LO230

(1)

LO230 Capacity Planning

(2)

LO230 Capacity Planning ...0-1 Copyright ...0-2 Production Planning ...0-4 Prerequisites ...0-5 Target Audience ...0-6 Introduction...1-1 Course Goals ...1-2 Course Objectives ...1-3 Course Content...1-4 Overview Diagram 1 ...1-5 Main Business Scenario ...1-6 Overview...2-1 Overview: Objectives...2-2 Overview Diagram 2 ...2-3 Overview: Business Scenario...2-4 Integration of Capacity Planning (1) ...2-5 Capacity Planning Environment (1) ...2-6 Planning Views ...2-7 Capacity Planning / Elements ...2-8 Work Center Data ...2-9 Types of Display ...2-10 Overview: Summary ...2-11 Capacity Evaluation ...3-1 Capacity Evaluation: Objectives ...3-2 Overview Diagram 3 ...3-3 Capacity Evaluation: Business Scenario ...3-4 Capacity Planning Environment (2) ...3-5 Procedure in Capacity Evaluation ...3-6

(3)

Configuration Sequence Capacity Planning (1) ...3-17 Capacity Planning / Overall Profile Evaluations...3-18 User Parameters - Evaluation...3-19 Selection Profile (Capacity Evaluations) ...3-20 Options Profile (Capacity Evaluations)...3-21 Extended Evaluation (Standard Overview) ...3-22 Extended Evaluation (Detailed Capacity List) ...3-23 Structure of a Profile (Extended Evaluation) ...3-24 Structure of a Set (Extended Evaluation) ...3-25 Capacity Evaluation: Summary...3-26 Data used in the exercises ...3-27 Capacity Evaluation Exercises ...3-29 Capacity Evaluation Solutions ...3-34 Capacity Leveling (Part 1) ...4-1 Capacity Leveling (Part 1): Objectives ...4-2 Capacity Evaluation ...4-3 Capacity Leveling (Part 1): Business Scenario ...4-4 Capacity Planning Environment (3) ...4-5 Capacity Leveling Measures ...4-6 User Interface for Capacity Leveling ...4-7 Capacity Planning Table (Tabular Form)...4-8 Capacity Planning Table ...4-9 Dispatching ...4-10 Dispatching Procedure ...4-11 Types of Dispatching (tabular)...4-12 Capacity Leveling (part 1): Summary ...4-13 Capacity Leveling (Part 1) Exercises ...4-14 Capacity Leveling (Part 1) Solutions ...4-16 Available Capacity ...5-1 Available Capacity: Objectives...5-2 Overview Diagram 5 ...5-3 Available Capacity: Business Scenario...5-4 Capacity Planning Environment (4) ...5-5 Capacities at a Work Center...5-6 Available Capacity at the Work Center...5-7 From Work Time to Operating Time ...5-8

(4)

Maintaining and Assigning Factory Calendar...5-12 Work Center Hierarchy ...5-13 Configuration Sequence Capacitiy Planning (2) ...5-14 Shift Sequences and Shifts ...5-15 Available Capacity: Summary ...5-16 Available Capacity Exercises...5-17 Available Capacity Solutions ...5-21 Capacity Requirements and Reduction ...6-1 Capacity Requirements and Reduction: Objectives ...6-2 Overview Diagram 6 ...6-3 Business Scenario ...6-4 Capacity Planning Environment (5) ...6-5 Planning Levels...6-6 Determining Capacity Requirements ...6-7 Formulas ...6-8 Link between Formula and Standard Values ...6-9 Setting up a Formula ...6-10 Examples of Formulas...6-11 Capacity Reduction ...6-12 Determining Remaining Capacity Requirements...6-13 Capacity Requirements and Reduction: Summary...6-14 Capacity Requirements and Reduction Exercises ...6-15 Capacity Requirements and Reduction Solutions ...6-18 Scheduling...7-1 Scheduling: Objectives...7-2 Overview Diagram 7 ...7-3 Scheduling: Business Scenario...7-4 Work Center and Lead Time Scheduling ...7-5 Lead Time Scheduling - Basics...7-6

(5)

Capacity Leveling (Part 2) ...8-1 Capacity Leveling (Part 2): Unit Objectives ...8-2 Overview Diagram (8) ...8-3 Business Scenario ...8-4 Capacity Planning Environment (1) ...8-5 Capacity Planning Table ...8-6 Types of Dispatching (Graphical) ...8-7 Dispatching Operations...8-8 Planning Details at the Work Center / Capacity...8-9 Lead Time Scheduling - Finite Scheduling...8-10 Finite Scheduling ...8-11 Rescheduling / Deallocating ...8-12 Midpoint Scheduling I...8-13 Midpoint Scheduling II ...8-14 Structure of a Profile (Leveling) ...8-15 Dispatching to Freely-Definable Period split ...8-16 Enhanced Handling Functions 1 ...8-17 Strategy Profile ...8-18 Planning Direction ...8-19 Dispatching at the Earliest Time ...8-20 Planning Strategy: Strategy Profile ...8-21 Treatment of Queue Time ...8-22 Use of Order Floats / Operation Floats ...8-23 Various Functions ...8-24 Configuration Sequence Capacity Planning (3) ...8-25 Capacity Leveling - Overall Profile ...8-26 Standard Overall Profiles for Capacity Leveling ...8-27 Control Profile...8-28 Selection Profile ...8-29 Planning- (Scheduling) Levels ...8-30 Time Profile ...8-31 Evaluation Profile ...8-32 List Profile ...8-33 Profile for Capacity Planning Table (tab.) ...8-34 Period Profile ...8-35 Profile for Capacity Planning Table...8-36

(6)

