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© SAP AG TAAP1W Automotive with DI46C2 - 1
Automotive with DI46C2 (SAP R/3)
IBS Manufacturing, IBU AutomotiveSAP AG
© SAP AG TAAP1W Automotive with DI46C2 - 2
Integrated S&P Planning – overlay between SNP & PP/DS Bjoern Bernard
Shelf Life Enhancements only in PP/DS
SAP AG 2002, Title of Presentation, Speaker Name 2
New Processes supported by SAP APO 3.1
Supply Chain Planning Supply Chain Design Demand Planning Supply Planning Distribution
PlanningProduction Planning
Transportation Planning
Supply Chain Execution Procurement Manufacturing Order Promising
& DeliveryWarehouse
ManagementTransportation
Execution
Foreign Trade/Legal
Services
Fulfillment Coordination
Supply Chain Coordination Supply Chain Event Management Supply Chain Performance Management
Supply Chain Networking Supply Chain Portal Collaboration Services Supply Chain Integration
SC PlanningIntegrated Supply&Production PlanningShelf Life (Production Planning)Forecast Consumption based on DP Char.Extended Demand Prioritization in CTMExtended Order Generation (*)
SC ExecutionMultilevel ATPCampaign PlanningOrder Driven Final Mix & PackagingIPPE based repetitive Manufacturing(**)
SC CollaborationCollaborative Management of Delivery Schedules (CMDS)
(*) process requires industry solution mySAP Mill Products
(**) process requires Industry Solution mySAP Automotive
© SAP AG TAAP1W Automotive with DI46C2 - 3
SNP – Model Consistency Check
Planning of Scheduling Agreements – integration R/3 APO
Mass Maintenance Tools for Master Data
Model Consistency Checks
SAP AG 2002, Title of Presentation, Speaker Name 3
Process Enhancements with SAP APO 3.1
Supply Chain Planning Supply Chain Design Demand Planning Supply Planning Distribution
PlanningProduction Planning
Transportation Planning
Supply Chain Execution Procurement Manufacturing Order Promising
& DeliveryWarehouse
ManagementTransportation
Execution
Foreign Trade/Legal
Services
Fulfillment Coordination
Supply Chain Coordination Supply Chain Event Management Supply Chain Performance Management
Supply Chain Networking Supply Chain Portal Collaboration Services Supply Chain Integration
SC PlanningModel Consistency ChecksDescriptive Characteristics in CTMMass Maintenance Tools for Master Data
SC ExecutionOrder Fulfillment with GATPTransportation ManagementPP/DS with comprehensive integration to R/3 Advanced Block Planning Multi-Line Model Mix Planning (**)Rapid Planning Matrix supporting activities (**)
(*) process requires industry solution mySAP Mill Products
(**) process requires Industry Solution mySAP Automotive
© SAP AG TAAP1W Automotive with DI46C2 - 4
SAP AG 2002, Title of Presentation, Speaker Name 4
Repetitive Manufacturing with iPPE
This process describes how to execute Repetitive Manufacturing in APO on the basis of the integrated Product and Process Engineering. Scheduling and material requirement calculation in APO is carried out as takt-based scheduling. You can enter the backflush data for the production backflush in APO. The backflush data is then posted in the DI System. This procedure is very fast and is therefore ideal for planning high configurable products with a large number of components.
Solution based on Discrete Industry system and APO designed for Automotive and High-Tech manufacturing
Contents:
© SAP AG TAAP1W Automotive with DI46C2 - 5
SAP AG 2002, Title of Presentation, Speaker Name 5
Unit Objectives
Understand the Automotive Manufacturing scenario based on Discrete Industry system (DI46C2) and SAP APO 3.1
Have a basic knowledge about the principles of the SAP APO functions used in this scenario
Have the awareness about the business processes where it’s recommended to use such a scenario
At the conclusion of this unit, you should be able to:
© SAP AG TAAP1W Automotive with DI46C2 - 6
SAP AG 2002, Title of Presentation, Speaker Name 6
Collective Order
Rapid Planning Matrix
liveCacheliveCache
Planning in APO
Execution in R/3
SAP APO and SAP R/3 in Automotive System
iPPE
CMP ACT FLO
CIF
iPPE
CMP ACT FLO
© SAP AG TAAP1W Automotive with DI46C2 - 7
Process Steps
Create Master Data (iPPE) ... Initialize CIF Interface
Create Sales Orders
Run Model-Mix Sequencing
Explode Requirements in the RPM
MM Planning of Components
Action Handler
Execute Backflush
SAP AG 2002, Title of Presentation, Speaker Name 7
Customer requirements
04/15/00 - 20 units04/16/00 - 15 units
...
Customer requirements
04/15/00 - 20 units04/16/00 - 15 units
...
BOM Explosion: RPM
SDR/3-DI
Model Mix Planningand Sequencing
APO-PP/DS
PP/MRP
MM Delivery Schedules(R/3 or APO)04/15/00 - 200 pcs04/16/00 - 150 pcs
...
MM Delivery Schedules(R/3 or APO)04/15/00 - 200 pcs04/16/00 - 150 pcs
...
Automotive Functions in SAP APO: Planning Process
43
ComponentRequirements
APO
Postings(MM/IM)
Backflush
Action Handler
1 2
3
4 5
5
7
Event
Production Tracking
Trigger Backflush
PCS
6
Order Headers
iPPE
iPPE
© SAP AG TAAP1W Automotive with DI46C2 - 8
SAP AG 2002, Title of Presentation, Speaker Name 8
Challenges from Engineering to Production
„Time-to-Market” „Time-to-Customer”
Product-EngineeringProduct-Engineering
ProductionProduction
P
C1 C2 C3 C4
Process-EngineeringProcess-Engineering
ACT 40ACT 40
ACT 31ACT 31 ACT 32ACT 32
ACT 20ACT 20
ACT 10ACT 10
Station 1 Station 2 Station 3 Station 4
Line 1
© SAP AG TAAP1W Automotive with DI46C2 - 9
With takt scheduling the lead time equals the number of takts multiplied by the takt time. The system does not calculate the lead time based on the duration of single operations. Thus, scheduling enables you to execute high volume scenarios with short system response time.
Note: Takt = Tact
SAP AG 2002, Title of Presentation, Speaker Name 9
Takt-based Scheduling
Station 1 Station 2 Station 3
Takt time Takt time Takt time
Line
Takt-based Scheduling
very fast, since
lead time = number of Takts * Takt time
as compared to lead time scheduling
lead time = sum of all operation durations
© SAP AG TAAP1W Automotive with DI46C2 - 10
SAP AG 2002, Title of Presentation, Speaker Name 10
... and relationships between all objects
iPPE
CMP ACT FLO
Data and Object Model for iPPE
ACT 40
ACT 31 ACT 32
ACT 20
ACT 10
Routings and Activities
Station 1 Station 2 Station 3 Station 4
Line 1
Factory Layout
Product Variant Structure
© SAP AG TAAP1W Automotive with DI46C2 - 11
The goal of the PVS is to provide a redundancy-free description of products or product families that have many variants, as well as a consistent data basis for all enterprise areas that work with the product structure or parts of it.
