Sap Apo: Global ATP Production Planing & Detailed Scheduling

SAP APO
Global ATP
Production Planing &
Detailed Scheduling
Claus Grnewald
Hans-Ulrich von Helmolt
Bernhard Lokowandt
Andreas Wojtyczka
SAP AG 1999 SCAAC.ppt (C.Grnewald) / 1
APO Global ATP - Highlights APO 1.1
Online ATP check (OLTP
APO OLTP)
Integration scenario (Rules based ATP)
Alternative locations
Alternative products
Alternative components
Integration scenario (Multi level ATP)
CTP - Integrated with Production Planning
High Tech Industry - assembly process

(outlook)
17
Non-interlaced
.26 dp monitor
Desktop,
small footprint
case
ATP OK
Only partial ATP OK
No ATP
333 MHz
FastBus III
motherboard
CPU
Keyboard,
mouse
user manual,
cables, and CD
kit
Board
....
....
....
APO Global ATP - global fulfillment
(third party order)
delivery
R/3
R/3
3.1h system
4.0b system
:::::::
?
delivery
::::::: :::::::
::::::: :::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
ATP request
confirmation
Sales order
DC
Frankfurt
DC
Milan
1.
Global APO Server

DC
Munich
delivery
2.
3.
Time Series
R/3
DB
Rule:
1. DC Frankfurt
2. DC Munich
3. DC Milan
plant
Mannheim
R/3
DB
APO Global ATP - global fulfillment (stock transfer order)
R/3
R/3
3.1h system
4.0b system
:::::::
?
delivery
::::::: :::::::
::::::: :::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
ATP request
confirmation
Sales order
DC
Frankfurt
DC
Milan
1.
Global APO Server

DC
Munich
2.
3.
Time Series
Rule:
1. DC Frankfurt
2. DC Munich
3. DC Milan
plant
Mannheim
R/3
DB
R/3
DB
APO multi level ATP - regional fulfillment
R/3
R/3
3.1h system
4.0b system
:::::::
::::::: :::::::
::::::: :::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
ATP request
confirmation
Sales order
DC
Frankfurt
DC
Milan
1.
Global APO Server

DC
Munich
2.
Time Series
:::::::
Planned order
delivery
plant
Mannheim
::::::: :::::::
::::::: :::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
:::::::
Rule:
1. DC Frankfurt
2. DC Munich
3. Plant Mannheim
3.
R/3
DB
R/3
DB
Bill of Material Explosion - Integration in R/3
Sales Order
R/3
Confirmation
SD
SD Sales
Sales &
& Distrib.
Distrib.
APO
ATP Request
ATP
ATP
No ATP
Planned
Planned Orders
Orders
Materials
Planning
Planned
Orders
Update
Time Series
Production
Rapid
Rapid Response
Response
Production
Production Planning
Planning
Time Series
Capable-to-Promise (CTP)
Available
Assigned
First Load
Sales order
Requested
Date and
Quantity
Final Load
Confirmed
Date and
Quantity
Capacity 1
Capacity 2
Capacity 3
Time
Today
APO Global ATP - Highlights APO 1.1
Explanation and Simulation Tool

ATP Alert
Monitor
ATP Quantities
Benefits
High Performance even with
a high volume of data
Higher Requirements Visibility

Increased Customer Services
Scenario for High Tech Industry (outlook)
ATP OK
Only partial ATP OK
No ATP
17
Non-interlaced
.26 dp monitor
Requirement: 10 PCs
Desktop,
small footprint
case
Keyboard, mouse
user manual,
cables, and CD
kit
333 MHz
FastBus III
motherboard
5 assembled
boards
available
No CPUs
available
CPU
Board
....
....
....
....
APO Global ATP - outlook 99
Technical agenda
Authorization concept (APO wide, integrated in other components)
Locking (persistent, conservative/progressive)
Distributed ATP (regional APO
global APO)
ATP Check Methods
Strategic Supply
Chain Management
ATP time series and characteristics
Global ATP
Component level ATP with time

series
Complete integration with DP/SNP

ATP Alert Monitor
Production,
detailed scheduling,
plant level
Forecast,
distribution
planning, per
market
Conservative locking
1) end
2) new request
3) posting
Global APO Server
ATP request
70 PC
100 PC
-70 PC
=30 PC
OLTP
System
confirmation
70 PC
V 70
live
Cache
liveCache
Time Series
OLTP
DB
ATP request
40 PC
OLTP
System
confirmation
30 PC
OLTP
DB
delete
1) end
2) new request
V 70
Global APO Server
30 PC
+70 PC
=100 PC
-40 PC
OLTP
System
=60 PC
OLTP
DB
New ATP check

