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SAP APO Overview

Page 1

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SAP APO Architecture


A Solution to Provide An Integrated & Synchronized SC
Process

SAP Advanced Planner & Optimizer (APO)


DP
Business
Warehouse
(Reporting)

SNP

PP/DS

TP/VS

ATP

SC Cockpit
APO
Solvers

liveCache
APO

Application Link Enabling

Model Generator, Mapping, Connectivity


OLTP

R/3
Page 2

1997 SAP AG APO 2

R/3

Legacy
OLTP

Non-R/3
OLTP

Non-R/3
OLTP

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SAP APO Application Architecture

R/3

Supply Chain Cockpit

BIW

Advanced
Advanced Forecasting
Forecasting and
and Demand
Demand Planning
Planning

Historical
Data

Customer
order
Manufacturing
Execution
Inventory
Management

Page 3

ATP
ATP

Production
Planning and
Scheduling

Deployment
Deployment

Supply
Supply
Network
Network
Planning
Planning

Key
Perform.
Indicators
External
data
(e.g.POS)

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Multiple System Environment


Legacy
Systems

Planning
Systems

Internet
&
EDI

ALE
WebGUIs

APO
infocubes
liveCache

SAPGUIs

R/3
4.x

BW

Page 4

R/3
3.x

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liveCache
Production Process
Model

Optimized for realtime scheduling and


pegging (supply
demand, constraints)

Time Series
+10

+20

Optimized for
fast
response ATP

Page 5

-5

APO Solvers

liveCache

Model Generator,
Metaheuristics,
Optimizing Algorithms
Heuristics

Memoryresident data
object
processing

Supply Chain
Network

Application

Representation of
the extended supply
chain
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liveCache
Application
Manages large amounts of data in main memory
Uses both relational and object-oriented functionality
(ADABAS)

Integration with R/3


Uses SQL Interface

Standard Transaction Handling


Locks, Rollbacks, Commits

Advantages (Performance)
Avoids disk I/O
References object via pointers
Stores complex data structures in object oriented data
structures
Recovers quickly in case of system crash
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liveCache

Page 7

A tool
A tool for processing large volumes
of data in main memory.
Main objective = higher performance
Avoid disk I/O
Stores optimized data structures
Scalability
number of processors within one liveCache
number of liveCaches

liveCache
Memoryresident data
object
processing

Application

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liveCache

Main objective = higher performance:


Performance critical routines (in C++) are running in address space
of liveCache Management System
=> no heavy data transfer between application and data storage

Application
Application

Application

> 1 ms
Data
DataStorage
Storage

Page 8

< 10 s

Data Storage
liveCache

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liveCache Integration with R/3

Forecast

DP

liveCache
Supply Plans
On Hand
In transits
Purchase Reqmts
Purchase Order

Sales Order

Sales Order

SD
Page 9

Production Order
Confirmation
Purchase Reqmts
Transport Reqmts Planned Order
Transport Orders

MM

PP
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Optimizer
Optimizers are used for:
Supply Network Planning (SNP)
Production Planning / Detailed Scheduling (DPS)
Capable to Match (CTM)

Optimizer routines are developed in C++, which increases


the speed of the program
Only available on NT and Windows 2000
Communication between the Optimizer routines and APO
through SAP Gateway

Page 10

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SAP APO Integration


For SAP R/3 instances, SAP provides the Core Interface Facility (CIF) which
dramatically simplifies integration to/from APO. Integration with non-R/3
systems is achieved through ALE and SAP provided BAPIs.:

APO
R/3
R/3
R/3
4.x
4.x
4.x

Supply Network
Planning
Supply

R/3
R/3
R/3
4.x
4.x
3.x

R/3
R/3
Non
4.x
4.x
R/3
Page 11

Demand Planning
A
T
P

Production Planning
/ Detail Scheduling

Chain
Cockpit
Live
Cache
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APO - R/3 Integration

Core Interface Facility (CIF)


CIF is an online transaction that defines active data
channel(s) in R/3 for data transfer between R/3 Systems
and APO. It has the following features :
Real Time Interface
Determines Source and Target Systems within Complex System
Environments
Supplies APO with Relevant Master and Transaction Data
Forwards Data Changes (Transaction Data)
Returns Planning Results to SAP R/3

Page 12

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CIF : Core Interface


APO Core Interface (CIF) is the communication layer to
be applied to R/3 to enable an exchange of data between
R/3 and APO.
APO-CIF is delivered as a plug-in . This is a general
product name given by SAP for the R/3 interfaces to the
new dimension applications.

