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1. Site Integrated Planning Overview SAP R/3
2. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
3. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
4. R/3 Integration R/3 Client / Server ABAP/4 CO Controlling AM Fixed Assets Mgmt. PS
Project System WF Workflow IS Industry Solutions MM Materials Mgmt. HR Human
Resources SD Sales & Distribution PP Production Planning QM Quality Mgmt. FI
Financial Accounting PM Plant Maintenance
5. Supply Chain Planning SIP Material Requirements Planning Derive material
requirements by exploding the production plan through a bill of material (BOM) and
inform the customers SIP DRP Deployment Develop transport recommendations based
on available inventory and firm production plans and execute them. SIP Site Master
Production Planning Create a feasible production plan including sequencing of runs,
managing inventory and line capacities. CSP Rough Cut Capacity Planning Match
supply & demand by leveling capacity over a longer horizon over different plants at an
aggregated or detailed level. CSP SIP DRP Planning Net off the inventory and actual
orders and roll-up the demand through a distribution network to the producing plant CSP
Source Allocation Allocating the forecast to different DCs DP Demand Planning Creating
a forecast per week and Country / Customer Group
6. Definition
o Site Integrated Planning -
o Is the process of developing realistic supply plans and schedules for all levels of
the operation that support the business strategies and objectives .
7. Definition
o … Realistic …
o - Accounts for different levels of precision required for different parts of the
horizons
8. Definition
o … All Levels of the Operation …
o - Plans and schedules for finished products, intermediates, and raw materials.
9. Definition
o … Support the business strategies and objectives.
10. Oliver Wight MRP II Chart Business Planning Demand Management Master Production
Scheduling Detailed Capacity Planning and MRP Execution (Prod.&Purch.) Rough-Cut
Capacity Planning Production & Supplier Scheduling Sales & Operations Planning
Distribution Requirements Planning S I P APO - SNP A dvanced P lanner O ptimizer S
upply N etwork P lanner
11. Plan Strategy Improved Results Integrated Planning Work Processes Planning
Parameters Business Operating Strategy
12. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
Demand Planning
Category Supply Planning
Site Integrated Planning
o 2. Fully Support MRPII Class A
single plan
supports integration of execution & planning
data accuracy & integrity
minimum 18 month horizon
supports planning reliability & schedule stability zones
clear responsibility & accountability
supports MRPII Measures
o 3. Take Full Advantage of SAP Capabilities
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
o Global data client feeds new material codes into SAP through interfaces
o The interface creates the Basic Data View in SAP (code#, description and unit of
measure)
o The CMDC communicates to each row through a single point of contact that new
master data is needed
o CMDC is responsible to monitor “Material Master Missing Views” report
20. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
o Scheduling
o Enable SAP to generate a “rough plan” that supports the operating strategy
23. Parameter Management Parameters (Master Data) are used by SAP to create a supply
plan by the MRP/MPS “calculator” Forecast Master Data Inventories Supply Plan &
Projected Inventories When the calculation is started it re-evaluates the existing plan
based on the changes since the last time the MRP/MPS calculations occurred.
24. Site Integrated Planning Processes Manage Master Data Perform Long-Term Planning
Perform Short-Term Planning Perform Daily Planning Perform Special Planning
Generate Reports Perform Integrated Planning Measures Related Work Processes
25. Master Data - Parameter Management
o The term “master data” is frequently used to refer to such things as material
master, BOM’s, resources, recipes, etc.
o Master data contains planning parameters such as lead time, safety stock, order
quantities, etc.