40 PC
OLTP
System
OLTP
DB
confirmation
40 PC
V 70
V 40
Time Series
live
Cache
liveCache
delete
3) posting
V 70
Global APO Server
DB commit
100 PC
-70 PC
=30 PC
OLTP
System
confirmation
70 PC
V 70
live
Cache
liveCache
Time Series
OLTP
DB
post 70PC
ATP request
40 PC
OLTP
System
confirmation
30 PC
OLTP
DB
Persistent locking
OLTP
System
5.
0001
1. ATP request
70 PC
OLTP
DB
Global APO Server

10 PC
Time Series
0001
2.
6. ALE
4. confirmation
70 PC in 0002
Time Series
0002
OLTP
7a.
System
0002
8. delete 70 PC &
update time series 0002
OLTP
DB
7b.
100 PC
-70 PC
= 30 PC
3.
V 70 PC
Rules based ATP

Rules at component level
Enhancement of rules and constraints
Advanced Functionality
Backorder processing
Deployment/rescheduling
Simulation (what if)
Tracking of rules
APO 2.0 Functions
zz
zz
ATP
ATP
Planning
Planning
zzMulti-Acivity
Multi-Acivityresource
resource
zzWork
In
Process
Work In Process--WIP
WIP
zzHeuristics
Heuristics
zzCharacteristics-based
Characteristics-basedplanning
planning
APO 2.0 Functions
zz
zz
Decision
DecisionSupport
Support
zzOnline
OnlineReports
Reportswith
withALV
ALV
zzStrategic
StrategicReports
Reportswith
withBW
BW
zzView
of
planning
quality
View of planning quality
zzGraphical
Graphicalview
viewof
ofplanning
planningconflicts
conflicts
zzOrder
&
Operation
net
Order & Operation net
Interface
Interfaceto
toMES
MES
Multilevel ATP: Rollout
z
z
z
z
z
z
Alternative PPM -> 1.0

Alternative source-location -> 1.0
Alternative products for components -> 2.0
All existing PPMs and transfer lanes define the search space
-> 1.0
Consider Rules from rules based ATP -> 2.0
Order split -> 2.0
Multilevel ATP with order split
Available
1st Loading attempt
Occupied
Final loading
Customer Order
Desired date
and quantity
capacity 1
capacity 2
capacity 3
t
today
Multilevel ATP: Splitting scope
50
50
100
100
100
50
50
Multilevel ATP: Rules for order split
z
z
z
z
Splitting (y/n)
Maximum number of splits
Minimum quantity for one lot
Splitting mode
Splitting based on resource availability
Static splitting
Splitting scope
Split complete orders

Split of activities only
Planning: Multi-Activity resource
Parallel Operations
start at the same time.
Multi R
Planning: Multi-Activity resource
Only orders with identical

characteristics could be
scheduled at the same time.
Multi R
Set-Up
Planning: WIP as a time buffer
2h 3h
Bottleneck mit
1h
2h 1h 3h
min WIP-Buffer = 1h
1h
capacity 2
1h
capacity 3
1h
2h
3h
t
Planning: WIP as a intermediate storage
2h 3h
30 Pcs
Bottleneck
2h
30 PCS
50 Pcs
3h
30 Pcs
50 PCS
Max WIP = 100 PCS

110 PCS > Max WIP!
capacity 2
30 Pcs
capacity 3
50 Pcs 30 Pcs
2h
3h
Planning: Heuristics
zz
zz
zz
zz
zz
zz
zz
zz
Back-Log
Back-Log
Bottle-Neck
Bottle-NeckResource
ResourcePlanning
Planning
Minimize
MinimizeGaps
Gaps
Priority
PriorityPlanning
Planning
Sequence
SequencePlanning
Planning
Resource
Resourceutilization
utilization
Push-production
Push-production
Periodic
Periodicand
anddynamic
dynamiclot
lotsizing
sizingprocedures
procedures
Heuristics: When is a heuristic carried out
zz
zz
zz
Interactively
Interactively
Periodically
Periodically
atatthe
thebeginning
beginningof
ofeach
eachshift
shift
week
end
every
every week end
Event-based
Event-based
after
afterconfirmation
confirmation
after
aftergoods
goodsmovement
movement
Heuristics: Framework
Select resource interactively

