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LTI Knowledge Capture Document - SAP Knowledge Capture Document SAP Wave Name Debriefing Session Knowledge Recipients
2. Business Process 3. Transaction Codes used 4. Test Cases and Reference Test data 5. Tools used 6. Developments / Modifications / User Exits 7. Reports 8. Interfaces 9. Knowledge Base documents identified 10. Exceptions 11. Existing pain area and future plans 12. References 13. Glossary of terms Version (x.y)* Change Date (dd/month/yy) Changed For Prepared by Reviewed by
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1.0
DEFINE AND POSITION APS & ERP SYSTEM WHAT IS APS SYSTEM?
APS (Advanced Planning System) is a general term used for Planning Software that acts as a modeling tool that enables the supply chain planning process. Using this users can model What if Scenarios to solve problems, incorporate resource and capacity constraints and optimize plans and schedules around those constraints. Example: SAP APO ERP (Enterprise Resource Planning) System is a class of software for enterprise wide planning which provide the functionality for: Receiving customer orders, Delivery Material Management and planning for replenish all needed materials according to customer orders and forecasts.
SAP R/3 IS AN EXAMPLE OF ERP. NOTE: Enterprise Resource Planning systems (ERPs) integrate (or
attempt to integrate) all data and processes of an organization into a unified system. A typical ERP system will use multiple components of computer software and hardware to achieve the integration. A key ingredient of most ERP systems is the use of a unified database to store data for the various system modules.
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1.2
WHAT IS APO?
Advanced Planning Optimizer is an APS which is used to
Increases the overall visibility of information of the supply chain and provide forecasting, planning and optimization functionality.
Creates Distribution, Stocking, Production and Purchasing Plans. Focuses on the optimization of a total supply chain. Integrates directly with SAP R/3 through a standard interface called Core Interface (CIF). APO consists of different planning modules such as 1. Demand Planning. 2. Supply network plan. 3. Production Planning/Detailed Scheduling. 4. Global Available to promise. 5. Transportation Planning/Vehicle Scheduling.
POINTS TO BE NOTED:
1.3 APO is a Supply Chain Management tool that offers a fully integrated pallet of functions that is used for planning a supply chain network starting from our end customers all the way back to our suppliers. 1.4 SAP APO helps Chevron to achieve the goal of improving the bottom line by minimizing costs while meeting customer demand and service levels. This is achieved by being able to streamline and simultaneously plan across the whole supply chain network.
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LTI Knowledge Capture Document - SAP 1.5 Other planning modules in APO are: PP/DS is used for short term (within production horizon) to-the-minute planning (both for in-house production and external procurement) in the production plant. It is tightly integrated with the execution system transfers planning results to R/3. GATP provides an on-line search to verify across the network that the requested product can be provided in the quantity and date requested. Transportation Planning/Vehicle Scheduling (TP/VS) is used for Transportation planning and consolidation, Vehicle scheduling and route determination.
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NOTE: With SAP SCM Demand Planning, you can use univariate
forecasting methods and advanced macro techniques to do the following: Create forecasts from the demand history; test predefined, and userdefined forecast models, and forecast results; use a consensus-based approach to consolidate the demand plans of different departments. You can use forecast corrections and promotions to take account of marketing intelligence and management adjustments.
Multi-variate uses a statistical technique called Multiple Linear Regression. It tries to mathematically quantify the relationship between a dependent variable and one or more independent variables for example Demand for lubricants and crude oil prices.
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LTI Knowledge Capture Document - SAP Composite combines forecasts from different statistical models e.g. Univariate, Multivariate, etc. Forecast can be combined by: Averaging the forecasts by giving each one equal or different weights Varying the weights assigned to each forecast over time Chevron uses Univariate statistical forecasting. Univariate statistical forecasting assumes that what has happened in the past will continue out into the future. Here Future Forecast is based on past historical values.
2005
2006
2007
2008
LTI Knowledge Capture Document - SAP 1. Constant: Varies very little from the stable mean value.
