sap apo ppds for automotive.pdf

© SAP AG TAAP1W Automotive with DI46C2 - 1

Automotive with DI46C2 (SAP R/3)

IBS Manufacturing, IBU AutomotiveSAP AG


Integrated S&P Planning – overlay between SNP & PP/DS Bjoern Bernard

Shelf Life Enhancements only in PP/DS

SAP AG 2002, Title of Presentation, Speaker Name 2

New Processes supported by SAP APO 3.1

Supply Chain Planning Supply Chain Design Demand Planning Supply Planning Distribution

PlanningProduction Planning

Transportation Planning

Supply Chain Execution Procurement Manufacturing Order Promising

& DeliveryWarehouse

ManagementTransportation

Execution

Foreign Trade/Legal

Services

Fulfillment Coordination

Supply Chain Coordination Supply Chain Event Management Supply Chain Performance Management

Supply Chain Networking Supply Chain Portal Collaboration Services Supply Chain Integration

SC PlanningIntegrated Supply&Production PlanningShelf Life (Production Planning)Forecast Consumption based on DP Char.Extended Demand Prioritization in CTMExtended Order Generation (*)

SC ExecutionMultilevel ATPCampaign PlanningOrder Driven Final Mix & PackagingIPPE based repetitive Manufacturing(**)

SC CollaborationCollaborative Management of Delivery Schedules (CMDS)

(*) process requires industry solution mySAP Mill Products

(**) process requires Industry Solution mySAP Automotive


SNP – Model Consistency Check

Planning of Scheduling Agreements – integration R/3 APO

Mass Maintenance Tools for Master Data

Model Consistency Checks


Process Enhancements with SAP APO 3.1

Supply Chain Planning Supply Chain Design Demand Planning Supply Planning Distribution

PlanningProduction Planning

Transportation Planning

Supply Chain Execution Procurement Manufacturing Order Promising

& DeliveryWarehouse

ManagementTransportation

Execution

Foreign Trade/Legal

Services

Fulfillment Coordination

Supply Chain Coordination Supply Chain Event Management Supply Chain Performance Management

Supply Chain Networking Supply Chain Portal Collaboration Services Supply Chain Integration

SC PlanningModel Consistency ChecksDescriptive Characteristics in CTMMass Maintenance Tools for Master Data

SC ExecutionOrder Fulfillment with GATPTransportation ManagementPP/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



Repetitive Manufacturing with iPPE

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

Contents:



Unit Objectives

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

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



Collective Order

Rapid Planning Matrix

liveCacheliveCache

Planning in APO

Execution in R/3

SAP APO and SAP R/3 in Automotive System

iPPE

CMP ACT FLO

CIF

iPPE

CMP ACT FLO


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


Customer requirements

04/15/00 - 20 units04/16/00 - 15 units

...

Customer requirements

04/15/00 - 20 units04/16/00 - 15 units

...

BOM Explosion: RPM

SDR/3-DI

Model Mix Planningand Sequencing

APO-PP/DS

PP/MRP

MM Delivery Schedules(R/3 or APO)04/15/00 - 200 pcs04/16/00 - 150 pcs

...

MM Delivery Schedules(R/3 or APO)04/15/00 - 200 pcs04/16/00 - 150 pcs

...

Automotive Functions in SAP APO: Planning Process

43

ComponentRequirements

APO

Postings(MM/IM)

Backflush

Action Handler

1 2

3

4 5

5

7

Event

Production Tracking

Trigger Backflush

PCS

6

Order Headers

iPPE

iPPE



Challenges from Engineering to Production

„Time-to-Market” „Time-to-Customer”

Product-EngineeringProduct-Engineering

ProductionProduction

P

C1 C2 C3 C4

Process-EngineeringProcess-Engineering

ACT 40ACT 40

ACT 31ACT 31 ACT 32ACT 32

ACT 20ACT 20

ACT 10ACT 10

Station 1 Station 2 Station 3 Station 4

Line 1


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


Takt-based Scheduling

Station 1 Station 2 Station 3

Takt time Takt time Takt time

Line

Takt-based Scheduling

very fast, since

lead time = number of Takts * Takt time

as compared to lead time scheduling

lead time = sum of all operation durations



... and relationships between all objects

iPPE

CMP ACT FLO

Data and Object Model for iPPE

ACT 40

ACT 31 ACT 32

ACT 20

ACT 10

Routings and Activities


Line 1

Factory Layout

Product Variant Structure


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)..