Page 13

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CIF Functions Architecture


ERP -> APO
Master Data

Transaction Data

Locations
Products
PPMs (BOM+Routing)

Characteristics

Capacities

Planned/Production
Orders
Sales Orders
Purchase Orders
Stocks
ATP Requests

APO -> ERP

Planning Results

ATP Results
Manufacturing Orders
Procurement Orders
VMI Sales Orders

APO

ERP

BW

APO

ERP

ERP
APO

Page 14

ERP

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Technical Considerations

Page 15

Modules being Implemented


Multiple Parallel Rollouts
Distributed vs. Central Architecture
UNIX vs. NT
Single Client Strategy
Number / Location of Users
Amount of ALE Traffic
Volume of Data

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SAP APO
Demand Planning

Page 16

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Supply Chain Planning Cycle

Planning horizon
Demand Planning (DP)

Supply Network Planning (SNP)

Production Planning (PP)


Detailed Production Scheduling (DPS)

Deployment

Transportation Plan / Vehicle Sched.


Page 17

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Planning Area Functionality


Defined like an InfoCube
Contains Characteristics and Key Figures
Maps where key figures for the planning area are
stored (InfoCube, Orders in liveCache, Time Series in
liveCache)
Planning Areas can be relevant for DP and SNP at
the same time
Forecast settings are done for planning area
Creation of time series objects

Page 19

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Planning Area Flow


Planning objects

Key Figures
Sales

Production

Stock

Assign Key Figures


by Aggregate

Aggregate

Brand

Sales

Customer

Production

Details

APO Planning Version


Planning UOM
Time Bucket Profile
Page 20

Brand
Product
Customer

Sales
Production
Stock

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Consistent Planning

Planning

at
io
re
g
Ag
g

ati

Lowest
Level

on

Page 21

Pro Rata
or
Proportional
Factors

g
re
gg

Proportion
al values
generated

sa
Di

Planning
Level

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Statistical Toolbox

Univariate Forecasting

Moving Average
Simple Linear Regression
Exponential Smoothing
Holt-Winters
Crostons Model (for sporadic demand)

Causal Analysis
Multiple Linear Regression

Composite Forecasting
Weighted Averaging of Multiple Models
(Ex. Constant, Trend, Seasonal, MLR)

Page 22

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Forecast Profiles
Profiles:
Assign a Planning Area
Define which key figure you
want to be forecasted
Define past and future
periods
Specify models to be used
for:
Univariate forecast
Multiple linear regression
Composite forecast
Page 23

Master
Forecast profile

Univariate profile

MLR profile

Composite profile

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SAP APO Overview:


Supply Network Planning

Page 24

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The Supply Chain: Original Supply


to Final Consumption

INFORMATION FLOW

Transfer

Transfer

Supplier

Manufacturing

Transfer

Distribution

Transfer

Retail Outlet

Consumer

CASH FLOW

Supply Chain Optimization

Increase Customer Responsiveness at Least Cost


Page 25

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What is Supply Network


Planning ?
A planning approach to create Tactical Plans and
Sourcing Decisions that takes the complete supply
network into consideration
Supply Network
Planning
Deployment

Page 26

Transport
Load Builder

Meet Forecast and Actual Demand by:


Optimal use of Manufacturing, Distribution and
Transportation Resources
Consider all constraints in the supply chain

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SNP Planning Functionality

Supply Network Planning Strategies

Heuristics
Optimization
Capable to Match
Propagation

SNP
PP/DS

Deployment
Fair share, push rules and deploy to order
Optimization

Deployment

Transport Load Builder


Leveling in transport loading

Page 27

TLB

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APO Planning Functionality Sequence


Planning Horizon
Demand Planning (DP)
Supply Network Planning (SNP)
Production Planning (PP)
Detailed Production Scheduling (DPS)
Deployment
Transport Load Builder (TLB)
Transportation Planning and Vehicle
Scheduling (TPVS)