The PVS offers an integrated data model that serves as the basis for an efficient IT management of the product structures. In addition, you can use it to adequately portray the product creation process (with the main focus on Product Data Management) and also production (the main focus being rapid requirements planning – the rapid planning matrix which is executed in the APO system)..
SAP AG 2002, Title of Presentation, Speaker Name 11
Product Variant Structure (PVS): Concept
Product structure for highly variant products
New structure elements: nodes and variants
Multi level hierarchy and multiple usage of the nodes
Direct product reference
Product Lifecycle Management (PLM)
Consistent data basis for different views of the product
Modeling of functional structures (no reference to a material number)
Logistics
Basis for efficient material requirements planning (RPM)
© SAP AG TAAP1W Automotive with DI46C2 - 12
An integrated solution for the Product Data Management (PDM) throughout the supply chain is displayed by the integrated engineering change management (ECM).
ECM is a central, integral part of product data management (PDM) in the SAP R/3 System and ensures a complete history of any changes made to product data.
The components of ECM are:
Master data management (material master records, PVS, Activity Modes)
Document management
Classification
CAD interface
Workflow
Configuration
SAP AG 2002, Title of Presentation, Speaker Name 12
ClassificationClassification
Document Document ManagementManagement
VariantVariantConfigurationConfiguration
Master Master DataData
W O R K F L O WW O R K F L O W
CAD InterfaceCAD Interface
Engineering Change
Management
Engineering Change Management as part of the iPPE
Material
© SAP AG TAAP1W Automotive with DI46C2 - 13
SAP AG 2002, Title of Presentation, Speaker Name 13
Use of Lines
Capacity planning in Repetitive Manufacturing
Line Balancing
Determination of supply areas for PVS components
Demand planning in the Rapid Planning Matrix
Backflush
© SAP AG TAAP1W Automotive with DI46C2 - 14
Because each component is assigned to a specific activity and the activity is assigned to a line (via the line balance) we can know, based on the simple takt scheduling logic, exactly when the components will be needed.
SAP AG 2002, Title of Presentation, Speaker Name 14
Calculation of Exact Component Demand times
Line 1
Station 1 Station 2 Station 3 Station 4
Takt time Takt time Takt time
C1C1 C2C2 C3C3 C4C4
ACT 1ACT 1 ACT 2ACT 2 ACT 3ACT 3 ACT 4ACT 4
C5C5
C1 Requirement:
Order StartC2 & C3 Requirements:
Order Start + 1 TaktC4 Requirement:
Order Start + 2 Takts
ACT 5ACT 5
C5 Requirement:
Order Start + 3 Takts
Takt time
© SAP AG TAAP1W Automotive with DI46C2 - 15
SAP AG 2002, Title of Presentation, Speaker Name 15
Production Resources in iPPE
Line Net
ACT Head
ACT1
ACT2
Line 1 Line 2 Line 3
ACT3
RES2
RES1
RES1 RES2 RES3
RES3
Line Balance
The same resource can be assigned to activities and line objects. This is either the Human Resources or the Production Resource.
© SAP AG TAAP1W Automotive with DI46C2 - 16
SAP AG 2002, Title of Presentation, Speaker Name 16
New Node Types – DI4.6.C2
ALG
Line Net
Alternative Line Group (ALG):• Contains alternatives, under which Line nodes can be assigned. Only one
Line node can be assigned per alternative (for use with order activities).
• Are assigned directly underneath the Line Net or can represent a Line structure (access) itself.
• Relationships can exist at Line level or Alternate Line Group level.
Part Line Net:• Represents the part (number of) Line nodes within the complete Line Net
available.
• Technical: Alternative Segment on the Line Net nodes
• Collects Line nodes that have to be a part of the specified Line Net.
• Can be specified in the production version as a specific production line access object.
Line AreaLine Area• Is an additional structuring of Line nodes which are part of a Line Net.
• Has no other function and can not be used in the production version.
© SAP AG TAAP1W Automotive with DI46C2 - 17
SAP AG 2002, Title of Presentation, Speaker Name 17
Model Mix Planning and Sequencing
Model Mix Planning and Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 18
SAP AG 2002, Title of Presentation, Speaker Name 18
Model MixPlanning Sequencing
A2
A1B1
B2
C1
C2
A3 C3
X1 X2
Reservation Planning
A2
A1B1
B2
C1
C2
A3 C3
X1 X2
Re-Sequencing
Big Picture
© SAP AG TAAP1W Automotive with DI46C2 - 19
Purpose:
Determine the sequence of orders on line segments and determine the start and end date of the orders, so that specific goals can be pursued under consideration of certain restrictions.