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)


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


ClassificationClassification

Document Document ManagementManagement

VariantVariantConfigurationConfiguration

Master Master DataData

W O R K F L O WW O R K F L O W

CAD InterfaceCAD Interface

Engineering Change

Management

Engineering Change Management as part of the iPPE

Material



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


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.


Calculation of Exact Component Demand times

Line 1


Takt time Takt time Takt time

C1C1 C2C2 C3C3 C4C4

ACT 1ACT 1 ACT 2ACT 2 ACT 3ACT 3 ACT 4ACT 4

C5C5

C1 Requirement:

Order StartC2 & C3 Requirements:

Order Start + 1 TaktC4 Requirement:

Order Start + 2 Takts

ACT 5ACT 5

C5 Requirement:

Order Start + 3 Takts

Takt time



Production Resources in iPPE

Line Net

ACT Head

ACT1

ACT2

Line 1 Line 2 Line 3

ACT3

RES2

RES1

RES1 RES2 RES3

RES3

Line Balance

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



New Node Types – DI4.6.C2

ALG

Line Net

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.

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 AreaLine 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.



Model Mix Planning and Sequencing

Model Mix Planning and Sequencing



Model MixPlanning Sequencing

A2

A1B1

B2

C1

C2

A3 C3

X1 X2

Reservation Planning

A2

A1B1

B2

C1

C2

A3 C3

X1 X2

Re-Sequencing

Big Picture


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)


Orders Line network

Model-Mix Planning: Situation

ObjectiveGeneration of a feasible and optimal plan for configurable products with high volume

Adherence to promised delivery date

Position

Equaldistribution

Block

X in Y

Distance

Quantity

Business valueBalanced usage of production resources

Early identification of potential bottlenecks

Reliable delivery date leads to increased customer satisfaction

Restrictions



Model Mix Planning and Sequencing: Result

Sequencebased on takts

Model Mixbased on buckets (Day/Week/Month)

3

4

334

3

futurenow

X days from today



Example: Model Mix Planning (1)

Week 1 Week 2 Week 3 Week X

Model Mix

Production line 1

Sales Orders

This Week, Day X

1. Period-oriented planning





Model Mix

Production line 1

Sales Orders

This Week, Day X

1. Period-oriented planning





Model Mix

Production line 1

Sales Orders

This Week, Day X

1. Period-oriented planning+ Quantity restriction




Model Mix

Production line 1

Week 1 Week 2 Week 3 Week XThis Week, Day X

Sales Orders

1. Period-oriented planning+ Quantity restriction




Model Mix

Production line 1

Sales Orders

Week 1 Week 2 Week 3 Week XThis Week, Day X

+ Quantity restriction1. Period-oriented planning




Day 1

Day 3 Day XDay 2

Model Mix

Production line 1

Sales Orders

2 . Sequencing




Day 1

Day 2

1. Not two in a sequence

Model Mix

Production line 1

Restrictions:

2 . Sequencing




Day 1

Day 2

1. No two in a sequence

Model Mix

Production line 1

Restrictions:

2 . Sequencing




Day 1

Day 2

Model Mix

Production line 1 1. No two in a sequence

Restrictions:

2 . Sequencing




Day 1

Day 2

Model Mix

Production line 1

Restrictions:

2 . Sequencing

a) No two in a sequence




Day 1

Day 2

b) At least two red carsin sequence

Model Mix

Production line 1 a) No two in a sequence

Restrictions:

2 . Sequencing




Day 1

Day 2

Model Mix

Production line 1

Restrictions:

2 . Sequencing





Types of restrictionsQuantity (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 distributionPosition

