost collector cost collector set as “APO cost collector“ in first backflush

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Overall Process

APO

CIF

Read and check order, write creation document

Automotive System

Receive creation document, generate and write backflush document

Registr. docum.

No stock/requirement updates. Capacity reduction

Stocks list of backflushes

Stock adjustments, requirements reduction update of order status

Stock posting


APO Backflush Profile flexible access to backflush transaktion backflushing via action handler possible APO orders available Enter backflush data backflushing via action handler possible Capacities are reduced immediately Information for IM transferred to R/3 Automotive System R/3 Goods Movements all GRs and GIs of synchronous materials are posted immediately GIs of asynchronous materials are periodically aggregated and posted Processes can be distributed to several processes and servers Usage of application log instead of document log Postprocessing for failed goods movements Cumulative and individual records Postprocessing records for GRs as well Providing BW with backflush data Archiving functions for backflush tables © SAP AG

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Example Steps: Backflush for Components 1. Explode sales orders 2. Backflush at reporting points 3. CO postings of aggregated goods issues 4. Synchronously posted goods receipts 5. Determination of WIP 6. Backflush with scrap 7. Period end closing 8. Goods receipts with price variances 9. WIP after price changes  SAP AG 2002, Title of Presentation, Speaker Name 77

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Explode Sales Order

APO SO1 SO2 SO3

C1 C2 C3 C4 C5 ....

X X

X

X

X X

X

X X

X

X

...

...

...

X X

X X

X X

X

X X

X

Sales order SO3 Sales order SO3 A140 A140 Mat. No.: A Class Mat. No.: A Class Value Sales Value Salesorder orderSO2 SO2 assignment A160 assignment A160 Mat. Mat.No.: No.:AAClass Class Value Sales order Value Sales orderSO1 SO1 assignment A140 assignment A140 Mat. Mat.No.: No.:AAClass Class Value Value assignment assignment

R/3

iPPE


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Example: Backflush, Initial Situation

X

X

C2,

Stat. 10 RP1, ∆T = 10

X

C3,

Stat. 20 RP2, ∆T = 20

C4,

Stat. 20 RP2, ∆T = 20

X

X

C5,

Stat. 30 RP3, ∆T = 30

X

X

X

...

Stat. 10 RP1, ∆T = 0

...

C1,

• Body • Paint • Assembly

...

SO 2

Line Design (Stations)

SO 1

Start Times:

SO 3

Matrix Order

X

X

X

X

X

X

X

X X X

X X

X

...

RP 1

RP 2

RP 3

SO6 SO5 SO4 SO3 SO2 SO1

Station 10

Station 20

C1

C3

C2

C4

Station 30

C5


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Backflush of Sales Order 1 (SO 1) at Rep. Point 1 (RP 1)

APO C1

RP 1

C2 C3 C4 C5 ....

RP 1 RP 2 RP 2 RP 3

SO1 SO2 SO3 ...

0 0

X

X

X X

X

X X

X

X

X X

...

...

X X

X X

X

R/3 C1 1 pc C2 4 pc

SO 1 RP 1

X X

X

RP 1

SO6 SO5 SO4 SO3 SO2

RP 2

RP 3

SO1

Station 10

Station 20

C1

C3

C2

C4

Station 30

C5


Backflushing in APO always carried out for a reporting point Reporting point structures can be changed during production One order always refers to exactly one reporting point structure Definition of reporting points in Line Design: Beginning and/or end of line segment No reporting point definition at activities Document-neutral reversal only Reversal always is a posting using opposite movement direction Valuations in Controlling (WIP and GR cost estimate) based on actual postings

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Backflush of SO 1 at RP 3, SO 2 at RP 2

APO C1

RP 1

C2 C3 C4 C5 ....

RP 1 RP 2 RP 2 RP 3

SO1 SO2 SO3

0 0

0 0 0

0 0

X

X

X

...

...

...

X X

X X

X X

X X X

X X

X

SO 1 RP 1

C1 1 pc C2 4 pc

SO 2 RP 1 SO 1 RP 2

C1 1 pc

SO 2 RP 2

C3 2 pc C4 5 pc

SO 1 RP 3

C5 1 pc

RP 1

R/3

C4 5 pc

RP 2

SO6 SO5 SO4 SO3

RP 3

SO2

Station 10

Station 20

C1

C3

C2

C4

SO1

Station 30

C5



© SAP AG

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CO Postings of Aggregated Goods Issues Reporting points of cost collector

Backflushed components of SO 1 and SO 2:

C1 1 pc C2 4 pc

SO 1 RP 1 SO 2 RP 1

C1 1 pc

SO 1 RP 2

C4 5 pc

SO 2 RP 2

C3 2 pc C4 5 pc

SO 1 RP 3

C5 1 pc

Valuation C1 C1 1pc 1pc==100,100,C2 C2 1pc 1pc==25,25,C3 C3 1pc = 1pc =200,200,-

APO C1 C2 C3 C4 C5 ...

RP 1 RP 1 RP 2 RP 2 RP 3

SO1 SO2 SO3 SO4 SO5 SO6 X X X X

X

X

X X X

X

X X

X X

X X

X

X X

X X

C4 C4 1pc 1pc==10,10,C5 C5 1pc = 1pc =500,500,-

Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5

WIP WIP debit debit 22 44 22 10 10 11

Period Period11 WIP WIP credit credit 00 00 00 00 00

Scrap Scrap 00 00 00 00 00

Product cost collector Model series A Class GI C1 200.GI C2 100.GI C3 400.GI C4 100.GI C5 500.-

ACT = 1300.-


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Goods Receipt SO 1, Synchronously Posted Reporting points of cost collector SO 1 RP 1

C1 1 pc C2 4 pc

SO 2 RP 1

C1 1 pc

SO 1 RP 2

C4 5 pc

SO 2 RP 2

C3 2 pc C4 5 pc

SO 1 RP 3 SO 1


C5 1 pc

Valuation

GR

C1 C2 C3 C4 C5 ...