Customer specific selection of ressources
Popup to choose heuristic
select all aktivities on selected resource
SAP standard heuristic

Put results into order network (liveCache)
(Alerts in case of material problems)
Customer specific heuristic
Heuristics: Framework
Select Product
interactively
Select Product via

planning proposal
Customer specific
selection
Determine sequence of planning

(low level code or stage-numbering)
popup to choose
heuristic
select all receipts and requirements for one product
Customer specific heuristics
SAP standard heuristics

Put results into order network (liveCache)
(Alerts in case of material problems)
Heuristics: Eliminate Backlog
Now
RES.1
RES.2
A/10
A/20
RES.3
A/30
Strategy: Forward, search for gap, dont consider internal relationships

RES.1
RES.2
A/10
A/20
RES.3
A/30
Strategy: Forward, insert operation, dont consider internal relationships

RES.1
RES.2
RES.3
A/10
A/20
A/30
Strategy: Forward, insert operation, consider internal relationships

RES.1
RES.2
RES.3
A/10
A/20
A/30
Heuristics: Sequence planning

Now
RES.1
RES.2
A/20
RES.3
Prio 1
Prio 5
Prio 6
Prio 4
Prio 3
Prio 2
A/30
Strategy: Forward, sorting by priority, dont consider internal relationships

RES.1
RES.2
A/20
RES.3
Prio 1
Prio 5
Prio 2
Prio 3
Prio 4
Prio 6
Prio 4
Prio 6
A/30
Offset
Strategy: Forward, sorting by priority, consider internal relationships

RES.1
RES.2
A/20
RES.3
Prio 1
Prio 5
Prio 2
Prio 3
A/30
Offset
Strategy: Forward, sorting by priority, consider internal relationships

RES.1
RES.2
A/20
RES.3
Prio 1
Prio 2
Prio 3
Prio 4
Prio 5
Prio 6
A/30
Offset
Characteristics-based planning
zz
zz
All
Allindustries
industries
Certain
Certainrules,
rules,e.g.
e.g.in
inATP
ATP
Semiconductor,
Semiconductor,Metals
Metalsand
andPaper
PaperIndustry
Industry
Configurable
Configurablematerials
materials
Identification
Identificationof
ofmaterials
materialsnot
notby
bymaterial
materialnumber
numberbut
butby
by
characteristics
characteristics
Selection
Selectionof
ofcomponents
componentsand
andoperations
operationsby
bycharacteristics
characteristics
Campaign
Campaignplanning
planning
Batches
Batches
Characteristics-based
Characteristics-baseddefinition
definitionof
ofSet-Up
Set-Upmatrix
matrix
Characteristics for APO Objects (cont.)
zz
aavaluation
valuationis
isthe
theassignment
assignmentof
ofvalues
valuesto
tothe
thecharacteristics
characteristics
of
the
class
a
object
is
classified
by
of the class a object is classified by
aaconstraint
constraintis
isthe
theassignment
assignmentof
ofranges
rangesto
tothe
the
characteristics
characteristicsof
ofthe
theclass
classaaobject
objectis
isclassified
classifiedby
by
aaconstraint
constraintdefines
definesrequirements
requirementsfor
forrelated
relatedobjects
objectse.g.
e.g.
pegging
requirements
at
input
nodes
or
technical
pegging requirements at input nodes or technical
requirements
requirementsfor
forresource
resourceselection
selection
zz
zz
Customer
order
St37 2,5m
St37 1,5m
valuation
constraint
Characteristics in orders
z
MatNo: 12
Length: 1.5 m
Size:
medium
z
Act
Res
Size: medium
or small
I
MatNo: 14
1.6m <= Length <= 1.7m

