PPDS Planning Enhancements v5

SAP AG 2005

RKT SCM 5.0PP/DS

Planning - Enhancements in SCM 5.0

SAP AG 2005

Planning - Enhancements in SCM 5.0

Content:

- Withdrawal from Alternative Location

- CTP Enhancements

- Fix Pegging in ATP/CTP Process

- New Heuristic Enhancements

- Capacity Push Heuristic

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Unit Objectives

z Work with the process withdrawal from alternative locationz Understand the CTP enhancementsz Create fix pegging relationships in a ATP/CTP Processz Use the new heuristic enhancementsz Execute the Capacity Push Heuristic

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

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Withdrawal from alternative location

The Withdrawal from Alternative Location Process:

the component demand of an inhouse production is created in a location different from the production location. Goods issue of the component is posted directly in this issuing location.

Withdrawal from alternative plant is also available in R/3. In R/3 the process is controlled with a special procurement key. In R/3 customizing of the special procurement key 70 is an example for withdrawal from alternative plant. Thats why the process is also known as the SOBSL-70 process.

Withdrawal from Alternative Location can be combined with:

- phantom assemblies- MRP areas (issuing plant)- Co-Products- subcontracting

Product substitution heuristic can be carried out in the issuing location only

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Production plant Issuing location

Step 1Planned ordercreation

Component demandwithdrawn fromother location

Step 2Planningcomponents Pegging

Planned receipt

Production plant Issuing location

Step 3Procurementof components

Stock

Step 4Withdrawcomponent

Business Process

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Advantages of Withdrawal from Alternative Location versus stock transfer orders:

- Less administrative effort No need to manage stock transfer orders. No need to post goods issue and goods receipt for the stock transfer order.

- Using stock transfer orders would require managing stock in two different locations.Monitoring stock would be more difficult. Planning would be more difficult. Responsibility for stock would be obscured.

- In the stock transfer process the receiving location assumes responsibility for the product at the time of goods issue in the delivering location. This contradicts Kanban and JIT philosophy, where the supplier of a component should be responsible for the component stock.

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Limitations:

- not supported by iPPE, because iPPE does not support location dependent attributes on BOM item level

- not supported by the PPM

- issuing location must be either a production plant or a distribution center.

- currently not supported by SNP

- PDS has to be regenerated after a change of the special procurement key in R/3

- heuristic for the supersession chain can only be executed in the issuing location

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R/3 Customizing:

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The special procurement key can be entered in BOM on item level or in the components material master.

Special procurement key

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Phantom assemblies

Withdrawal in an alternative location can be mixed with phantom assemblies. If a component is a phantom assembly in the issuing location, then the BOM of the component is exploded in the issuing location. All components of the phantom assembly are by default withdrawn from the issuing location unless the component of the phantom assembly has got its own different issuing location

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76587710696340530051 5899

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Plant Issuing plant Phantom Order components

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CTP Enhancements

In SCM 5.0 the change capabilities of CTP, based on fix pegging, was enhanced.

Multiple changes of already saved sales order items are vital elements of the business process. To assure consistent planning behavior, the possibilities for changes are restricted. For efficient changes of sales order items the planning algorithms of CTP (and MATP) have to determine the receipt elements, which are assigned to the sales order items. This is quite easy in a make-to-order scenario, where the receipts are linked to the demands via accounting.

The assignment in a make-to-stock scenario can change during time. Often one receipt is assigned to more than one demand. This makes it quite difficult to propagate the changes properly through the supply chain. The re-create receipt elementsfunctionality was therefore restricted to make-to-order sales order items until SCM 4.1.

Now the functionality is provided for a make-to-stock scenario as well. This will lead to better confirmation results.

