sap sd variant configuration for beginners
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CE v5.6
Lars Friedrich
Munich, 11.05.2006
Planning of variant configured products with SAP SCMfor the discrete industry
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CE v5.8 © 2006 Capgemini - A"A#$A%& C(%F$) 2
Short Terms
BOM Bill of Material
OPP Order-Penetration-Point
POS Point-of-Sales
KPI Key Performance Indicators
APO Advanced Planning and Optimizer
DP Demand Planning
PP/DS Production Planning / Detailed Sceduling
!B" !arateristics Based "orecasting
!DP !arateristics Dependent Planning
iPP# Integrated Product and Process #ngineering
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AGENDA
Introduction to variant configuration
Managemen! varian! cmpe3i!4
(vervie panning prcess r cnigured prduc!s
"arian! cnigura!in and panning i!h A CM 5.0
enei!s 7 )aps
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ariants of a product are mutations of the !asic model !y adding orleaving out components
Definition $%ariants&
i!h7i!hu! middearmres!
i!h7i!hu! pevicgirde
i!h7i!hu! rarmres!
i!h7i!hu!!res!
i!h7i!hu! !hreepin! girde
i!h7i!hu! spin!s4s!em
incina!in r 9ac:res! 20 r 0
9us sea! i!hea!her r nrma
The number of the selectable components drive the complexity of the BOM.
The number of the selectable components drive the complexity of the BOM.
265 variants combination
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The change on customer demand and increased mar"et competition hasled to a variant e#plosion
ariants past and today
!enry "ord#$%ou can buy your carin any color& so long as
its blac'.(
)*)* + )*2* ariants
combinations possible
),*- 2**5
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The increase of variant comple#ity is mainly caused !y e#ternal factors
Main driver for variant comple'ity
xternal
a!ura!in mar:e!s
$ncreasing cmpe!i!in pressure
earch r mar:e! niches anddiversiica!in
Las and nrms r dieren! mar:e!
;uic:er prduc! ie c4ces
$ncreasing g9ai<a!in - dieren!re=uiremen!s r a prduc! 94 regin
xternal drivers can notbe influenced by the
company
Internal factors can beinfluenced through
process optimi/ation
Internal
$ncreasing cmpan4 si<e
>eici!s inrma!in andcrdina!ini!hin !he cmpan4 depar!men!s
>minance !he crea!ive devepers
and saes depar!men!
mu!ipe surcing
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AGENDA
$n!rduc!in ! varian! cnigura!in
Management of variant complexity
(vervie panning prcess r cnigured prduc!s
"arian! cnigura!in and panning i!h A CM 5.0
enei!s 7 )aps
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Successful variant management must !e understood as a strategiccorporate target
Main strategic action for reduction of variant complexity
100
80
50
successful companiesafter process optimi/ation
less successful companies
before process optimi/ation
percen!
!urnver
%um9er prduc! varian!s pr100 Mi *@ !urnver
50 100 150 200 250 /00
ariant analysis
ariant reductions
ariant controlling
urce ein< %i3dr $ns!i!u!e
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AC - !urnver7prduc! ana4<e
$or a %ualitative evaluation of the variant variety an com!inedA&C and '() analysis can !e used
Methods for variant analysis
A C
D
D -!urnver7cus!mer ana4<e
p r 1 d u c !
cus!mer
C
A
D
cri!ica area
"arian! ana4sis
"arian! reduc!ins
"arian! cn!ring
cus!mer 1prduc! L
cus!mer /prduc! L
cus!mer 2prduc! %
cus!mer /prduc!
cus!mer 1prduc! #
cus!mer 2prduc! #
cus!mer /
prduc! #
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Product modulari*ation is implemented !y the multiple use of the sameparts+ classes and assem!ly
Metods of modularization
0tandardi/ation
Individuali/ation
Modulari/ation
ariant structure
The impacts on variant complexity should be already analy/edduring the development process of a product.
The impacts on variant complexity should be already analy/edduring the development process of a product.
