RoughCut Capacity Planning in SCM EGN 5623 Enterprise
- Slides: 56
Rough-Cut Capacity Planning in SCM EGN 5623 Enterprise Systems Optimization Fall, 2013
Rough-Cut Capacity Planning in SCM Theories & Concepts EGN 5623 Enterprise Systems Optimization
Hierarchical Planning Framework (review) Procurement Long term Mid term -Material programs - Supplier selection - Cooperation Distribution Production - Plant location - Production systems - Subcontractors - Physical distribution structure - Transportation strategy -- Personnel training -- Contracts -- Material Requirements Planning -- Master production Scheduling -- Capacity planning -- Distribution planning -- Personnel scheduling -- Material ordering -- lot-sizing - operations scheduling - shop floor control Short term Flow of goods - Product program - Strategic sales planning -- Mid-term sales planning - Warehouse replenishment - Transportation planning -- Mid-term sales planning EXECUTION Sales Information Feedback
The APICS-Standard Planning Framework (review)
Production Process (review) Requirements for Production Planning: • to meet the demand • to consider the resource capacities and the material availabilities • to improve utilisation of the resources • to lower the setup time • to minimize the stock, and • to minimize the work in process (WIP) • to improve stability of the plan
Rough-cut Capacity Planning The main goal in rough-cut capacity planning is to identify where overloading or under-loading of production capacity occurs and revise the MPS as required. • Overloading means that too much production of products has been planned in the facility and insufficient capacity exists to produce planned quantities of products required in MPS. • Under-loading means that not enough production of products has been planned to fully load the facility.
Rough-Cut Capacity Planning in APO-SNP
Order Life Cycle for Make-to-Stock
Order Life Cycle for Make-to-Order
Forecast Consumption Mode and Horizon (Backword consumption of 4 days and a forward consumption of 3 days)
Transactional Data for Transferring • Starting from a demand plan, SNP checks the resource capacities and delivers a medium/long-term plan for the estimated sales volumes. • The plan includes the quantities to be transported between locations (e. g. , DC-customer, or plant-DC) and the quantities to be produced (and procured), taking available capacity into consideration. • SNP creates planned orders, purchase requisitions, and stock transfers that can be transferred directly to the connected OLTP systems.
Capacity Levelling Capacity leveling supports the following resource categories: • Production resources • Transportation resources Capacity levelling supports the following resource types: • Bucket resources • Single-mixed resources • Multi-mixed resources • Transportation resources
Capacity Levelling The planner can use the following methods to adjust the plan: • Backward scheduling of the capacity load to fulfill demand using high priorities without due date violations. This rescheduling does not create any orders in the production horizon. • Forward scheduling of the capacity load for lower priority demand use of demand priorities to minimize due date violations • A combination of backward and forward scheduling of the capacity load.
Capacity Levelling Profile The main settings in the capacity leveling profile are scheduling direction, prioritization, and method. • • • Scheduling Direction controls whether Forward, Backward or Combined scheduling is used. Prioritization for the heuristic run defines how leveling determines the sequence of orders. The two possible choices for prioritization (to be sorted by ascending or descending order) are • by order size or • by product priority. The three Method choices are • Heuristic, • Optimizer or • Badi (Business Aided-in).
Time-based Capacity Levelling
Capacity Levelling
Heuristics-based Capacity Levelling • Heuristic-based capacity leveling compares, period by period, the capacity load on a resource with the requested load, either from the beginning or from the end of the planning horizon – depending on which scheduling direction is selected (forward or backward scheduling). • If the resource is found overloaded, the system first selects all the activities or orders that cause the overload in this period. It then sorts these orders according to the priority that is defined and shifts orders or partial orders, one by one into subsequent or previous periods until the required maximum resource utilization is reached.
Heuristics-based Capacity Levelling • For forward scheduling, the system moves the orders so far that the first activity using the resource to be leveled only begins after the overloaded period. • For backward scheduling, the system moves the orders so far that the last activity using the resource to be leveled actually ends before the overloaded period. • The system takes the lot sizes and rounding values defined in the master data into account when moving the orders.