Constraints:
Production of variants or configurable products in model-mix
Production on lines with restricted production rates(finite capacity)
Sequence or quantity restrictions at characteristic level (variants)
Aims:
Day and/or shift packages(period segments)
Full and even capacity utilization of production line
Order sequence in short-term horizon(for example, X days)
Precise determination of component requirements (to the hour/minute)
SAP AG 2002, Title of Presentation, Speaker Name 19
Orders Line network
Model-Mix Planning: Situation
ObjectiveGeneration of a feasible and optimal plan for configurable products with high volume
Adherence to promised delivery date
Position
Equaldistribution
Block
X in Y
Distance
Quantity
Business valueBalanced usage of production resources
Early identification of potential bottlenecks
Reliable delivery date leads to increased customer satisfaction
Restrictions
© SAP AG TAAP1W Automotive with DI46C2 - 20
SAP AG 2002, Title of Presentation, Speaker Name 20
Model Mix Planning and Sequencing: Result
Sequencebased on takts
Model Mixbased on buckets (Day/Week/Month)
3
4
334
3
futurenow
X days from today
© SAP AG TAAP1W Automotive with DI46C2 - 21
SAP AG 2002, Title of Presentation, Speaker Name 21
Example: Model Mix Planning (1)
Week 1 Week 2 Week 3 Week X
Model Mix
Production line 1
Sales Orders
This Week, Day X
1. Period-oriented planning
© SAP AG TAAP1W Automotive with DI46C2 - 22
SAP AG 2002, Title of Presentation, Speaker Name 22
Example: Model Mix Planning (2)
Week 1 Week 2 Week 3 Week X
Model Mix
Production line 1
Sales Orders
This Week, Day X
1. Period-oriented planning
© SAP AG TAAP1W Automotive with DI46C2 - 23
SAP AG 2002, Title of Presentation, Speaker Name 23
Example: Model Mix Planning (3)
Week 1 Week 2 Week 3 Week X
Model Mix
Production line 1
Sales Orders
This Week, Day X
1. Period-oriented planning+ Quantity restriction
© SAP AG TAAP1W Automotive with DI46C2 - 24
SAP AG 2002, Title of Presentation, Speaker Name 24
Example: Model Mix Planning (4)
Model Mix
Production line 1
Week 1 Week 2 Week 3 Week XThis Week, Day X
Sales Orders
1. Period-oriented planning+ Quantity restriction
© SAP AG TAAP1W Automotive with DI46C2 - 25
SAP AG 2002, Title of Presentation, Speaker Name 25
Example: Model Mix Planning (5)
Model Mix
Production line 1
Sales Orders
Week 1 Week 2 Week 3 Week XThis Week, Day X
+ Quantity restriction1. Period-oriented planning
© SAP AG TAAP1W Automotive with DI46C2 - 26
SAP AG 2002, Title of Presentation, Speaker Name 26
Example: Model Mix Planning (6)
Day 1
Day 3 Day XDay 2
Model Mix
Production line 1
Sales Orders
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 27
SAP AG 2002, Title of Presentation, Speaker Name 27
Example: Model Mix Planning (7)
Day 1
Day 3 Day XDay 2
Model Mix
Production line 1
Sales Orders
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 28
SAP AG 2002, Title of Presentation, Speaker Name 28
Example: Model Mix Planning (8)
Day 1
Day 2
1. Not two in a sequence
Model Mix
Production line 1
Restrictions:
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 29
SAP AG 2002, Title of Presentation, Speaker Name 29
Example: Model Mix Planning (9)
Day 1
Day 2
1. No two in a sequence
Model Mix
Production line 1
Restrictions:
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 30
SAP AG 2002, Title of Presentation, Speaker Name 30
Example: Model Mix Planning (10)
Day 1
Day 2
Model Mix
Production line 1 1. No two in a sequence
Restrictions:
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 31
SAP AG 2002, Title of Presentation, Speaker Name 31
Example: Model Mix Planning (11)
Day 1
Day 2
Model Mix
Production line 1 1. No two in a sequence
Restrictions:
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 32
SAP AG 2002, Title of Presentation, Speaker Name 32
Example: Model Mix Planning (12)
Day 1
Day 2
Model Mix
Production line 1
Restrictions:
2 . Sequencing
a) No two in a sequence
© SAP AG TAAP1W Automotive with DI46C2 - 33
SAP AG 2002, Title of Presentation, Speaker Name 33
Example: Model Mix Planning (13)
Day 1
Day 2
b) At least two red carsin sequence
Model Mix
Production line 1 a) No two in a sequence
Restrictions:
2 . Sequencing
© SAP AG TAAP1W Automotive with DI46C2 - 34
SAP AG 2002, Title of Presentation, Speaker Name 34
Example: Model Mix Planning (14)
Day 1
Day 2
Model Mix
Production line 1
Restrictions:
2 . Sequencing
b) At least two red carsin sequence
a) No two in a sequence
© SAP AG TAAP1W Automotive with DI46C2 - 35
SAP AG 2002, Title of Presentation, Speaker Name 35
Example: Model Mix Planning (15)
Day 1
Day 2
Model Mix
Production line 1
Restrictions:
2 . Sequencing
b) At least two red carsin sequence
a) No two in a sequence
© SAP AG TAAP1W Automotive with DI46C2 - 36
SAP AG 2002, Title of Presentation, Speaker Name 36
Example: Model Mix Planning (16)
Day 1
Day 2
Model Mix
Production line 1
Restrictions:
2 . Sequencing
b) At least two red carsin sequence
a) No two in a sequence
© SAP AG TAAP1W Automotive with DI46C2 - 37
SAP AG 2002, Title of Presentation, Speaker Name 37
Example: Model Mix Planning (17)
Day 1
Day 2
Model Mix
Production line 1
Restrictions:
2 . Sequencing
b) At least two red carsin sequence
a) No two in a sequence
© SAP AG TAAP1W Automotive with DI46C2 - 38
SAP AG 2002, Title of Presentation, Speaker Name 38
Types of restrictionsQuantity (position) e.g. number of V8 engines <= 200 pieces per day
Spacing e.g.: max every third engine is US version
K in M e.g.: three air condition out of five vehicles
Block e.g.: at least 2 engines for RH-drive vehicles in a row
Even distributionPosition
Basic informationCreated within a planning version e.g.: active version or simulation version
Assigned to a production line e.g.: body shop, paint shop, assembly line
Uses characteristics e.g.: engine type, US version, air condition
Sequencing: Restrictions
© SAP AG TAAP1W Automotive with DI46C2 - 39
SAP AG 2002, Title of Presentation, Speaker Name 39
Weighting
Restrictions are grouped into two categories:Hard (= ‘0‘)Soft (= ‘1, 2, ..., 9‘).
