Supply Chain Planning with SAP APO

Transcription

Supply Chain Planning with SAP APO
Functional Solution Management SCM
Apri 2010
Pain Points in your Global Supply Chain
Do you have problems with …
Forecast quality?
Excess inventory?
Lack of visibility in your supply chain?
Capacity shortages?
Creating an optimized finite production plan?
… and therefore face
Lost sales due to missing capacity / components or
unnecessary production and high inventory
Excessive work-in-capital; high scrap/expiry costs for
products with shelf life or short life cycle
No systematic consideration of inventory in your supply
chain, which results in lost sales and/or excess inventory
Lack of information for right planning decisions
High set-up costs/times and low resource utilization
© SAP 2008 / Supply Chain Planning with SAP APO / 2
Do you therefore need a tool to …
… improve forecast
quality?
… support you in
creating optimized
production plans in all
your factories?
… systematically consider
your inventory and
calculate safety stock
figures?
… improve your sales
order entry confirmation
and provide reliable sales
order confirmation dates?
… increase the visibility
in your global supply
chain?
… optimize your short
term distribution and
transportation planning?
How SAP APO is structured
Advanced Planning & Optimization
Demand Planning
APO DP: Improves the forecast quality and
planning accuracy
Supply Network Planning
Global Available-to-Promise
Transportation Planning &
Vehicle Scheduling
Alert Monitor
Production Planning &
Detailed Scheduling
Synchronize supply with demand in your
global supply chain by balancing push and
pull network-planning processes and by
handling replenishment and production
based on actual demand.
APO SNP: Improves visibility across your global
supply chain and lowers inventory
APO PP/DS: Supports you in creating optimized
production plans
APO gATP: Allows state-of-the-art sales order
confirmation planning processes
APO TP/VS: Optimizes transportation loads and
minimizes transportation costs
APO Alert Monitor: Powerful exception message
system integrated in all APO planning modules
Customers and releases
SAP APO by the Numbers
First release:
SAP APO 1.1 (1998)
Current release:
SAP APO 7.0 (9th APO release) - part of SAP SCM
7.0
Outlook:
Planned next APO shipment: Q4/2009 Enhancement package 1 for SAP SCM 7.0 (APO
7.01)
Active customers:
2000+
Top Industries Adoption:
CP, HighTech, Mill, IM&C, Chemicals,
Automotive, Life Sciences
APO DP (Demand Planning)
Calculate and determine future demand to improve demand quality
and accuracy
Features
Key Benefits
Comprehensive forecasting tool-set
Improved forecast quality
Statistical forecasting with causal
and time-series methods
One tool for power and business user
Selection of best-fit model
Automatic outlier detection available
Highly configurable planning books
with macro functionality
Supporting aggregation /
disaggregation logic
Lifecycle planning
Plan promotions separately from the
rest of your forecast
Track & monitor forecast accuracy
Seasonal planning
Collaborative demand planning
Consolidated demand plan (different
regions, countries, departments, …)
Statistical Forecasting Methods
Causal Analysis
Constant
A
U
T
O
M
A
T
E
D
Exponential smoothing
Moving average
Weighted moving average
Trend
Linear Regression
Multiple Linear Regression (MLR)
Influence Variables
Climate (e.g. Temperature)
Price
Advertising
Distribution
...
Season (without trend)
P
I
C
K
Trend - Season
Manual Forecasting
Seasonal linear regression
B
E
S
T
Others
© SAP 2008 / Page 7
Croston (sporadic demand)
History
No Forecast
External Forecast
Composite Forecast
Own defined model selection
based on error measure
Combine different forecasts
Weight each forecast (time
independent or dynamic)
Demand Planning Master Data:
Characteristic Value Combinations
Characteristics
Characteristic
values
Product
Prod01
Prod02
Prod03
Location
DC01
DC02
DC03
Customer
Cust01
Cust02
Cust03
© SAP 2008 / Page 8
Characteristic
value combinations
(CVCs)
Prod01, DC01, Cust01
…….
Planning
Object
Structure
Duet Demand Planning (not part of APO)
Duet Demand Planning enables managers, sales executives,
and planners to utilize the full Microsoft Excel capabilities as
an intuitive planning front end for SAP SCM
Faster and accurate plans aligned to customer demand
requirements
Leverages the full capabilities of Microsoft Excel (formulae,