Cumulation of Available Capacity / Capacity Requirements...8-40 Cumulation of Available Capacity using Period Split ...8-41 Capacity Leveling (Part 2): Summary...8-42 Capacity Leveling (Part 2) Exercises ...8-43 Capacity Leveling (Part 2) Solutions ...8-49 Extended Planning Functions...9-1 Extended Planning Functions: Unit Objectives...9-2 Overview Diagram 9 ...9-3 Business Scenario ...9-4 Sequencing 1 ...9-5 Sequencing 2 ...9-6 Sequencing 3 ...9-7 User Exits...9-8 Additional Functions 1...9-9 Additional Functions 2...9-10 Material Stock Curves...9-11 Planning in Non-Work Periods / Fixing...9-12 Temporarily Saving Results of Planning...9-13 Mass Processing...9-14 Capacity Planning with Production Versions...9-15 Notes on Documentation...9-16 Extended Planning Functions: Summary ...9-17 Extended Planning Functions Exercises...9-18 Extended Planning Functions Solutions...9-26 Detailed Planning...10-1 Detailed Planning: Unit Objective ...10-2 Overview Diagram 10 ...10-3 Detailed Planning: Business Scenario...10-4 Application Criteria for Splits ...10-5

(7)

Detailed Planning: Summary ...10-16 Detailed Planning Exercises...10-17 Detailed Planning Solutions ...10-21 Integration ...11-1 Integration: Unit Objectives 1 ...11-2 Integration: Unit Objectives 2 ...11-3 Overview Diagram 11 ...11-4 Integration: Business Scenario ...11-5 Integration of Capacity Planning (2) ...11-6 CRP Along the Process Chain...11-7 Planning Phases...11-8 Integrated Planning Levels...11-9 Simultaneous Use of Different Planning Levels ...11-10 Overall Profiles in the Applications ...11-11 Integration Types ...11-12 Integration: Sales and Distribution (SD) ...11-13 Integration: Sales and Operations Planning - Planning Table (SOP) ...11-14 Integration: MRP/MPS...11-15 Integration: Long-term Planning 1 ...11-16 Integration: Long-term Planning 2 ...11-17 Available Capacity and Requirements Versions ...11-18 Integration: Repetitive Manufacturing (REM)...11-19 Repetitive Manufacturing with Production Versions ...11-20 Integration: Shop Floor Control (SFC) ...11-21 Integration: Unit Summary ...11-22 Integration Exercises...11-23 Integration Solutions ...11-27 Appendix...12-1 Change Mode and GUI Status...12-2 Layout of the Planning Table ...12-3 Chart Sequence ...12-4 Chart Sequence (cont.) ...12-5 Actual Capacity Requirements...12-6

(8)

LO230 Capacity Planning

©SAP AG

LO230

Capacity Planning

R/3 System Release 4.6B March 2000 50034893

(9)

Copyright 2001 SAP AG. All rights reserved.

Neither this training manual nor any part thereof may

be copied or reproduced in any form or by any means,

or translated into another language, without the prior

consent of SAP AG. The information contained in this

document is subject to change and supplement without prior

notice.

All rights reserved.

Copyright

Trademarks:

Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.

Microsoft®, WINDOWS®, NT®, EXCEL®, Word® and SQL Server® are registered trademarks of Microsoft Corporation.

IBM®, DB2®, OS/2®, DB2/6000®, Parallel Sysplex®, MVS/ESA®, RS/6000®, AIX®, S/390®, AS/400®, OS/390®, and OS/400® are registered trademarks of IBM Corporation.

ORACLE® is a registered trademark of ORACLE Corporation, California, USA.

INFORMIX®-OnLine for SAP and Informix® Dynamic ServerTM are registered trademarks of Informix Software Incorporated.

UNIX®, X/Open®, OSF/1®, and Motif® are registered trademarks of The Open Group.

HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Laboratory for Computer Science NE43-358, Massachusetts Institute of Technology, 545 Technology Square, Cambridge, MA 02139.

JAVA® is a registered trademark of Sun Microsystems, Inc. , 901 San Antonio Road, Palo Alto, CA 94303 USA.

JAVASCRIPT® is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape.

(10)

over the world. All other products mentioned are trademarks or registered trademarks of their respective companies.

(11)

Production Planning

Level 2

Level 3

Manufacturing Planning & Execution for Discrete & Repetitive

LO050 5 days Engineering Change Management LO980 3 days Batch Management LO955 3 days KANBAN LO235 2 days Classification LO985 3 days Special Features of LIS in Production LO275 2 days Logistics Info Planning LO935 2 days CAP Calculation of Standard Values LO720 2 days Repetitive Manufacturing LO225 3 days Capacity Planning LO230 5 days Logistics Information System (LIS) Reporting LO930 2 days Basic Data Part 2 LO206 3 days Basic Data for

Discrete Manufacturing LO205 3 days Production Orders LO215 5 days Production Planning LO210 5 days Variant Configuration Part 1 LO990 5 days Variant Configuration Part 2 LO991 3 days

(12)

Prerequisites

z

LO050 - Planning & control for discrete manufacturing and

repetitive manufacturing

z

LO205 - Basic data for discrete manufacturing

(13)

Target Audience

z

Participants

Members of the project team responsible for the implementation of capacity planning

Members of shop floor control

z

Duration: 5 days

Notes to the user

The training materials are not teach-yourself programs. They complement the course instructor's

(14)

Introduction

z

Course goal

z

Course objectives

z

Course contents

z

Course overview diagram

z

Main business scenario

z

Introduction to course

(15)

z

Understand how to use capacity planning within PP

z

At the conclusion of this course you will be able to:

z

Describe connections between the elements of

capacity planning

z

Use the capacity evaluation and the capacity

planning tables

z

Make system settings

This course will enable you to:

(16)

z

Create available capacities

z

Execute capacity evaluations

z

Execute leveling of capacity requirements

and available capacities

This course will enable you to:

(17)

Unit 7

Scheduling

Unit 8

Capacity leveling (part 2)

Unit 9

Extended planning

functions

Unit 10

Detailed planning

Unit 11

Integration

Unit 1

Introduction

Unit 2

Overview

Unit 3

Capacity evaluation

Unit 4

Capacity leveling (part 1)

Unit 5

Available capacity

Unit 6

Capacity requirements /

reduction

Preface

Appendix

(18)

© SAP AG 1999 Work Center Work Centers Jul' 98 W 28 W 27 W 26 W 29 Jul' 98 W 28 W 29 1310 1320 1330 Mont. 1 Mont. 2 Material Order 100-500 18752 500-300 600001650 100-500 18770 500-300 600001699 Jun' 98 1310 1320 1330 Work Centers

Overview Diagram 1

©SAP AG Capacity evaluation Capacity evaluation

Capacity leveling (part 1) Capacity leveling (part 1) Available capacity Available capacity

Capacity reqmts / reduction Capacity reqmts / reduction

Scheduling Scheduling

Capacity leveling (part 2) Capacity leveling (part 2)

Detailed planning Detailed planning Integration Integration Extended planning functions Extended planning functions Overview

Overview

Introduction

(19)

z

You are running a manufacturing company and

aim to deliver materials for orders received by

the dates promised. Thus you want to provide

available capacity that is sufficient but not

excessive to cover requirements generated by

orders. This is why you are using capacity

planning; for example to spot overloads in time

or to carry out leveling for the requirements

dates using the capacities available and to fix

the requirements.

(20)

Overview

z

Integration of capacity planning

z

Capacity planning environment

z

Overview of elements and types of display

(21)

At the conclusion of this unit you will:

Overview: Objectives

z

Have an overview of the integration of

capacity planning in the PP System and the

main elements of capacity planning.

(22)

Arbeitsplatz / Work Center

Arbeitsplätze / Work Center

Jul' 98 W 28 W 27 W 26 W 29 Jul' 98 W 28 W 29 1310 1320 1330 Mont. 1 Mont. 2

Material Auftrag / Order

100-500 18752 500-300 600001650 100-500 18770 500-300 600001699 Jun' 98 1310 1320 1330 Arbeitsplätze Introduction Introduction Capacity

Capacityevaluationevaluation Capacity leveling

Capacity leveling ((part part 1)1) Available

Available capacitycapacity Capacity

Capacityreqmtsreqmts/ -/ -reductionreduction Scheduling Scheduling Capacity leveling

Capacity leveling ((part part 2)2)

Detailed

Detailedplanningplanning Integration Integration Extended

Extendedplanningplanningfunctionsfunctions

Overview

(23)

z

You are running a manufacturing company and

need an overview of capacity planning.

Therefore you want to find out about the

capacity planning environment. You are

particularly interested in the basic data such as

the work center and the pegged requirements.

(24)

R/3

FI FI CO CO AM AM PS PS WF WF IS IS MM MM PD PD SD SD PM PM QM QM

PP

Client / Server Client / Server ABAP/4 ABAP/4 PP - BD Basic Data PP - MPS

Master Prod. Scheduling PP - MRP

Mat. Reqmts Planning PP

PP --CRPCRP Capacity

Capacity ReqmtsReqmtsPlanningPlanning PP - SFC

Shop Floor Control PP - PI

Process Industries PP - SOP

Sales and Operations Planning PP - REM

Repetitive Manufacturing

Integration of Capacity Planning (1)

The PP production planning component consists of several integrated components. Capacity planning is flexible and can be adapted to the relevant point of view.

The user has a planning instrument he can use to help in planning limited resources on various planning levels (detailed, production-rate and rough-cut). It can be used for every application area and it has specially-defined functions.

Capacity leveling is an integrated component of the following R/3 applications. y SD Sales and distribution

y SOP Sales and Operations Planning

y MPS/MRP Master Production Scheduling / Material Requirements Planning y REM Repetitive

(25)

Basicdatadata Production planningProduction planning PM / PSPM / PS

Capacity evaluation

Capacity evaluation//--levelingleveling

4

Calendar Arbeitsplan Routing TskLstGrp C 1 10Center 1 20 30 Bill of material Material Material A Planned orders Production orders Process orders SOP orders Plant maint. Projects

Capacity Planning Environment (1)

With the help of R/3 basic data such as Material Masters, work plans and work centers, as well as planned orders and production orders, a database is created, which can show the available capacity and the capacity required.

Available capacity indicates which activity produces a capacity each day. A capacity is always assigned

to at least one work center.

Capacity requirements shows how much capacity the individual orders need at a certain point in time.

Capacity requirements are determined during lead time scheduling.

In Capacity evaluation, these requirements can now be compared with the available capacity.

In Capacity levelling, orders can be shared out to avoid overloading. This way it is possible to leverage the suitable resources or to plan optimal scheduling with sort criteria.

(26)

SOP

MPS

MRP/SFC

Today

Today Months laterMonths later

Planning Views

There are different planning levels available for the individual application areas. For example, you can plan MRP requirements in the following three ways depending on how specific you want your planning to be:

Rough-cut planning with a rough-cut planning profile Production-rate planning with a rate routing or a routing Detailed planning with a routing

(27)

Capacity evaluationandand-leveling-leveling

Capacity reduction Capacity reduction

Capacity Planning / Elements

The available capacity represents the capacity available for production.

Scheduling the sequence of operations determines the times for the capacity requirements.

The system calculates the capacity requirements using formulas and dates and quantities for production.