Validity
Validity has two categories: Time: interval (e.g from t1, to t2 and from t3 to t4 ... )Location: assignment to a
Line netLine Line segment
Restrictions Weighting & Validity
© SAP AG TAAP1W Automotive with DI46C2 - 40
SAP AG 2002, Title of Presentation, Speaker Name 40
Genetic Sequence Optimizer
Single line (multi line available with APO 3.1)All types of restrictions Hard and soft weighting of restrictions (Hard violation means no result)Due dateFinite
Linear Program Algorithm
Multi-line (daily buckets)Quantity restrictions and transformed spacingHard and soft weighting of restrictionsDue dateFinite
Optimization Algorithms: Procedures - overview 1
© SAP AG TAAP1W Automotive with DI46C2 - 41
SAP AG 2002, Title of Presentation, Speaker Name 41
Prioritized Equal Distribution Heuristic
Single lineQuantity, M of N restrictions, spacing, positionNo different weighting of restrictionsHard means “violation only if there is no other way“ -> Typically at the end of the sequenceFinite
Percentage Smoothing Heuristic
Single lineSmoothing on product variant levelNo restrictions, only capacityFinite
Interface for Customer heuristics
Optimization Algorithms: Procedures - overview 2
© SAP AG TAAP1W Automotive with DI46C2 - 42
SAP AG 2002, Title of Presentation, Speaker Name 42
Horizon 2 Horizon 3 Horizon 4(e.g. 2 days) (e.g. 5 days) (e.g. 2 month)
Sequencing Bucket-oriented Model Mix
= Distribution of orders to lines and to time buckets= Order sequence on lines
Procedure I(e.g. genetic algorithm)
Procedure II( e.g. heuristic with restrictions)
Procedure III(e.g. equal distribution)
Horizon 1(e.g. 2 days)
Manual Planning / Correction
Single items
All restrictions
Quantities per period
only capacity restrictions
Quantities per period
e.g. only quantity and capacity restrictions
Single items
All restrictions
Procedures
© SAP AG TAAP1W Automotive with DI46C2 - 43
SAP AG 2002, Title of Presentation, Speaker Name 43
Planned Orders
UnscheduledOrders
Restrictions
Sequencing: Interactive planning
© SAP AG TAAP1W Automotive with DI46C2 - 44
SAP AG 2002, Title of Presentation, Speaker Name 44
Model Mix Planning and Sequencingin SAP APO 3.1
Model Mix Planning and Sequencing in SAP APO 3.1
© SAP AG TAAP1W Automotive with DI46C2 - 45
SAP AG 2002, Title of Presentation, Speaker Name 45
A2
A1B1
B2
C1
C2
A3 C3group of
alternative lines
planning segment
X1 X2
buffer
A typical example for a line net of an OEM is
D1 E1F1
F2Y1 Y2
planning segment
asse
mbl
ylin
e I
asse
mbl
ylin
e II
Line Net
© SAP AG TAAP1W Automotive with DI46C2 - 46
SAP AG 2002, Title of Presentation, Speaker Name 46
A2
A1B1
B2
C1
C2
A3 C3
X1 X2
In general the products are not buildable on the whole linenet. Therefore one defines partial line nets and then assigns the products to the partial line nets by their production versions.
B2A3
X1A2B2
C2
A3 C3
X1 X2
A1B1
C1
C2X1 X2
Partial Line Nets
© SAP AG TAAP1W Automotive with DI46C2 - 47
SAP AG 2002, Title of Presentation, Speaker Name 47
A2
A1
B1
B2
C1
C2
A3C3
The planning is based on the following assumptions :
1. Each line has a capacity profile.
12 PCS / H
1 PCS / 10 MIN
. . .
. . .
. . .
. . .
. . .
. . .
2. One can assign spacing restrictions to the lines.
3. One can assign quantity restrictions to the lines or thegroups of alternative lines.
min distance 1for convertibles
max 2 in 4air conditioning
X2X1
max 25 sedanper day
max 15 RED per day
Capacities and Restrictions
© SAP AG TAAP1W Automotive with DI46C2 - 48
SAP AG 2002, Title of Presentation, Speaker Name 48
The capacity profiles and the spacing restrictions are converted intoquantity restrictions, for example
max 2 in 4air conditioningC3. * capacity:
20 PCS / shift =max 10 air cond.per shift
Rate1 PCS / 10 MINC2. * shift duration
8 H / shift = max 48 PCSper shift
min distance 1for convertiblesA3. * capacity:
16 PCS / shift =max 8 convertiblesper shift
A2
A1B1
B2
C1
C2
A3 C3
X1 X2
Conversion
© SAP AG TAAP1W Automotive with DI46C2 - 49
SAP AG 2002, Title of Presentation, Speaker Name 49
A3
B1 C1
A3
B1C2
The line net is decomposed into the possible paths. Forsimplicity not all paths areshown in the sketch.
Based on this decomposition a restriction can be assigned to several paths (although it‘s basically assigned to just oneline).
Furthermore certain products canonly run on certain paths depending on the productionversion.
X1 X2
X1 X2
A3
B1
C3X1 X2
. . .
. .
..
. .
. . .
A3 B2
C1X1 X2
max 2 in 4air cond.
no redcolour
Paths through the Line Net
© SAP AG TAAP1W Automotive with DI46C2 - 50
SAP AG 2002, Title of Presentation, Speaker Name 50
. . .
. .
..
. .
. . .
A linear program will now assign theorders to the paths while respectingthe restrictions and productionversions.
A3
B1 C1
A3
B1C2
X1 X2
X1 X2
A3
B1
C3X1 X2
A3 B2
C1X1 X2
The Planning
© SAP AG TAAP1W Automotive with DI46C2 - 51
SAP AG 2002, Title of Presentation, Speaker Name 51
The model mix plan is obtained by adding the paths‘ loads segment by segment :
A1
A2
A3
B1
B2
C3
C1
C2
The Result
© SAP AG TAAP1W Automotive with DI46C2 - 52
SAP AG 2002, Title of Presentation, Speaker Name 52
At a certain point one has to create a sequence out of the bucket orders(bucket size can be shift or day). Since one has already considered aggregated spacing restrictions in the model mix planning it should basically be possible to obtain a feasible sequence out of the bucketorders.
A2
A1B1
B2
C1
C2
A3 C3
X1 X2
The sequence is built in the planning segment and will later on also be manipulated there. Theresult is propagated to the other segments.
Planning segment
Gap: Since the sequence is built on the planning segment and simply propagated without any further re-sequencing in the buffers, only restrictions from the planning segment will be taken into account during this process.
From Buckets to Positions
© SAP AG TAAP1W Automotive with DI46C2 - 53
SAP AG 2002, Title of Presentation, Speaker Name 53
Due to unplanned down times or problems with the supply to line there can be the need to change the path of an order.
Obviously only those lines can be chosen which belong to the partial linenet in the production version.
A2
A1B1
B2
C1
C2
A3 C3
X1 X2A2B2
C2
A3 C3
X1 X2
Assume there are problems on line A2 and C2. Therefore the paths of the green car has to be changed.
A2B2
C2
A3 C3
X1 X2
Line Switch
© SAP AG TAAP1W Automotive with DI46C2 - 54
SAP AG 2002, Title of Presentation, Speaker Name 54
Rapid Planning Matrix(RPM)
Rapid Planning Matrix (RPM)
© SAP AG TAAP1W Automotive with DI46C2 - 55
There are several options for planning products. Depending upon the need for various functions, like rapid planning, highly configurable products, or integration back to standard R/3 functions a customer may choose a combination of these planning options. For example, the higher level more expensive parts can be planned within APO and the lower level or consumption based materials can be planned in the R/3 system.