functions, graphics, etc.)
Presents an intuitive interface that requires minimum training
Delivers improved user acceptance and productivity through simple
and timely access to relevant business information
Designed as a composite application based on Enterprise SOA
APO SNP (Supply Network Planning)
Calculates quantities to be produced and delivered to the locations
to match customer demand and maintain desired service levels.
Features
Key Benefits
Integrate purchasing, manufacturing,
distribution, and transportation
Increased visibility over the overall
supply chain
Consider constraints and penalties to
plan the product flow along the
supply chain
Optimized sourcing and capacity
utilization
Advanced safety stock methods
considering multilevel supply chain
networks and demand variability
Improved customer service
Supports system wide inventory
modeling and planning
Enable planning on different levels of
detail (aggregated planning)
Choice of heuristic-, rule- or
optimization-based algorithm
Reduced inventory levels
Algorithm: SNP Heuristic
Planned Production
Orders
70%
Demands
60%
30%
40%
Planned Stock
Transfers
Planned Purchase
Requisitions
100%
100%
Demands
Local DC
SNP Heuristic is a heuristic without considering
constraints in
the supply network.
Supplier
SNP Heuristic does the sourcing based on quota arrangements
and priorities.
Plant
As additional planning step, Capacity Levelling can be
performed in order to resolve capacity overloads.
© SAP 2008 / SNP Overview, Dr. Gerald Heisig, 11
DC
Algorithm: Capable-To-Match (CTM)
Planned Production Orders
-> Production Capacities
-> Priority of PPM/PDS
Prio 1
Demands
-> Priority Classes
Prio 1
Prio 2
Prio 2
Planned Stock Transfers
-> Transportation and Handling Capacities
-> Quota Arrangements and Procurement Priority
Planned Purchase Requisitions
-> Procurement Priorities
Prio 1
Prio 1
Demands
-> Priority Classes
CTM planning uses a constraint-based heuristic
planning
Local DC
approach for the cross-supply-chain checks of capacities as well
as material availability.
CTM considers predefined supply categories and demand
priorities
CTM supports characteristic-based planning (as of SCM 7.0)
Supplier
Plant
DC
Algorithm: SNP Optimization
Planned Production Orders
-> Production Capacities
-> Production Costs
$
$
$
Demands
-> Cost for
- non deliveries
- late deliveries
$
Planned Stock Transfers
-> Transportation and Handling Capacities
-> Transportation Cost
Planned Purchase Requisitions
-> Procurement Costs
$
$
Local considering
DC
SNP Optimization is a cost-based optimization
all
capacity constraints and material availability in the supply
network.
SNP Optimization determines the optimal solution based on
predefined costs for supply alternatives and demands.
Supplier
Plant
DC
Distribution Planning: Deployment and Transport
Load Builder
Supply
Stock
Supply
Demand
Stock
Stock
Deployment determines the best short-term
solution to allocate available supply to meet
demand and to replenish stocking locations.
Deployment confirms or changes the supply
network plan depending and creates a
optimized plan for stock transfers
The rules-based Deployment Heuristic
distributes the products according to
quotations and priorities.
The Deployment Optimizer distributes the
products according to cost while also
considering specific rules.
The Transport Load Builder (TLB)
groups deployment results for single
products (i.e. confirmed stock
transport purchase requisitions) to
multi product stock transport orders.
The TLB considers factors like
volume, weight or number of pallets to
fill transport vehicles optimal.
Plant
DC
Operational Planning – Production Planning
and Detailed Scheduling (PP/DS)
Purpose
Create procurement proposals
Optimize and plan the resource schedule and the
order dates/times in detail
Plan critical products and bottleneck resources
Create executable production plans
Benefits:
Reduce lead times
Increase on-time delivery performance
Increase the throughput of products
Reduce the stock costs, through better coordination
of resources, production, and procurement
Optimization integrated into PP/DS
© SAP 2007 / PP/DS Overview 15
APO PP/DS (Production Planning & Detailed
Scheduling)
Production Planning delivers a short term plan that matches overall supply
to demand, given available resources and production methodology.
Features