Basic informationCreated 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

Sequencing: Restrictions



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 netLine Line segment

Restrictions Weighting & Validity



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 dateFinite

Linear Program Algorithm

Multi-line (daily buckets)Quantity restrictions and transformed spacingHard and soft weighting of restrictionsDue dateFinite

Optimization Algorithms: Procedures - overview 1



Prioritized Equal Distribution Heuristic

Single lineQuantity, M of N restrictions, spacing, positionNo different weighting of restrictionsHard means “violation only if there is no other way“ -> Typically at the end of the sequenceFinite

Percentage Smoothing Heuristic

Single lineSmoothing on product variant levelNo restrictions, only capacityFinite

Interface for Customer heuristics

Optimization Algorithms: Procedures - overview 2



Horizon 2 Horizon 3 Horizon 4(e.g. 2 days) (e.g. 5 days) (e.g. 2 month)

Sequencing Bucket-oriented Model Mix

= Distribution of orders to lines and to time buckets= Order sequence on lines

Procedure I(e.g. genetic algorithm)

Procedure II( e.g. heuristic with restrictions)

Procedure III(e.g. equal distribution)

Horizon 1(e.g. 2 days)

Manual Planning / Correction

Single items

All restrictions

Quantities per period

only capacity restrictions

Quantities per period

e.g. only quantity and capacity restrictions

Single items

All restrictions

Procedures



Planned Orders

UnscheduledOrders

Restrictions

Sequencing: Interactive planning



Model Mix Planning and Sequencingin SAP APO 3.1

Model Mix Planning and Sequencing in SAP APO 3.1



A2

A1B1

B2

C1

C2

A3 C3group of

alternative lines

planning segment

X1 X2

buffer

A typical example for a line net of an OEM is

D1 E1F1

F2Y1 Y2

planning segment

asse

mbl

ylin

e I

asse

mbl

ylin

e II

Line Net



A2

A1B1

B2

C1

C2

A3 C3

X1 X2

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.

B2A3

X1A2B2

C2

A3 C3

X1 X2

A1B1

C1

C2X1 X2

Partial Line Nets



A2

A1

B1

B2

C1

C2

A3C3

The planning is based on the following assumptions :

1. Each line has a capacity profile.

12 PCS / H

1 PCS / 10 MIN

. . .

. . .

. . .

. . .

. . .

. . .

2. One can assign spacing restrictions to the lines.

3. One can assign quantity restrictions to the lines or thegroups of alternative lines.

min distance 1for convertibles

max 2 in 4air conditioning

X2X1

max 25 sedanper day

max 15 RED per day

Capacities and Restrictions



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

max 2 in 4air conditioningC3. * capacity:

20 PCS / shift =max 10 air cond.per shift

Rate1 PCS / 10 MINC2. * shift duration

8 H / shift = max 48 PCSper shift

min distance 1for convertiblesA3. * capacity:

16 PCS / shift =max 8 convertiblesper shift

A2

A1B1

B2

C1

C2

A3 C3

X1 X2

Conversion



A3

B1 C1

A3

B1C2

The line net is decomposed into the possible paths. Forsimplicity not all paths areshown in the sketch.

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

Furthermore certain products canonly run on certain paths depending on the productionversion.

X1 X2

X1 X2

A3

B1

C3X1 X2

. . .

. .

..

. .

. . .

A3 B2

C1X1 X2

max 2 in 4air cond.

no redcolour

Paths through the Line Net



. . .

. .

..

. .

. . .

A linear program will now assign theorders to the paths while respectingthe restrictions and productionversions.

A3

B1 C1

A3

B1C2

X1 X2

X1 X2

A3

B1

C3X1 X2

A3 B2

C1X1 X2

The Planning



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

A1

A2

A3

B1

B2

C3

C1

C2

The Result



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 bucketorders.

A2

A1B1

B2

C1

C2

A3 C3

X1 X2

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

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.

From Buckets to Positions



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.

A2

A1B1

B2

C1

C2

A3 C3

X1 X2A2B2

C2

A3 C3

X1 X2

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

A2B2

C2

A3 C3

X1 X2

Line Switch



Rapid Planning Matrix(RPM)

Rapid Planning Matrix (RPM)


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.


