03- Master Data

Business Consulting Services

SCM APO TRAINING COURSE IN SUPPLY NETWORK PLANNING

Unit 3: Master Data

2

COURSE OVERVIEW DIAGRAM

1Course OverviewIntroductions

2SNP Overview

4SNP Transaction Data

5SNP Run Using Heuristics

3SNP Master Data

6SNP Run Using Optimizer

8Deployment Run Using Optimizer

7Deployment Run Using Heuristics

9Integration

3

SNP PROCESS FLOWPlanning Area Administration

Planning Method Determination & Profile Settings

Supply NetworkPlanning Run

Transport Load Building

Deployment Run

Conversion intoPP/DS orders

PP/DS Planning

Release of SNPPlan to DP

Interactive Planning

APO Master Data Setup

Model/Version Creation

Supply Chain Model Setup

Release of Demand Plan to SNP

Simulation

Management by Exception

4

MASTER DATA FOR SNP

• Locations• Products• Resources• Production Process Models• Transportation Lanes• Quota Arrangements

Contents:

Unit5: Master Data | 2005

5

MASTER DATA FOR SNP: UNIT OBJECTIVES

• Identify the master data required to support supply network planning

• Create locations, products, resources, and production process models

• Set up transportation lanes and quota arrangements

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


6

MASTER DATA FOR SNP: BUSINESS SCENARIO

• A Company bought a new production plant. This plant must be modeled in the Supply Chain Engineer.

• Products, resources and production process models must be created.

• Transport lanes to suppliers, distribution centers and quota arrangements must be added to the model.


7

MASTER DATA Master Data is the static data used

during planning (as opposed to transactional data)

We map the organization to the system using Master Data

Master Data is required to build a supply chain model and execute planning

It allows us to have standardized information across the entire enterprise

8

MASTER DATA Key master data

Locations Products Resources Production Process Models

Specific Master data for planning methods Directly created or transferred from an

OLTP system

9

MASTER DATA TRANSMISSION

• The Master Data in APO is directly correlated to that in SAP R/3.

• Initially, the data can be transferred from R/3 to APO with subsequent maintenance.

R/3 MASTERDATA Initial Transfer

Incremental transfer

APO MASTERDATA

• Product• Work Center• Plant/

Storage Location

• BOM/ Routing

• Product• Resource• Location

• PPM


LOCATION

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MASTER DATA -LOCATION

Produc tio n Distributio n Stora g e C ustome r Supp lie r

Loc a tion Typ e

• A Location is a place where you perform an activity.

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A LOCATION IN THE SUPPLY NETWORK

Products can be stored at this location

Demands to be covered from this location

Storage, handling, supply and production capacities

Calendars for production and shipment

Storage cost per unit for each product Purchasing cost per unit for each product,

material per supplier

13

CREATE A LOCATION IN THE SC ENGINEER

Create Locations Type of Location Name of Location Geographical Information Time Zone

Supplier CustomerDCPlant


PRODUCT/ MATERIAL MASTER


15

PRODUCT MASTER Product master is where we store

all static data related to the product (such as dimensions)

all data related to APO processing (such as Procurement Type)

Allows you to maintain Global or Location specific data


16

PRODUCT/ MATERIAL MASTER - GLOBAL

ATP Attributes

UOM Classification

SNP 1

Views


17

SNP RELEVANT DATA: GLOBAL VIEW

Attributes Gross weight Volume Material Group

Classification Units of measure

SNP 1 Penalty for non-delivery Delay penalty Maximum delay

ATP Data Product Allocation Procedure Sequence


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PRODUCT/ MATERIAL MASTER LOCATION SPECIFIC

Administration Attributes

Unit of Measure Classification

SNP 1 ATP

SNP 2 PP/DS

Procurement GR/GI

Extra

Views

Demand Lot Size

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SNP RELEVANT DATA: LOCATION VIEW

Administration Production Planner SNP Planner Demand Planner Transportation Planner

