Four SAP VC modelling Challenges

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October 2010

Four VC Modeling Challenges

Lawrence MatusekManaging PartnereLogic Group LLC

[email protected]

Copyright 2010, eLogic Group, LLC, All rights reservedC 2

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• eLogic provides full-service business solutions that allow companies to

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• Our organization, methodologies and tools are tailored to enable a

rapid and efficient adoption of proven breakthrough practices in quote

and order simplification / automation.

• eLogic brings specialized expertise in sales channel, product,

information technology and change management needed to tackle the

most complex configurable and engineered product environments.

• By leveraging industry best practices, eLogic can guarantee dramatic

improvements in productivity, cycle-time and quality with improved

customer satisfaction.

• For more information, please visit our website at www.elogicgroup.com

http://www.elogicgroup.com/


The Four Challenges are…1. Dynamic BOM Structure – The super BOM may not directly

contain all configurable components at design time

2. Adjacency Restrictions – Relationships among configurable materials are based on the manner in which they are connected

3. Summation – Sum the value of numeric characteristics within a multi-level configuration

4. Multiple Instances of the Same KMAT – The multi-level configuration will contain the same configurable material configured in different ways under the same sales document item

…using Compatible Mode Configuration


A Simple Example – Piping NetworkUp to 9 instances comprised of the following piping components

1. Straight Pipe (STRT_PIPE)2. Elbow (ELBOW)3. Reducer (REDUCER)

http://www.google.com/imgres?imgurl=http://web.tradekorea.com/upload_file2/product/723/P00225723/cbe9caa5_3ff5fc69_41af_4e12_b8b1_ded029a355c1.jpg&imgrefurl=http://www.tradekorea.com/products/elbow.html&usg=__0pxBJ75a3j3Mz4dFlrKSqDcswDY=&h=259&w=280&sz=9&hl=en&start=9&itbs=1&tbnid=MR9KCoxZ3joodM:&tbnh=105&tbnw=114&prev=/images?q=pipe+elbow&hl=en&gbv=2&tbs=isch:1


http://www.google.com/imgres?imgurl=http://www.airflowco.net/products/hvac/hvac_spiral_pipe_elbow_90_short.jpg&imgrefurl=http://www.airflowco.net/Air-Flow-Sheet-Metal-Categories.aspx?typeid=10&usg=__9gsJV2iNy7FJkKPtjLOICi3NEF0=&h=371&w=398&sz=19&hl=en&start=10&itbs=1&tbnid=tluF8xvtpmePIM:&tbnh=116&tbnw=124&prev=/images?q=pipe+elbow&hl=en&gbv=2&tbs=isch:1


Sample Configuration 16 Components:#1: Straight Pipe#2: Elbow#3: Elbow#4: Straight Pipe#5: Reducer#6: Straight Pipe


Sample Configuration 25 Components:#1: Straight Pipe#2: Reducer#3: Elbow#4: Straight Pipe#5: Reducer


Let’s Start with the Type 300 Classes

The Piping Network Material will use a class (PIPE_NETWRK) with these characteristics.

COMPONENT_QTY Number of components in networkCOMPONENT_1 Type of component 1 (e.g. elbow, reducer,

etc.)COMPONENT_2 Type of component 2And so on…

Each Piping Component Material will have its own class that is subordinate to a superior class P_COMPONENT shown below. DIA_1 Diameter of the first end (in millimeters)DIA_2 Diameter of the second end (in millimeters)LENGTH Length of the component (in meters)INSTANCE Instance number assigned to a component





Here is our Class Hierarchy for ComponentsThis design is flexible and makes our constraints easy to write.


Let’s Impose Some Simple Constraints1. Straight Pipes and Elbows are Constant Diameter– DIA_1

must equal DIA_2 for each instance of a straight pipe or elbow

2. Reducers are Variable Diameter– DIA_1 must not equal DIA_2 for any instance of a reducer

3. Components have the Same Diameter at their Connections –DIA_2 of the preceding component must equal DIA_1 of the succeeding component


Let’s Impose Some Simple Requirements1. KISS Design – Each piping component has the same characteristics

and bill of materials (i.e. make the design as modular as possible)

2. Fabricate and Assemble the Components – Each piping component must be fabricated from blanks (raw materials) and then welded together to form the finished piping network

3. Total Length of Piping Network– Must calculate the total length of the piping network


Let’s Create the BOM StructureOption 1: BOM contains every possible component for each instance

PIPE_NETWORK

0010 N STRAIGHT_PIPE0010 N ELBOW0010 N REDUCER

0020 N STRAIGHT_PIPE0020 N ELBOW0020 N REDUCER

And so on… (7 more groups)

0100 N DUMMY

Commentary• All components for a given

instance must have the same BOM item number (and are mutually exclusive)

• Not very elegant but easy enough to understand

• Maintenance looks painful especially if component types or positions are added





Let’s Try a More Concise BOM StructureOption 2: BOM contains one item for each possible instance

PIPE_NETWORK

0010 N STRT_PIPE0020 N ELBOW0030 N REDUCER0040 N REDUCER0050 N REDUCER0060 N REDUCER0070 N REDUCER0080 N REDUCER0090 N REDUCER0100 N DUMMY

