make to stock overview

8/9/2019 Make to Stock Overview

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S35 Make-to-Stock

Scenario OverviewSAP Best Practices forSupply Chain ManagementSAP AG



Make-to-Stock: Scenario Focus

1. Sales-orer-inepenent planning an prouction

!. "ocus is on planning processes ranging from long term eman planning to

short term prouction planning.

#. $sing SAP Advanced Planning and Optimization (SAP APO) to enhance an

e%isting SAP &'P solution with sophisticate planning functions.



Sales and Marketing ProductionProcurement and

Distribution

Demand Planning /

Collaborative DP

Monitoring

Supply NetworkPlanning

Production Planning /Detailed Scheduling

1. Demand Planning

Statistical orecast isgenerated based on

historical sales data

Consensus based planning

!elease o inal demand plan

".Supply Network Planning #$ecutable plans are created

or procurement% production

and transportation

Deployment

&ransport 'oad (uilder

). Production Planning

Plan and optimi*e

production while taking into

account product and

capacity availability

Make-to-Stock: Process Overview



Demand Planning / Collaborative Demand

Planning


Distribution

Demand Planning /

Collaborative DP

Monitoring



+ploading historical data

,rom #$cel sheet

-ia (usiness normation

arehouse

,rom 0'&P system

nteractive demand planning run

(est Practices delivers a speciic

planning book

Macros are deined tosupport planning

Promotion planning and

consensusbased planning are

also taken into consideration

Communicating via the nternet%

partners cooperate in orecasting

the demand to obtain a

consensusbased orecast

!eleasing the demand plan

!elease to 2P0 SNP

!elease to S2P #CC Demand

Planning



Collaborative Demand Planning

Demand

Planner

2P0 DPinsert forecast

"

"1

1

3

3a l e r t b r o a d c a s t i n g ( e . g . e - m a i l

)

4

4 f o r e c a s t a d j u s t m e n t

create

statistical

forecast

C52NN#' P2!&N#! M2N+,2C&+!#!

2ccount

Manager

nternet

6

6

review

forecasts

nternet

)

)

create

consensus

forecast



dded !alue in PO Demand Planning

Avance forecasting methos (M)' * Croston+

Promotion planning an life cycle planning

"le%i,le alert hanling

Colla,orative planning scenarios using we, applications

igh integration with SAP &CC B/ S&M )O-)/S

igh aapta,ility ,ecause of macro usage (no nee for programming efforts+



Su""l# $etwork Planning %&'

Customers

Storage

locations

Plants

Suppliers

D

#M

2

N

D

S+

P

P

'

7



Su""l# $etwork Planning %('


Distribution

Demand Planning/

Collaborative DP

Monitoring



Starting rom the demand plan%

SNP determines a medium

term plan or ulilling the

estimated sales volumes

&his plan covers

8uantities that must be

transported between two

locations 9or e$ample% roma distribution center to the

customer or rom a

production plant to a

distribution center:

8uantities to be produced

and procured



Su""l# $etwork Planning %PO-S$P'

Customer1

Customer " Customer 3 Customer 4

Central

warehouse 2

Central

warehouse (

Plant " Plant 1

Supplier 1 Supplier "

Crossplant planning 9SNP:;

&he planning is based on demand <uantities calculated or the customers 9DP:

=

!e<uest to central warehouse (

9orecast:

threshold value or the days> supply

in C ( is not reached; !e<uest to plant 1

=

&here is a capacity bottleneck in plant 1

!e<uest to plant "=

!e<uested <uantity is available in

plant "; Planned order is dispatched

!aw material and packaging is

procured

8uantity is conirmed in Demand

Planning 9constraint orecast:

Customer 6Customer )