26. Master Data Parameters Material Master(s) Resource BOM Recipe Production Version -
firm zones - lead times - lot sizing - safety stocks - scrap factors - hours available -
planned downtime - efficiency - factory calendar - cost centers - material / resource
combination - capacity data / rates (machine & labor) - sequence preference - formula
card structures - usage quantities - alternate BOM - BOM / recipe combination - time-
phase planning (i.e. change in raw material) - Quota Arrangement Allocate percentage of
business: - Production Version allocation - Capacity allocation - Source allocation
(vendor, plant)
27. Master Data Set Up MRP 1 View - 1
28. Master Data Parameters Material Master(s) Resource BOM Recipe Production Version -
firm zones - lead times - lot sizing - safety stocks - scrap factors - hours available -
planned downtime - efficiency - factory calendar - cost centers - material / resource
combination - capacity data / rates (machine & labor) - sequence preference - formula
card structures - usage quantities - alternate BOM - BOM / recipe combination - time-
phase planning (e.g. change in raw material) Allocate percentage of business: -
Production Version allocation - Capacity allocation - Source allocation (vendor, plant)
Quota Arrangement
29. Master Data Set Up BOM - Material Item Overview
30. Master Data Parameters Material Master(s) Resource BOM Recipe Production Version -
firm zones - lead times - lot sizing - safety stocks - scrap factors - hours available -
planned downtime - efficiency - factory calendar - cost centers - material / resource
combination - capacity data / rates (machine & labor) - sequence preference - formula
card structures - usage quantities - alternate BOM - BOM / recipe combination - time-
phase planning (change in row material eg.) Quota Arrangement Allocate percentage of
business: - Production Version allocation - Capacity allocation - Source allocation
(vendor, plant)
31. Master Data Set Up Resources: Intervals of Avail. Capacity
32. Master Data Parameters Material Master(s) Resource BOM Recipe Production Version -
firm zones - lead times - lot sizing - safety stocks - scrap factors - hours available -
planned downtime - efficiency - factory calendar - cost centers - material / resource
combination - capacity data / rates (machine & labor) - sequence preference - formula
card structures - usage quantities - alternate BOM - BOM / recipe combination - time-
phase planning (change in row material eg.) Allocate percentage of business: - Production
Version allocation - Capacity allocation - Source allocation (vendor, plant) Quota
Arrangement
33. Master Data Set Up Master Recipes: Overview
34. Master Data Parameters Material Master(s) Resource BOM Recipe Production Version -
firm zones - lead times - lot sizing - safety stocks - scrap factors - hours available -
planned downtime - efficiency - factory calendar - cost centers - material / resource
combination - capacity data / rates (machine & labor) - sequence preference - formula
card structures - usage quantities - alternate BOM - BOM / recipe combination - time-
phase planning (i.e. change in row material) Allocate percentage of business: - Production
Version allocation - Capacity allocation - Source allocation (vendor, plant) Quota
Arrangement
35. Master Data Set Up - Production Version
36. Master Data Parameters Material Master(s) Resource BOM Recipe Production Version -
firm zones - lead times - lot sizing - safety stocks - scrap factors - hours available -
planned downtime - efficiency - factory calendar - cost centers - material / resource
combination - capacity data / rates (machine & labor) - sequence preference - formula
card structures - usage quantities - alternate BOM - BOM / recipe combination - time-
phase planning (i.e. change in row material) Allocate percentage of business: - Production
Version allocation - Capacity allocation - Source allocation (vendor, plant) Quota
Arrangement
37. Master Data Set Up - Quota Arrangement
38. Time Bucket & Evaluation Area
o Work Process Focus Time Bucket Evaluate Area
o is feasible
o Master data
o Balanced long-term plan by superior resource, for alignment with the S&OP plan
INPUT OUTPUT
o Convert the weekly schedule to a daily schedule within the planning time fence
INPUT OUTPUT
Daily Planning is a set of work processes that are performed daily to monitor the
execution of the integrated plan. The processes are designed to :
INPUT OUTPUT
o All functions must work together and be aligned to the operating strategy
49. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
o Production/Execution
o Shipping/Receiving
o Purchasing
o Accounting
o Maintenance
The effective execution of the operating strategy requires the coordinated efforts of:
o (i.e.: IndReq 100, Order 20, MRP run >> Order becomes an order of 20 and
IndReq is reduced to 80. The total requirement is still 100)
o Transfer of Requirements (TOR) is transmitted to SIP during the sales order
creation. (TOR must be configured according to the MM and PP inputs)
o Delivery consumes physically the stock
o Control Key
o Printed Report
Production Execution Production rqmts Planned order Process control Manually
o Order Type
SIP-PP/PI WH QA SIP PE CO
56. SIP-Purchasing
o Purchasing Vision Planning
o - Auto PO
57. Purchasing Vision Planning Vendor Master Material Master Request for Quotation Entry
of quotation data Quotation Comparison Create Outline Agreement Create Source List
Create Quota Arrangement SIP-Purchasing
58. Scheduling Agreement Delivery Schedules Send to Vendor Valid Source List Purchasing
Vision Execution Manual Delivery Schedules Generation Manual Creation SIP-
Purchasing
59. Purchasing Vision Execution Delivery Schedules MRP Sch. Agreement SIP Master Data
Requirements Source List Automatic Delivery Schedules Generation SIP-Purchasing
Send to Vendor
60. Approved Requisition Purchase Order Send to Vendor Allocate Source and process
Purchasing Vision Execution Manual Purchase Order Generation (Assign&Process) SIP-
Purchasing
61. Automatic Purchase Order Generation (Auto PO) Approved Requisition Quota
Arrangement Send to Vendor Purchase Order Run Auto P.O. Program Source List Non-
Sourced Requisition Purchasing Vision Execution SIP-Purchasing
62. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
o Capacity Evaluation
o (Logistics/Production/Capacity Planning)
o Planning Table
o (Logistics/Production/Repetitive Manufacturing)
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
o - Reports & Measures
70.
o Use of Forecast Consumption
Demand Management
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
73. MPS/MRP
o What is it?