Page 28

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SNP Process Flow


Planning Area Administration
APO Master Data Setup
Model/Version Creation
Supply Chain Model Setup
Release of Demand Plan to SNP
Planning Method Determination
& Profile Settings
Transport Load Building

Simulation

Supply Network
Planning Run

Interactive Planning

Deployment Run
Management
by Exception
Conversion into
PP/DS orders

Release of SNP
Plan to DP
PP/DS Planning

Page 29

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Examples : SNP Business uses


Beyond day-to-day planning
High level capacity planning and macro global scheming
to aid with capital equipment decision making based on
sales runs.
Support system for modeling what if scenarios that
would impact the bottom line.
Visibility for planning with confidence. System provides
cost- trend analysis for control on manufacturing
expansion, Out-sourcing, 3rd party supply, etc.

Page 30

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Beyond Traditional DRP

Production Process
Model

Manufacturer
Plant
Manufacurer
DC
Customer DC
Supplier Plant

Supplier WH

Page 31

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SNP Distribution Network

Transport Order

Planned Order / Procurement

Customer
Demands
Distribution
Centers

Plants

Suppliers
Page 32

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Objects in the Supply Chain Network


Objects include:
Locations
Products
Resources
Production Process Models
Transportation Lanes provide links
between objects in a supply chain
model

Page 33

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Vendor Managed Inventory


MANUFACTURER

RETAILER

APO

Plant

Inventory
Warehouse Inventory Distribution
(integrated)
(EDI 852)

Center

Forecast
(integrated)

SNP
R/3,
Sales order
Legacy
Page 34

Forecast
(EDI 830)

VMI

Order (EDI 855)


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SNP Process Flow

Planning Area Administration


APO Master Data Setup
Model/Version Creation
Supply Chain Model Setup
Release of Demand Plan to SNP
Planning Method Determination
& Profile Settings
Transport Load
Building

Simulation

Supply Network
Planning Run

Interactive Planning

Deployment Run
Management
by Exception
Conversion into
PP/DS orders

Release of SNP
Plan to DP
PP/DS Planning

Page 35

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SNP Planning Area Administration


- Process Flow

Page 36

Create Planning
Object structure

Characteristics

Create
Planning Area

Key figures

Initialise
Planning area

Attributes

Create
Planning book

Storage
bucket profile

Create
Planning views

Planning Version

Assign users to
Planning book

Planning
bucket profile
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Resources
The resources are used to define
Capacities of equipment, machines, personnel, means of
transport, warehouses

Resource data are relevant for planning order dates,


taking working time and the capacity of the resources
into account
Resource types:
Bucket Resources
Single activity/ Multi-activity resource
Single Mixed and Multi-Mixed Resource

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Planning Parameters
Parameters in the resource that are relevant to
scheduling, which the system uses in PP/DS and
SNP.
Used to control in detail how the system schedules
orders to resources.
Examples: Overload, Bottleneck resource, activity
overlap periods, etc.

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Capacity Models

Shift sequences
Shift sequences
Day number
Validity

Breaks

Shift
factors

Shifts

Quantities / rates

A
Time
Page 39

A B
C
D

Volume

$
Weight

Costs
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Production Process Model (PPM)

PPM summarizes

Process

Routing
BOM

PPM supports
Location-dependent (PPM ID) and
location-independent (Plan No.)
Min/max lot sizes for the master material
Operations
Set of different process steps Bucketed time
intervals for each process step
Resources assigned to production steps

Validity periods
Planning Order

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Production Process Model

Header: Costs, Lot size range


Operations:
Supply

material

Pre-assembly

Activities:

Final

Setup

Produce

Product

Tear down

Relationship

Queue time

Resources

assembly

Inspection

In / Out
Sequence

Resource consumption

Page 41

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What is a Quota arrangement ?