The capacity evaluation gives you an overview of the load and the requirements for production. Capacity leveling allows you to achieve optimal planning and an optimal load.

(28)

General Generaldatadata

Default

Defaultvaluesvalues

Capacity data Capacity data Scheduling data Scheduling data Personnel system Personnel system data data Basic data Default values Capacity Scheduling Assignments

Work Center Data

z Name and description

z Standard values key

z Effíciency rate key

z Control key

z Standard text key

z Wage data

z Available capacity

z Formula key

z Individual capacities

z Scheduling basis

z Queue and move time

z Formula key

z Labor

z Positions

z Qualifications

The work center contains several groups of data that are located on different screens. Only the most important ones are shown in this example.

(29)

Capacity requirements

Available capacity

Printing of standard overview and det. cap. list

Planing table

Planing table(tabular(tabular)) Planning tablePlanning table((graphicalgraphical)) Capacity

Capacityevaluationevaluation DiagramsDiagrams

Types of Display

Capacity planning uses several types of display. It uses evaluation lists, block diagrams, bar charts, line graphs and Gantt charts.

(30)

z

You have an overview of the integration,

environment and elements of capacity

planning.

(31)

Capacity Evaluation

z

Capacity overviews

z

Order detail lists

z

Graphics

z

Printing functions

z

System settings

(32)

At the conclusion of this topic you will know:

z

What options there are for comparing the

capacity requirements with the available

capacity

z

How to create new overall profiles

(33)

100-500 18752 500-300 600001650 100-500 18770 500-300 600001699 Jun' 98 1310 1320 1330 Arbeitsplätze Introduction Introduction

Capacity

evaluation

Capacity leveling

Capacity leveling ((part part 1)1) Available

Detailed

Extendedplanningplanningfunctionsfunctions Overview

Overview

(34)

Capacity Evaluation: Business Scenario

z

You want to evaluate the work center load for

production. You use the capacity evaluation

functions to compare capacity requirements with

available capacity. You can see the pegged

requirements from the results of the evaluation

and thus decide whether you need to take

measures to keep to the production dates.

(35)

Basic data Production planningProduction planning PM / PSPM / PS

Capacity evaluation/-leveling Capacity evaluation/-leveling Planned orders Production orders Process orders SOP orders Plant maint. Projects

4

Calendar Arbeitsplan Routing TskLstGrp C 1 10Center 1 20 30 Bill of material Material Material A Capacity evaluation/leveling

Capacity Planning Environment (2)

In the capacity evaluations, the capacity requirements are compared to the available capacity. Capacity evaluation has to perform the following:

yDetermination of available capacity yDetermination of capacity requirement

(36)

Initial screen Accessing Capacity Planning Accessing Capacity Planning

Capacity evaluation Capacity evaluation Settings Selection Standard overview Variable overview Detailed capacity list Work center Load Orders ... Variable Profile 1 ... ...

Procedure in Capacity Evaluation

Capacity evaluations are basically accessed using two menu options:The menu Work center view accesses evaluations for loads, orders, released orders, order in backlog or overloads.The menu Variable allows you to access evaluations using profiles created for your specific needs.

When accessing the capacity evaluation the settings are pulled from the overall profile. This overall profile can be one provided by SAP or a user-specific profile.

To access the evaluation via the work center you can use standard profiles and user-specific profiles. You can change display using the menu option Settings.

(37)

Medium Detailed

Characteristics Characteristics

Month Week Day

WCtr area WCtr group Work ctr

Incomplete Complete

Time - Display of periods Location - Work center

hierarchies Planning data

Capacity Planning Phases

Capacity planning can use different planning phases. For example, the level of detail of planning can depend on how close the planning date is to the completion date.

(38)

Graphics ListsLists Printing

Work center Capacity Detailed capacity list

t t Capacity evaluation Capacity evaluation Branch Standard overview Detailed capacity list Variable overview

Standard Overview

The standard overview compares the available capacity and the capacity requirements for the selected work centers for each capacity category. The loads and remaining available capacity are also listed. From the standard overview you can generate graphics, print lists, maintain work centers and capacities

and from the detailed capacity list you can process orders.

The standard overview can be limited using minimum and maximum load percentages. You can predefine these in the options profile.

(39)

Target / remaining requirement General

General

Time segment / Periods Time segment / Periods

Hierarchy Hierarchy

Distribution Distribution

Requirement prioritizing and comparison of offers can be either static or dynamic

Selection of period to be displayed Period split for display

Selection and Display Parameters

Through distribution keys

from work center in production orders

from operation or work center in network plans / maintenance orders

from standard setting of capacity planning per capacity category

The selection and display parameters can be predefined in profiles. They can, however, be changed in the menu settings.

(40)

Display notcumulatedcumulated

Cumulated display Cumulated display

Cumulated Display

The cumulated display has the following significance for the standard overview and the variable overview:

yFor every period the capacity requirements and the available capacity result from the sum of the capacity requirements/available capacity in this and the preceding periods. The starting point for the cumulation is the first period displayed. In this way you get an overview of the period available for reducing the capacity requirements.

(41)

Period Split

To display the evaluations you can choose between the following period displays: y Month

y Week y Day

y Factory calendar day y Posting period

(42)

Work center Capacity

. . . . . . Order Stock-/ reqmts list Order Stock-/ requirements list t t Standard overview Detailed capacity list Variable overview Branch Capacity

CapacityEvaluationEvaluation

Detailed Capacity List and its Functions

In the detailed capacity list the orders and their operations are listed by period depending on the work center selected. They may be sorted, for example, by order number, date, and priority.

From this list you can make changes to the work center, the capacity and the order.

You can call up additional information on the material and the stock/requirements situation. You can predefine the display using the list profile and change it using the settings menu.