Attribute Stacking Factor Shelf Life

Unit Of Measure Classification

SNP 1 Penalty for non-delivery Delay penalty Maximum delay

20


ATP Product Allocation Procedure Sequence Checking Mode Checking Horizon ATP Group Checking Horizon Calendar Display Unit/Measure

Demand Demand Profile Strategy Dependant Demand

Always collective requirements

Possible customer individual requirement

Collective order (fixed pegging)

21

EXAMPLE - DEMAND CONSUMPTION

A new sales orders reduce the forecast

Day 1 2 3 4 5 6 735 32 28 23 14 3 112 13 20 15 5 5 547 45 48 38 19 8 8

ForecastTotal Demand

Sales OrderSales Order

Mat 1 2 St 1.000 DMMat 2 5 St 7.500 DM

8.500 DM

Reduce the forecast

Increase the Sales orders


22


Lot size Lot size profile Processes

Lot for Lot Fixed Lot Size By Period Reorder Point

Scheduling Safety Day’s Supply Available Data Indicator

Quantity Determination Min/Max Lot Size Target Stock Level Method Assembly Scrap Rounding Value Rounding Profile Target Day’s Supply

23


SNP 2 SNP Demand profile SNP Supply profile Deployment profile Procurement info

Procurement Procurement

Procurement type Planned Delivery Time

Stock Procurement Costs Stock Costs

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Goods Receipt/Issue– Processing Time in Days

– Capacity Consumption

– Shipping

– Completion Confirmation

– Network Design

– Goods Issue Posting

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PRODUCT/ MATERIAL MASTER - PROFILES

The relevant fields of the master data are populated by the data specified in the profiles selected.

If the data in the product master is changed, the product master can not be globally maintained via the profiles

26

EXERCISE 5 Carry out the exercises for Product

Master


RESOURCES


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RESOURCES The resources are used to define

Capacities of equipment, machines, personnel, means of transport, warehouses

Resource data are relevant for planning order dates, taking working time and the capacity of the resources into account

Resource types: Single activity/ Multi-activity resource Single Mixed and Multi-Mixed Resource

29

TYPES OF RESOURCES - PP/DS AND SNP CTM

1) SINGLE ACTIVITY/ MULTIPLE ACTIVITY RESOURCES :

These can be scheduled with an accuracy of a second. Scheduling in PP/DS determines the exact production dates of orders and operations. You define the capacity of these resources as a time capacity, based on work time data.


30

CAPACITY OF SINGLE & MULTI-ACTIVITY RESOURCES

Time Capacity

Shift sequences

Day 1

Sequence 1 Day 1 Day Day 3 Day Day 4 Day 2 Day

Sequence 2 Day Day

Sequence 3

Shift definitions

24:00

16:00

95 %

21:0020:00

16:0008:00

98 %

13:0012:00

93 %

05:0004:00 00:00

08:00

Sequence 3Sequence 1 Sequence 2

Intervals of the capacity variant

08/22/99 08/23/9908/01/9907/31/99

Break patterns

21:0020:0005:00

04:00

13:0012:00Shift factors

93 %95 %

98 %Individualresources Resource utilization

Day 6 Day 1


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RESOURCE CATEGORIES

TransportProduction

Storage Handling


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RESOURCE CATEGORIES Describes the usage of the resource

It is a purely descriptive characteristic that can be used for selecting resources for resource maintenance

It is not linked with a planning functionality


33

RESOURCE MASTER DATA

Standard Capacity

General Data

Planning Parameters

Short Text

Resource Master Data

Characteristic

Down Times


34


General Data Resource Category Location Time Zone Planner Planning Calendar Active Variant Reference Resource


35

PLANNING PARAMETERS Parameters in the resource that are

relevant to scheduling, which the system uses in PP/DS and SNP.

Used to control in detail how the system schedules orders to resources.

Examples: Overload, Bottleneck resource, activity overlap periods, etc.