SAP AG 2002, Title of Presentation, Speaker Name 55
Alternatives in Requirements Planning
Optimized for real time planning
2. Order NetworkiPPE RTO
(explosion type=3)
Optimized for high volume scenarios
1. Rapid Planning Matrix
(explosion type=4)
APOAPOliveliveCacheCache
R/3R/3APOAPOliveliveCacheCache
PVS Explosion
R/3R/3
BoM Explosion
3. MRP (PVS) 4. MRP (BOM)
© SAP AG TAAP1W Automotive with DI46C2 - 56
Maximum BoM has 40,000 components including all historical changes
Exploded customer order has 2,000 components of the maximum BoM selected
results in storage of 60 Gigabyte dependent requirements in R/3-MRP in database in relational form
need to write and read that amount of data during an MRP-run
Explosion must look at all historical changes at a component variant
1.2 billion checks of effecitivity parameters
in the worst case 1.2 billion checks of selection conditions
LiveCache
storage in RAM instead of disk
forces optimized form (little memory usage): matrix representation
matrix representation allows simultaneous explosion of all orders instead of order by order
RPM is the name of this new algorithm
SAP AG 2002, Title of Presentation, Speaker Name 56
Classic MRP: Performance Bottlenecks
Maximum bill of material contains 40,000 components
30,000 individual customer orders Storage on a relational database means movement of 60 Gigabyte of dataExplosion of maximum BOM order by order means more than one Billion checks of effectivity-parameters and selection conditions
Solution: Keep Data in RAM in optimized form liveCache main memory databaseMatrix form for data storage, object oriented accesssimultaneous BOM explosion for all orders-> RPM (Rapid Planning Matrix)
liveCache
© SAP AG TAAP1W Automotive with DI46C2 - 57
The first step is to convert the assembly view of the PVS into a flat list of the master data
material number, quantity, selection condition, effectivity parameters
Second step is to include the assembly orders:
due date
quantity
configuration
Third step
explode the BoM for the orders
a ‚cross‘ means: component selected for order
one cell in the matrix = one bit
30,000 orders, 40,000 components about 350 Megabytes
SAP AG 2002, Title of Presentation, Speaker Name 57
Contents of Logical Matrix
x x
--
--
xxx
x
x
x
x
-x
x
x--x-x
-
-x x
-
--
-
--
-
-
xx
BOM-Explosion- interpretation of effectivity- interpretation of dependencies3
Assy
View
Mat A Mat B Mat C Mat D
Components
1Data of assembly orders
Order01
Order02
Order03
Order04
Order05
Order06
2 Orders
Bumpers green
Bumpers whiteBumpers redNavigation Advisor GPS
Engine 2.5Disk
© SAP AG TAAP1W Automotive with DI46C2 - 58
Write:
MRP (daily)
Backflush (every two minutes)
Impulse (update dates every two minutes)
Read:
All functions which need:
- BOM of the order
- Component requirements
Examples: Component MRP, Backflush, Delivery schedules...
SAP AG 2002, Title of Presentation, Speaker Name 58
Functions Using Logical Matrix I
Component list for selected order
BackflushSequenced JIT callsSequencing
Reading and Interpreting Columns
Data of assembly orders
Order01
Order02
Order03
Order04
Order05
Order06 ...
x xx x
x x x-
-x
x x-
-- -
- --
x- - -
-
xx
- x
x x-x
x ---
..
..
..
..
..Bumpers green
Bumpers whiteBumpers redNavigation Advisor GPS
Engine 2.5Disk
..
Access to component list via Logical Matrix
‘From the top’
© SAP AG TAAP1W Automotive with DI46C2 - 59
Time buckets are created for component requirements
Requirements from Matrix
Time buckets are input for MRP requirements
In APO: As APO orders (e.g. purchase orders)
In R/3: As delivery schedules (daily requirements only)
Size of time bucket is variable
Short term horizon with more precise than long term horizon
SAP AG 2002, Title of Presentation, Speaker Name 59
Functions Using Logical Matrix II
ReportingStock/requirements list
Coverage calculation
Delivery scheduling
Pull-list
Day 1 Day 2
1Bump red 01GPS 33Disk 3
Component Day 1 Day 2 ...
Data of assembly orders
Order01
Order02
Order03
Order04
Order05
Order06 ...
x xx x
x x x-
-x
x x-
-- -
- --
x- - -
-
xx
- x
x x-x
x ---
..
..
..
..
..Bumpers green
Bumpers whiteBumpers redNavigation Advisor GPS
Engine 2.5Disk
..
Reading and Interpreting Rows
‘From the Left’
Aggregation to time buckets
Aggregation in customized time buckets:
• Hour• Shift• Daily• ...
© SAP AG TAAP1W Automotive with DI46C2 - 60
SAP AG 2002, Title of Presentation, Speaker Name 60
K1, RP1, ∆T = 0
K2, RP1, ∆T = 10K3, RP2, ∆T = 20
K4, RP2 , ∆T = 20
K5, RP3 , ∆T = 30
K6, RP4 , ∆T = 40
A1 A2 A3 A4 A5 A6
X X X X X X
RP 3 RP 2 RP 2 RP 1 RP 1
X X X X X X
X X X X X X
X X X X X X
X X X X X X
X X X X X X
LineDesign
Matrix Orderstart times• body• paint• assembly
Integration of Line Design Information
RP1, RP2, RP3: Reporting points per line defined in Line design
© SAP AG TAAP1W Automotive with DI46C2 - 61
SAP AG 2002, Title of Presentation, Speaker Name 61
Scheduling Components using Line Design
C1, T1, ∆T = 0
C2, T 2 ∆T = 10
C3, T 2, ∆T = 20
C4, T3 ∆T = 20
C5, T4 ,∆T = 30
C... T ...
