安盛咨詢---SAP系統(tǒng)實(shí)施英文.ppt

1、SAP 系統(tǒng)實(shí)施XXXX,目錄,PP03 - Production Planning,November 2000,Contents,Topic 1: Sales & Operation Planning Topic 2: Demand Management Topic 3: Master Production Scheduling Topic 4: MRP Run Topic 5: Capacity Planning & Scheduling,Planning levels,Profitably analysis - Revenue plans - Sales plans (quantitie

2、s) -,Sales and Operations Planning - Sales plan - Production plan,Master Planning - Demand program - Adjusted master plan,Material Requirements Planning - Dependent requirements - Master plan - Procurement plan,o.k.?,o.k.?,o.k.?,o.k.?,Feedback/corrections,CO/PA,Product Groups,Detergents,5,2,Dishwash

3、ing soap,Powder,Liquids,Lemon Liquid 5l,Lemon Liquid 2l,grouping of Materials or Product Groups plant dependent proportional factors,30%,70%,50%,50%,Product Group Structure,Proportional factor,0.70.3,Aggregation factor,11.1,Unit conversion,0.0010.05,Multiple assignment,Planning: Overview,Sales Produ

4、ction Stock level Target stock level Days supply Target days supply,Product groupXJ 12 - 13Switch Plant9999 Philadelphia,Version000Annual planning 1994active,M 01/1994M 02/1994M03/1994Unit,Planning Data: Creating a Sales Plan,Generating a Production Plan,Version Management,Member proportions,Sum of

5、member values,Product group,Disaggregation,Selection of PG members,Disaggregation strategy,Transfer to Demand Management,Demo for SOP,Contents,Topic 1: Sales & Operation Planning Topic 2: Demand Management Topic 3: Master Production Scheduling Topic 4: MRP Run Topic 5: Capacity Planning & Scheduling

6、,Planning levels,Profitably analysis - Revenue plans - Sales plans (quantities) -,Sales and Operations Planning - Sales plan - Production plan,Master Planning - Demand program - Adjusted master plan,Material Requirements Planning - Dependent requirements - Master plan - Procurement plan,o.k.?,o.k.?,

7、o.k.?,o.k.?,Feedback/corrections,Logistics chain,Purch. orders,Creating the demand program by entering planned independent requirements,Demand program,Requirements plan,Material,Quantity,Date/period,Quantity,Date,Planned ind. reqmts,Date,Quantity,Planned ind. reqmts,Demand Program,Version XX inactiv

8、e,Version 01 inactive,Version 00 active,Planned independent requirements,Day/week/month/posting period,Time,Demand Program,Planned ind. reqmts,Period,Splitting,Splitting,Total quantity + splitting periodor quantity per periods,Quantities split over smaller periods,Splitting Requirement: Automaticall

9、y,Reduction,Reducing independent requirements,Planning Strategies,Make-to-stock production Make-to-order production Production by lot size Planning with final assembly Planning without final assembly Planning with planning material Planning at assembly level,Make-to-Stock Production,Reduction,Make-t

10、o-Stock Production,IRPlanned indep. reqmts WSWarehouse stock POPlanned order,WS,WS,IR,IR,IR,PO,PO,PO,WS,WS,IR,IR,IR,PO,PO,PO,Make-to-Order Production,Production,Invoicing,MRP,Goods issue,Delivery,Sales order,Stocks,Planned,Actual,Reduction,Individual customer reqmt,Production by Lot Size,Reduction,R

11、eduction,RRequirements POPlanned order,PO,PO,PO,R,R,R,R,R,R,Quantity,Quantity,Time,Time,03/01,03/07,03/14,03/21,03/01,03/07,03/14,03/21,Production by Lot Size for Sales & Stock Orders,Planning with Final Assembly,Sales order,Indep. reqmts.,Production,Quantity,Time,Consuming Planning Quantities with

12、Customer Requirements,Quantity,Time,Quantity,Time,Consumption Mode,Availability Check According to ATP Logic,(Master plan),Stock,( + ),Stock,( - ),Stock,Time,Availability Check During Requirements Allocation,Time,IR,IR,SO,SO,Time,KA,IR,SO,05/01,06/01,05/10,05/20,Completely confirmed,Partially confir

13、med,Rest can be delivered 1.6.,Planning without Final Assembly,Sales order,Indep. reqmts.,Production,Final assembly,Planning with Make-to-Order Production,Ind. reqmts.,Sales order,PUSH,PULL,High value materials- determine per customer,Low value materials,Stocking level,Planning with Planning Materia

14、l,Sales order,Indep. reqmts,Production,Final assembly,Demo for Demand Management,Contents,Topic 1: Sales & Operation Planning Topic 2: Demand Management Topic 3: Master Production Scheduling Topic 4: MRP Run Topic 5: Capacity Planning & Scheduling,Master Production Scheduling,Material requirements p

15、lanning(planning the entire production structure),Single-level specificationof dependent reqmts,Planning the rest ofthe BOM structure,Separate Planning Run,Interactive Master Production Scheduling,- Automatic planning - Adjusting plans,- Manual change - Date and quantity of the planned order,Simulat

16、ion,Current master plan,Adjusted master plan,Capacity,Capacity comparison,Contents,Topic 1: Sales & Operation Planning Topic 2: Demand Management Topic 3: Master Production Scheduling Topic 4: MRP Run Topic 5: Capacity Planning & Scheduling,Planning levels,Profitably analysis - Revenue plans - Sales

17、 plans (quantities) -,Sales and Operations Planning - Sales plan - Production plan,Master Planning - Demand program - Adjusted master plan,Material Requirements Planning - Dependent requirements - Master plan - Procurement plan,o.k.?,o.k.?,o.k.?,o.k.?,Feedback/corrections,CO/PA,Logistic chain: overv