Supply
Supply Chain
Chain Model
Model

Liste

60% 40%

APO

Sourcing
Sourcing
Production
Production &&
Purchasing
Purchasing
Requirements,
Requirements,
Inventory
Inventory levels
levels
Page 42

Definition

Forecasts,
Incoming quotas
Forecasts,
Customers
Production lead times
Customers orders
orders
Transportation lead times
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Quotas
Production Location

Distribution Center (DC)

O
ut

70%
30%
60%

go
i

Product
ng

uo
ta
s

40%

Quota
60%
Incoming Quotas

Page 43

?
Supplier

40%

Supplier

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Planning Process

Demand Planning
Forecast
Supply Network Pl.

Production Planning
Detailed Scheduling

Planned
Orders

Recommended
TransportOrders

Deployment

Transport Load
Builder
Transportation Planning
& Vehicle Scheduling

Page 44

Confirmed
Transport Orders

Transport
Orders

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SNP Heuristic

Heuristic is an algorithm that


has pre-defined set of
parameters and workflow to
influence the creation of a
solution
The plan is not necessarily
feasible
Planner must use capacity
leveling to formulate a
feasible plan

Page 45

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SNP Run Using Heuristics:


Heuristic is used as part of a repair-based planning
process consisting of the Heuristic, Capacity Leveling,
and Deployment
The Heuristic processes each planning location
sequentially and determines sourcing requirements
Heuristic processing lumps all requirements for a given
material in the location into one requirement for the
period
Heuristic determines the valid sources and quantity
based on pre-defined percentages for each source, then
passes the requirements through the supply chain to
calculate a plan

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SNP Run Using Heuristics:


Heuristic plans all distribution requirements for all
locations in the distribution network before exploding the
BOM and processing dependent demand in the
production locations
System explodes the BOM only when the Multi-level
Heuristic run option is chosen
Scope of the planning run
Multi-level
Network
Location

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Factors Considered in the Heuristic Run

Transportation lanes
Lead Times
Quota arrangements
Lot sizing
Scrap
Component
Availability
PPMs

Page 48

Location Products
SNP Demand Profile
SNP Supply Profile
Demand Profile

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Heuristic Processing - Results


Replenishment Plan
list of procurement
production orders
transportation orders

Results can be viewed in the interactive planning


table
If the Level ID option is used, the Heuristic calculates
an intersection of the following entries
Model Version
Products and Locations
Level ID from product-location hierarchy

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Capacity Leveling
Capacity leveling is a function within Interactive
Planning
Enables to smooth production schedule
Manual or using a methods-based approach
Provides opportunity to build up inventory or increase
capacity
Alternatives can be easily analyzed
Re-plan even re-forecast before putting the plan into
production.

Page 50

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Optimization-Based Planning
Models
In constraint-based planning, production processes can
be represented as optimization models.
A production model based on optimization consists of
Objective Function(s), Decision Variables, and
constraints based on market conditions, physical
processes, and resources/capacity.
These kinds of models are usually called mathematical
programs.

Page 51

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Optimization - Components

Page 52

Decisions variable are the


independent variables of the
problem
The Objective Function is
the single benchmark for
evaluating all combinations
of decisions that satisfy the
constraints
Constraints represent
limitations on which decision
can be made and how
decisions can be made

F(x,y2)=

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Optimization of the Network

Sourcing
Sourcing
production
production &&
purchasing
purchasing
requirements
requirements

Control costs
Penalty costs

Forecasts
Forecasts
Customers
Customers orders
orders

Priorities for:
demand types
defined via
costs

Goal: Minimize costs


Goal: Maximize Profits*

Page 53

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Optimization Methods

Linear Programming
Continuous Linear Optimization Problems
Primal Simplex Method
Dual Simplex Method
Interior Point Method

Discrete Linear Optimization Problems


Mixed Integer Linear Programming

Page 54

Prioritization
Decomposition
Vertical Aggregated Planning
Horizontal Aggregated Planning
Discretization

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Optimization Parameters

Decision Variables
Production lot sizes
Transportation lot sizes
Capacity increase

Objectives

Lateness
Storage costs
Transportation costs
Production costs
Penalty for increasing
capacity
Penalty cost for not
maintaining safety stock*
Penalty cost for late or non
delivery*
Page 55

Constraints

Production capacities
Transportation capacities
Handling capacity
Due dates (demands)
Safety stock
Discrete Values
Production Lot Size
Transportation Lot Size

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Optimization Relevant Profiles