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CTP EnhancementsRe-create Receipt Elements for fix pegged Receipts

This CTP functionality is an extended method of the product availability check. It will be available, if in the ATP check instruction the re-create receipt elements indicator is set. Additionally fix. Pegging in CTP/ATP in the PP/DS planning procedure is set. In the case of moving requirement dates the system behavior is as follows :

t

a v a i l a b i l i t y c h e c kf o r t h e r e q u e s t e d d a t e :n o a v a i l a b i l i t y

t

n e w r e c e i p t c r e a t e d b y C T P :c o n f i r m a t i o n d a t e = r e q u i r e m e n t s d a t e

t

r e c h e c k o f t h e s a l e s o r d e ri t e m f o r a n e a r l i e r d a t e ,i g n o r i n g t h e o l d r e c e i p t

t

a n e w r e c e i p t i s c r e a t e d f o ra n e a r l i e r d a t e ( i f p o s s i b l e )r e s u l t i n g i n a b e t t e r c o n f i r m a t i o n

1 . 2 .

3 . 4 .

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In the case of increasing the item quantity the system behaves in that way:

t

sa les o rd er item w h ichh as b een c rea ted w ith C T P

t

rech eck of th e sa les o rd eritem w ith a h igh er q u an tity

t

ava ila b ility ch eck c on firm sn o th in g a n d th e p ro d u ctionis ca lled fo r th e to ta l q u an tity

t

for on e sa les o rd er itemon ly o n e rec e ip ts h as b eencrea ted

1 . 2 .

3 . 4 .

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CTP EnhancementsRedistribution of Receipt Elements for Production Directly

The standard behavior of the CTP scenario is as follows. A newly created sales order item is always confirmed against surpluses, which have been present before the creation and/or receipts which have been created during the ATP transaction, although from planning perspective it could be confirmed on the requirements date.

t

sa les o rd er in th e fu tu rew as c on firm ed a g a in st anearly rec e ip t

1 .

t

a n ew sa les o rd er item w ith anearlie r req u irem en ts d a te isA T P -ch ec k ed

2 .

t

A T P can n o t c on firm an d C T Pis ca lled . U n fo rtu n a te ly th ecrea ted rec e ip t is la te

3 .

t

T h e n ew sales o rd er item iscon firm ed a gain s t th e la terec e ip t

4 .

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To get the new behavior Production Directly must be set in the ATP check instruction and Direct Production with Receipt Redistribution indicator is switched on in the PP/DS planning procedure (also Fix Pegging in CTP/ATP)

t

sales order in the futurewas confirmed against anearly receipt

1.

t

a new sales order item iscreated and checked via net-requirements calculation

2.

t

The receipt is created on thedate with the deficit which isfar in the future

3.

t

the sales order item can beconfirmed for the requirementsdate, because there is no deficit

4.


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Fix pegging in ATP/CTP process

Fixed Pegging synchronization to ATP

Previously, you needed to carry out the heuristic SAP_PP_019 Create Fixed Pegging Relationships in the ATP and CTP process several times a day after confirming the sales order. This fixed the assignments between the requirement and receipt elements created by the ATP or CTP check. The confirmation situation may have also changed by the time the heuristic was carried out because the heuristic was normally executed in a separate planning step.

As of Release SCM 5.0, the PP planning procedure was enhanced in such a way, that the system now automatically creates fixed pegging relationships between customer requirements and receipt elements in an ATP and CTP process, after you have saved the confirmed sales order. This fixes the assignment that the ATP/CTP check created at the finished product level. A confirmed sales order item is therefore fixed to the relevant receipt element.

Now ATP confirmation and material flow determination in PP/DS is matching.

