Project EL ARABY

BUSINESS BLUEPRINT
Capacity Planning


El Araby Group
EL ARABY Business Blueprint
BP-PP: Capacity Planning
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& El Araby Group
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


Re'i(ion )i(tory
Created
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Created
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Appro'ed
By:
Appro'al
*ate:
El Araby Group Bu(ine(( -+ner Sign-off
.a/e:
Po(ition:
Sign-off
*ate:
Signature
:
El Araby Group 0S Support 1ea/ Sign-off
.a/e:
2r 3ael Seli/ 2r A4/ed 1alaat
Po(ition:
Sign-off
*ate:
Signature
:
SAP - Con(ultant Sign-off
.a/e: A(4i(4 Sri'a(ta'a
Po(ition: Con(ultant
Sign-off *ate:
Signature:
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& El Araby Group
Page "
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


Pro5ect *irector6 Pro5ect 2anager( Sign-off
.a/e: 2r(& 2a4a .a((ar 2(& 2ai Raafat 2r& Sadanand
7ota(t4ane
Po(ition: El Araby Pro5ect
*irector
El Araby Pro5ect
2anager
SAP Pro5ect 2anager
Sign-off *ate:
Signature:
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& El Araby Group
Page ,
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


1able of Content(
1. SCENARIO OVERVIE......................................................................!
". RE#UIRE$ENTS % E&PECTATIONS...............................................'
(. SAP OR)ANISATION STRUCTURE.................................................'
!. BUSINESS PROCESS............................................................................'
4.1 BUSINESS PROCESS FLOW CHART......................................................5
4.2 BUSINESS PROCESS DESCRIPTION.......................................................7
'. C*AN)ES TO E&ISTIN) OR)ANISATION...................................+
,. -EY BUSINESS I$PROVE$ENT.....................................................+
.. /ESCRIPTION O0 0UNCTIONAL /E0ICITS.................................1
+. NOTES ON 0URT*ER I$PROVE$ENTS.......................................1
1. SYSTE$ CON0I)URATION CONSI/ERATIONS.........................1
12. /EVELOP$ENTS CONSI/ERATIONS......................................12
10.1 DATA CONVERSION CONSIDERATIONS..............................................10
10.2 INTERFACE CONSIDERATIONS...........................................................10
10.3 REPORTING CONSIDERATIONS..........................................................10
10.4 FORM CONSIDERATIONS...................................................................10
10.5 ENHANCEMENT CONSIDERATIONS....................................................10
11. AUT*ORISATION CONSI/ERATIONS......................................12
Confidential & Proprietary to SAP
& El Araby Group
Page !
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


& Scenario -'er'ie+
To be able to perform Capacity Requirement Planning in the plants during
Production Planning
Purpo(e
Capacity leveling is used in various areas of a company and at different planning
levels with the following objectives:
High capacity load
Adherence to dates
hort lead times
!ow stoc"s
The objectives of capacity leveling include:
!eveling overloads and underloads at wor" centers
Achieving optimum commitment of machines and production lines
election of appropriate resources
#ou can carry out capacity leveling in the within the following application areas:
Production planning and control
The capacity leveling process in production planning $PP% depends on the
planning level at which it is to be carried out&
't is important to distinguish between the following planning levels:
ales and operations planning $(P%
!ong)term planning $!TP%
*aterial requirements planning $*RP%
Repetitive manufacturing $R+*%
hop floor control $,C%
-hether rough)cut. production rate or detailed planning is used depends on the
planning level& #ou can easily move between the individual planning levels&
Confidential & Proprietary to SAP
& El Araby Group
Page 8
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


Planning le'el: S-P
'n ales and (perations Planning $(P%. you specify sales volumes for the long)
term and medium)term and the production activities necessary to reali/e these
sales& The system will carry out rough)cut planning to estimate the production
levels necessary to support these figures& 'n capacity leveling. the quantities to
be produced should be roughly compared to the productive capacity&
Planning le'el: L1P
'n long)term planning. you can plan several versions of the demand program
using a simulated planning run& #ou can chec" the results using special
evaluations so as to gain an early overview of future plans for production and
procurement&
Planning le'el: 2RP
Confidential & Proprietary to SAP
& El Araby Group
Page 9
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"!!#$$%&docCapacity
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Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