A1 A2 A3 A4 A5 A6
RP 3
RP 2
RP 2
RP 1
RP 1
+ + + + +
+ + + X X X
+ + + X X X+ X X X X XX X X X X X
+ + + + + X
Matrix Orderstart times• body• paint• assembly
P r o
d u
c t
i o n
P r o
d u
c t
i o n
ACT 5
ACT 4
ACT 2
ACT 1
ACT 3
C5
C4
C3
C2
C1
Takt 1
Takt 3
LineDesignTakt 2
Subdaily on Supply Area Level
© SAP AG TAAP1W Automotive with DI46C2 - 62
SAP AG 2002, Title of Presentation, Speaker Name 62
Rapid Planning Matrixin SAP APO 3.1
Rapid Planning Matrix (RPM) in SAP APO 3.1
© SAP AG TAAP1W Automotive with DI46C2 - 63
SAP AG 2002, Title of Presentation, Speaker Name 63
RPM - Activity Matrix
Integration:
Backflush (Posting all activities performed, capacity reduction) Controlling (Value of all activities per vehicle, resource capacity) Model-mix (Material matching of necessary activities against resources)
x x
--
--
xxx
x
x
x
x
-x
x
x--x-x
-
-x x
-
--
-
--
-
-
xx
Order01
Order02
Order03
Order04
Order05
Order06
Install Xenon light
Fit air conditioning Fit navigation systemFit child‘s seat
Polish wheel rimsCheck oil
Necessary information from the iPPE routing
Planning production activities per order (analogous to components)
© SAP AG TAAP1W Automotive with DI46C2 - 64
SAP AG 2002, Title of Presentation, Speaker Name 64
Activity Matrix: Calculation of Actual Resource Requirements in Sequencing
Challenge:Optimization of utilization of stations when manufacturing variants
New:The Activity Matrix allows the calcualtion of actual resource requirements per stationAggregation of all activities which are carried out at a stationMatching of actual working hours with working hours available Production scheduler can adjust resource availability to requirements
© SAP AG TAAP1W Automotive with DI46C2 - 65
SAP AG 2002, Title of Presentation, Speaker Name 65
Activity Matrix: Integration with Action Handler
A2
A1
B1
C1
C2
Example:
Vehicle passes tracking point:Planned: Final assembly on Line C2Actual: Vehicle is assembled on line C1
Technique: Change of Production Version:RPM: Change of matrix (Components and activity)Required: New BoM explosion and correction of requirements
Line Change: Vehicle was planned on one line, but is manufactured on another:Automatic recognition when passing the corresponding reporting point or tracking point Automatic adjustment of the components and activities in the matrices
© SAP AG TAAP1W Automotive with DI46C2 - 66
SAP AG 2002, Title of Presentation, Speaker Name 66
Activity Matrix: Integration with Action Handler
A2
A1
B1
C1
C2
Example:
Vehicle passes tracking pointComponents for line segment have to be fixed (until backflush), and shop floor papers are printedVehicle is produced according to shop floor papers
Technique: Components are moved from the matrix to a order networkMixed order: Some components are stored in the matrix, other are stored in order networksAdditional functions: Specific components for MTO can always be planned in order networks in order to ensure full traceability via the pegging function
Mixed Order Some components are in the matrix, some are in the APO order network Components can be dynamically moved from the matrix into the order network(with firming etc.) Unrestricted pegging for important components
© SAP AG TAAP1W Automotive with DI46C2 - 67
SAP AG 2002, Title of Presentation, Speaker Name 67
Production Action Handler
Manufacturing Execution: Action Handler
© SAP AG TAAP1W Automotive with DI46C2 - 68
SAP AG 2002, Title of Presentation, Speaker Name 68
Production Control System / Assembly Control System
LineLine Station 1Station 1 Station 2Station 2 Station 3Station 3
EventEvent
Tracking point ‘1’ Tracking point ‘2’
Event
Tracking point ‘3’
Production Tracking Trigger JIT for a component Backflush
Actions to do
BackflushBackflush
Overview
© SAP AG TAAP1W Automotive with DI46C2 - 69
SAP AG 2002, Title of Presentation, Speaker Name 69
Production Control System / Assembly Control System
LineLine Station 1Station 1 Station 2Station 2 Station nStation nStation 3Station 3
SAP APO
Get Sequence
Warehouse pull
Event
Trackin gpointwith event and action
informations
Event
Server
Client
Action HandlerAction Handler
Customer Function Module
Trackinginformation
Insert & Update
Triggers
Tracking point ‚S01‘ Tracking point ‚S02‘
Actions
RFC with Tracking point & order & Customer data
RealtimeRealtime Delayed(FIFO Queue)
Delayed(FIFO Queue)
Event Manager
Analyse eventand
dispatch to action
Event Manager
Analyse eventand
dispatch to action
Tracking evaluationTracking evaluation
Feedback
Action Handler & SAP Business Workflow
© SAP AG TAAP1W Automotive with DI46C2 - 70
PBS = painted body storage (buffer after paint shop)
Prerequisite for WIP-counting (supply area inventory): action handler provides the actual sequence!!!
SAP AG 2002, Title of Presentation, Speaker Name 70
Action Handler Standard Actions
Save Tracking dataBusiness Add-Ins to insert additional customer data into standard tables with customer includes.
Order ModifyAdjust order start time (example vehicle leaves Paint Shop)Change activity status
Backflush
© SAP AG TAAP1W Automotive with DI46C2 - 71
SAP AG 2002, Title of Presentation, Speaker Name 71
P r o
d u
c t
i o n
P r o
d u
c t
i o n
ACT 5
ACT 4
ACT 2
ACT 1
ACT 3
C5
C4
C3
C2
C1
RP 1
RP 2 Event X
Goods Issue Load Reduction.
Interaction of Action Handler and Backflush
© SAP AG TAAP1W Automotive with DI46C2 - 72
SAP AG 2002, Title of Presentation, Speaker Name 72
ProductionConfirmation
(Backflush)
Manufacturing Execution: Backflush
© SAP AG TAAP1W Automotive with DI46C2 - 73
SAP AG 2002, Title of Presentation, Speaker Name 73
Overview
Solution for high-volume scenarios
Usage of Rapid Planning Matrix (RPM)
Work in Process (WIP) calculation
Sales order specific cost estimate at GR posting
Aggregated and parallel GI posting
Capacity reduction at reporting point backflush
© SAP AG TAAP1W Automotive with DI46C2 - 74
SAP AG 2002, Title of Presentation, Speaker Name 74
APOAPO Automotive SystemAutomotive SystemCIFCIF
Process Overview
Buffer
Postings(MM/IM)
Scenariowithout RPM RPM scenario
© SAP AG TAAP1W Automotive with DI46C2 - 75
Create iPPE
Create production version and maintain iPPE data
production version used to determine cost collector
Enter REM profile in material master
Movement types, batch and stock determination
Determine in material master of components whether GI is posted synchronously or asynchronously
Create classes und characteristics
Create sales orders and assign characteristic values
Create product cost collector
cost collector set as “APO cost collector“ in first backflush
SAP AG 2002, Title of Presentation, Speaker Name 75
APOAPO Automotive SystemAutomotive System
Prerequisites from a Backflush View
MaterialMasterSales
Orders
ProductionVersions
ProductCost
Collector
Orders
ProductMaster
ProductionVersions
iPPEiPPE
SalesOrders
CIF
CIF
CIF
CIF
© SAP AG TAAP1W Automotive with DI46C2 - 76
APO Backflush Profileflexible access to backflush transaktionbackflushing via action handler possible
APO orders availableEnter backflush data
backflushing via action handler possibleCapacities are reduced immediatelyInformation for IM transferred to R/3 Automotive SystemR/3 Goods Movements
all GRs and GIs of synchronous materials are posted immediatelyGIs of asynchronous materials are periodically aggregated and postedProcesses can be distributed to several processes and serversUsage of application log instead of document log
Postprocessing for failed goods movementsCumulative and individual recordsPostprocessing records for GRs as well
Providing BW with backflush dataArchiving functions for backflush tables
SAP AG 2002, Title of Presentation, Speaker Name 76
APOAPO Automotive SystemAutomotive SystemCIFCIF
Overall Process
Read and check order,write creation document
No stock/requirement updates.