SNP Heuristic as Location, Network, and Multi-Level Heuristic
Scheduling in SNP Heuristic
Period Factor
Production Scheduling for Multiple BOM Levels
Scheduling in CTM
Heuristics-based Capacity Levelling • Only orders that cause overloads are changed. • This proves advantageous when a lot of orders exist but only some of them overload the resource. • Prioritization is done by product or by product quantity. • Select “Capacity Leveling” to balance the required work loads. from the menu
Benefits of SNP with SCM The benefits of Supply Network Planning with SAP SCM are as follows: 1. Cross-plant medium-term rough-cut planning 2. Cross-plant optimization of resource utilization • Simultaneous planning of procurement, production and distribution • Simultaneous material planning and finite capacity scheduling of production, storage, and transportation resources 3. Planning of critical components and bottleneck resources 4. Prioritization of demands and receipts 5. Collaborative supply planning over the Internet
Linear Programming (LP) EGN 5623 Enterprise Systems Optimization
Operation Research (OR) Operation research refers to the application of quantitative methods and techniques to business problems in order to best utilize a company’s resources. OR is used by many leading companies in recent years to optimize their limited resources in order to maximize their profits or minimize their costs. Linear programming (LP) is one of the most important tools of operation research.
Linear Programming (LP) Five common types of LP problems: • Product mixed • Ingredient mix • Transportation • Production plan • Assignment
Five common types of LP problems
Five common types of LP problems
Steps in Formulating LP Problems 1. Define the objective 2. Define the decision variables 3. Write the mathematical function for the objective (objective function) 4. Write a one- or two-word description of each constraints 5. Write the right-hand side (RHS) of each constraint, including the unit of measure. 6. Write<=, =, or >= for each equation 7. Write all the decision variables on the left-hand side of each constraints 8. Write the coefficient for each decision variable in each constraint.
Formulating LP
Formulating LP
Formulation LP
Formulation of Problem
Objective and Constraints
Steps in Graphical Solution Method
Graphical Solution
Graphical Solution
Graphical Solution
Graphical Solution
Transportation (Network) Problem
Requirement Assumption
Feasible Solutions Property
Cost Assumption
Parameter Table for Transportation Problem Supply S 1 S 2. Sm
Transportation Problem Model Any problems (whether involving transportation or not) fits the model for a transportation problem if it can be described completely in term of a parameter table like Table 8. 5 and it satisfies both the requirements assumption and cost assumption. The objective is to minimize the total cost of distributing the units. All the parameters of the model are included in this parameter table.
Objective Function & Constraints
Rough-Cut Planning in SCM SAP Implementation EGN 5623 Enterprise Systems Optimization
Planning Book and Views
Capacity Check view Now switch to the CAPACITY CHECK view. In the Selection profile section double click on ## RESOURCES. Double click on the work center (plant ##A 1). Switch the TB Profile to 12 MONTH. We appear to have enough capacity in the work center at the aggregated monthly level. Now change the TB Profile to 180 DAYS. We are overloaded in the first couple days as SCM has tried to produce all that is needed to satisfy safety stock in those days.
Capacity Levelling Scroll over to the next capacity usage. We are also overloaded in those periods. Multilevel Heuristic does not take capacity into consideration. Select
Key Figures and Category Group in SNP Standard Planning Book
HW 6: Exercises: (Due date: 10/08/13) 1 Setup Transactional Data Transfer between SCM and ERP 1) Maintain integration settings in SCM system § § § Maintain distribution definitions in SCM system Maintain Objects specifics settings in SCM system Define transfer of SNP orders in SCM system 2) Create integration model for transactional data in SAP ERP system § § § Create and activate integration model for planned orders and production orders in SAP ERP system Create and activate integration model for purchase orders and purchase requisitions in SAP ERP system Define transfer of SNP orders in SCM system 2. Supply Chain Modeling 1) Global Bike Company (GBC) Supply Chain 2) Transactional data used in supply chain planning § § § Interactive SNP planning Selection profile Review forecast values for production
2. Please solve the following LP problem. Objective: Min Z = 10, 000 X 1 + 15, 000 X 2 S. T. X 1 + 2 X 2 >= 4 X 1+ X 2 >= 2. 5 1) Draw a graph 2) Plot the constraint function 3) Outline the feasible solution 4) Circle the optimal solution point.
3. The Green Up Fertilizer Company ships fertilizer from three manufacturing plants to four distribution centers (DC). The shipping cost per truckload of fertilizer from each plant to each DC is: Plant Distribution Center (DC) 1 2 3 A B C D $464 $352 $995 $513 $416 $682 $654 $690 $388 $867 $791 $685 Plant 1 has a monthly capacity of 75 truckload, Plant 2 has a monthly capacity of 125 truckload, and the Plant 3 has a monthly capacity of 100 truckload. The monthly DC demand is A = 80 truckload, B = 65 truckload, C = 70 truckload, and D = 85 truckload. Please formulate an LP problem to determine how much truckload of fertilizer should be shipped from each plant to each DC per month to minimize monthly shipping cost. 1) Define the objective. 2) Define the decision variables. 3) Write the mathematical function for the objective. 4) Write the constraints. 5) Solve the LP problem
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