(43)

Overall profile

Options profile Selection profile List profile Graphics profile

Order set Initial set Capacity category set Work center set

Structure of a Profile

The overall profile contains the names of four subprofiles:

y The selection profile determines which sets are used to generate the various selection screens and for what period the capacity requirements are read from the database.

y The list profile defines the layout of the detailed capacity list and the variable overview. y The graphics profile defines the layout of the graphics.

y In the options profile the default parameters are set for the type of display, the display period, the distribution and for branches in change or display mode.

(44)

Multi-dimension set

Basic

Basicsetset BasicBasicsetset

Value

Value VariableVariable VariableVariable ValueValue Basic Basicsetset

Work center Capacity cat. Capacity planner

101 &KAPART

&KAPLATZ PP-MONT1

Structure of a Set

It is important to distinguish between basic sets that always refer to one criterion and multidimension sets that group together any number of basic sets.

For example, which selection criteria are displayed in a dialog box for selection depends on the basic sets the multidimension set consists of.

Multidimension sets are always used in the selection profile, in the combinations and in the column definitions in the variable overview.

Whether and how you can specify values for a selection criterion is determined by the structure of the relevant basic set. You can use the basic set to specify:

y- whether an individual value or a value range can be specified

(45)

Detailed capacity list Capacity evaluation Capacity evaluation Standard overview Detailed capacity list Variable overview Branch

Functions in the Variable Overview

You can define the form and content of the variable overview. You use it to display any capacity data you wish.

In the first column appear the periods. In the following columns you can display, for example, capacity requirements, available capacities and formulas.

(46)

© SAP AG 1999 Display Maintain Display/maintain Detailed capacity list Goods receipt for order t t Work center Work center Capacity Capacity Order Order Confirmation 434518 759691 4 Stock/ reqmts list Pegged requirements

Material That´s what I want ! Auftragskopf Arb eitsvorgänge Materialkompon enten Fertigungshilfsmittel KostenPlan Soll Ist 20 50 100

Capacity Planning Environment

From the detailed capacity screen you can use the menu Environment to branch to further sections of PP in change mode or in display mode.

In the options profile in Customizing you can specify that the system is to branch to orders, the work center and the capacity in change mode or in display mode.

You can also get the system to branch by double-clicking on the fields for the order, the work center or the capacity.

(47)

Creating work center hierarchies

Maintaining and cumulating available capacity

Profiles for capacity evaluations

Profiles for capacity leveling/extended evaluation Defining distribution of requirements

M

O O D D

Configuration Sequence Capacity Planning (1)

Legend:

M = Mandatory action (mandatory) O = Optional action (optional)

(48)

Overall

Overallprofileprofile

Options profile

Selection profile

List profile

Graphics profile

Capacity Planning / Overall Profile Evaluations

The overall profile contains four subprofiles.

In the options profile the default parameters are specified for the type of display, the display period, distribution and branching in display or change mode. Most of the settings can be changed in the application using the menu options Settings General for this evaluation run.

The selection profile determines which sets are accessed to generate the various selection screens and for which period the capacity requirements are read from the database.

The list profile specifies the layout of the detailed capacity list and the variable overview and determines which list is automatically displayed.

The graphics profile contains settings for the layout of the various graphics: y Determining the earliest/latest dates of operations

(49)

Overall

profile evaluation

Parameter /

Std profile

Work center view

Load

Orders

Released

Backlog

Overload

Variable

CY1

CY2

CY3

CY4

CY5

CY7

SAPX911

SAPX912

SAPX913

SAPX914

SAPX915

User Parameters - Evaluation

(50)

Overall Overall profileprofile

Selection profile Selection control:

Initial set:

Capacity reqmts category set: Work center set: Order set:

Scheduling level:

Version of available capacity

Selection period for reading from the database (KBED)

Read KBED records for work center(s) Read KBED records for order type(s)

Read KBED records for capacity reqmts categories

Fields for initial screen

Selection of KBED records according to detailed-, production rate- or rough-cut scheduling and specifying order categories (take account of scheduling levels table TCX00)

Selection Profile (Capacity Evaluations)

You use the selection profile among other things to specify which sets are used to define the layout of the various dialog boxes.

You can also specify the database read period in the selection profile in the section Interval period. In the evaluation only those capacity requirements are read from the database where at least one date (for example, the earliest start date) falls in the period defined. The display period (see settings) must also lie in the database read period.

During the capacity evaluation you can specify another selection profile with the menu options Planning -> Profiles -> Selection profile.

(51)

Overall Overall profileprofile

Options profile

General settings: Cap. Unit, Remaining requirements, planned requirements, cumulated display, load restrictions

Cumulating

available capacity:

Hierarchy: Yes / no, dynamic, hierarchy name

Interval settings: Start / end of display, period split, cumulate backlog to

Distribution of capacity requirements:

From work center, operation or profile

Goto: Work center, branches in display / change mode

Options Profile (Capacity Evaluations)

The options profile groups together general settings. You can change most of these settings during the evaluation with the menu options: Settings -> General.

You can change the following parameters during the capacity evaluation using other menu options or a function key:

yValues for the minimum and maximum load displayed in the standard overview yThe standard distribution key for work orders and networks/maintenance orders You cannot change the following parameters during the capacity evaluation:

yDate for dispatching the backlog: If remaining requirements are displayed then all the

requirements whose finish dates lie before the date for dispatching the backlog are dispatched to the period that contains this date.

yIndicator "Production order": The indicator specifies whether you branch to production orders in display mode or in change mode.

yIndicator "Planned order": The indicator specifies whether you branch to planned orders in display mode or in change mode.

yIndicator "Work center": The indicator specifies whether you branch to work centers or capacities in display mode or in change mode.