2. Trend: Falls or Raises constantly over a long period of time with only occasional deviations.
3. Seasonal: Periodically recurring peaks and troughs differ significantly from stable mean value.
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With Promotion
No Promotion
Forecast
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Old Product
New Product
Like Modeling:
Sales
Lifecycle
Time
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The goal of Supply Network Planning (SNP) is to: balance supply and demand throughout the supply chain provide advanced early warning regarding supply chain problems or proactive signaling.
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Plants
D E M A N D
S U P P L Y
Suppliers
Purchase Order
The SNP planning engines can concurrently plan distribution at all DCs, schedule production for finished products at the manufacturing plants, and determine the material requirements for raw material components simultaneously all in one run.
1
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LTI Knowledge Capture Document - SAP Demand or requirement from one distribution could be fulfill by a transport order (stock transfer order) from another distribution center or from a manufacturing plant. Requirement of finished products will be processed. APO then will create the dependent requirement to components and capacity requirement of resources (work centers, machine, labor) by taking into account the Production Data Structure created from production version from R/3 which consists of the bill of materials and routing information. Planned order for production will be generated for production planner to review (adjust and adopt) and then convert to production order for shop floor execution. Purchase requisition for external procured component then will be created and can be converted Purchase Order (PO) which will be issued to supplier.
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APO SNP provides the ability to model the entire supply network and all of its constraints such as resource capacities, storage limits, transportation capacities, material availability, safety and target stock levels, etc.
Suppliers
Resource Resource
Transportatio n Lane
Distribution Center
Distribution Center
EXPLAIN:
The diagram represent South Africa. Presenter will explain the meaning of each icon and arrow: Plant Manufacturing Plant Resources This is equivalent to work center in R/3 Production Data Structure: The PDS generated from the R/3 Production Version, which is composed of the: Bill of Material (BOM) contains the breakdown of the raw material components Routing contains the operations and activities involved to produce the final product
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LTI Knowledge Capture Document - SAP Work Center the capacity needed to convert the raw material components into the final product e.g. Filling Machine, Blending Machine and/or Group of Labor 4.Distribution Centers (DC) or Depot 5.Suppliers In Chevron Global Lubricants implementation, we will only bring in the subcontracting vendors into APO Supply Chain Model. 6.Transportation lane Master Data in APO which represents a transportation route between two locations in a supply chain model.
Suppliers
Plant
Capacity level
100%
Week 1 Week 2
Week 3 Week 4
Week 5
Distribution Center
Distribution Plan
Capacity Leveling
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LTI Knowledge Capture Document - SAP The heuristic is used as part of a repair-based planning process consisting of the heuristic and capacity leveling. The heuristic plans an ideal state without considering capacity constraints. It is then needed to evaluate the capacity of all bottleneck resources using capacity leveling and alerts. SNP Heuristic performs distribution, production and material requirements planning (DRP, MPS, MRP) for the whole or a subset of the supply chain. Planning results is unconstrained by material or resource availability (assumes infinite capacity) and therefore can be infeasible. If a feasible plan is wanted, a separate capacity leveling step needs to be performed
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SNP Heuristic
Pros
Finished product
Simple to explain results Fastest Execution Plans at all levels in the network Works with Quotas
Cons
Components
Must plan capacity manually Does not consider costs Does not consider priorities for demand or supply
The heuristic is used as part of a repair-based planning process consisting of the heuristic and capacity leveling. The diagram shows the process flow of SNP heuristic logic. The heuristic run processes each planning location and BOM level sequentially and determines supply requirements for the next level. The heuristic groups all demands for a given product at a location into one demand for the week. The demands are then passed through the supply chain to calculate a supply plan.
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LTI Knowledge Capture Document - SAP However, this plan is not necessarily feasible. Capacity leveling is then used to adjust the plan to create a feasible plan.
Capacity level
BACKWARD
FORWAR D
100 %
Week 1
Week 2
Week 3
Week 4
Week 5
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LTI Knowledge Capture Document - SAP Capacity leveling is used to constrain planning by available resource capacity. A resource is usually a machine or a group of machines at a production plant. These resources will have a certain limited amount of capacity (usually in hours/day) that is used up in the process of converting raw material into finished products. Capacity leveling helps by moving production/resource usage from overloaded weeks into underloaded weeks. Leveling is executed for each resource. Depending on available capacity and leveling strategy used, it moves orders generated by the SNP Heuristic either: into past weeks (backward) into future weeks (forward) or both (backward + forward) This effectively moves some production orders earlier or later than the expected date.