Multi-level production planning
Order Pegging
Use existing or own developed heuristics
Key Benefits
Determines how, when, and where resources
and materials should be deployed to
accomplish the production goals.
Master planning for materials
and capacity (resource loads).
Detailed Production Scheduling determines optimal production sequence
for execution to meet delivery commitments based on actual constraints on
the shop floor.
Features
Capacity-Load Optimization
Optimal Sequencing
Flexible & Graphical Activity Scheduling
What-if Analysis & Simulation
Configurable Exception Alert Monitor …
Key Benefits
Optimal production sequence that is feasible
and can be executed.
Allows simulation of various planning
scenarios to determine optimal schedule.
Optimization based on actual constraints
ensures reliable delivery due date promises.
Powerful Tools : Detailed Scheduling Planning
Board
Resource View
Save your own
simulation
Product View
Feature: Multi-level problem solving with order
pegging
Sales Order
10
20
10
10
20
40
10
30
100
30
100
40
60
50
Shortage
Planned Order
Dependent Req.
20
30
50
50
50
30
50
(+20)
Planned Order
Excess
coverage
50
Dependent Req.
50
50
20
80
Pur. Requisition
50
30
70
Delay
(-10)
50
Screenshot: Order context (table view)
Demand
Which orders cover
the demand…
Feature: Capacity Reservations
Guarantee most profitable capacity
utilization
Import from SNP optimization result
Flexible levels of finite check
Release capacity prior to production to fill
total capacity
Conversion from time to production unit
Example
Capacity Reservations for named
customers
Unreserved capacity everyone can use it
Collective reservation not named
customers can use it
Industry Solutions
IMC and AD:
Scheduling for Project Manufacturing
Mill and Mining:
Block Planning
Auto:
Model Mix Planning
Production Scheduling
Project
Planning
Advance
Procurement
Engineering
Production
Planning &
Optimization
Production
Scheduling
Manufacturing
Execution
Engineering
Change
Management
Quality
Assurance &
Control
Shipping,
Assembly &
Start-Up
Monitor alerts on projects / main assemblies
Pegging – automatic matching of demand and supply
Visualization of complete order context
Alerts - Early warning system late orders, bottlenecks
Project Planning
Manufacturing
Filter on alerts in order context, sort late orders by delay
Interactive scheduling to reduce late projects, orders
Detect critical path for order context
Reduce buffers on critical path
Reduce duration of project order operations
Multi-level forwards/backwards scheduling
Interactive scheduling to reduce capacity overload
Evaluate resource utilization, filter on overload
Alternative work centers, sequences, production versions
Switch to external procurement, subcontracting
Work overtime, run additional shifts
Adaptiveness and Simulation
What-if simulation, compare alternatives
Procurement /
Warehouse
Block Planning (Mill and Mining)
Business Requirement
Combine optimal resource utilization and precise customer due dates
Consider constraints like minimal and maximal lot sizes, setup time, fixed maintenance
intervals etc.
Plan bottleneck resources in an early planning phase where the final products and product
characteristics are not known
Solution
Define time intervals on a resource where products with certain characteristics can be
produced
Operations of orders are scheduled into matching blocks
100 to, grade A, grammage 180
Product xy
A, 180
Quality S
Width 1000
Product vb
A, 200
Quality M
Width 1200
120 to, A, 200
75 to, C, 150
Model-Mix Planning: Situation
Orders
Line network
Restrictions
Quantity
Distance
X in Y
Block
Equal
distribution
Position
Objective
Business value
Generation of a feasible plan
for highly configurable
products with high volume
Balanced usage of production
resources
Adherence to promised
delivery date
Early identification of potential
bottlenecks
Reliable delivery date leads to
increased customer
satisfaction
Model-Mix-Planning
Period Slot
1
Sequencing
2
day 1
day x
day x+1
day y
A snapshot of SAP SCM customers
Demand Planning and
Supply Planning
Production Planning &
Detailed Scheduling
SAP
2007
/ PP/DS
©©
SAP
2008
/ Page
26 Overview 26
Order Fulfillment & Transportation Management
Supply Network Collaboration
SAP SCM
Ms. Sherry Gong
[email protected]
Ms. Fan Li
[email protected]
Q&A
Thank you for your
interest!
www.sap.com/scm
“This presentation is a preliminary version and not subject to your