74. MPS/MRP
o A set of SAP programs that are designed to calculate a production plan based on
configuration settings, master data and raw data inputs.
What is it?
75. MPS/MRP
o Processes one code at a time
o Safety Time
o Safety Stock
o Coverage Profile
MRP List : 1. Is a static picture of the planning position as of the last mrp run 2. Has
exception messages that provide useful information regarding the plan Stock
Requirements List: 1. Is a dynamic list that reflects the most up to date picture of all the
mrp elements 2. Does not have all the exception messages generated during the mrp run
3. Is the same as the mrp list at the end of the mrp run but then deviates as changes are
made to the mrp elements.
84. MPS/MRP
o MRP Elements and their relationships
85. DRP
o What is it?
Planning
Deployment
o Planning
Determines how much and when inventory and planned supplies should be
deployed to distribution centers, importers and direct customers taking
into account of lead time, transportation mode, schedule, loadability, order
mixing, and other constraints
o Deployment
89. Distribution Resource Planning Bill of Distribution Customer Orders Sales Forecasts
Inventory Records In-Transit Shipments To: Master Production Scheduling No Yes
Transportation Planning Warehouse Space & Resource Planning Distribution
Requirements Planning Realistic?
90. Distribution Network Planning Tools Sales to Customers Sales to Customers Sales to
Customers Sales To Customers MPS MRP Warehouse (A) DRP Warehouse (B)
Warehouse (C) Puree Chemical Company Main Plant Warehouse
91. Parameter Management Planning Tools Sales to Customers Sales to Customers Sales to
Customers Sales To Customers Inventory policy F/c Consumption logic Sourcing
plant/DC Total Order Lead time Replenishment Frequency Local Repacking Warehouse
(A) Warehouse (B) Warehouse (C) Puree Chemical Company Main Plant Warehouse
MPS MRP DRP
92. Upload of Forecast Sales to Customers Sales to Customers Sales to Customers Planning
Tools Sales To Customers Forecast Forecast Forecast Forecast Warehouse (A) Warehouse
(B) Warehouse (C) Puree Chemical Company Main Plant Warehouse MPS MRP DRP
93. Generating Replenishment Plan Sales to Customers Sales to Customers Sales to
Customers Planning Tools Sales To Customers Forecast Forecast Forecast Forecast
Warehouse (A) Warehouse (B) Warehouse (C) Puree Chemical Company Main Plant
Warehouse MPS MRP DRP
94. MRP Element Linkage MPS run MRP run MRP run
95. Deployment Process
o Evaluating the day-to-day capability of the source sites to ship the required ideal
DRP replenishment orders.
o Simulating deployment plans and analyzing impact on individual markets/DCs if
required*.
o Developing priorities & alternatives plans when all of the DRP replenishment
orders cannot be met.
o Creating orders for properly weighted & cubed vehicles for shipping.
MRP1 view - general data, material owner, and lot size data
MRP2 view - lead time scheduling and inventory strategy
MRP3 view - planning and availability check
MRP4 view - enablers (BOM and material transition)
97. DRP - Material Master - MRP Group
o Pre-set control parameters representing category specific planning strategy
o Quota for importers determine how supply will be allocated across multiple
external source (exporters).
o Importers’ quota setup also defines if ‘ Planned Stock Tr ansfer Order (STO)’ is
used .
99. DRP - Quotas - Data Entry Screen
o Quota Setup to enable Planned STO (net demand) link to supply site:
o This the use of the special procurement key (or type) can be used in situations
where there is a single source.
o Just need to enter the newly defined SP type in MRP 2 will allow the link of
demand without quota setup.
o Maintained in customizing (OMD9)
101. DRP - Special Procurement Type (2) Receiving Plant Source Plant Special Proc.
Type* F: External Procurement Defines the procurement more specifically
102. DRP
103. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
104.
o Performs netting, lead time offsetting, lot sizing, BOM explosion, sourcing
(according to Supply Parameters)
o Works Multi-level, e.g. from FP to Intermediate to Raw/Pack materials
o 1. Aggregation Capabilities
o 2. Capacity Evaluation
o 3. Automatic Leveling Tool
109.
o Data Accuracy Audit Support
110. Agenda
o -What is Site Integrated Planning?
o - Key Responsibilities
o - Planning Strategies
o - Integration Points
o - Capacity Evaluation
o - Demand Management
o - DRP/MPS/MRP
o Defining the “Final Organization Setup“ early in the project. (before BAT)
o - Migration Strategy
o - Migration Tools