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Plant
Distribution Center
Capable-to-Match (CTM) is a rules-based, cross-plant planning method that can take into account constraints such as available capacity and materials during the planning run (finite planning). The feasibility of receipts is checked successively against priorities and the first feasible solution is scheduled. On a location by location basis, CTM matches a set of prioritized customer demands and forecast to a set of categorized supplies.
CTM planning is controlled using priorities. There are approximately 20 criteria, such as priorities for products, locations, order type, order due dates, procurement and stock transfers. Demand priorities are set based
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LTI Knowledge Capture Document - SAP on the order type (Sales Orders have a higher priority than Forecast) and on the product and location master (Product A at Location B has a higher priority than Product C at Location D). The supply priorities are usually set on the master data in the supply model (Alternative transportation lanes and PDSs).
CTM performs sequential leveling of prioritized customer requirements and forecasts against feasible receipts in the network, during which component availability and production capacities are taken into account at several levels.
CTM considers capacity when planning supply, it can be difficult however to interpret the result of CTM at finished product level due to constraint at other levels of the supply chain model, making it difficult to identify the origin of the problem.
Chevron will use CTM used for Supply Constrained Planning at the plant.
Capable to Match (CTM) allows planning with finite capacity. Capable to Match considers material and capacity constraints for production and also considers the priorities for demand and supply. With Capable to Match we can plan at all levels In the network and can work with quotas. This also does not consider costs similar to Heuristic and also does not search for the best possible solution.
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Considers capacity constraints for production Considers priorities for demand or supply Plans at all levels in the network Works with Quotas
Cons
Components
Does not consider costs Does not search for the best solution
CTM use priorities to influence the sequence of demands and the selection of the supply alternatives.
The diagram shows the process flow of CTM logic. CTM planning does not consider the individual production and distribution levels one after the other, such as the Heuristic run, but considers them at the same time for a demand order. CTM will plan the prioritized demand orders sequentially through the whole supply chain. It is an order-based planning procedure,
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LTI Knowledge Capture Document - SAP which uses pegging methods to track supply orders back to the individual demand order.
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DP
Resource Overload Supply Shortage Safety Stock Level Shortfall Target Stock Level Exceeded
SNP
Modules Alert Monitor
Alert Types
The Alert Monitor correspond to the exception situations that could arise in demand planning: Univariate forecasting alerts
The Alert Monitor in Supply Network Planning enables you to display and resolve resource and location product alerts. During planning, the system can trigger the following alerts: Over-utilized (more than 100% utilization) Under-utilized (less than 50% utilization) Utilized 100% (to display bottlenecks) L&T Infotech Confidential Page 26 of 44
LTI Knowledge Capture Document - SAP Safety stock shortage Over/under target days' supply
Both forecast alerts and supply / demand planning alerts can be used in APO's Demand Planning and Supply Network Planning applications. An alert is generated if it exceeds threshold values defined in the alert profile.
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Data is extracted from the R/3 source system with the help of BW into APO. Based on source data, a demand plan is prepared in DP and release to SNP for validation. SNP creates planned independent requirements to be sent to R/3. The R/3 system provides APO with data relevant for planning (master data and transaction data). Products are planned in the APO System and the planning results are transferred back to the R/3 system. If necessary, planning is completed in the R/3 system for products that are not planned in APO. The R/3 to APO data flow can be summarized as follows: 1. Transfer Historical Data from R/3 to BI cube 2. Copy Sales History and orders from BI to APO
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LTI Knowledge Capture Document - SAP 3. Generate Statistical Forecast 4. Release Demand Forecast to SNP 5. Perform Supply Network Planning 6. Release SNP results to R/3 (CIF) 7. Save SNP planning results to BI
The SAP Core Interface (CIF) technology is an R/3 software plug-in which enables the integration of master and transactional data between R/3 and APO.