The objective of material requirements planning $*RP% is to ensure that material
is available. that is. to plan the quantities required both by production and by
sales and distribution& *RP determines what material is needed at what date and
then creates the necessary order proposals& ,or products made in)house.
material requirements planning always generates an order proposal as a planned
order& The planned order contains specifications for the lot to be produced and
the resources required for production& The system will calculate capacity
requirements using the order specifications& These capacity requirements are the
basis of capacity leveling&
Planning le'el: RE2
Repetitive manufacturing is used for the repeated production of the same product
over a long period of time& 't is used to create and process master plans for a
defined period and a specified quantity& Repetitive manufacturing uses production
versions& #ou create a run schedule header $Planned (rders% covering a certain
period for a production version of a material& 'n the material master you specify
tas" list and 0(* alternatives as well as a production line for a production
version& The tas" lists are generally rate routings& Capacity leveling will be carried
out on the basis of a production line&
Planning le'el: S:C
hop floor control converts *RP planning data into concrete production orders& A
production order specifies what material is to be produced or what activity is to be
carried out where and at what time& 't also e1plicitly determines the wor" centers
to be used&
-hen you create a production order. the system will automatically carry out lead
time scheduling and writes capacity requirements records& Capacity leveling at
the production order level is used for detailed planning&
14e current p4a(e of i/ple/entation 4a( follo+ing (cope of Capacity
Planning in EL Araby:
Gla(( /anufacturing plant will carry out capacity evaluations $overloads
etc% and leveling to balance the wor" centers2production lines and to decide
on proper production plan across them& Capacity planning will be based on
rate based scheduling2!ead time scheduling& The basis of capacity
evaluations and leveling could be wor" center2production lines2planned order
or production orders&
La/p /anufacturing plant will carry out capacity evaluations $overloads etc%
and leveling to balance the wor" centers2production lines and to decide on
proper production plan across them& 3se of alternative resources2production
lines is also possible& Capacity planning will be based !ead time scheduling&
The basis of capacity evaluations and leveling could be wor"
center2production lines2planned order or production orders&
Confidential & Proprietary to SAP
& El Araby Group
Page $
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


A;C /anufacturing plant will carry out capacity evaluations $overloads etc%
and leveling to balance the wor" centers2production lines and to decide on
proper production plan across them& 3se of alternative resources2production
lines is also possible& Capacity planning will be based !ead time scheduling&
The basis of capacity evaluations and leveling could be wor"
center2production lines2planned order or production orders&
Pla(tic plant <under A;C Co/pany= will carry out capacity evaluations
$overloads etc% and leveling to balance the wor" centers2production lines and
to decide on proper production plan across them& 3se of alternative
resources2production lines is also possible& Capacity planning will be based
!ead time scheduling& ince this plant can also produce the products of other
manufacturing plants which are not in scope for the current phase of
implementation. so the capacity planning related to the resources of this plant
are considered partial& 4uring the ne1t phase of implementation the full
capacity of the resources will be utili/ed and the capacity planning will be then
considered as complete& 't would require the efforts of master data
maintenance upto certain e1tent& The basis of capacity evaluations and
leveling could be wor" center2production lines2planned order or production
orders&
Pla(tic plant <under )o/e 0nd co/pany= will carry out capacity evaluations
$overloads etc% and leveling to balance the wor" centers2production lines and
to decide on proper production plan across them& 3se of alternative
resources2production lines is also possible& Capacity planning will be based
!ead time scheduling& ince this plant can also produce the products of other
manufacturing plants which are not in scope for the current phase of
implementation. so the capacity planning related to the resources of this plant
are considered partial& 4uring the ne1t phase of implementation the full
capacity of the resources will be utili/ed and the capacity planning will be then
considered as complete& 't would require the efforts of master data
maintenance upto certain e1tent& The basis of capacity evaluations and
leveling could be wor" center2production lines2planned order or production
orders&
"& Re>uire/ent( ; E?pectation(
To be able to perform capacity evaluations and perform rough cut
capacity planning based on production plant entered by sales plan
To be able to perform capacity data and formulae for calculating
capacity requirements in wor" center and production lines
To be able to perform capacity evaluations based on wor"
centers2Production !ines
To be able to perform capacity evaluations and do leveling based on
Planned (rders
To be able to perform capacity evaluations and do leveling based on
Production (rders
Confidential & Proprietary to SAP
& El Araby Group
Page @
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


(ption of perform lead time scheduling while running *RP
(ption of 3ser5s decision on whether to allow the production order
release based on capacity chec"s
ystem should consider capacity on a wor" center based on efficiency.
utili/ation. shifts and start 6 end time and availability of wor" center
hould be able to allocate or disallocate capacity from wor" centers
ystem should be able to suggest alternate resource if available. in
case of a used wor" center is fully occupied
(ption of automatic dispatch of the capacity requirements and leveling
based on pre defined strategies
,& SAP -rgani(ation Structure
The production 6 planning for the manufacturing plants of +! Araby group:
7lass manufacturing 6 !amp manufacturing under !ighting
Company
Air condition manufacturing under A2C Company
-ater Heater manufacturing under Home 'nd& Company
Plastic manufacturing under the company Home 'nd&
Plastic manufacturing under A2C Company
Central -or"shop
Are into consideration in current phase of implementation for production
planning
!& Bu(ine(( Proce((
8& Bu(ine(( Proce(( :lo+ C4art
In Sale3 4 Operation Planning
Confidential & Proprietary to SAP
& El Araby Group
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"!!#$$%&docCapacity
Planning
,inal ales Plan
Transfer to Production Plan
Perform Rough Cut Capacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


