Capacity Planning in SAP

1. Maintaining Work center capacity: 1. CR01 : Create Work center . 2. SM30 : Maintain Departments, Table: ZPP_DEPT_WC

In this table departments and their sitting capacity in various plants are maintained against the respective work centers 3. ZEMP : Maintain departwise Employees and their skills (Table: ZEMP ) In this table, for Each Plant, Each department. 1.Employee code, Emloyee name and its details are maintained. 2.Skill Level of each employee is maintained. Skill levels : S, SS, T Skill levels are considered to calculate the actual capacity of work center in the transaction ZPP3N and updating this to workcenter capacity by transaction ZPP5. S = 1 SS = 0.75 T = 0.5

4. ZPP3N :---Report of Actual capacity as per table ZEMP. ( Workcenters = Casting, filing, Polish, QCD, Sampling ) Actual capacity = ( Total of emp with S ) * 1 + (Total of empl with SS ) * 0.75 ) + (Total of emp with T ) * 0.5. Work Stations = sitting capacity.

5.ZPP5 :---Updating actual capacity / Sitting capacity whichever is lower. Into the standard workcenter capacity maintainance CR02

CR02-

Capacity

2.Maintaining ROUTING (Operation Details)

1.Maintaining Routing groups 2.Maintaining STM (Style Time master) CA01: - Maintaining routing groups : Fixed groups of Routing (operations sets) are maintained with common operation parameters like interoperation time., Split , and move ahead quantity. SKU s are assigned to suitable routing groups.

Move time

Splits

Min Send Ahead Qty

Routing groups are copied automatically during production order creation.

2.Maintainance of STMs:

SKU wise processing time for each operations mensioned in the rouiting are maintained separately in STM master (Table: ZPWCENTER). From there the processing time gets copied to order operations during order creation. By CAPP method. Process time calculation by CAPP , the parameters are maintained in the routing group as follows Group header: -- CA02

CAPP order Parameterprod. Order (2)

Calculation type CAPP

Non interactive CAPP calculation

Maintaining CAPP Transactions;

Create formula, method and process (tab:zpwcenter)

STM Maintainance: Process time is maintained in the table ZPWCENTER. Steps: 1.Sub operations Master 2.Conversion factors (Sub operation wise process time ) 3.Update Table ZPWCENTER.
1. SM30 (Table:- ZJOBOPERATION ):---Maintain Sub operation

Master .

Suboperation

Indicator planning Relevant

Suboperations within a workcenter are maintained in this master table. Planning relevant indicator is flagged X for those operations which are relevant for capacity booking. 2.ZJOB (Table: ZJOBCONVFACTORS). Process time entry. Process time in each department for individual SKU. is maintained via transaction ZJOB (Conversion factors)

2. ZWCENTER :- (Table ZPWCENTER) updating conversion

factors. This transaction updates sum of conversion factors from table ZCONVFACTORS where for the same SKU and same plant there are multiple suboperations for single department. Data is updated in a table ZPWCENTER.

Now we are ready for creating a production order. Capacities and capacity requirements will be generated.

Production Order Create:

Production order is created once the delivery block is removed in the sales order header. Before releasing production order get the diamond bagging commited Date from Diamond department. Considering this date as START date of the order schedule the order in the system. if diamonds are required for Wax setting.

Schedule Order.

Bagg. Avail date

Schedule the order with these start and finish dates as per customer request. And then check for any departments overload for capacity booking. In the transaction CM01.

Scheduling orders and capacity balancing. Workcenter load CM01:--System shows the capacity of each department and the requirement against it, overload if any. Datewise and details inside.

Click here

Group of workcenters together

Detail orders and cap. requirements

PPC date

Bagging date

NEW Transaction :- For updating Bagging date and PPC commited delivery date in the operations user fields in CO02 Which actually update the above User date fields User date 1 and User date 2. These dates appear in the above workload details screen helps to refer while adjusting the workload and controlling the finish date of order below the PPC commited delivery date. The requirements in the above screen appears in HRS. For reducing or increasing these loads for the same date same operation following steps need to be followed. If there is a overload for particular date in screen 2 1. Double click on the requirement. And goto detail load 2. Pick the order with delivery date (ppc date) most behind. 3. Click on the order and goto operation details screen of order

4. Select respective operation and goto details of operatios 5. Decrease splits or decrease move ahead quantity and reschedule. 6. Decrease or increase Move time of earlier operation 7. check for process time change and operation dates change. 8. Maintain the finish date of order below PPC date after any changes 9. Save order 10. Refresh the Screen of Workcenter load and see that total load is Reduced or no workload on that day. ( Order from load disappears ). Reduce the overload by rescheduling the orders by the same steps above.

Commitment of PPC delivery date of order.:-

New orders PPC date will be given by adding few buffer days in the finish date of the order after rescheduling loads of all critical departments. Entry of PPC date is done in the system by new transaction by which it gets updated in the user date fields. We can view the multiple workcenter loads by giving capacity planning group in the selection screen of CM01 Capacity planning group is maintained in work center master data. ***********************************************************