license agreement or any other agreement with SAP. This document
contains only intended strategies, developments, and functionalities of
the SAP® product and is not intended to be binding upon SAP to any
particular course of business, product strategy, and/or development.
Please note that this document is subject to change and may be
changed by SAP at any time without notice.
SAP assumes no responsibility for errors or omissions in this
document.”
Forecasting and Allocation in Supply-Chains
ORBIS Consulting Shanghai
(
)
Zao Fong Universe Building, 3D
1800 Zhongshan Xilu
200235 Shanghai
Tel.: +86 21 6440 1276
Fax: +86 21 6440 1279
http://www.orbis-china.com.cn
André Bohe
ORBIS Consulting Shanghai
www.orbis.de
AGENDA
Forecast and Planning situation
Supply Chain Structure
Methods / Conflicts
1.a) Definition of Goals and Functionalities in SAP R/3
1.b) Realisation with SAP R/3
2.a) Definition of Goals and Functionalities in SCM-DP
2.b) Realisation with SAP SCM-DP
3.a) Definition of Goals and Functionalities in SCM-SNP
3.b) Current Project Status SAP SCM-SNP
3.c) Next Steps
2
© ORBIS Consulting Shanghai
2010 4
Forecast and Planning Situation
3
2010 4
Forecast and Planning Situation – Supply Chain Structure
Logistic Center
Central Warehouse
Situation:
Production Sites
- Different SAP Systems with different Clients
- more than 100 SAP Locations
- more than 10 Non-SAP Locations
Demands
Material Supply
Material Supply
Demands
Cross Company Scenario‘s
Cross Client Scenario‘s
Sales Orders
Sales Orders
4
2010 4
Forecast and Planning Situation – Methods/Conflicts
Logistic Center
Central Warehouse
With Stock-Responsibility
Priority 1:
Demands, coming from
Real sales-orders
Unreliable Customer
Forecasts
Min/Max-Levels
(not flexible)
Safty Stock
(not dynamic)
Priority 2:
Min/Max-Triggers
Phase-In
Phase-Out
5
2010 4
Forecast and Planning Situation – Methods/Conflicts
Logistic Center
Central Warehouse
Not able to
distinguish between
demands
Priority 1:
real sales-orders
Priority of own
Cust.Demands
Calculate own
Forecast to Prod.
sites
Priority 2:
Min/Max-Triggers
6
2010 4
1.a) Definition of Goals and Functionalities SAP-R/3
7
2010 4
Definition of Goals and Functionalities
„Reduce Stocks in Logistic Center by replacing manual
Reorderpoint Planning with automatic consumption based
forecasting“
Automatic Calculation of consumtion based Forecast-Figures
Forecast-Figures and PIRs on weekly basis
Consumption of Forecast with Sales Orders
Automatic Transfer of Forecast-Figures to MRP
Automatic Creation of Transfer P.O.s after MRP
8
2010 4
Realisation with SAP R/3
9
2010 4
SOP
Demand Mgt
MRP
Purchasing
Projects an
„Independent
Forecast“ by week
based on 52 weeks
usage history. This
forecast is
transferred to
Demand Mgt. where
it is converted into
Planned Idependent
Requirements
Manages rules for
the impacts on
“PIRs” and for
adjusting “PIRs”
accordingly
Consumption by
Sales Orders
Keeps track of
impacting transactions
and PIR’s.
Calculates “Net
Requirements” for the
Coverage period,
based on Demand
Management figures.
Produces Purchase
Requisitions
Purchase Requisition will
be automatically
converted into Purchase
Orders according to
replenishment horzion
Run mass
Sales Forecast
Transfer into
PIRs for use in
MRP-Run
16 Weeks
forecast for
Product-Group
Requirements
Listing
Run
MRP
Stock,
PIR‘s
Sales Orders,
Transfer P.Os
Purchase
Requisitions
10
Purchase
Orders
2010 4
Still open Issues
No global view on stocks and Planning Situation (Cross System, cross Client
and Non-SAP Systems)
No Alert Functionality for critical Stock-Levels / Stock coverage
No possibility to track the Requirements (Customer orders / Stock refill)
No automatic mass processing in SOP for new products
“Isolated” Planning of single Logistic Centers
No Consideration of “non-working” periods
11
2010 4
2.a) Definition of Goals and Functionalities for SCM-DP
12
2010 4
Definition of Goals and Functionalities in SAP-SCM
A.) “Get Global view on stocks and planning situation”
Integrate all SAP-Systems/Clients and Non-SAP Systems
Define Alert Functionality for Stock-Levels and Stock coverage
B.) „Replace R/3 SOP-Forecast with SCM-DP Forecast and provide
Key-Figure for SNP-Planning“
Consider plant holiday in Forecasting mechanism
Include new Products automatically for Forecasting
Use Phase-In / Phase-Out Functionality
13
2010 4
14
2010 4