Alternatives in Requirements Planning

Optimized for real time planning

2. Order NetworkiPPE RTO

(explosion type=3)

Optimized for high volume scenarios

1. Rapid Planning Matrix

(explosion type=4)

APOAPOliveliveCacheCache

R/3R/3APOAPOliveliveCacheCache

PVS Explosion

R/3R/3

BoM Explosion

3. MRP (PVS) 4. MRP (BOM)


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


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 dataExplosion 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 databaseMatrix form for data storage, object oriented accesssimultaneous BOM explosion for all orders-> RPM (Rapid Planning Matrix)

liveCache


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


Contents of Logical Matrix

x x

--

--

xxx

x

x

x

x

-x

x

x--x-x

-

-x x

-

--

-

--

-

-

xx

BOM-Explosion- interpretation of effectivity- interpretation of dependencies3

Assy

View

Mat A Mat B Mat C Mat D

Components

1Data of assembly orders

Order01

Order02

Order03

Order04

Order05

Order06

2 Orders

Bumpers green

Bumpers whiteBumpers redNavigation Advisor GPS

Engine 2.5Disk


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...


Functions Using Logical Matrix I

Component list for selected order

BackflushSequenced JIT callsSequencing

Reading and Interpreting Columns

Data of assembly orders

Order01

Order02

Order03

Order04

Order05

Order06 ...

x xx x

x x x-

-x

x x-

-- -

- --

x- - -

-

xx

- x

x x-x

x ---

..

..

..

..

..Bumpers green


Engine 2.5Disk

..

Access to component list via Logical Matrix

‘From the top’


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


Functions Using Logical Matrix II

ReportingStock/requirements list

Coverage calculation

Delivery scheduling

Pull-list

Day 1 Day 2

1Bump red 01GPS 33Disk 3

Component Day 1 Day 2 ...

Data of assembly orders

Order01

Order02

Order03

Order04

Order05

Order06 ...

x xx x

x x x-

-x

x x-

-- -

- --

x- - -

-

xx

- x

x x-x

x ---

..

..

..

..

..Bumpers green


Engine 2.5Disk

..

Reading and Interpreting Rows

‘From the Left’

Aggregation to time buckets

Aggregation in customized time buckets:

• Hour• Shift• Daily• ...



K1, RP1, ∆T = 0

K2, RP1, ∆T = 10K3, RP2, ∆T = 20

K4, RP2 , ∆T = 20

K5, RP3 , ∆T = 30

K6, RP4 , ∆T = 40

A1 A2 A3 A4 A5 A6

X X X X X X

RP 3 RP 2 RP 2 RP 1 RP 1

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

LineDesign

Matrix Orderstart times• body• paint• assembly

Integration of Line Design Information

RP1, RP2, RP3: Reporting points per line defined in Line design



Scheduling Components using Line Design

C1, T1, ∆T = 0

C2, T 2 ∆T = 10

C3, T 2, ∆T = 20

C4, T3 ∆T = 20

C5, T4 ,∆T = 30

C... T ...

A1 A2 A3 A4 A5 A6

RP 3

RP 2

RP 2

RP 1

RP 1

+ + + + +

+ + + X X X

+ + + X X X+ X X X X XX X X X X X

+ + + + + X

Matrix Orderstart times• body• paint• assembly

P r o

d u

c t

i o n

P r o

d u

c t

i o n

ACT 5

ACT 4

ACT 2

ACT 1

ACT 3

C5

C4

C3

C2

C1

Takt 1

Takt 3

LineDesignTakt 2

Subdaily on Supply Area Level



Rapid Planning Matrixin SAP APO 3.1

Rapid Planning Matrix (RPM) in SAP APO 3.1



RPM - Activity Matrix

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)

x x

--

--

xxx

x

x

x

x

-x

x

x--x-x

-

-x x

-

--

-

--

-

-

xx

Order01

Order02

Order03

Order04

Order05

Order06

Install Xenon light

Fit air conditioning Fit navigation systemFit child‘s seat

Polish wheel rimsCheck oil

Necessary information from the iPPE routing

Planning production activities per order (analogous to components)