Commentary• BOM item component

(IDNRK) is overwritten by dependency

• BOM explosion will fail if overwritten component MATNR is invalid in plant

• Each component material that can be used must generally appear as a BOM component at least once to avoid low level code issues





Let’s Try an Advanced BOM StructureOption 3: Use Type 300 Class Node for each Piping Component

PIPE_NETWORK

0010 K COMPONENT_TYPE0020 K COMPONENT_TYPE0030 K COMPONENT_TYPE0040 K COMPONENT_TYPE0050 K COMPONENT_TYPE0060 K COMPONENT_TYPE0070 K COMPONENT_TYPE0080 K COMPONENT_TYPE0090 K COMPONENT_TYPE0100 N DUMMY

Commentary• Multiple classification of

KMATs is needed• Component type mapped

from root to BOM item by a procedure or constraint

• Maintenance is modular and straightforward

• Class node user exits add very powerful capabilities

• This option does not appear to work for this example for technical reasons





Let’s Constrain the Straight Pipe and Elbow

OBJECTS: C IS_A (300) ELBOW.

RESTRICTION: C.DIA_1 = C.DIA_2.

INFERENCES: C.DIA_1, C.DIA_2.

For each instance, starting and ending diameter must be equal





Let’s Constrain the Reducer

OBJECTS: C IS_A (300) REDUCER.

RESTRICTION: C.DIA_1 <> C.DIA_2.

For each instance, starting and ending diameter must not be equal





Let’s Constrain the ConnectionsOption 1: Use PART_OF statement

Commentary• Syntax is easy but each

connection requires a separate restriction

• Maintenance needed for additional connections

OBJECTS: PN IS_A(300) PIPE_NETWRK,C1 IS_A(300) P_COMPONENT,C2 IS_A(300) P_COMPONENT.

RESTRICTION: C1.DIA_2 = C2.DIA_1 IF PART_OF( C1, PN, ‘0010’) AND PART_OF( C2, PN, ‘0020’),

C1.DIA_2 = C2.DIA_1 IF PART_OF( C1, PN, ‘0020’) AND PART_OF( C2, PN, ‘0030’),

And so on… (6 more restrictions)

INFERENCES:C1.DIA_2, C2.DIA_1.





Let’s Constrain Connections Another WayOption 2: Use an instance characteristic in constraint condition

Commentary• Each instance

characteristic is set by procedure or constraint (there are easy ways to do this)

• This option scales well but watch performance in very large models

OBJECTS: C1 IS_A(300) P_COMPONENT,C2 IS_A(300) P_COMPONENT.

CONDITION: C1.INSTANCE = C2.INSTANCE + 1.

RESTRICTION: C1.DIA_2 = C2.DIA_1.

INFERENCES:C1.DIA_2, C2.DIA_1.





Let’s Add Up the LengthsUse native SUM_PARTS statement Commentary

• Native approach is not very elegant

• Sums all components (no conditions)

SUM_PARTS( $PARENT, LENGTH)

From the SAP help:

• The procedure can only be processed properly if all the relevant BOM components are known in the configuration. For this reason, only process the procedure at the end of the BOM explosion.

• You can create a configurable dummy material to use as the last item in a BOM.

• You use a constraint to transfer this value to the superior characteristic





Let’s Build ItIf each component in the pipe network is built to order, then how are different instances of same piping component managed?

Commentary• Multiple

requirements for same component configured differently in the same sales item may present an IM issue (i.e. GR/GI)

• Reservations are managed properly with individual configurations

Look at transaction MD04





What do we do now?

Summary of Workarounds:1. The requirement is not sent on the upper level (but at lower levels)2. A separate material is created for each lower-level configurable material3. Lower-level configurable materials are defined as phantom assemblies4. Lower-level configurable materials are switched to direct production





What does all that mean for our example?1. The requirement is not sent on the upper level

Each pipe component must have its own sales order item and the pipe network must be field assembled (i.e. not in the factory)

2. A separate material is created for each lower-level materialExample: REDUCER_INST1, REDUCER_INST2, and so on

3. Lower-level materials are defined as phantom assembliesThe pipe network and its components are all built under a single production order (orders for individual components are not possible)

4. Lower-level materials are switched to direct productionThe pipe network and its components all have separate production orders, but component inventory is not managed in sales stock

And what if you don’t like these options?





Talk with eLogic @ (585) 506-4600 This presentation only scratches the surface of how these problems can be solved. A few solutions that eLogic has implemented:

1. Order BOMs with Instantiation – Allows ad hoc addition / deletion of configurable assemblies in a configuration and supports matching and automatic creation of assembly material variants

2. Manual Sales Sets – Like order BOMs, allows ad hoc addition and deletion of configurable assemblies as sales items in a configuration

3. Custom Summing Functions – Sum values conditionally (i.e. not all materials in BOM) and without a dummy material in the BOM

4. Configuration Browser Modifications – Show material descriptions by default and change descriptions by dependency

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Four SAP VC modelling Challenges