SNP Optimization Profile


Specifies the linear programming method to be used and
the constraints to be considered during the Optimization
run

SNP Cost Profile


Specifies the weight given to different categories of costs
in the objective function

Optimization Bound Profile*


Specifies the time buckets where the new plan is
constrained by an upper and lower limit on the allowable
change

Page 56

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Optimization Total Costs

Total Cost (Sum Total)

Page 57

Source of cost data

Production

PPM

Storage

Resource

Storage expansion

Resource

Penalty cost for safety stock

Cost Profile

Transport cost

Resource

Handling capacity expansion

Resource

Transport capacity expansion

Resource

Production resource expansion

Resource

Penalty for non-delivery

Master data

Delay
Penalty
Procurement
costs

Master data
Master data
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SNP Optimization Run Results

Page 58

Distribution Plan
Production Plan
SNP Resulting Costs
Alerts

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CTM Process (Overview)


Constraint-based
heuristics to conduct multisite checks of production/
transportation capabilities
Supply categorization
Demand prioritization

Demand
Prioritization

CTM Engine
Create CTM application
model
Match supply to demand
using the CTM algorithm

Page 59

Supply
Categorization

CTM Process
CTM Engine
Phase 1
Build CTM
application
model

Phase 2
Match supply
to demand

Orders in
liveCache

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Demand Prioritization

Demands
forecasts
(from APO Demand
Planning)
sales orders

Prioritization based on

order type
customer priority
product priority
due date

Defined in Sort Profile*

Page 60

Prioritized
demands

Demands

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

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Supply Categorization

Supplies include
inventory
purchase orders

Categorization is based
on supply limits
for each location
for each product

Supplies

Categorized
Supplies

excess

normal

target

Page 61

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CTM Results

Categorized
Supplies

Prioritized
Demands

Capable to Match
1.
2.
3.
4.
5.
6.
7.
8.
9.

Multi-site capacity and


transportation capability check

Page 62

10.
11.

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Rule Based Capable to Match*


Allows to influence the supply and demand matching
process, depending on a demands specific attribute
Determines the following based on the attributes of
individual demands
find the product/location substitutes for the particular
demand with substitution
influence the solution process for a particular demand using
demand-dependent constraints

Page 63

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Sales and Operations Planning: Overview


Supports interactive SNP Planning
create a feasible plan for the entire supply chain

Considers resource capacities (Production and


Transport)
Flexible Controlling via quotas, priorities,and cost
Parameters are time dependant
No lot size Planning
No optimization
No Orders

Page 64

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Sales and Operations Planning:


Overview
Product

DP: (dis-) Aggregation

Location x Product

Location x Product x Channel

SNP: Propagation (finite, multi-level)


Page 65

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Sales and Operations Planning:


Features

Pre-configured Planning Environment


Bucketed Planning based on Time Series
Aggregated Planning possible
Fully integrated with Demand Planning
statistical forecasting
promotion planning

Planning books can be configured to compare real


world (OLTP) with tactical plan

Page 66

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Conversion of SNP Orders to PP/DS Orders

System automatically stores the final supply


network plan in liveCache
Converting SNP Orders to PP/DS orders
makes it available for finite scheduling
PP/DS enables to synchronize production
planning with execution
PP/DS creates a viable plan
Two ways of conversion
Conversion of SNP Orders in Production Horizon
Conversion of Individual SNP Orders

Page 67

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Collaborative Supply Planning Overview


The goal of collaborative supply planning is the
exchange of materials requirements at an early stage
between manufacturers and suppliers so that all
parties involved can adjust their supply and
production plans
Partners can exchange data in two ways:
automatically using time series data exchange between SAP
systems
manually via a web browser for collaboration between SAP
and non-SAP systems

Page 68

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Collaborative Supply Planning

Supplier

Both

Manufacturer

Business Benefits

Business Benefits

Better Transparency

Better service level of supplier


Front End
Agreements

Reduced costs by less inventory

Better Service level

More stability in demand

Easy communication with


all related parties

Page 69

Supply
Supply Network
Network
Planning/Production
Planning/Production
Planning
Planning

Exchange
Component
Component
requirements/
requirements/
constr-aint
constr-aint or
or
unconstraint
unconstraint
forecast
forecast