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 stationAggregation of all activities which are carried out at a stationMatching of actual working hours with working hours available Production scheduler can adjust resource availability to requirements



Activity Matrix: Integration with Action Handler

A2

A1

B1

C1

C2

Example:

Vehicle passes tracking point:Planned: Final assembly on Line C2Actual: 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

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



Activity Matrix: Integration with Action Handler

A2

A1

B1

C1

C2

Example:

Vehicle passes tracking pointComponents for line segment have to be fixed (until backflush), and shop floor papers are printedVehicle is produced according to shop floor papers

Technique: Components are moved from the matrix to a order networkMixed order: Some components are stored in the matrix, other are stored in order networksAdditional functions: Specific components for MTO can always be planned in order networks in order to ensure full traceability via the pegging function

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



Production Action Handler

Manufacturing Execution: Action Handler



Production Control System / Assembly Control System

LineLine Station 1Station 1 Station 2Station 2 Station 3Station 3

EventEvent

Tracking point ‘1’ Tracking point ‘2’

Event

Tracking point ‘3’

Production Tracking Trigger JIT for a component Backflush

Actions to do

BackflushBackflush

Overview



Production Control System / Assembly Control System

LineLine Station 1Station 1 Station 2Station 2 Station nStation nStation 3Station 3

SAP APO

Get Sequence

Warehouse pull

Event

Trackin gpointwith event and action

informations

Event

Server

Client

Action HandlerAction Handler

Customer Function Module

Trackinginformation

Insert & Update

Triggers

Tracking point ‚S01‘ Tracking point ‚S02‘

Actions

RFC with Tracking point & order & Customer data

RealtimeRealtime Delayed(FIFO Queue)

Delayed(FIFO Queue)

Event Manager

Analyse eventand

dispatch to action

Event Manager

Analyse eventand

dispatch to action

Tracking evaluationTracking evaluation

Feedback

Action Handler & SAP Business Workflow


PBS = painted body storage (buffer after paint shop)

Prerequisite for WIP-counting (supply area inventory): action handler provides the actual sequence!!!


Action Handler Standard Actions

Save Tracking dataBusiness Add-Ins to insert additional customer data into standard tables with customer includes.

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

Backflush



P r o

d u

c t

i o n

P r o

d u

c t

i o n

ACT 5

ACT 4

ACT 2

ACT 1

ACT 3

C5

C4

C3

C2

C1

RP 1

RP 2 Event X

Goods Issue Load Reduction.

Interaction of Action Handler and Backflush



ProductionConfirmation

(Backflush)

Manufacturing Execution: Backflush



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



APOAPO Automotive SystemAutomotive SystemCIFCIF

Process Overview

Buffer

Postings(MM/IM)

Scenariowithout RPM RPM scenario


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


APOAPO Automotive SystemAutomotive System

Prerequisites from a Backflush View

MaterialMasterSales

Orders

ProductionVersions

ProductCost

Collector

Orders

ProductMaster

ProductionVersions

iPPEiPPE

SalesOrders

CIF

CIF

CIF

CIF


APO Backflush Profileflexible access to backflush transaktionbackflushing via action handler possible

APO orders availableEnter backflush data

backflushing via action handler possibleCapacities are reduced immediatelyInformation for IM transferred to R/3 Automotive SystemR/3 Goods Movements

all GRs and GIs of synchronous materials are posted immediatelyGIs of asynchronous materials are periodically aggregated and postedProcesses can be distributed to several processes and serversUsage of application log instead of document log

Postprocessing for failed goods movementsCumulative and individual recordsPostprocessing records for GRs as well

Providing BW with backflush dataArchiving functions for backflush tables


APOAPO Automotive SystemAutomotive SystemCIFCIF

Overall Process

Read and check order,write creation document

No stock/requirement updates.

Capacity reduction

Receive creation document,generate and write backflush

document Registr.docum.