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CTP and multilevel planning actions due to PP planning procedure

SD ATP PP finished good PP component

Createsales order

Run CTP Create order

Check PP planning procedure focomponent

Check availability / Create order

for component

Adjust order date/Delete order

Check production date /availability

Confirm sales order

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Lack of Consistency

SD ATP PP DS

Createsales order

Run ATP confirmation

Run PP fix pegging

Run productionplanning

Run detailed scheduling

Run backorderprocessing

Adjust material flowbefore PP (optional)

Adjust material flowafter DS (optional)

Adjust material flowafter BOP (optional)

Adjust material flowbefore DS (optional)

MRP process

Run CTP

ATP process

OPT process

CTP process

Time shiftDifferent behaviour

Less usability

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Settings in Planning Procedure:

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Differences of the two possible ABAP Classes:

For the CTP process, the standard class /SAPAPO/CL_RRP_CTP is offered. This class controls system behavior in the CTP check in connection with fixed pegging. As an alternative to this ABAP class, you can use the standard class of the ATP process/SAPAPO/CL_RRP_FIX, if you wish to have a different system behavior in the CTP process.

The key difference between the two classes is, that in the case of the class /SAPAPO/CL_RRP_CTP the system deletes the existing fixed pegging relationshipsand reassigns the customer requirements to the receipt elements with each new invocation of the CTP check for an already confirmed sales order (if you change the desired date/time in the sales order for example). The system then creates new fixed pegging relationships to fix the assignment.

In the case of the class /SAPAPO/CL_RRP_FIX, on the other hand, the fixed pegging relationships are retained. A renewed check is always carried out against the fixed pegging. The system merely adjusts the pegging quantities, if necessary, but leaves the fixed pegging relationships unchanged.

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Settings in ATP-Check Mode:

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Settings in Global Parameters:

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Settings in Material Master (only necessary, if Global Settings for Fixed Peg. = 2):

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Limitations:

- only for ATP with production type characteristic evaluation (ATP check mode)

- only for sales documents like sales orders, quotations and request f. quotation

- ATP allocations cannot be supported

- fixed pegging creation within BOP is limited to PP/DS ATP

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Heuristic EnhancementsOverview

Order Re-explosionPerformed whenever changes in master data occur. Up to SCM 4.1 only forcomplete pegging areas with loss of scheduling dates. Changes in the far futurecould so affect current production plans

Now scheduling dates are kept, if possible Re-explosion can now be performed for a selection of orders Those Enhancements werde made for the heuristics SAP_PP001 - 005,

SAP_PP_013, SAP_PP_017, SAP_PP_SL001, SAP_PP_C001, SAP_PP_CTP

More selection fields and flexible safety time Enhancements for the Bottom-up and Top-down Re-scheduling Heuristics

SAP_PP_009 and SAP_PP_010)

Creation/deletion and replacement of a fixing or a planning interval for a resource Enhancement for the Heuristic SAP_DS_03

New service heuristic for Multi-level Order Planning to perform order and activity enabled heuristics in a reasonable sequence for a

selection of resources, orders or activities (SAP_PP_022)

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Heuristic EnhancementsOrder Re-explosion

GX

GY

GZ

GW

Initial situation

G2

G3

G1

G4

Behavior until SCM 4.1

G2

G3

G1

G4

New behavior

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Heuristic EnhancementsOrder Re-explosion

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Heuristic Enhancements

Rescheduling heuristics bottom-up and top-down (SAP_PP_009 and SAP_PP_010)

These heuristics have been enhanced, so that you can interactively select only one order or activity (and leave other orders of the pegging area untouched) for rescheduling. This is a single-level process. If you want to execute multilevel rescheduling for an entire order network, you must include the heuristic in the new service heuristic SAP_PP_022.

In addition, both heuristics have been enhanced with the safety time field. You can now choose whether or not you want to use the safety time of the product master, or if you want to use the safety time only as long as it does not cause scheduling violations.

Multilevel planning of individual orders (SAP_PP_022)

This new service heuristic enables multilevel planning of an order with consideration of the low-level codes. From the detailed scheduling table, you can interactively select resources and activities or directly select an order. The system determines the dependent orders and executes multilevel planning. To do this, the system works with the heuristic you have assigned to SAP_PP_022. The rescheduling heuristics can be used bottom-up or top-down.