More accurate supply


Supply Network
Planning/Production
Planning

Reduced costs by less inventory


Easy communication with
all related parties

Collaborate on
exceptions
Supply Network
Planning/Production
Planning

Supply Network
Planning/Production
Planning

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Collaborative Supply Planning Process Flow

Manufacturer

Supplier

Supply
Planner

Alert
broadcasting
(email)

Da

APO SNP
plan

R/3

Page 70

ta

a
ch

e
ng

orm
f
n
i

e
(al
n
o
ati

ds
Committe

m
rt,e

)
ail

Review
requirements

n
upply pla

replan

Account
Manager

Internet

Supplier
System

Purchase order

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Planning Process & Time Buckets

Network Design (ND)

Year, Quarter, Month

Demand Planning (DP)


Supply Network Planning (SNP)

Year, Quarter, Month, Week

Production Planning (PP)

Quarter, Month, Week, Day

Detailed Scheduling (DS)

Week, Day, Hour, Minute

Deployment

Month, Week, Day, Hour

Transport Load Builder (TLB)


Vehicle Scheduling

Page 71

Week, Day, Hour, Minute

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Which products should be planned


using PP/DS?
Externally procured products with long replenishment
lead time
All in-house products produced on a bottleneck
resource

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What PPDS delivers?


Consistent Model through Production Process Model
Simultaneous Capacity (CRP) and Material (MRP)
Planning
Creation of Feasible Production Plans
Multi-level Forward and Backward Scheduling
Automatic Multi-level Transfer of Changes (e.g.
orders)

Page 73

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Why perform Production Planning/


Detailed Scheduling?

Page 74

Improve customer response (due date performance)


Improve throughput
Reduce inventory/Reduce WIP
Reduce overtime expense
Increase asset utilization
Reduce cycle time

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How SAP delivers this solution?


Built for quick response (liveCache)
Designed for a multi-plant heterogeneous
environment
Packaged to support R/3 implementations
Simultaneous material and capacity planning
Constraint solving & optimization engine
Simulation and what-if analysis
Exception driven decision support tool

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Differences between SNP and PPDS

SNP

PPDS

Capacity and product receipts


and requirements are
considered in a bucketed
fashion
No material problem if all
receipts until a certain bucket
equal all requirements until that
bucket
Sequence not relevant
LP-optimizer can:

Both, capacity and


product are checked with
exact time.
It is a potential problem if
material receipt is 1
second after
requirement.
Sequence relevant
Optimizer can:
alter sequence of
existing orders

generate orders
optimize lot size
best for sourcing problems
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Sourcing,
Confirmation
(SC)

Inventory

Deployment

Transport
Orders

ATP

Actual
Sales
Orders

Historical
DP
Data

Unconstrained SNP
Demand
Plans

Final
Production
Plan

Planned
Orders

PP

Feasible
Schedule

s
Alert Queries

MasterData

SCC

DS

SC

Page 77

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Total Process Flow: APO

Core

Order Creation
(OLTP, SNP, PP/DS)

PP

Production Process Model


Evaluation / Selection

MRP

PPM Explosion
Availability check against
unassigned receipts

APO

Order
Stock

Creating Order Network

Transfer
Orders
Page 78

Planning Functionality

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PP/DS Setup and Planning Cycle

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Features in PP
Automatic planning
When integrated with R/3 continually, this can provide the
most up-to-date information

Manual planning
to handle critical products that require particular attention
when planning

Interactive planning
Planning board feature

Cross-plant planning
Stock transfer or between parties in a supply chain

Page 80

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Features in PP -

(Continued)

Lot-size calculation
Lot-for-Lot Order Quantity
Fixed Lot Size
Rounding profile

Scrap calculation
Scrap at assembly level
Scrap at activity level

Calculation of Days Supply


Planning with shelf-life data

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Features in PP

Page 82

(Continued)

Production Process Model (PPM) explosion


Pegging (Fixed and Dynamic)
Evaluation Options
Execution Functions in APO and R/3

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Pegging

Demand

Pegging network:

50
Output node

80

50

50

30

20
Order

Page 83

20

Input node

Pegging edge

Used for
supply/demand
allocation
Changes have to be
propagated to all
dependent orders
Find unassigned
order quantity