Stock postingStockslist of backflushesStock adjustments,

requirements reductionupdate of order status



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



Explode Sales Order

SO1 SO2 SO3 ... ... ...

X X X X

C1C2

C4C3

C5

X X X X

X X X X X

X X

X X X X X X

....

Sales order SO3A140

Mat. No.: A ClassValue

assignment

Sales order SO3A140


assignmentSales order SO2A160


assignment

Sales order SO2A160


assignmentSales order SO1A140


assignment

Sales order SO1A140


assignment

APO R/3

iPPE



C1, Stat. 10 RP1, ∆T = 0

C2, Stat. 10 RP1, ∆T = 10C3, Stat. 20 RP2, ∆T = 20

C4, Stat. 20 RP2, ∆T = 20

C5, Stat. 30 RP3, ∆T = 30

...

SO 1

SO 2

SO 3

... ... ...

X X X X X X

X X

X X X X

X X X X X

X X X X

LineDesign

(Stations)

Matrix OrderStart Times:• Body• Paint• Assembly

Example: Backflush, Initial Situation

RP 2 RP 3RP 1

SO1SO2SO3SO4SO5SO6

C1 C2 C3 C4 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


SO1 SO2 SO3 ... ... ...

X X X X

C1 RP 1C2 RP 1

C4 RP 2C3 RP 2

C5 RP 3

0 X X X

X X X X X

X X

0 X X X X X

....

APO R/3Backflush of Sales Order 1 (SO 1) at Rep. Point 1 (RP 1)

SO 1 RP 1 C1 1 pcC2 4 pc

RP 2 RP 3RP 1

SO1SO2SO3SO4SO5SO6

C1 C2 C3 C4 C5












SO1 SO2 SO3 ... ... ...

0 X X X

C1 RP 1C2 RP 1

C4 RP 2C3 RP 2

C5 RP 3

0 0 X X X

0 X X X X

0 X

0 0 X X X X

....

APO R/3Backflush of SO 1 at RP 3, SO 2 at RP 2

RP 2 RP 3RP 1

SO1SO2SO3SO4SO5SO6

C1 C2 C3 C4 C5



SO 2 RP 1 C1 1 pcSO 1 RP 2 C4 5 pc


SO 1 RP 3 C5 1 pc



CO Postings of Aggregated Goods Issues


SO 2 RP 1 C1 1 pc

SO 1 RP 2 C4 5 pc


SO 1 RP 3 C5 1 pc

ACT = 1300.-

GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-

C11pc = 100,-

C11pc = 100,-

C21pc = 25,-

C21pc = 25,-

C41pc = 10,-

C41pc = 10,-

C51pc = 500,-

C51pc = 500,-

C31pc = 200,-

C31pc = 200,-

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2 0 0C2 4 0 0C3 2 0 0C4 10 0 0C5 1 0 0

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2 0 0C2 4 0 0C3 2 0 0C4 10 0 0C5 1 0 0

Valuation

Reporting points of cost collector

Product cost collectorModel series A Class

Backflushed components of SO 1 and SO 2:

SO1 SO2 SO3 SO4 SO5 SO6

C1 RP 1 X X X X X X

APOX X X X

X X X X X XX X X X X

C2 RP 1C3 RP 2C4 RP 2C5 RP 3...



Goods Receipt SO 1, Synchronously Posted

ACT = 550.-

GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0

ValuationComp. Quant. Price

C1 1 100.-C2 4 100.-C3 0 0.-C4 5 50.-C5 1 500.-

750.-


SO 2 RP 1 C1 1 pc

SO 1 RP 2 C4 5 pc


SO 1 RP 3 C5 1 pc

SO 1 GR


GR SO 1-750.-



C1 RP 1 X X X X X X

APOX X X X


C2 RP 1C3 RP 2C4 RP 2C5 RP 3...