Capacity reduction
Receive creation document,generate and write backflush
document Registr.docum.
Stock postingStockslist of backflushesStock adjustments,
requirements reductionupdate of order status
© SAP AG TAAP1W Automotive with DI46C2 - 77
SAP AG 2002, Title of Presentation, Speaker Name 77
Example Steps: Backflush for Components
1. Explode sales orders
2. Backflush at reporting points
3. CO postings of aggregated goods issues
4. Synchronously posted goods receipts
5. Determination of WIP
6. Backflush with scrap
7. Period end closing
8. Goods receipts with price variances
9. WIP after price changes
© SAP AG TAAP1W Automotive with DI46C2 - 78
SAP AG 2002, Title of Presentation, Speaker Name 78
Explode Sales Order
SO1 SO2 SO3 ... ... ...
X X X X
C1C2
C4C3
C5
X X X X
X X X X X
X X
X X X X X X
....
Sales order SO3A140
Mat. No.: A ClassValue
assignment
Sales order SO3A140
Mat. No.: A ClassValue
assignmentSales order SO2A160
Mat. No.: A ClassValue
assignment
Sales order SO2A160
Mat. No.: A ClassValue
assignmentSales order SO1A140
Mat. No.: A ClassValue
assignment
Sales order SO1A140
Mat. No.: A ClassValue
assignment
APO R/3
iPPE
© SAP AG TAAP1W Automotive with DI46C2 - 79
SAP AG 2002, Title of Presentation, Speaker Name 79
C1, Stat. 10 RP1, ∆T = 0
C2, Stat. 10 RP1, ∆T = 10C3, Stat. 20 RP2, ∆T = 20
C4, Stat. 20 RP2, ∆T = 20
C5, Stat. 30 RP3, ∆T = 30
...
SO 1
SO 2
SO 3
... ... ...
X X X X X X
X X
X X X X
X X X X X
X X X X
LineDesign
(Stations)
Matrix OrderStart Times:• Body• Paint• Assembly
Example: Backflush, Initial Situation
RP 2 RP 3RP 1
SO1SO2SO3SO4SO5SO6
C1 C2 C3 C4 C5
Station 10 Station 20 Station 30
© SAP AG TAAP1W Automotive with DI46C2 - 80
Backflushing in APO always carried out for a reporting point
Reporting point structures can be changed during production
One order always refers to exactly one reporting point structure
Definition of reporting points in Line Design: Beginning and/or end of line segment
No reporting point definition at activities
Document-neutral reversal only
Reversal always is a posting using opposite movement direction
Valuations in Controlling (WIP and GR cost estimate) based on actual postings
SAP AG 2002, Title of Presentation, Speaker Name 80
SO1 SO2 SO3 ... ... ...
X X X X
C1 RP 1C2 RP 1
C4 RP 2C3 RP 2
C5 RP 3
0 X X X
X X X X X
X X
0 X X X X X
....
APO R/3Backflush of Sales Order 1 (SO 1) at Rep. Point 1 (RP 1)
SO 1 RP 1 C1 1 pcC2 4 pc
RP 2 RP 3RP 1
SO1SO2SO3SO4SO5SO6
C1 C2 C3 C4 C5
Station 10 Station 20 Station 30
© SAP AG TAAP1W Automotive with DI46C2 - 81
Backflushing in APO always carried out for a reporting point
Reporting point structures can be changed during production
One order always refers to exactly one reporting point structure
Definition of reporting points in Line Design: Beginning and/or end of line segment
No reporting point definition at activities
Document-neutral reversal only
Reversal always is a posting using opposite movement direction
Valuations in Controlling (WIP and GR cost estimate) based on actual postings
SAP AG 2002, Title of Presentation, Speaker Name 81
SO1 SO2 SO3 ... ... ...
0 X X X
C1 RP 1C2 RP 1
C4 RP 2C3 RP 2
C5 RP 3
0 0 X X X
0 X X X X
0 X
0 0 X X X X
....
APO R/3Backflush of SO 1 at RP 3, SO 2 at RP 2
RP 2 RP 3RP 1
SO1SO2SO3SO4SO5SO6
C1 C2 C3 C4 C5
Station 10 Station 20 Station 30
SO 1 RP 1 C1 1 pcC2 4 pc
SO 2 RP 1 C1 1 pcSO 1 RP 2 C4 5 pc
SO 2 RP 2 C3 2 pcC4 5 pc
SO 1 RP 3 C5 1 pc
© SAP AG TAAP1W Automotive with DI46C2 - 82
SAP AG 2002, Title of Presentation, Speaker Name 82
CO Postings of Aggregated Goods Issues
SO 1 RP 1 C1 1 pcC2 4 pc
SO 2 RP 1 C1 1 pc
SO 1 RP 2 C4 5 pc
SO 2 RP 2 C3 2 pcC4 5 pc
SO 1 RP 3 C5 1 pc
ACT = 1300.-
GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-
C11pc = 100,-
C11pc = 100,-
C21pc = 25,-
C21pc = 25,-
C41pc = 10,-
C41pc = 10,-
C51pc = 500,-
C51pc = 500,-
C31pc = 200,-
C31pc = 200,-
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2 0 0C2 4 0 0C3 2 0 0C4 10 0 0C5 1 0 0
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2 0 0C2 4 0 0C3 2 0 0C4 10 0 0C5 1 0 0
Valuation
Reporting points of cost collector
Product cost collectorModel series A Class
Backflushed components of SO 1 and SO 2:
SO1 SO2 SO3 SO4 SO5 SO6
C1 RP 1 X X X X X X
APOX X X X
X X X X X XX X X X X
C2 RP 1C3 RP 2C4 RP 2C5 RP 3...
© SAP AG TAAP1W Automotive with DI46C2 - 83
SAP AG 2002, Title of Presentation, Speaker Name 83
Goods Receipt SO 1, Synchronously Posted
ACT = 550.-
GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0
ValuationComp. Quant. Price
C1 1 100.-C2 4 100.-C3 0 0.-C4 5 50.-C5 1 500.-
750.-
SO 1 RP 1 C1 1 pcC2 4 pc
SO 2 RP 1 C1 1 pc
SO 1 RP 2 C4 5 pc
SO 2 RP 2 C3 2 pcC4 5 pc
SO 1 RP 3 C5 1 pc
SO 1 GR
Reporting points of cost collector
GR SO 1-750.-
Product cost collectorModel series A Class
SO1 SO2 SO3 SO4 SO5 SO6
C1 RP 1 X X X X X X
APOX X X X
X X X X X XX X X X X
C2 RP 1C3 RP 2C4 RP 2C5 RP 3...