APO offers fixed and


dynamic pegging
Global setting in
APO

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Strategy Profile
& Scheduling Modes

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Scheduling Strategy Profile

Infinite Scheduling
Schedule an operation without considering resource
capacity

Finite Scheduling
Schedule an operation only when resource capacity is
available
Alert is only generated when planning using finite
scheduling only
Finite
Infinite
Strategy
Strategy
Finite Scheduling
Infinite Scheduling

Page 85

Finite scheduling

Infinite scheduling

Alert display

Alert display

Infinite scheduling

No Alert display

Infinite scheduling

No Alert display
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Scheduling Modes

Infinite loading
Finite loading only
forward
Finite loading only
backwards
Finite loading with
direction switch
Search for a slot in
schedule

Page 86

Insert operation to
close gaps in
schedule
Squeeze-in
operation
Add an operation at
end
Dispatch to nonworking time

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Finite Scheduling - Backward Only

Available

New Order

Occupied

Customer Order
Desired date
and quantity

Resource 1

Resource 2

Resource 3

today
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confirm

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Finite Scheduling - Forward Only

Customer Order

Available
Occupied

Desired date
and quantity

New Order

Resource 1

Resource 2

Resource 3

today
Page 88

Confirmed date
and quantity

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Finite Scheduling - Backward with


Reverse
Available

1st Loading attempt

Occupied

Final loading

Customer Order
Desired date
and quantity

Confirmed date
and quantity

Resource 1

Resource 2

Resource 3

today
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Simultaneous Material and Resource


Planning
Available
Occupied

1st loading
Infinite planning strategy

Due Date

Resource 1
Resource 2 (bottleneck)
Resource 3

ALERTS:

Material 1

Resource Overload
Supplier Delivery Time Violated

Delivery time
today

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Simultaneous Material and Resource


Planning
Available
Occupied

1st loading
Infinite planning strategy
2nd Loading
Finite planning strategy

Due Date
Feasible Due Date

Resource 1 (finite scheduling)


Resource 2 (bottleneck)
Resource 3

Material 1

Delivery time
today
t

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Features in Detailed Scheduling


Determine production date by taking account of the
constraints entered in the strategy profile and in the
resources for scheduling
Changes in DS (e.g. orders, operations, ) will
automatically propagate through to all relevant
objects
Taking sequence-dependent set-up times and/or
costs into consideration
If a constraint is relaxed (this is not considered in
optimization run) and it is violated in scheduling, the
system creates alerts

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Real Time Planning vs Batch


Optimization
Real Time Planning
supports interactive scheduling
finds a feasible solution

Batch Optimization
takes into account
complete situations

real time answering

optimizes feasible
solutions

Examples

answering time depends


on user-defined run time

backward/forward propagation
scheduling in free slots
simultaneous material and
capacity planning

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Examples
complete rescheduling
of planning window

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Concept: Optimization
Order 1

Order 2

Order 3

Order 4

Resource 6
Resource 5
Resource 4
Resource 3
Resource 2
Resource 1

time
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Concept: Optimization
Order 3

Order 4

Order 1

Order 2

Resource 6
Resource 5
Resource 4
Resource 3
Resource 2
Resource 1

time
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Foundation of Optimizer in DS:


Metaheuristics

Objective
obtain quality solution for given time frame
(scalability for a given problem size)

Purpose
simplify the problem

Metaheuristics consists of
time decomposition
resource decomposition
constraint relaxation

Local improvement Strategy

Objects
(resources, orders,
ops, constraints, )

Reduced
opt model

Focus on a sub-problem and optimize


planning window
Time

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Metaheuristics Time Decomposition


Resources

Current window

Time

Sliding window (Rolling time Horizon)


1. Optimize only in window
2. Move window by a time delta
3. Go to first step
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Metaheuristics Bottleneck Decomposition


Resources

Bottleneck

Time

Bottleneck
1. Determine bottleneck
2. Schedule bottleneck resources only
3. Fix sequence on bottleneck resource
4. Schedule all resources
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Metaheuristics Constraint Relaxation


A way to make a constraint less restrictive or
remove certain constraints
5 choices