In $RP%RE$%Pro56ction Proce33ing an5 Pro56ction E7ec6tion
Confidential & Proprietary to SAP
& El Araby Group
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"!!#$$%&docCapacity
Planning
Change Planned
'ndependent requirement
*489
Production Plan
Run *RP
Review *RP !ist toc"2Requirement
!ist
Planned (rders
$Purchase2toc"
Transfer%
Planned (rders
$Production2Run chedule
header in R+*%
Perform Capacity
+valuations 6 !eveling
Convert Planned (rder into
Production (rder
Chec" Capacity situation and
Perform ,inite Capacity leveling
to deallocate or shift load from
the wor" centers if needed
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


9& Bu(ine(( proce(( *e(cription
Step
A
*epart/ent B(er Role Proce(( *e(cription SAP
2odule
Capacity ituation in ales 6 (peration Planning
: Planning
Capacity
Planner2Production
cheduler
Perform Rough Cut Capacity
evaluations in (P planning
table
PP
Capacity ituation after *RP Run
9 Planning
Capacity
Planner2Production
cheduler
Chec" capacity situations in
toc"2Requirement !ist
PP
;arious (ptions of Capacity Planning
< Planning
Capacity
Planner2Production
cheduler
Perform capacity evaluations
in !TP planning table
PP
Capacity Planning in R+* Planning Table
= Planning
Capacity
Planner2Production
cheduler
Perform Capacity Planning in
R+* Planning Table based
on run schedule header$R+*
Planned (rders% from *RP
PP
eparate tools for Capacity Planning
> Planning
Capacity
Planner2Production
cheduler
Perform Capacity evaluations
based on wor"
centers2Production
!ines2Planned
(rders2Production (rders
PP
8 Planning
Capacity
Planner2Production
cheduler
Perform Capacity +valuations
based on wor"
centers2Production
!ines2Planned
(rders2Production (rders
PP
Confidential & Proprietary to SAP
& El Araby Group
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


$& C4ange( to E?i(ting -rgani(ation
Plastic manufacturing facility will be defined as separate plant which
will be included for capacity planning. although it would be partial
allocation considering the current scope of implementation
Production activities will be performed separately at plastic
manufacturing plant
@& 7ey Bu(ine(( 0/pro'e/ent
Automatic functions available to perform capacity evaluations and
leveling
;alidations available to allow the user to decide on further business
functions in case of critical capacity
7raphical representations available
7ood standard reports available
%& *e(cription of :unctional *eficit(
Ref&
A
*e(cription of :unctional *eficit( Reco//endation to :ul
fill :unctional *eficit(
:& ?one
#& .ote( on :urt4er 0/pro'e/ent(
Advance planner and optimi/er $AP(% implementation in future could be
considered for demand planning $4P%. upply ?etwor" Planning $?P%
and Production Planning 6 4etailed cheduling $PP4% modules which
would further enhance and help improving the processes at +l Araby
considering big volume of data and transactions&
& Sy(te/ Configuration Con(ideration(
tandard ;alue Parameters
,ormulae
tandard ;alue @ey for wor" centers2production lines
Confidential & Proprietary to SAP
& El Araby Group
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


Capacity profiles
trategy
"& *e'elop/ent( Con(ideration(
,& *ata Con'er(ion Con(ideration(
Ref&
A
*e(cription of -b5ect( ; *ata to be
Con'erted
*ata Con'er(ion
2et4od <CA116
LS236
*e'elop/ent=
Reference
*e'elop/ent
Specification
.u/ber
:& ?one
!& 0nterface Con(ideration(
Ref&
A
*e(cription of Sy(te/ ; Proce(( to be
0nterfaced
Reference 0nterface
Specification *ocu/ent
.u/ber
:& ?one
8& Reporting Con(ideration(
Ref&
A
*e(cription of Report Re>uire/ent( Reference Report
*e'elop/ent
Specification
:& tandard reports will be used. development of
reports are not required&
9& :or/ Con(ideration(
Ref&
A
*e(cription of :or/( Reference En4ance/ent
Specification .u/ber
: ?one
$& En4ance/ent Con(ideration(
Ref&
A
*e(cription of En4ance/ent
Re>uire/ent(
Reference En4ance/ent
Specification .u/ber
: ?one
@& Aut4ori(ation Con(ideration(
Rough Cut Capacity A *CBB
toc" Requirement !ist A *4C=
!TP toc" Requirement !ist A *C=
Confidential & Proprietary to SAP
& El Araby Group
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"!!#$$%&docCapacity
Planning
Project EL ARABY
BUSINESS BLUEPRINT
Capacity Planning


Planning table)!TP A *,C
Planning Table)R+* A *,>C
Capacity +valuation A C*>C2C*>92C*C:
Capacity !eveling A C*9:2C*9D2C*<:
Confidential & Proprietary to SAP
& El Araby Group
Page
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"!!#$$%&docCapacity
Planning