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safety time

Heuristic EnhancementsRe-scheduling with Flexible Safety Times

Respectingfull safety time

Partiallyrespecting safety time

(no adjustment)

Not respectingsafety time

Selected order

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Heuristic EnhancementsRe-scheduling with Flexible Safety Times

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Heuristic Enhancements

Heuristic SAP_DS_03

You can use this heuristic to create, delete, and replace a fixing or a planning interval for a resource. This heuristic can be included in the production planning run and can be accessed interactively from the DS planning board.

New functionalities of this heuristic:

- Deactivate sequence-dependent setup activities in the fixing interval - to ensure a stable planning situation in the short-term horizon. The setup time determined from the setup matrix is retained, when the operation sequence on a resource changes due to confirmations.

- Fix operations

Operations in the fixing interval are fixed, meaning the operations are protected from any potential changes made by detailed scheduling. The associated orders are not date fixed or PP-fixed. This means that these orders can be changed at any time by an MRP run. To protect these operations/orders from changes by production planning, you can use the Fix Operations field in the heuristic settings to define, that the operations in the selected fixing interval are date fixed and PP-fixed.

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Capacity Push Heuristic

Task of the new Heuristic (SAP_PP_CDOC)

Typically a resource is not loaded 100% at a time. Often time-slots occur, which should be filled with orders consuming the available capacity. This will lead to a better resource utilization. The new Capacity-Push-Heuristic, which can be used in the Detailed scheduling planning board and the Resource planning table, willinteractively fill available time-slots.

The Capacity-Push-Heuristic will create or change planned orders to fill a given time-slot on a resource as good as possible.

The heuristic itself might act as possible template for other heuristics which deal with capacity push.

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General remarks:

- planned orders can be created or changed

- production orders with the status not released can be changed

- production orders with the status released but not yet (partial) confirmed can be changed

- orders can have more than one operation.

- The date of an order could vary from now to the end of the planning horizon by taking account of validity horizons of the sources of supply. Heuristic settings shall allow creating/elongating the order into the past.

- The planned operation of an order cannot spread over a time-slot, where other operations are available unless there is enough capacity on a multi-resource.

- Authorizations for creating/changing of orders are considered.

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Limitations:

- Only one resource will be considered at a time

- Only time-continuous resources are considered; no bucket resources and thus time-slots within a bucket

- designed for interactive use only

- not in every case the heuristic will fill the resource 100%. In some cases small capacity gaps may still remain in the selected time period.

- You cannot use the heuristic, if a variable continuous consumption has been maintained in the source of supply of the product for multi-resources.

- You cannot include the heuristic in a production planning run.

- The order quantity is adjusted by taking into account the capacity of the selected resource. If an order reserves additional resources, the system will not take the capacity of those resources into account when adjusting the quantity.

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1 Extend forward2 Extend backward3 Create new

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Operations on a ressource:

Serveral new orders due to lot-size

One new order

Elongating to the right

Elongating to the left

Initial situation

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Special topics for multi-resources:

Adjusting an existing order will use the capacity-requirements of this order. If there is enough capacity on the multi-resource over the given time-frame this order will be placed parallel to existing orders. If the free capacity over the time-frame is not constant the elongation of the order will stop before filling the whole time-frame at that point in time, where not enough capacity exist.

Creation of new orders, which positioned parallel to each other orders:A new order can be placed parallel to some already existing orders if there is enough capacity at the resource.But no orders will be created which are placed parallel to just newly created orders at the actual heuristic call.

If order-creation stops due to restrictions of the lot-size no new additional orders will be created.

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Planning - Enhancements in SCM 5.0 - Unit Summary

You are now able to:

Work with the process Withdrawal from Alternative Location

Understand the CTP Enhancements

Create Fix Pegging relationships in ATP/CTP Process

Use the New Heuristic Enhancements

Execute the Capacity Push Heuristic

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PPDS Planning Enhancements v5