Page 99

Remove max time constraint


Set resource utilization rate to 100%
Remove calendar
Do not consider sequence-dependent setup
Undo fixing of orders/operations/activities

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Scope and Size of Optimization: An


Example

Non-work times
Fixed operations
Operations, that
may be rescheduled
Relationships
Optimization range
Page 100

Start

End

Transferred Resources B, C, D
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Optimization Model in PPDS:


Scheduling

Decision Variables
Resource Allocation
Alternative Machines
Alternative Storage

Start dates
End dates

Objective Functions (Minimize)

Total Lateness
Maximum Lateness
Total Leadtime
Total Setup Times
Total Setup Costs

Constraints
Time Constraints
Maximal (Shelf Life)
Minimal

Deadlines
Production and Storage
Capacities
Calendar (Shifts and Breaks)
Sequence- and Resourcedependent Setup times
Resource Network
Breakable activities
Effectivity of BOMs and
Routings
Productivity (per Shift)

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Two Ways to Perform DS


Optimization Procedures
Constraint Programming
Constraint propagation
Branch and bound

Genetic Algorithm
Priority rules
Sequencing

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Constraint-Based Programming

Approach/method
checks hard constraints during scheduling
propagates constraints during scheduling
additional reduction of the search space
early detection of dead ends
reduces back tracking

Tradeoff
Dynamic propagation needs time
but improves quality of search decisions

Advantages
High-performance constraint propagator (iLog)
Dedicated to complex scheduling problems
Example: shelf life / expiration

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Constraint-based Programming:
Example

Propagate consequence
of each decision
Dynamic constraint
propagation
checks hard constraints
during scheduling

Prune the search tree


Remove unfeasible
solution
Remove worse solution

Page 104

Initial Solution
Solution
with
Changed
Variables

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Genetic Algorithms
(GA)

Based on Concept of Evolution


Population of candidate solutions
New candidate solutions by
Crossover/Recombination
Mutation
Exchanging sequence of activities
Change resource allocation of activities

Page 105

Preferring the better ones as parents


Eliminating the worse ones

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GA - Procedures

Generate initial schedules

Selection of good schedules


Generate new schedules by
mutation and recombination
Evaluate new schedules
Survival of new schedules

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GA- Advantages

High-performance in sequencing
Dedicated to not too complex scheduling
problems
Feasibility should be not the problem
Example: no shelf life / expiration

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Optimization Profile

Maintain in
Customizing
Settings
Optimizing procedure
Constraint-based
Scheduling
Genetic Algorithm

Runtime
Objective Functions and its
Weights

Page 108

Total lead-time
Set-up times
Set-up costs
Maximum delay
Average delay

Constraint Relaxation
Remove maximum time
constraints
Set utilization rate of all
resources to 100%
Remove calendar
Do not consider set-up
times/costs
Undo fixing of activities

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Techniques in Solving
Complex Production
Processes and
Optimization Models in
APO

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APO Computational Solvers

APO Solvers

A wide variety of computational solvers


applied to specific planning functions with
industry-specific variations
Linear Programming /
Mixed Integer Linear
Programming

Supply
Network
Planning

Genetic Algorithms,
Constraint-based
Production
Programming

Planning &
Scheduling

Heuristic Methods

Exponential Smoothing
Holt Winters
Multiple Linear Regression

Page 110

Demand
Planning

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Complexity in Real-life Production


Models
They are too complex to solve. For example, we may
have nonlinear equation(s), integer decision
variables, scale, ...
In such cases, we will have to rely on algorithm,
heuristics, and other intelligent methods.
Most APS systems mix optimization and heuristic
methods.

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Where is Constraint-based Planning


Used in APO?
Creating Production Process Models (PPMs) in SNP
and PP/DS are based on Theory of Constraint and
Constraint-based Planning
Where are the decision variables? Where are the
constraints identified? Where are the objective
identified?
For example, in PPDS, the decision variables are
given in the planning table (which resource is used to
produce a given order and its start and end times);
objective function is given in the optimizer screen;
and the constraints are stated in master data.

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Example: Decision Variables in DS

End Time

Start Time

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Example: Objective Functions in DS

Optimization methods

Obj. functions and its weights


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Optimization Models in APO

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