(52)

Work center view

Printing Standard overview list

Work center Capacity Det.capacity list

Indiv. capacity

view Order view Project view

Labor

t t

Extended Evaluation (Standard Overview)

In the extended evaluation you can display all relevant objects (persons, individual capacities, SOP requirements).

(53)

Work center view

Printing Det. capacity list

Work center Capacity

Indiv.capacity

view Order view Project view

Person

Order

Operation

t t

Extended Evaluation (Detailed Capacity List)

In the extended evaluation you can display all relevant objects (persons, individual capacities, SOP requirements).

(54)

Control profile List profile_{List profile}

Period profile Period profile Requirements grouping Requirements grouping Evaluation profile Evaluation profile Time profile Time profile

Structure of a Profile (Extended Evaluation)

The overall profile for the extended evaluation contains six subprofiles whose settings are compatible with one another. You can maintain them in Customizing for Capacity leveling and Extended evaluation. In the selection profile you specify which sets are used for the layout of the various selection screens. In the list profile you specify which list is displayed when you access the extended evaluation. You can

branch from one list to another with the menu option Goto.

In the time profile you specify for what time period the capacity requirements are read from the database. The database read period, the evaluation period, the planning period and the date for dispatching the backlog are specified in the time profile. All the requirements are accessed that lie wholly or partly in the database read period.

(55)

Multidimension set Multidimension Multidimensionsetset

Object set Object set Variable Variable Variable &5KPLANRV &5KPLANRV Basic Set Basic Set Basic Set Cap. planner group PLANR Cap. planner group PLANR Value Value Value 1000 1000 Basic Set Basic Set Basic Set Plant CRHDWERKS Plant CRHDWERKS Variable Variable Variable &5KEARBP &5KEARBP Basic Set Basic Set Basic Set Work center ARBPL Work center ARBPL Basic Set Basic Set Basic Set Capacity category KAPAR Capacity category KAPAR Variable Variable Variable &5KKAPARV &5KKAPARV

Structure of a Set (Extended Evaluation)

It is important to distinguish between a basic set and a multidimension set.

The object set stands for a multidimension set. A multidimension set groups together several basic sets. The field names for the selection fields are defined in the basic set. You can specify values or variables

for these field names.

(56)

Capacity Evaluation: Summary

In this unit you have learnt about:

z

The procedure with overview lists in the

capacity evaluation

(57)

Data used in the exercises

Explanation of symbols in the exercises and solutions

Exercises

Solutions

Course Objectives

Business Scenario

Tips & Tricks

Warning or Attention

Data in the exercises

Type of data

Data in the training system

Plant

1000 and 1200

Material and routings

T-F2## and T-F1## ( T-CV )

Material and rate routing

R-1000

Product group

PG-100

Work centers

T-M##, T-V##, T-L##, T-E##,

T-F##, T-P##, V## and KS##

Work center hierarchies

T-V, T-E and H-##

Pooled capacity

VOR##

Capacity category

P##

Grouping key

52 Formula

parameters

(58)

Z230-GES##

(59)

Capacity Evaluation Exercises

Unit: Capacity Evaluation

Topic: Standard Overview

At the conclusion of these exercises, you will be able to:

• Use the standard overview in the capacity evaluation

• Change the display

You are a capacity planner and have to show an overview of the

capacity requirements versus the available capacity for your

organization. To do this, you choose the standard overview in the

capacity evaluation and, if necessary, switch to the cumulated

display.

1-1

Look at the capacity loads for your work centers using your capacity planner group 0##

in the standard overview.

1-1-1 In which evaluation period were the capacity requirements read?

______________________

1-1-2 Specify the menu path that you would use to find this out.

_____________________________________________________

1-1-3 Change the settings in such a way that only those periods are displayed with a

load greater than 40%.

1-2

Now call up the standard overview for the work center T-M##.

1-2-1 Change the display for the standard overview by defining a period as three

days.

1-2-2 Specify the menu path and name the indicator for a standard overview with

cumulated capacity requirements and available capacities over the entire

evaluation period.

______________________________________________________

1-2-3 Only analyze the pegged requirements in the first period. What sort of pegged

requirements are there?

(60)

Exercises

Unit: Capacity Evaluation

Topic: Detailed Capacity List

At the conclusion of these exercises, you will be able to:

• Use the detailed capacity list in the capacity evaluation

• Test various selection options

• Make changes to the detailed capacity list

You are a capacity planner and want to see in an overview the

pegged capacities for the work centers for which you are

responsible. After seeing an overview, you want to release a

production order.

2-1

Call up the detailed capacity list in the capacity evaluation for your work centers T-L##

and T-V##.

2-1-1 Describe

the

option for calling up the detailed capacity list directly.

_____________________________________________________

2-1-2 You want to call up the detailed capacity list for 2 special work centers. To do

this you need an additional menu option. Restrict the selection of work centers

on the dialog box with the entry T-*. Describe the additional menu options.

_____________________________________________________

(61)

Save the changes made to the detailed capacity list in your list variant

ZAPDETC##. Note that the subprofile ‘SAPDETF0’ is not changed for the

displayed fields. Before saving, overwrite this profile with ZAPDETF##.

2-2-3 Release the production order with the requirements quantity 80 and update the

evaluation so that you can see the status change directly in the detailed capacity

list.

2-2-4 Look at the detailed capacity list for your work centers T-L## and T-V## again.

Switch to the list variant you saved previously to control the detailed capacity

list you created.

(62)

Exercises

Unit: Capacity Evaluation

Topic: Creating an Overall Profile

At the conclusion of these exercises, you will be able to:

• Define an overall profile with a new entry screen

You are a capacity planner and want to use certain work centers

in the entry screen for selection. You therefore create a new

initial set and include this in a new overall profile. In addition,

you always want to call up this overall profile automatically when

you choose Evaluation -> Variable.