Production Planning / Detailed Sc)eduling


Distribution

Demand Planning/

Collaborative DP

Monitoring



2utomatic Production Planning

2utomatic creation oprocurements proposals

'ot si*e planning

Se<uence optimi*ation

nteractive Planning

2naly*ing the planning

situation

Creating and changing orders

Planning products or which

you have set a manual

planning procedure Solving problems% or e$ample

order delays or resource

overloads



*)e Constraints o+ M,P

/nfinite capacity planning (infinite resources+

today

Ca"acit# situation

?@ 1? 11 1" 1) 13 16 14

?@ 1? 11 1" 1) 13 16 14

Capacity limit

Demands

,ecei"ts



Planning using SP PO

"inite capacity planning (finite resources+

Ca"acit# situation

?@ 1? 11 1" 1) 13 16 14

Capacity limit

Demands

,ecei"ts

?@ 1? 11 1" 1) 13 16 14



PP/DS Planning Functions

AStateotheartB

algorithmsMulticriteria

optimi*ation

2ll constraints on all

levels

AStateotheartB

algorithmsMulticriteria

optimi*ation

2ll constraints on all

levels

Detailed multilevel

material and capacityplanning

Creation o order

network/pegging

8uick identiication o

constraint violations

Detailed multilevel

material and capacityplanning

Creation o order

network/pegging

8uick identiication o

constraint violations

!e<uirements Planning/M!P !un!e<uirements Planning/M!P !un

0ptimi*ation0ptimi*ation

ManualPlanningManual

Planning

2utomaticPlanning

2utomaticPlanning

Create/Change/DeleteCreate/Change/Delete

0ptimi*ation 2lgorithms0ptimi*ation 2lgorithms

2utomatic Planning2utomatic Planning

Selective PlanningSelective Planning

Scheduling 5euristicsScheduling 5euristics

Planner works interactively

-isuali*ation o resources%order network and material

lows

Pool o planning unctions

9heuristics:

Planner works interactively

-isuali*ation o resources%order network and material

lows

Pool o planning unctions

9heuristics:

2 l e r t s



Planner.s *ool DS Planning 0oard

!esource -iew!esource -iew

Component viewsComponent views

Stock viewsStock views

StrategiesStrategies0ptimi*ation0ptimi*ation

2lert monitor 2lert monitor

DS planning board;

&he planning situation

and resource

schedule are

displayed in antt

charts

!eschedule orders oroperations manually

with certain rules andcertain scheduling

constraints

0rders can be

scheduled in anoptimum se<uenceusing DS optimi*er



Create

Production "lanning using SP PO

and SP 1CC

Demand planning/demand mgmt

Planned independent re<uirement

Production planning 9PP/DS:Planned order

Production order

Production order

Shop loor controlS2P #CC

#$ecuteCreate

Planned independent re<uirement

S2P #CC

S2P 2P0



2P0 allows the planner to make the ollowing considerations and

assumptions;hat would happen i;

... All orders were completed by the desired date with the

shortest possi,le lea time0

... A machine ha a planned downtime0

... uring the vacation period a shop floor area change the shift

scheule0

... /n May a resource pool was reduced from 2 to # employees0

... An aitional urgent order ha to ,e processe0

... An orer was deallocated an another orer was e$pedited

instea0

...3

2)at can #ou ac)ieve wit) t)e simulation



S#stem su""ort: O"timi4ation

0ptimi*ed planning oers the ollowing beneits;

Best possi,le deliverytopromise rate

'euce lead times

Minimi4e setup activities

Optimi4e resource selection



0ene+its o+ PP/DS "lanning

Material an capacity planning in one planning process

ate etermination ,ase on actual ca"acit# load incl. confirmations

increase of planning accuracy

!isibilit# on the material flow (pegging+

System supports the planner with alerts

imulation capa,ilities

Automatic selection of sources o+ su""l#

etect bottlenecks and tec)nological alternatives on resources

C)angeovers are ynamically calculate an can ,e automatically o"timi4ed

a+et# and stabilit# in "lanning ecreases safety stoc5s

/mprove anal#tics- and re"orting tools



2utomatic data transer to and rom S2P #CC

!ealtime data synchroni*ation and dynamic e$ception messages

Seamless integration o S2P SCM to industryspeciic solutions

9e.g. block planning% campaign% modelmi$ planning% se<uencing:

Cross plant planning; Production locations are connected%

Products und 2ssemblies planned together Material and capacity re<uirements planning in one process

Multilevel capacity re<uirements planningE bidirectional

propagation o order changes.

#$tensive detailed scheduling and optimi*ation possibilities

+serspeciic planning algorithms with heuristic ramework

Creation o easible plans over the entire supply chain

0ene+its SP SCM PP/DS



Monitoring


Distribution

Demand Planning/

Collaborative DP

Supporting the user in early

identiying e$ceptions and

<uickly responding to changes

Fey points

ncreased supply chain

visuali*ation and transparency

#nables management by

e$ception

Substantial decision support


Monitoring




Order-Pegging

Distribution

orders

Distribution

orders

Production

orders

Production

orders

Purchase

orders

Purchase

orders

Sales order Sales order

1?

)?

)?

6?

6?

G? H?

6?

6?

6?

6?

6?

"? 1? 3? 4?

1??

1??

)? "? 6?

)?6?"?

)?

1? "? 1? 3? 6?

9I"?:

91?:

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