© SAP AG TAAP1W Automotive with DI46C2 - 84
SAP AG 2002, Title of Presentation, Speaker Name 84
Determination of Work in Process (WIP)
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2 1 0C2 4 4 0C3 2 0 0C4 10 5 0C5 1 1 0
ValuationComp. Quant. Price
C1 1 100.-C2 0 0.-C3 2 400.-C4 5 50.-C5 0 0.-
550.-
WIP quantity = WIP debit - WIP credit
Comp. WIPC1 2 - 1 = 1C2 4 - 4 = 0C3 2 - 0 = 2C4 10 - 5 = 5C5 1 - 1 = 0
Comp. WIPC1 2 - 1 = 1C2 4 - 4 = 0C3 2 - 0 = 2C4 10 - 5 = 5C5 1 - 1 = 0
Reporting points of cost collector
ACT = 550.-WIP = 550.-
GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-1 pc C1
2 pc C35 pc C4
550.-
Product cost collectorModel series A Class
© SAP AG TAAP1W Automotive with DI46C2 - 85
Backflushing in APO always carried out for a reporting point
Reporting point structures can be changed during production
One order always refers to exactly one reporting point structure
Definition of reporting points in Line Design: Beginning and/or end of line segment
No reporting point definition at activities
Document-neutral reversal only
Reversal always is a posting using opposite movement direction
Valuations in Controlling (WIP and GR cost estimate) based on actual postings
SAP AG 2002, Title of Presentation, Speaker Name 85
SO1 SO2 SO3 ... ... ...
0 0 X X
C1 RP 1C2 RP 1
C4 RP 2C3 RP 2
C5 RP 3
0 0 X X X
0 0 X X X
0 0
0 0 0 X X X
....
APO R/3Backflush of SO 3 at RP 2, Scrap
RP 2 RP 3RP 1
SO3SO4SO5SO6
C1 C2 C3 C4 C5
Station 10 Station 20 Station 30
SO 3 RP 1 C1 1 pc
...SO 3 RP 2 ´C3 2 pc
Scrap!
© SAP AG TAAP1W Automotive with DI46C2 - 86
SAP AG 2002, Title of Presentation, Speaker Name 86
Comp. Quant.C1 1C2 0C3 2C4 0C5 0
Backflush SO 3 at RP 2, Scrap
ACT = 1050.-
GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-GI C1 100,-GI C3 400,-
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2+1 1+1 1C2 4 4 0C3 2+2 0+2 2C4 10 5 0C5 1 1 0
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 2+1 1+1 1C2 4 4 0C3 2+2 0+2 2C4 10 5 0C5 1 1 0
SO 3 RP 1 C1 1 pc
... C11pc = 100,-
C11pc = 100,-
C21pc = 25,-
C21pc = 25,-
C41pc = 10,-
C41pc = 10,-
C51pc = 500,-
C51pc = 500,-
C31pc = 200,-
C31pc = 200,-
Valuation
SO 3 RP 2 ´C3 2 pc
List of compontentsfor scrap
Reporting points of cost collector
2 pc C3400.-
Product cost collectorModel series A Class
SO1 SO2 SO3 SO4 SO5 SO6
C1 RP 1 X X X X X X
APOX X X X
X X X X X XX X X X X
C2 RP 1C3 RP 2C4 RP 2C5 RP 3...
© SAP AG TAAP1W Automotive with DI46C2 - 87
SAP AG 2002, Title of Presentation, Speaker Name 87
Period-End Closing
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 3 2 1C2 4 4 0C3 4 2 2C4 10 5 0C5 1 1 0
Period 1Compon
entWIPdebit
WIPcredit
Scrap
C1 3 2 1C2 4 4 0C3 4 2 2C4 10 5 0C5 1 1 0
Valuation
Comp. Quant. PriceC1 1 100.-C2 0 0.-C3 2 400.-C4 5 50.-C5 0 0.-
550.-
WIP quantity = WIP debit - WIP credit
Comp. WIPC1 3 – 2 = 1C2 4 – 4 = 0C3 4 – 2 = 2C4 10 – 5 = 5C5 1 – 1 = 0
Comp. WIPC1 3 – 2 = 1C2 4 – 4 = 0C3 4 – 2 = 2C4 10 – 5 = 5C5 1 – 1 = 0
Comp. Quant. PriceC1 1 100.-C2 0 0.-C3 2 400.-C4 0 0.-C5 0 0.-
500.-
Reporting points of cost collector
ACT = 1050.-WIP = 550.-Scrap = 500.-
GI C1 200.-GI C2 100.-GI C3 400.-GI C4 100.-GI C5 500.-GR -750.-GI C1 100,-GI C3 400,-1 pc C1
2 pc C35 pc C4
550.-
500.-
WIP
Scrap
Product cost collectorModel series A Class
© SAP AG TAAP1W Automotive with DI46C2 - 88
SAP AG 2002, Title of Presentation, Speaker Name 88
Backflushin SAP APO 3.1
Backflush in SAP APO 3.1
© SAP AG TAAP1W Automotive with DI46C2 - 89
SAP AG 2002, Title of Presentation, Speaker Name 89
Overview
iPPE cost estimate (concurrent costing)
Sales order costing at goods receipt
Posting of material consumption
Posting of activities
Posting of variances
Comprehensive reporting functions in R/3 and BW
© SAP AG TAAP1W Automotive with DI46C2 - 90
SAP AG 2002, Title of Presentation, Speaker Name 90
Overview
TP
TP TP TP
Material AMaterial B
10 min / Station 120 min / Station 2
Inventory Management
Quantity
Value at GR
CO / FI
Reporting
BW
Costs
Quantity
Work in Process
Variances
APO3.0DI4.6C1
APO3.1DI4.6C2
or
Order NetworkRPM
Line Network
© SAP AG TAAP1W Automotive with DI46C2 - 91
SAP AG 2002, Title of Presentation, Speaker Name 91
OEM Workshop IAU250: Engineering (iPPE) & Manufacturing
IntroductionDiscrete Industries OverviewmySAP Automotive Portals & Workplaces
IPPEiPPE Workbench Overview Product Variant Structure iPPE PLMEngineering Change ManagementProcess & Factory Layout Structures
Production Planning ScenariosOverview Planning Basics and APOHeuristics Planning/Rapid Planning MatrixModel-Mix Sequencing with Restrictions
ManufacturingAction HandlerBackflush
© SAP AG TAAP1W Automotive with DI46C2 - 92
SAP AG 2002, Title of Presentation, Speaker Name 92
Copyright
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