"arian! ana4sis
"arian! reduc!ins
"arian! cn!ring
eries ac:e!s
a!rms uiding se!s
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The num!er of assem!ly variants can !e reduced !y positioning the,rder-Penetration-Point downstream in the production process
ariant structure "arian! ana4sis
"arian! reduc!ins
"arian! cn!ring
p 1 i n
! - 1 2 - s a e s
p 1 i n ! - 1 2 - s a e s
cus!mer ann4mus4 prduc!in cus!mer speciic prduc!in
cus!mer ann4mus4 prduc!in cus!mer speciic prduc!in
6 e 2 1 r e
A 2 ! e r
conomies of 0cales conomies of 0cope
(
(
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The reduction of variant comple#ity should !e continuouslymeasured !y using a predefined set of .P/s
#'amples of KPIs for variant controlling "arian! ana4sis
"arian! reduc!ins
"arian! cn!ring
1I
%um9er p!ina cmpnen!sin cmparisn i!h
!!a par!s end prduc!
%um9er varian!sin cmparisn i!h
!urnver
ri! per varian! in cmparisn i!h!!a pri! margin
Cs! 94 charac!eris!ic vaue;1 ;2 ;/ ;
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AGENDA
$n!rduc!in ! varian! cnigura!in
Managemen! varian! cmpe3i!4
Overvie3 of planning process for configured products
"arian! cnigura!in and panning i!h A CM 5.0
enei!s 7 )aps
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Purchasing and preproduction of assem!lies is driven !y the forecast whereas the final production is triggered !y the configured sales order
Overvie3 of planning process for variant configured products in discrete industry
roduction xecutionroduct configuration
and order entryroduction planning of
end item
urchasing andreproduction
"orecasting
ee:s
n u m 9 e r 1 2 G
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Characteristics of a product drive the comple#ity of a Super-&,M
!aracteristics and Super-BOM
ump type unger
#!ar4 +ing +e! pi!
4onnection #igh!-anged ange #und ange
otationdirection Cc:ise cc:ise !h
4olor ue ac:
#ed
Mode Manua Eec!ric
Maximum
pump lift 2 - 100 m
ump for +a!er (i +as!e a!er uspensin
ange (pen Csed
Options +i!h
suppr! +i!hdraing
5**
0uper BOM
Manue Eec!ric
(i+a!er +as!e+a!er
us-pensin
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The purchasing and preproduction is e#ploded !y using apre-planning &,M
Industry e'ample for variant configured
7
) 250 50
B
) 250 50
ump -500
7) 2
0,5 0,5
0,25 0,25 0,25 0,25
The re8uirements for components is based on usage probability.The re8uirements for components is based on usage probability.
anning (M
uper (M
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The purchasing and pre-production is !ased on acharacteristics !ased forecast
Planning process (it !B"
ump -500
"aue 1 "aue 2
"aue 1 "aue 2
4haracteristics value combinations
A11 A1 2 A2 1 A2 2
4haracteristics 7 4haracteristics B
7) B) 7) B2 72 B) 72 B2
100 100 50 50
100 100 50 50
BOM xplosion
3ee' 5**
1 /00
2 /00
9emand lan "orecast
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AGENDA
$n!rduc!in ! varian! cnigura!in
Managemen! varian! cmpe3i!4
(vervie panning prcess r cnigured prduc!s
ariant configuration and planning 3ith 07 04M 5.*
enei!s 7 )aps
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The DP and PP0DS modules have !een used for demo scenario
Scope of used SAP S!M )*+ modules
07 04M 5.*
other modules
> e m a n d . a n n i n g
. r 1
d u c ! i 1 n . a n n i n g 7
> e ! a i c h e d u i n g
u p p 4 % e ! 5 1 r :
. a n n i n g
)
1 9 a - A v a i a 9 e -
! 1 - . r 1 m i s e
& r a n s p 1 r ! " e h i c e
c h e d u i n g
e r v i c e . a r ! s
. a n n i n g
$ n v e n ! 1 r 4 C 1 a 9 1 r a ! i 1 n
, u 9
H u
p p 4 C h a i n E v e n !