Length = 1.6 m
Output nodes have one

valuation
Input nodes have constraints
defining which output nodes
can be pegged and a default
valuation if a new PPM
explosion is necessary
Activities have constraints
defining on which resource the
activity can be scheduled
Definition of Campaigns
z
z
z
z
z
Campaigns are defined as time-dependent properties of

resources
Match between characteristics of operations and
characteristics of the resource is checked during scheduling
(characteristics are treated as additional constraints)
Match is user-definable
UI for definition and change of campaigns available in APO
Change of a campaign results in
Rescheduling of operations in the changed campaign

Changes of neighboring campaigns
Rescheduling of their operations
...
Campaign as Resource Property
Customer orders
Campaigns
Shift schedule
Campaign Changes
Campaigns
Orders
Postpone blue campaign

Campaigns
Orders
Shorten blue campaign

Campaigns
Orders
Decision Support: APO - BW Integration
Detailed
DetailedScheduling
Scheduling
Confirmation Data,
Production Data,
Planning Quality,
liveCache Data
Business
Information
Warehouse
ALV
ALVReports
Reportsfor
for
online
onlineData
Data
Scheduling specific data
z
z
z
z
z
Dispatch lists
Resource utilization
Order status information
Detail operation data
Planning quality
Central Data Pool
z
z
z
z
Summarized Data
Historical Data
Production Information
Resource utilization
Decision Support: View of planning quality
Display of Optimization & Scheduling results
Decision Support: Alert Monitor
Graphical View of
objects with existing
Alerts
Decision Support: Operation net
Marked
operation
Processing time
of operation
Set-Up
Bottleneck
Purchased
material
Operation violating
constraints
Sales order
Interfaces to MES
z
z
z
z
z
Industry specific detailed scheduling algorithms are not part

of APO (coffin shape, trim optimization,...)
Execution is a R/3 task down to a certain level
MES systems may have to be linked to R/3 (for execution,
operation confirmation,...) and APO
Schedule is transfered from APO to the MES system. APO
gets back refined schedule, if changes affect planning
granularity of APO
Vision: exits in the liveCache to plug in industry/ customer
specific routines provided by IBU or 3rd party vendors
Questions: Whats more important

1.
z
z
Static splitting based on process dependent lots

dynamic splitting based on resource availability
2.
z
z
Splitting results in two or more parallel seperate orders:

advantage: partial confirmation
disadvantage: more production orders must be processed
splittng results in parallel activities
3.
Which rules are most important to control order splits?

Example:
max number of splits in complete BOU structure
max number of splits per level
min quantity of splits per level

Sap Apo: Global ATP Production Planing & Detailed Scheduling

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Sap Apo: Global ATP Production Planing & Detailed Scheduling

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Авторское право:

Доступные форматы

SAP APO

APO Global ATP - Highlights APO 1.1

Online ATP check (OLTP

Integration scenario (Rules based ATP)

Integration scenario (Multi level ATP)

CTP - Integrated with Production Planning

High Tech Industry - assembly process

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 2

APO Global ATP - global fulfillment

(third party order)

Global APO Server

APO Global ATP - global fulfillment (stock transfer order)

Global APO Server

APO multi level ATP - regional fulfillment

Global APO Server

Bill of Material Explosion - Integration in R/3

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 6

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 7

APO Global ATP - Highlights APO 1.1

Explanation and Simulation Tool

Higher Requirements Visibility

Scenario for High Tech Industry (outlook)

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 9

APO Global ATP - outlook 99

ATP Check Methods

ATP time series and characteristics

Component level ATP with time

Complete integration with DP/SNP

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 10

APO Global ATP - outlook 99

Global APO Server

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 11

APO Global ATP - outlook 99

New ATP check

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 12

APO Global ATP - outlook 99

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 13

APO Global ATP - outlook 99

Global APO Server

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 14

APO Global ATP - outlook 99

Rules based ATP

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 15

APO 2.0 Functions

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 16

APO 2.0 Functions

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 17

Multilevel ATP: Rollout

Alternative PPM -> 1.0

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 18

Multilevel ATP with order split

1st Loading attempt

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 19

Multilevel ATP: Splitting scope

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 20

Multilevel ATP: Rules for order split

Splitting based on resource availability

Split complete orders

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 21

Planning: Multi-Activity resource

SAP AG 1999 SCAAC.ppt (C.Grnewald) / 22

Planning: Multi-Activity resource

Only orders with identical