3-1

Create for your group an overall profile for a new initial set. You want to see the

following entry fields in the initial set when you call up this overall profile:

Work center from:

Work center to:

Capacity cat.:

Capacity planner group:

Plant:

(63)

3-1-4 Copy the overall profile SAPX912 as a separate profile with the name

Z230-GES## and swap the selection profile with the profile created in 3-1-3. Choose

##-GES as a descriptive text.

3-1-5 You always want to call up this overall profile automatically when you choose

Evaluation

→

Variable. Maintain your user parameters by entering your overall

profile for this parameter.

(64)

Capacity Evaluation Solutions

Unit: Capacity Evaluation

Topic: Standard Overview

1-1

Look at the capacity loads for your work centers using your capacity planner group 0##

in the standard overview.

1-1-1 Logistics →

Production

→

Capacity planning

→

Evaluation

→

Work center

view

→

Load

60 days as of today

1-1-2 Specify the menu path that you would use to find this out.

Settings

→

General

1-1-3 Change the settings in such a way that only those periods are displayed with a

load greater than 40%.

Settings

→

Evaluations

→

Standard overview

1-2

Now call up the standard overview for the work center T-M##.

1-2-1 Change the display for the standard overview by defining a period as three

days.

Settings

→

Evaluations and radio button Day, period duration 3

1-2-2 Specify the menu path and name the indicator for a standard overview with

cumulated capacity requirements and available capacities over the entire

evaluation period.

Settings

→

General

(65)

Solutions

Unit: Capacity Evaluation

Topic: Detailed Capacity List

2-1

Call up the detailed capacity list in the capacity evaluation for your work centers T-L##

and T-V##.

2-1-1 Describe

the

option for calling up the detailed capacity list directly.

Evaluations

→

Work center view

→

Orders

2-1-2 You want to call up the detailed capacity list for 2 special work centers. To do

this you need an additional menu option. Restrict the selection of work centers

on the dialog box with the entry T-*. Describe the additional menu options.

Planning

→

Selection

→

Work center

Once you have specified the restrictions choose Detailed selection

2-2

You want to be able to see which production orders are to be released, and therefore

you want to copy the field "Overall order status" into the detailed capacity list after the

column for pegged requirements. To ensure that the standard list is not overwritten

when saving, you have to first create your own list variant in Customizing.

2-2-1 Copy the list variant SAPDETC0 in Customizing for Capacity Planning

(Evaluation). Your detailed list profile should be called ZAPDETC##. Before

saving, it is possible to protect this profile from being changed by other users.

Tools

→

Accelerated SAP

→

Customizing

→

Edit Project. Button Enterprise

IMG.

Production

→

Capacity planning

→

Evaluation

→

Lists

→

Define list

variants for capacity detail list.

(66)

2-2-2 Call up the detailed capacity list for your work centers T-L## and T-V## again.

Enter a column for the ‘Overall order status’ after the column for pegged

requirements. Reduce the column width for the "Overall order status" to 20 and

the column width for "Material" to 8 spaces.

Save the changes made to the detailed capacity list in your list variant

ZAPDETC##. Note that the subprofile ‘SAPDETF0’ is not changed for the

displayed fields. Before saving, overwrite this profile with ZAPDETF##.

Choose Choose fields.

Choose Overall order status and transfer it to the list Selected fields.

Select Overall order status and place the cursor on the line material. Press

Move.

Change the column width for the Overall order status and for Material and

save this list under your list variant name.

Settings

→

Capacity detail

→

Save list variant

2-2-3 Release the production order with the requirements quantity 80 and update the

evaluation so that you can see the status change directly in the detailed capacity

list.

Double-click on the order number and in the order header choose Release and

Save. Press Refresh.

2-2-4 Look at the detailed capacity list for your work centers T-L## and T-V## again.

Switch to the list variant you saved previously to control the detailed capacity

list you created.

Call up the capacity detail list again and go to your list variant.

(67)

Solutions

Unit: Capacity Evaluation

Topic: Creating an Overall Profile

3-1

Create for your group an overall profile for a new initial set. You want to see the

following entry fields in the initial set when you call up this overall profile:

3-1-1 In the first step create a new basic set Z230-PLZ## for the entry Work center

from/to for the field name ARBPL. As descriptive text choose ##-Work center

from/to. Take two variables for the entry fields and set the value T-V##.

Customizing Capacity Planning

→

Evaluation

→

Selection set

→

Define sets.

Create set.

For the variables, place the cursor in the entry field and press Variable.

3-1-2 In the second step create a new multidimension set Z230-EIN## for the

complete initial screen. Copy this set using 5kstart1 as a reference. As a

descriptive text, choose ##-Work center, CapCat, CapPl. Change the

multidimension set for the entry fields according to the defaults and the

sequence in 3-1.

Change the copied multidimension set as follows:

Substitute the set in line 001

Insert the set 5KKAPARV before line 002

3-1-3 Copy the selection profile SAPA010 as a separate profile with the name

Z230-AUS## and switch the initial set with the multidimension set created in 3-1-2.

Choose ##-AUSW as a descriptive text.

Customizing capacity planning

→

Evaluation

→

Profiles

→

Define selection

profiles.

3-1-4 Copy the overall profile SAPX912 as a separate profile with the name

Z230-GES## and swap the selection profile with the profile created in 3-1-3. Choose

##-GES as a descriptive text.

Customizing Capacity Planning

→

Evaluation

→

Profiles

→

Define overall

profiles.

(68)

3-1-5 You always want to call up this overall profile automatically when you choose

Evaluation

→

Variable. Maintain your user parameters by entering your

overall profile for this parameter.