M a n a g e m e n !
u p p 4 C h a i n
C 1 a 9 1 r a ! i 1 n
F 1 r e c a s ! a n d
#
e p e n i s h m e n !
H E 3 ! e n d e d + a r e h 1 u s e
M a n a g e m e n !
07 :;
7O modules
>
Charac!eris!ics vaue
cm9ina!in are
adIus!a9e >emand pan i!hCF is cnigura9e
7>
#e=uiremen!s can9e e3pded
saes rder can 9ecnsumed i!hre=uiremen!s
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The Super-&,M and Super-1outing represents the main master data inSAP for variant configuration
Master 9ata re8uired for planning processes
Material Master
9ependencies
recndi!in, rcedure, Ac!in, Cns!rain!s N
4lass
4onfiguration
profile 0uper outing0uper BOM
ne eve
Mu!i Leve
rice for
variants
"1 O200 P
"2 O200 P
"/ O200 P
4haracteristics
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The master data for variant configuration is transferred via C/$ fromSAP 102 to AP,
Integration of master data for variant configuration
4I"
:; 7O
Material masters
lant
4lasses:
4haracteristics
<or' center r: cen!er r -500
$n!egra!in mder: cen!er
CL'5001 Q 2?
$n!egra!in mdeCLA7CA#
1000$n!egra!in mde
an!
-500 Rcmpnen!s
$n!egra!in mdeMa!eria
roduction schedule
BOM structureouting structure
prduc!in versini!h (M
#u!ing s!ruc!ure
$n!egra!in mde>
prere8uisite for 9
prere8uisite for :90
=ocation
roduct
esource
roduction 9ata 0tructure
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Changes on Product Data Structure must !e reali*ed via 102 andnot in AP,
Structure of PDS
-500
Manue Eec!ric
(i+a!er +as!e+a!er
us-pensin
-500
Manue
Eec!ric(i
+a!er
+as!e+a!er
uspensin
i!hu! >
i!h >
7O
rduc!in versin
(M s!ruc!ure
#u!ings s!ruc!ure
:;
1
2
/
Ma!eria Mas!er
Cass 7 Chara!eris!ics
an!
+r: cen!er
am9urg
am9urg
Integrated Product and Process #ngineering > i ? is another possibility for the transfer ofstructure data. "or the scenario 3e have used 90.
Integrated Product and Process #ngineering > i ? is another possibility for the transfer ofstructure data. "or the scenario 3e have used 90.
4I"
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The Planning &oo" is used to create the Demand Plan !ased on thecharacteristics value com!ination
Demand Planning (it !arateristics %alue !om,ination
e demand for eac caracteristic is calculated ,y a prognosis ,ased onistorical data in te Info !u,e*
e demand for eac caracteristic is calculated ,y a prognosis ,ased onistorical data in te Info !u,e*
Chse charac!eris!icsr prduc! and panning
9:
eec!ed (9Iec! "ie
eec! speciic charac!er vaue cm9ina!in r
demand pan
ead "ie
Crea!e demand panr charac!eris!icscm9ina!ins
>emand pan
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After release of the demand plan from DP to PP0DS the &,M is e#plodedcreating re%uirements on component level
BOM e'plosion in PP/DS
9emand lan
roduct 9emand
-500 /00
4haracteristics 9emand
A11 100
A12 100
A21 50
A22 50
4onfigure product level
4haracteristics valuecombinations
:90
7> crea!eindependen!re=uiremen!s
-500
>e3pde
Crea!ere=uiremen!s
r cmpnen!s
PP/DS creates planned independent re.uirements at configured product level*en te PDS is e'ploded0 te system determines te dependent demand for
te components ,y referring to te demand plan for te caracteristic com,inations*
PP/DS creates planned independent re.uirements at configured product level*en te PDS is e'ploded0 te system determines te dependent demand for
te components ,y referring to te demand plan for te caracteristic com,inations*
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Sales order in 102 consume planned independent re%uirementsfor the same configuration
!onsumption (it sales order
9emand lan
4haracteristics 9emand
A11 100
A12 100
A21 50
A22 50
characteristics valuecombinations
0ales order :;
4haracteristics order
A11 10
A12 120
A21 0
A22 0
sales order
configured product
4haracteristics demand
A11 B0
4onsumption :90
A12 -20
A21 50
A22 50
A!er crea!e saes rder in#7/ !he > cnsume !here=uiremen!s i!h cniguredprduc!