36


Standard Capacity Down Times

Validity of down times Start and end time of down times Type of down time

Characteristics Short Texts


PRODUCTION PLANNING MODEL


38

PRODUCTION PROCESS MODEL (PPM)

PPM summarizes Routing BOM

PPM supports Location-dependent (PPM ID) and

location-independent (Plan No.) Min/max lot sizes for the master material Operations

Set of different process steps (e.g. setup, etc.) Bucketed time intervals for each process step Resources assigned to production steps

Planning Order

Process


39

INPUT/OUTPUT COMPONENTS

Input Components Identification of “raw

material” Output components

Co-products Model bin splits No explicit head

material for processes

Co-products

Processes

R R

R R


40

TIME-DEPENDENT PROCESS PARAMETER

Time-dependent process parameters for Yield Duration Capacity consumption Quantities of input /

output components

yield 100%

yield 70%

yield 50%

yield 100%

Process

50 %

100 %

0 %Yield (learning curve) t


41

PRODUCTION PROCESS MODEL

Operations: Supply material Pre-assembly Final assembly Inspection

Activities: Setup Produce Tear down Queue time

Product Relationship Resources

In / Out

Resource consumption

Header: Costs, Lot size range $

Sequence


42

SNP MATERIAL FLOW LOGIC

• PPM rough cut plan

• Activity time bucket

1. timebucket

2. timebucket

Input Output

Orders:1001100510071009

Quantities:100200300100

Time bucket = 700


43

PPM - PROCESS FLOW

Create Operations Define Activities for each of the

operations Assign Resources to the

Operations Assign Components to the PPM Establish the activity

relationship Set up time dependant

parameters Perform the product plan

assignment


44

PPM - CONSISTENCY CHECK The consistency check function

analyzes the PPM and determines whether all of the logical assignments are correct.

It will give an alert to warn of incorrect assignments or missing elements.


45

EXERCISE 6 Carry out the exercises for Resources

and PPMs.


TRANSPORTATION LANES


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Represent a business relationship between locations.

Can be created by dragging from the source location and dropping on the target location on the Supply Chain Model.

Unit5: Master Data | 2005 48


Multiple transportation modes per lane

Products that can be carried by a transportation mode

Transportation capacity by volume, weight, pallets

Transportation costs per unit, product and transportation

mode


49

CREATE A TRANSPORT LANE IN THE SC ENGINEER

Maintain Transportation Lanes Transportation Methods Validity Period Transportation Duration Costs Material Independent Priority Transportation Resource TLB Profile


QUOTA ARRANGEMENTS


51

WHAT IS A QUOTA ARRANGEMENTS ?

Forecasts,Customers orders

Sourcing Production &Purchasing

Requirements,Inventory levels

APO

Liste

Definition

Incoming quotas Production lead times Transportation lead times

Supply Chain Model

40%60%


QUOTAS IN THE SNP RUN Netting calculation (for

example, inventories, in transits)

Requirements are passed through the network, accounting for: Delivery times Incoming quota

arrangements Single-sourcing Multi-sourcing

Result: Production or procurement quantities

50

30

70

50


INCOMING QUOTAS

40%60%30%

70%

Incoming Quotas

Production Location Distribution Center (DC)

Quota

?Supplier

60% 40%

Product


OUTGOING QUOTAS

40%60%30%

70% Outgoing Quotas

Production Location Distribution Center (DC)

Quota

?Supplier

60% 40%

Product


55

MAINTAIN QUOTA ARRANGEMENTS

Determines what percentage of a certain product will be shipped to/ from a specific location

Quotas are location specific, but model independent

Quotas can be incoming or outgoing from a location

Expressed as a percentage Each quota arrangement has a priority Quota arrangement uses Lot Size Profile


56

CREATING A QUOTA ARRANGEMENT USING THE SC ENGINEER

Maintain quota arrangements for use in SNP heuristics Validity Period Location Quota % Material-Dependent Priority Lot Size Profile

60%

40%


57

EXERCISE 7 Carry out the exercises for

Transportation Lanes and Quota Arrangements


58

MASTER DATA FOR SNP: UNIT SUMMARY

Identify the master data required to support supply network planning

Create locations, products, resources, and production process models

Create transportation lanes and set up quota arrangements

You are now able to:

Documents

03- Master Data