The basic idea of the Core Interface is to transfer data from the source system (R/3) to APO once an event (a master or transactional data change) is triggered. The actual data set that is transferred is determined by what is called the CIF Integration Model which contains the selection of master/transactional data that will be transferred .
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Two types of data will be transferred between SAP R/3 and SAP APO 1. Master Data 2. Transactional Data Master Data: The master data used for mapping the supply chain is generally taken from the SAP R/3 System. Master Data required for planning are the following: Locations, products, resources, PDS and Transportation Lane In SAP APO, the resources and the PDS are used to plan in-house production. This data is transferred from SAP R/3 to SAP APO. SAP R/3 work center capacities are mapped onto SAP APO resources, and SAP R/3 BOM and routings are mapped onto a PDS.
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LTI Knowledge Capture Document - SAP For routings and BOMs to be transferred from SAP R/3, a corresponding production version must be present in the SAP R/3 material master. The production version determines a manufacturing process by specifying a routing and a bill of material. In the SAP R/3 material master, several production versions can be defined (for different lot size intervals, for example). Each of these production versions is transferred to SAP APO as an individual PDS. To plan external procurement, SAP R/3 Purchasing Info Records and Contracts can be transferred as procurement relationships to SAP APO. Transactional Data: Transactional data such as stocks and sales orders are transferred one wayonly from R/3 to APO, since these types of data are created only from R/3. The rest of the transactional data such as planned orders, production orders, purchase requisitions and purchase orders are transferred bi-directionallyfrom R/3 to APO and vice versa since these types of data can be created either via the R/3 system or APO and would need to be kept synchronized at all times.
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Forecast from Demand Planning will be released to SAP R/3, so that user can will get the consistent data whether review it from APO or R/3 especially from same key transaction or screen e.g. MD04 in R/3 which display stock/requirement status. Without forecast released to R/3, the projected inventory from MD04 will mislead user i.e. excessive replenishment plan without requirement. Planned order, Purchase requisitions and Stock transfer requisition which are generated by SNP will be transferred to R/3 and will be converted to Production Order, Purchase Order and Stock Transfer Order respectively.
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Characteristic Characteristic Value Combination Key Figure Planning Book Macros Model and Version
2.1.1 Characteristic
A characteristic is a property that defines the planning levels in APO. They are the planning objects for which you aggregate, disaggregate and evaluate business data. Characteristics act much like database keys, they are used as a basis to retrieve the transactional/planning data associated to it. A characteristic can have one or more values belonging to it
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Key Figure
A key figure is essentially the planning data associated with a characteristic, or a set of characteristics. They contain either a quantity or a numerical value.
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Key Figures and their brief description: 1. Forecast - This will come from Demand Planning after DP release to SNP 2. Sales Order - This will come from R/3 into APO Via CIF. Sales orders will consume forecast. 3. Distribution Demand (Planned) -Stock transfers that are generated during the SNP planning process and updated in every planning phase. The distribution demand shows the supplying location's view of these stock transfers (the view from the receiving location is provided by the distribution receipts). This will be populated after DRP run for Non Subcontracting materials 4. Distribution Demand (Subcontracting) - Same as Distribution Demand (Planned) but for Subcontracting materials 5. Distribution Demand (Confirmed)Same as Distribution Demand
(Planned) but as stock transfer to Receiving plant, These are also called Deployment Requisitions. Distribution Demand Planned is populated by the Deployment process based on inventory available-to-deploy. Page 35 of 44
LTI Knowledge Capture Document - SAP Distribution Demand Confirmed will consume Distribution Demand Planned. 6. Distribution Demand (TLB) -Stock Transport Order (Created during TLB run). Distribution Demand TLB will consume Distribution Demand Confirmed. 7. Distribution Receipt (Planned) - Stock transfers that are generated during the SNP planning process and updated in every planning phase. The distribution receipt shows the receiving location's view of these stock transfers (the view from the supplying location is provided by the distribution demand). This will created as above, but on receipts side 8. Distribution Receipt (Subcontracting) - Same as Distribution Receipt (Planned) for Subcontracting materials (Receiving side) 9. Distribution Receipt (Confirmed) - Same as Distribution Receipt (Planned) but as stock transfer to plant (Receiving side) 10. Distribution Receipt (TLB) - Same as Distribution Receipt (Planned) but as STO plant (Receiving side) 11. In transit - The in transit quantity calculated by the SNP run that will