*se pan s!ra!eg4 56 in #7/r crrec! saes rder!ranser
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AGENDA
$n!rduc!in ! varian! cnigura!in
Managemen! varian! cmpe3i!4
(vervie panning prcess r cnigured prduc!s
"arian! cnigura!in and panning i!h A CM 5.0
Benefits : @aps
, ! d f l i f i d ! h
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CE v5.8 © 2006 Capgemini - A"A#$A%& C(%F$) 2
AP, can !e used for planning for variant product+ !ut there aresome restrictions of handling the comple#ity
Benefits and 1aps of variant configuration in SAP S!M )*+
Benefits
uppr! A #7/ is u4 in!egra!ed
E3ac!4 panning i!h charac!eris!ics9ased recas!ing
rgnsis i!h his!r4 da!a pssi9e
&ime4 !ranser demand pan! cus!mer pssi9e
Aggrega!in 7 disaggrega!in r saesca!in and cus!mer pssi9e
*sa9ii!4 r !her A CMcmpnen!s pssi9e
@aps
CF and C> canS! use !ge!her in !hesame !ime
J Charac!eris!ics >ependen! anning is use in prcessindus!r4, e.g. aper indus!r4 K
Mdue upp4 %e!r: anning cann! hande charac!eris!ics
Lac: usa9ii!4 i!h high num9er varian!s
%! man4 indus!r4 e3ampes here A(
is aread4 used r panning varian!cnigured prduc!s
@enerally 7O is feasible for planningvariant configured product for
discrete industry
@enerally 7O is feasible for planningvariant configured product for
discrete industry
!o3ever& 3ith a high number ofcharacteristics value combination andmultiple variant levels& 4B" can be to
complex.
!o3ever& 3ith a high number ofcharacteristics value combination andmultiple variant levels& 4B" can be to
complex.
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B741A
&AC.-3P
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Than" you very much for your attention4
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CE v5 8 © 2006 Capgemini A/
Curriculum vitae
ducation and competence
<or' experience
*niversi!4 Appied ciences Erur!$ndus!ria Engineer in &ranspr! and Cmmunica!insmain curse gis!ics, ma!eria , reigh! !raic inish in Tu4 2006, s!ar! in ep!em9er 94 Capgemini
&ngIi *niversi!4 hanghai, .#. China J 6 mn!hs KChinese 9usiness and anguage
Cmpe!ence in "arian! managemen! Lean rduc!in 4s!em Ue4 errmance $ndica!r A #7/, A(
=evel# 0tudent
Dationality# @erman
=anguage# @erman& nglish&0panish& 4hinese
9iploma thesis4apgemini 7@& Munich > ; E months ?
9epartment# 0upply chain management
rduc!in panning and de!aied scheduing r varian!cnigura!in i!h A CM 5.0
Internship 9aimler4hrysler 7@& 0tuttgart > 6 months ?
9epartment# Truc' roduct 4reation : =ogistics strategy
$mpemen!a!in a upp4 Ue4 errmance $ndica!e Q &in a aggrega!ins and assem94 pan!s 94 >C &ruc:
rettl company group& Fueretaro: Mexico > 6 months ?
9epartment# logistics& customer service
$mpemen!a!in Lean rduc!in 4s!em
anning ramp up r ne prduc! ine >evepmen! a suppier vaua!in !
0tudent assistant at department traffic and transportation
$mpemen!a!in and prepara!in ec!ure r !he inrma!inmanagemen! s4s!em A#$
Dame# =ars "riedrich