System

→

User parameters

→

Own data.

Tab card parameters.

Assign the value from your profile to parameter CY7.

3-1-6 Describe why requirements are also displayed for the work center T-V##.

The work center was also specified as a value in the basic set.

(69)

Capacity Leveling (Part 1)

z

Use of the capacity planning table (tabular

form)

z

Dispatching procedure

z

Preview of the capacity planning table

(70)

At the conclusion of this unit you will be able

to:

z

How to use the leveling functions on the

planning tables.

(71)

100-500 18752 500-300 600001650 100-500 18770 500-300 600001699 Jun' 98 1310 1320 1330 Arbeitsplätze Introduction Introduction Capacity

Capacityevaluationevaluation

Capacity leveling

(

part

1)

Available

Detailed

Extendedplanningplanningfunctionsfunctions Overview

Overview

(72)

Capacity Leveling (Part 1): Business Scenario

z

In your production you want to level the

capacity loads at the resources. To do this you

compare the capacity requirements with the

available capacity using the capacity leveling

functions. First capacity leveling should be

carried out with the tabular version of the

planning table. After simulating several

dispatching runs you save the results of your

planning and thus fix the capacity

requirements for processing in the planned

period.

(73)

Basicdatadata Production planningProduction planning PM / PSPM / PS

Capacity requirements t

4

Calendar Arbeitsplan Routing TskLst C 1 10Center 1 20 30 Bill of material Material Material A Planned orders Production orders Process orders SOP orders Plant maint. Projects

Capacity Planning Environment (3)

Dispatching operations is the main function in capacity planning. Operations are dispatched to fix them at a time when there is sufficient capacity for them to be executed.

Depending on whether finite scheduling is to take place, operations can be dispatched based on an unlimited available capacity or existing available capacity. The existing available capacity is equal to the difference between the available capacity maintained in the work center and the capacity requirements already dispatched. If necessary, you can specify a different work center when dispatching.

(74)

Lot reduction / splitting External processing Sequence planning Date shift

Alternative work center Increase available capacity

Capacity Leveling Measures

There are the following ways to achieve the objectives listed in the preceding slide:

y Adjust the available capacity by increasing the standard available capacity for the relevant capacity category or increase the available capacity by inserting an interval of available capacity.

y Determine an alternative work center with remaining available capacity, for example by calling up the planning table using a work center hierarchy.

y Find a period with sufficient remaining available capacity by dispatching using finite scheduling or manually on the planning table.

y Form optimal sequences to reduce setup times.

(75)

06.00 10.00 14.00 18.00

Order 100012 Operation 0010 Start 03.05.1998 Order 100014 Operation 0020 Start 15.05.1998 Order 100234 Operation 0030 Start 06.06.1998 Order 100333 Operation 0010 Start 09.05.1998 Order 100456 Operation 0050 Start 01.05.1998

Work center: Turning capacity: Machine

05.1998 06.1998 07.1998 Avail. cap.

Dispatched Pool

Capacity planning table

Capacity planning table((tabulartabular)) Capacity planning tableCapacity planning table

User Interface for Capacity Leveling

The capacity planning module offers two interfaces. The main capacity planning module and its various views.

y Work center view: You limit the selection for specific work centers. Work centers and capacities are displayed in the planning tables.

y Individual capacity view: You limit the selection for specific work centers. You can dispatch operations both to work centers/capacities and to the corresponding individual capacities.

y Order view: You limit the selection for specific orders. All the work centers and capacities affected are displayed for one or more orders.

Leveling directly from production order maintenance. Depending on the overall profile set for the production controller/order type you branch to one of the two planning tables. If no overall profile has been stored for the production scheduler then the planning table is called up using the overall profile SAPSFCG001.

(76)

Capacity Planning Table (Tabular Form)

z

Period-specific

z

Aggregate information on available capacity, capacity

requirements and capacity load

z

Distribution of capacity requirements by distribution keys

z

Important for shareable

capacities

z

Display actual capacity

load within a period

There are the following types of display on the capacity planning table (tabular form): y Work center/capacity with available capacity, load, dispatched and pool for several periods y Several work centers/capacities with available capacity and load for several periods

The planning table (tabular form) can be called up for the work center view, the individual capacity view and the order view. Available capacities and distributed capacities are displayed.

The unit of display for the available capacity and capacity requirements is stored in the evaluation profile.

The planning table (tabular form) is divided up into a resource section and a requirements section. The resource section contains the following: name of work center or capacity and capacity category,

(77)

Tuesday

Tuesday Work center

Order Op. Qty 14100 Lathe 14200 Lathe 2010 2020 2030 0010 0020 0010 10 5 10 Monday Monday 00:00 06:00 12:00 18:00 00:00 06:00 00:00 06:00 12:00 18:00 00:00 06:00 Cha rt Char t

Table section Diagram section

Work centers

Pool

Message line

Capacity Planning Table

- The capacity planning table enables you to carry out detailed planning of capacity requirements continuously over time.

- The capacity planning table consists of several charts in which the available capacity (operating time) and the capacity requirements (operation duration) are grouped according to various criteria and can be displayed on the same axis. For example, all the capacity requirements for one order or all the capacity requirements that have been dispatched to one capacity can be grouped together. - Each chart can have its own title bar and is made up of a table section and a diagram section: y The table section contains information for identifying and describing the objects displayed in the

diagram section.

y The diagram section has a window on the virtual time axis in which the available capacity and the capacity requirements are displayed in graphical form with the start and finish date. This window displays the same section for all the charts. This section can be changed as much as you like by altering the scale.

(78)

Dispatching

Automatic or manual dispatching of orders to times with remaining available capacity. Automatic as well as manual dispatching using planning strategies.