Preface

13

Target Audience

13

How to Read This Book

14

How This Book Is Organized

15

Conclusion

16

Acknowledgments

17

1 Introduction to Capacity Planning

19

1.1 Why Capacity Planning Matters in Manufacturing

19

1.1.1 Balancing Workloads

20

1.1.2 Avoiding Bottlenecks

21

1.1.3 Reducing Idle Time

22

1.2 Strategic Benefits

22

1.2.1 Improved Delivery Performance

22

1.2.2 Cost Optimization

23

1.2.3 Production Stability

23

1.3 Capacity Planning with SAP

24

1.3.1 Within Production Planning

24

1.3.2 Transactions CM* Versus SAP Fiori Apps

26

1.4 Phases of Capacity Planning

34

1.4.1 Short-Term Firefighting

34

1.4.2 Medium-Term Balancing

35

1.4.3 Long-Term Strategic Alignment

36

1.5 Key Elements for Capacity Planning

37

1.5.1 Work Centers, Capacity Categories, and Work Center Groups

37

1.5.2 Standard Value Keys, Formulas, and Operation

38

1.5.3 Order Types

39

1.6 Summary

39

2 Configuring Capacity Planning

41

2.1 Initial Configuration

42

2.1.1 Capacity Category

42

2.1.2 Capacity Planner

43

2.1.3 Available Capacity

44

2.1.4 Formulas

49

2.2 Scheduling

54

2.2.1 Relevant Settings for Scheduling

55

2.2.2 Production Orders Scheduling Parameters

60

2.2.3 Planned Order Scheduling Parameters

67

2.2.4 Scheduling Margin Key

75

2.3 Order Control and Availability Checks

76

2.4 Overall Profile for Capacity Availability Check

80

2.4.1 Selection Profile

83

2.4.2 Control Profile

85

2.4.3 Time Profile

87

2.4.4 Evaluation Profile

90

2.4.5 Strategy Profile

92

2.4.6 Period Profile

94

2.5 Overall Profile for Capacity Leveling

96

2.5.1 Selection Profile

99

2.5.2 Control Profile

100

2.5.3 Time Profile

100

2.5.4 Evaluation Profile

101

2.5.5 Strategy Profile

102

2.5.6 Capacity Planning Table (Tabular) Profile

102

2.5.7 Capacity Planning Table (Graphic) Profile

104

2.5.8 List Profile

106

2.6 Control Key

107

2.7 SAP User Roles

109

2.8 Install SAP liveCache for SAP Fiori Apps

112

2.9 Summary

113

3 Master Data Capacity Planning

115

3.1 Material Master

115

3.1.1 Scheduling Margin Key

116

3.1.2 Availability Check

118

3.1.3 Production Supervisor and Production Scheduling Profile

119

3.1.4 Production Version

120

3.2 Bill of Materials

123

3.2.1 Header Attributes

123

3.2.2 Components

126

3.3 Work Center/Resources

127

3.3.1 Setup and Data Elements

127

3.3.2 Basic Data

130

3.3.3 Default Values

132

3.3.4 Capacity

134

3.3.5 Scheduling

139

3.3.6 Manage Work Center Groups

144

3.4 Routing

150

3.4.1 Setup and Data Elements

151

3.4.2 Header

152

3.4.3 Sequence

156

3.4.4 Operation Overview

160

3.4.5 Assigning Material Components to Operations/Suboperations

168

3.5 Reference Master Data Model for Capacity Planning

170

3.6 Summary

171

4 Calculating Capacity Requirements

173

4.1 Introduction to Capacity Requirement

173

4.2 Sources of Capacity Requirements

174

4.3 Distribution of Capacity Requirements

181

4.4 Cumulation of Available Capacities and Requirements

186

4.4.1 Work Center Hierarchy

187

4.4.2 Available Cumulation Functions

188

4.5 Reducing Capacity Requirements

193

4.6 Summary

195

5 Capacity Scheduling

197

5.1 Elements of Scheduling

197

5.2 Calculation Rules for Scheduling

200

5.3 Scheduling Levels

210

5.4 Material Requirements Planning Run

212

5.5 Finite Scheduling

218

5.6 Midpoint Scheduling

219

5.7 Summary

220

6 Capacity Evaluation and Monitoring

223

6.1 Standard Capacity Evaluation Reports Overview

224

6.2 Manage Work Center Capacity App

233

6.2.1 Application Overview

233

6.2.2 Area of Responsibility

235

6.2.3 Load Personalization

236

6.2.4 Visual Checkboxes and Traffic Lights

237

6.2.5 Worklist Management and Columns Definition

237

6.2.6 Detection of Overloads and Underloads

239

6.3 Mass Maintenance of Work Center Capacity App

249

6.4 Evaluate Capacity App

254

6.5 Extended Evaluation Reports

259

6.6 Work Center Capacity Jobs

266

6.7 Summary

270

7 Capacity Leveling

271

7.1 Planning Tables for Capacity Leveling

272

7.1.1 Tabular Planning Table

274

7.1.2 Graphical Planning Table

288

7.2 SAP Fiori-Based Scheduling

291

7.2.1 Capacity Scheduling Table

293

7.2.2 Capacity Scheduling Board

312

7.3 Summary

323

8 Integration with Other Functions

325

8.1 Integration with Planning Tools

325

8.1.1 Sales and Operations Planning and Long-Term Planning

326

8.1.2 Material Requirements Planning

339

8.2 Integration with Production Execution, Service, and Project System

351

8.2.1 Discrete Manufacturing, Process Industries, and Repetitive Manufacturing

352

8.2.2 Plant Maintenance

359

8.2.3 Project System

364

8.3 Summary

367

9 Enhancements and Artificial Intelligence Capabilities

369

9.1 Enhancing Capacity Planning

370

9.1.1 Extensibility for Capacity Planning Using SAP Fiori Apps

370

9.1.2 UI Adaptations

382

9.1.3 Core Data Services Views and Analytic Extensions

384

9.1.4 Situation Handling

385

9.2 SAP Business AI

386

9.3 SAP Business Technology Platform

388

9.4 Summary

388

A Production Planning and Detailed Scheduling

391

A.1 Solution Overview

392

A.2 When to Use Production Planning/Detailed Scheduling

394

A.3 Summary

396