Determination of Work in Process (WIP)

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0

ValuationComp. Quant. Price

C1 1 100.-C2 0 0.-C3 2 400.-C4 5 50.-C5 0 0.-

550.-

WIP quantity = WIP debit - WIP credit

Comp. WIPC1 2 - 1 = 1C2 4 - 4 = 0C3 2 - 0 = 2C4 10 - 5 = 5C5 1 - 1 = 0

Comp. WIPC1 2 - 1 = 1C2 4 - 4 = 0C3 2 - 0 = 2C4 10 - 5 = 5C5 1 - 1 = 0


ACT = 550.-WIP = 550.-

GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-1 pc C1

2 pc C35 pc C4

550.-












SO1 SO2 SO3 ... ... ...

0 0 X X

C1 RP 1C2 RP 1

C4 RP 2C3 RP 2

C5 RP 3

0 0 X X X

0 0 X X X

0 0

0 0 0 X X X

....

APO R/3Backflush of SO 3 at RP 2, Scrap

RP 2 RP 3RP 1

SO3SO4SO5SO6

C1 C2 C3 C4 C5


SO 3 RP 1 C1 1 pc

...SO 3 RP 2 ´C3 2 pc

Scrap!



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

Backflush SO 3 at RP 2, Scrap

ACT = 1050.-

GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-GI C1 100,-GI C3 400,-

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2+1 1+1 1C2 4 4 0C3 2+2 0+2 2C4 10 5 0C5 1 1 0

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 2+1 1+1 1C2 4 4 0C3 2+2 0+2 2C4 10 5 0C5 1 1 0

SO 3 RP 1 C1 1 pc

... C11pc = 100,-

C11pc = 100,-

C21pc = 25,-

C21pc = 25,-

C41pc = 10,-

C41pc = 10,-

C51pc = 500,-

C51pc = 500,-

C31pc = 200,-

C31pc = 200,-

Valuation

SO 3 RP 2 ´C3 2 pc

List of compontentsfor scrap


2 pc C3400.-



C1 RP 1 X X X X X X

APOX X X X


C2 RP 1C3 RP 2C4 RP 2C5 RP 3...



Period-End Closing

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 3 2 1C2 4 4 0C3 4 2 2C4 10 5 0C5 1 1 0

Period 1Compon

entWIPdebit

WIPcredit

Scrap

C1 3 2 1C2 4 4 0C3 4 2 2C4 10 5 0C5 1 1 0

Valuation

Comp. Quant. PriceC1 1 100.-C2 0 0.-C3 2 400.-C4 5 50.-C5 0 0.-

550.-

WIP quantity = WIP debit - WIP credit

Comp. WIPC1 3 – 2 = 1C2 4 – 4 = 0C3 4 – 2 = 2C4 10 – 5 = 5C5 1 – 1 = 0

Comp. WIPC1 3 – 2 = 1C2 4 – 4 = 0C3 4 – 2 = 2C4 10 – 5 = 5C5 1 – 1 = 0

Comp. Quant. PriceC1 1 100.-C2 0 0.-C3 2 400.-C4 0 0.-C5 0 0.-

500.-


ACT = 1050.-WIP = 550.-Scrap = 500.-

GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-GI C1 100,-GI C3 400,-1 pc C1

2 pc C35 pc C4

550.-

500.-

WIP

Scrap




Backflushin SAP APO 3.1

Backflush in SAP APO 3.1



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



Overview

TP

TP TP TP

Material AMaterial B

10 min / Station 120 min / Station 2

Inventory Management

Quantity

Value at GR

CO / FI

Reporting

BW

Costs

Quantity

Work in Process

Variances

APO3.0DI4.6C1

APO3.1DI4.6C2

or

Order NetworkRPM

Line Network



OEM Workshop IAU250: Engineering (iPPE) & Manufacturing

IntroductionDiscrete Industries OverviewmySAP Automotive Portals & Workplaces

IPPEiPPE Workbench Overview Product Variant Structure iPPE PLMEngineering Change ManagementProcess & Factory Layout Structures

Production Planning ScenariosOverview Planning Basics and APOHeuristics Planning/Rapid Planning MatrixModel-Mix Sequencing with Restrictions

ManufacturingAction HandlerBackflush



Copyright

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