X

X

X X X

X

X X

X X

X X

X

X X

X X


Scrap Scrap 00 00 00 00 00

Product cost collector Model series A Class

Comp. Quant. C1 1 C2 4 C3 0 C4 5 C5 1

APO


GR SO 1

Price 100.100.0.50.500.750.-

-750.-

GI GI GI GI GI GR

C1 C2 C3 C4 C5

200.100.400.100.500.-750.-

ACT = 550.-


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Determination of Work in Process (WIP) Reporting points of cost collector WIP quantity = WIP debit - WIP credit Comp. Comp. C1 C1 C2 C2 C3 C3 C4 C4 C5 C5

WIP WIP 22- -11==11 44- -44==00 22- -00==22 10 10- -55==55 11- -11==00



Valuation

1 pc C1 2 pc C3 5 pc C4

Comp. Quant. C1 1 C2 0 C3 2 C4 5 C5 0

Price 100.0.400.50.0.550.-

550.-


Scrap Scrap 00 00 00 00 00

Product cost collector Model series A Class GI C1 200.GI C2 100.GI C3 400.GI C4 100.GI C5 500.GR -750.ACT WIP

= 550.= 550.-


© SAP AG

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Backflush of SO 3 at RP 2, Scrap

APO C1

RP 1

C2 C3 C4 C5 ....

RP 1 RP 2 RP 2 RP 3

SO1 SO2 SO3

0 0 0 0

0 0 0 0 0

0

R/3

...

...

...

X X

X X

X X

SO 3 RP 1

C1 1 pc

X

SO 3 RP 2

´C3 2 pc

...

0 X X

X

X

Scrap! RP 1

RP 2

SO6 SO5 SO4

RP 3

SO3

Station 10

Station 20

C1

C3

C2

C4

Station 30

C5



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Backflush SO 3 at RP 2, Scrap Reporting points of cost collector

List of compontents for scrap


Comp. Quant. C1 1 C2 0 C3 2 C4 0 C5 0

SO 3 RP 1

C1 1 pc

SO 3 RP 2

´C3 2 pc

C1 C1 1pc = 1pc =100,100,C2 C2 1pc 1pc==25,25,C3 C3 1pc 1pc==200,200,-

2 pc C3 C1 C2 C3 C4 C5 ...



Period Period11 WIP WIP credit credit 1+1 1+1 44 0+2 0+2 55 11

Scrap Scrap 11 00 22 00 00

Valuation

...

APO

WIP WIP debit debit 2+1 2+1 44 2+2 2+2 10 10 11

X

X

X X X

X

X X

X X

X X

X

X X

X X

C4 C4 1pc 1pc==10,10,C5 C5 1pc 1pc==500,500,-

400.-

Product cost collector Model series A Class GI C1 200.GI C2 100.GI C3 400.GI C4 100.GI C5 500.GR -750.GI C1 100,GI C3 400,-

ACT = 1050.-


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Period-End Closing Reporting points of cost collector Compon Compon ent ent C1 C1 C2 C2 C3 C3 C4 C4 C5 C5

WIP quantity = WIP debit - WIP credit Comp. Comp. C1 C1 C2 C2 C3 C3 C4 C4 C5 C5

WIP WIP 33––22==11 44––44==00 44––22==22 10 10––55==55 11––11==00

Valuation Comp. Quant. C1 1 C2 0 C3 2 C4 0 C5 0

Scrap

1 pc C1 2 pc C3 5 pc C4

Comp. Quant. C1 1 C2 0 C3 2 C4 5 C5 0

WIP

Price 100.0.400.0.0.500.-

Price 100.0.400.50.0.550.-



Scrap Scrap 11 00 22 00 00

Product cost collector Model series A Class GI C1 200.GI C2 100.500.GI C3 400.GI C4 100.GI C5 500.GR -750.GI C1 100,GI C3 400,550.ACT = 1050.WIP = 550.Scrap = 500.-


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Backflush in SAP APO 3.1

Backflush in SAP APO 3.1


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Overview iPPE cost estimate (concurrent costing) Sales order costing at goods receipt Posting of material consumption Posting of activities Posting of variances Comprehensive reporting functions in R/3 and BW


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Overview RPM

Value at GR

Variances

Quantity

Work in Process

Inventory Management

CO / FI

Order Network

or

Quantity Costs BW APO3.0 DI4.6C1 Material A Material B APO3.1 DI4.6C2

Reporting

10 min / Station 1 20 min / Station 2

Line Network

TP TP

TP

TP


© SAP AG

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OEM Workshop IAU250: Engineering (iPPE) & Manufacturing Introduction Discrete Industries Overview mySAP Automotive Portals & Workplaces

IPPE iPPE Workbench Overview Product Variant Structure iPPE PLM Engineering Change Management Process & Factory Layout Structures

Production Planning Scenarios Overview Planning Basics and APO Heuristics Planning/Rapid Planning Matrix Model-Mix Sequencing with Restrictions

Manufacturing Action Handler Backflush  SAP AG 2002, Title of Presentation, Speaker Name 91

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


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SAP APO PPDS for Automotive.pdf

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