18、iew,Purchaseorders,Planning procedures,Materials planning procedures,No materials planning,MRP including BOM explosion,Using the forecast for unplanned additional reqmts,Using the forecast for the total requirements,MPS represents a separate planning run,Stock,Time,Reorder point,Startdate,Delivery d

19、ate,Consumption-based planning,Manual reorder point planning,Automatic reorder point planning,Forecast-based planning,Safety stock,Prerequisites for MRP run,Carrying out the planning run,Carrying out the planning run I - total planning,Processing type Planning all the materials in a particular plant

20、, or Planning all the materials which have under- gone a change relevant to planning (net change planning),Planning interval Unlimited or Planning in the planning horizon,Planning,Plant,Planned receipts,Reqmts,Time,Planninghorizon,Mehrstufige Einzelplanung Planung einer gesamten Stcklistenstruktur m

21、anuelle nderungen des Produktionsplanesfr jedes Material in der Stckliste mglich. Einstufige Einzelplanung manuelle nderung der Planung mglich+ Erfassen+ Lschen+ ndern+ Umterminieren,Mehrstufige Einzelplanung Planung einer gesamten Stcklistenstruktur manuelle nderungen des Produktionsplanesfr jedes

22、Material in der Stckliste mglich. Einstufige Einzelplanung manuelle nderung der Planung mglich+ Erfassen+ Lschen+ ndern+ Umterminieren,Planning run II - single-item-planning,Multi-level, single-item planning Planning a complete BOM structure Option of manually changing the master planfor each materi

23、al in the BOM Single-level, single-item planning Option of manually changing planning+ create+ delete+ change + reschedule,Receipts,Time,Issues,MRP list and current stock/requirements list,Multi-level planning structure,Planned Customer,PLANUNGSLAUF,PLANUNGSLAUF,PLANNING RUN,Planning run,Maintaining

24、 planned orders(in-house production),Determining order proposals for ext. procurement,Lot-sizing procedures: overviews,Daily lot size,Weekly lot size,Static lot-sizing procedures,Receipts,Issues,Time,Planned warehouse stock =,Scheduling,or,by,for external procurement,for in-house production,by,Sched

25、uling for external procurement,1,2,3,Backward scheduling,Forward scheduling,Release date,Delivery date,Reqmts date,Processing timefor purchasing(workdays),Planned deliverytime(cal. days),Goods receipts processing time (workdays),Openingperiod,Reqmts date,Today,MRP date,Scheduling for in-house produc

26、tion,1,Order start date,Order finish date,Reqmts date,Openingdate (workdays),in-house productiondate(workdays),Goods receipt processing time (workdays),Backward scheduling for in-house production,1,2,Forward scheduling for in-house production,2,1,Lead time scheduling using the routing,10,30,20,Order

27、 finish date,Production finish date,Production start date,Order start date,Operations (from the routing),Float before production,Float before production,Determining the basic dates of an order,OS,OF,OS,OF,OS,OF,In-house production time,Reqmts date Product,Backward scheduling,Key :,Order start date,O

28、rder finish date,Time,In-house production time,OF,Planned delivery time,OS,Processing the planning result,Exception messages,BRING FORWARD OPERATIONCANCEL OPERATION,Rescheduling checks,08/03,08/15,08/03,08/15,08/03,07/15,Tolerance,Tolerance,Pegging,Demo for MRP Run,Contents,Topic 1: Sales & Operatio

29、n Planning Topic 2: Demand Management Topic 3: Master Production Scheduling Topic 4: MRP Run Topic 5: Capacity Planning & Scheduling,Business Background to Capacity Planning,Capacity Planning: Reconciliation of limited available resources and resource requirements Objective: Devise a feasible schedu

30、le for carrying out operations Means of achieving the objective: Find a period with enough available capacity to carry out the operation Find an alternative resource with remainingcapacity Adjust the available capacity of work center / capacity affected,Integration of Capacity Planning,PP SOP,PP MPS

31、,PP MRP,PP REM,PP SFC,PP PI,Capacity Planning,SD,PM,PM Service,PS,PD,Capacity Planning Environment,Master data,MaterialRoutingBill of material,CalendarWork center capacity,Productionplanning Planned ordersProduction orders. . .,Plant maintenanceProjects,Elements of Capacity Planning,Available capaci

32、ty Scheduling Capacity requirements Capacity display and leveling Capacity load reduction,Available Capacity,Capacities Defined for a Work Center,Work center,Available Capacity of the Work Center,Availablecapacity,Time,h,h,Interval 1,Interval 1Interval 2Interval 3,not a working dayaccording to calen

33、dar,Time,Cycle length,Length of the interval,from,to,A,B,Maintaining Avail. Caps. using Shift Sequence,Day 7,Day 1,Day 2,Start,Finish,Breaks,. . .,. . .,Working Hours to Productive Operating Time,Time:Working hoursWorking hoursProductiveminus breaksworkinghours,Work- Start- Operating-Capacity-Produc

34、tivecenter- Finish time perutilization operatingdata shift rate time,Breaktime,Number of hours,Technical andorganizationalmalfunctions,Productive Operating Time to Available Capacity,Time:Working hoursWorking hoursProductiveminus breaksworkinghours,Data at- Start- Operating- Rate of- Productivework

35、center- Finish time capacity operating per shift utilization time,Breaktime,Number of hours,technical andorganizationalmalfunctions,Productive operating timeper capacity category,XNumber of indiv. capacities,Dates in the Order,Order start/finish (MRP) Scheduled pro. dates Actual dates Earliest dates Latest dates Actual dates Requirements date,Scheduling Overview,PS,PS,Float beforeproduction,Le