reach the specified destination during the next period. 12. Production (Planned) - Production Planned at Manufacturing Plant
13. Production (Subcontracting) - Same as Production (Planned) but for Subcontracting Material. 14. Production (Firmed)- Same as Production (Planned) but for Confirmed Production 15. Stock On hand at a location - Current or Projected unrestricted inventory available
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LTI Knowledge Capture Document - SAP 16. Supply Shortage - Difference between Demand and Supply calculated by a Macro 17. Reorder Point - Threshold value for the available stock below which procurement proposals should be created (from Product Master) 18. Safety Days Of Supply - Target value for the days' supply of a location product (from Product Master) 19. Safety Stock Level - Represents a stock level that should be reached through planning in order to smooth out production and cover sporadic requirements 20. Days supply - The system calculates the days' supply as follows: stock is divided by daily demand (Macro Calculation)
Planning Book
The planning book is the screen that Demand Planners and Supply Planners use to display, enter and process data. Looks like an excel spreadsheet where the rows correspond to key figures and the columns are time periods. The main parts of APO planning book are Characteristics to select the data Key Figures displaying the retrieved data Data Selection to show the CVCs Selection Profiles to retrieve selected CVCs Planning Book and Data Views Macros L&T Infotech Confidential Page 37 of 44
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2.3 Macros
Macros are pre-set calculations that you can perform on the key figures found in the planning book. They are quite similar to the macros of an Microsoft Excel Macro. The planning book that we use has a standard set of macros that run behind the scenes to compute for the values of key figures such as total demand, total receipts, stock on hand and safety stock to mention a few. Marcos are also used to generate planning book alerts to let the planner know if we are below safety stock levels or if we have shortages. Macros are created and maintained from the Macro Workbench.
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2.4 APO SYSTEM ARCHITECTURE APO system architecture includes 1) Technology i) Live Cache ii) APO Solvers 2) Reporting i) Business Intelligence
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LTI Knowledge Capture Document - SAP It has a very large main memory size and Stores data in optimized structures. Has excellent speed and Allows simultaneous/concurrent data access.
It can take the advantage of multi-processor and multi-computer hardware technology (that is, parallel and distributed processing). It Allows forecasting, planning and optimization functions to be executed in near real-time.
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LTI Knowledge Capture Document - SAP The extracted data can then be used to generate, forecast or for reporting purposes
Advanced Planner and Optimizer (APO) offers a fully integrated pallet of functions that is used to plan and execute supply chain processes. APO supports all of the supply chain planning and optimization functions and processes. APO provides an integrated, holistic approach that encompasses a range of planning levels, models, and manufacturing methods. It provides faster response to changes in supply and demand. APO is seamlessly integrated with the R/3 system to integrate all the links of the supply chain. APO key functionalities include: Demand Planning and Supply Network Planning Other APO functionalities that are out of scope: PP/DS (Production Planning/Detailed Scheduling), Supply Chain Cockpit, and Global Available-toPromise. The Core Interface (CIF) technology allows seamless master and transactional data integration between R/3 and APO.
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LTI Knowledge Capture Document - SAP 3. NA 4.0 TEST CASES AND REFERENCE TEST DATA N.A 5.0 TOOLS USED N.A 6.0 DEVELOPMENTS/ MODS/ USER EXITS N.A
7.0 REPORTS N.A 8.0 INTERFACES N.A. 9.0 KNOWLEDGE BASE DOCUMENTS IDENTIFIED Tasks Identified For Service desk Associated Transactions Service desk Training Topics/ sessions identified Tools / Time Required Time Required Templates For Training To Prepare Service desk Knowledge Base Analyst document
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LTI Knowledge Capture Document - SAP 11.0 EXISTING PAIN AREA AND FUTURE PLANS N.A 12.0 REFERENCES No 1. File Name Demand Overview Description Planning Demand Overview Location Planning
N.A
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