1. Definition of Data-Flow model
Info-Cube Level
Info-Cube Level
Transformation Level: Field-Mapping and Rules
DataSource Level:
Definition of fields and Upload-process
Source-System Level:
SAP Systems
Non-SAP Systems
15
2010 4
2. Definition of Process-Chains and upload cycles
16
2010 4
3. Definition of Tableau
Country
Location
Prod. Hierarchy
Product
Nav. Attributes
17
2010 4
4. Definition of Alert-Monitor and Alert-Handling
Alerts, created after
Macro-Calculation
and Result-Check
Mail,
triggerd
by Alert
Creation
18
2010 4
B.) „Replace R/3 SOP-Forecast with SCM-DP Forecast and provide
Key-Figure for SNP-Planning“
1. Enlargement of existing Settings by Forecast Key-Figures and -models
InfoArea, InfoObjectCatalog, InfoObject
Planning Object Structure
Planning Area (expand with Forecast-Figures)
Planning Tableau (expand with Forecast-Figures)
2. Creation of Forecast Profile
19
2010 4
Realised Functionalities:
BW-functionality to collect data from Non-SAP systems
Process chain to define update and upload procedures
Global view on Stocks , Stockranges and other Key-Figures (across
Clients, across Systems) with Planning Tableau possible
Extended Planning structrues and levels (clearly arranged Display of KeyFigures and Graphics)
Automatic Integration of new products to be forecasted via Core Interface
20
2010 4
Realised Functionalities:
Individual Calculation of Key-Figures with Macro-Technology
Automatic Alert-Creation
Mail to responsible Person (direct link)
More forecasting methods available (e.g. Statistical Forecast, causal
analysis, Croston, Holt-Winters)
Considering Factory-Calendar in Forecast-Calculation
„Like-Modelling“ in Case of Phase-in /Phase-out Products
„SCM-DP is easier to handle more flexible and offers much more
functions and possibilities compared to R/3-Functionalities“
21
2010 4
3.a) Definition of Goals and Functionalities for SCM-SNP
22
2010 4
Definition of Goals and Functionalities in SAP-SCM
“Planning of entire Supply-Chain based on DP Forecast Key-Figures
with Prioritisation of actual Demands ”
„Calculate and allocate quantities for production plants
„Reduce Costs in entire Supply Chain”
23
2010 4
3.b) Actual Project Status SAP SCM-SNP
24
2010 4
Actual Project Status SAP SCM-SNP
Decision-Process for CTM or Optimization because Prioritization of
Demands necessary
Planning methods
Heuristic
CTM
Optimization
Infinite planning / (MRPII
- approach)
Rule-based finite planning
of individual needs
Integrated finite planning
Passes on demand /
generates reallocations
Prioritization of demand and
supply (rules)
Prioritization of demand and
supply (costs)
Generates reallocations
Generates reallocations
BOM explosion / generates
feasible supply
feasible supply
Constraint-based planning
Linear programming
supply
Interactive / local capacity
evaluation
25
2010 4
Actual Project Status SAP SCM-SNP
Optimization
With Optimzier it is only possible run a
bucket-based planning
Character based Optimization is not
provided (Variant Configuration)
Optimizer does not „know“ Make-toOrder production
Decision pro
CTM
26
2010 4
3.c) Next Steps
27
2010 4
Next Steps
To Do:
1. Create Prioritization rules for different demand categories (sales orders;
PIRs; Transfer P.o.)
2. Create Prioritization rules in between sales orders (material availability
date; delivery priority; recieving location)
3. Definie CTM-Planning Parameter with link of prioritized demands to
prioritized receipts
4. Create PP/DS Alerts (Quantity + Scheduling – Alerts) for open demands
after CTM-Run
5. Check Possibility to change CTM results with BEx-Analyzer and copy back
to SNP-Planningtableau via IP (integrated Planning)
28
2010 4
3rd SIG Automotive Meeting
Thank you for your Attention
André Bohe
ORBIS Consulting Shanghai Co., Ltd. ZAO FONG Universe Building, Office: 3D
No. 1800 Zhongshan Xilu (/Yishan Lu) 200235 Shanghai
Tel:
+86 21 6440 12- 76
Fax:
+86 21 6440 12- 79
Mobile:
+86 131 2215 2136
1800
3 D
Email: [email protected]
www.orbis-china.com.cn
29
2010 4

Supply Chain Planning with SAP APO

Transcription

Similar documents

Record of Achievement

Variant configuration

Formerly, Zygen Technology

unit 5: financials - [email protected]

Record of Achievement

Efficient project management – Although employees are

Supply Chain Through Mobility

High Voltage Maintenance

Angiosperm Latin Name: Euphorbia ingens Common Name

Record of Achievement