1 An Overview of Planning with SAP Supply Chain Management

21

1.1 SAP Supply Chain Management

21

1.2 SAP Advanced Planning & Optimization

23

1.3 Summary

27

2 An Overview of Production Planning with SAP ERP and SAP APO-PP/DS

29

2.1 Production Planning Functions

29

2.1.1 Material Requirements Planning

30

2.1.2 Multilevel Planning

33

2.1.3 Material Planning and Capacity Planning

35

2.2 Advanced Production Planning with SAP APO-PP/DS

38

2.2.1 Requirements Planning with Exact Times

39

2.2.2 Descriptive Characteristics

39

2.2.3 Simultaneous Quantity and Capacity Planning

40

2.2.4 Production Planning Runs with Several Steps

40

2.2.5 Pegging and Control of the Material Flow

41

2.2.6 Determining the Source of Supply and Cost-Based Planning

43

2.2.7 Advanced Alert Handling

45

2.2.8 Advanced Options in Capacity Planning

48

2.2.9 Simple Options for Enhancement with Custom Functions and Heuristics

50

2.3 Planning in SAP APO and Execution in SAP ERP

52

2.4 Summary

53

3 The SAP Advanced Planning & Optimization Core Interface

55

3.1 Design of the Core Interface

55

3.1.1 Plug-In

56

3.1.2 Connecting the Systems Using Remote Function Calls

59

3.1.3 SAP APO-Specific Settings

63

3.2 The Principle of Master Data Transfer

69

3.2.1 Initial Transfer of Master Data

72

3.2.2 Transferring New SAP APO-Relevant Master Data

84

3.2.3 Change Transfer of Master Data

86

3.3 The Principle of Transaction Data Transfer

96

3.3.1 Transaction Data in SAP ERP and SAP APO

97

3.3.2 Initial and Change Transfers for Transaction Data

98

3.3.3 Transfer of Transaction Data from SAP APO to SAP ERP

101

3.4 Core Interface Monitoring

104

3.4.1 The Principle of Queued Remote Function Calls

105

3.4.2 Tools for Troubleshooting Transfer Errors

108

3.4.3 Eliminating Transfer Errors

110

3.5 Summary

112

4 Master Data

113

4.1 Mapping Principle

113

4.2 Locations

114

4.2.1 Transferring Plants and Distribution Centers

116

4.2.2 Storage Location Material Requirements Planning Areas

118

4.2.3 Customers and Vendors

119

4.2.4 External Procurement Relationships and Transportation Lanes

121

4.3 Products

123

4.3.1 Header Data

125

4.3.2 ATP Settings

125

4.3.3 Requirements Settings

126

4.3.4 Lot Size Settings

128

4.3.5 Additional Settings

129

4.4 Resources

129

4.4.1 Resources in SAP APO

131

4.4.2 SAP APO Resource Data

132

4.5 Production Data Structures and Production Process Models

132

4.5.1 Production Process Model, Runtime Object, Production Data Structure, and SAP APO Releases

133

4.5.2 Release-Dependent Notes for Runtime Objects or Production Data Structures

134

4.5.3 Structure of the Production Process Model and Production Data Structure

136

4.5.4 Transfer from SAP ERP

138

4.6 Mass Changes to SAP APO Master Data

140

4.7 Summary

142

5 Basic Functions of Production Planning

145

5.1 Basic Settings

145

5.1.1 Core Interface Integration

145

5.1.2 Global Settings

146

5.1.3 Planning Procedure

148

5.2 Independent Requirements

152

5.2.1 Sales Orders

152

5.2.2 Planned Independent Requirements in SAP APO

155

5.2.3 Requirements Strategies

158

5.2.4 Reducing Planned Independent Requirements

164

5.2.5 Descriptive Characteristics

165

5.3 The Planning Procedure

168

5.3.1 Interactive Planning

168

5.3.2 Production Planning Run

171

5.3.3 Capable-to-Match

175

5.4 Heuristics

176

5.4.1 Product Heuristics

178

5.4.2 Heuristics for Flow Control

183

5.4.3 Service Heuristics

184

5.5 Example of a Complete Planning Run

186

5.6 Firming

188

5.6.1 Manual Firming

188

5.6.2 Firming Based on a Firming Period

189

5.7 Net Requirements Calculation and Lot Sizes

192

5.7.1 Net Requirements Calculation

192

5.7.2 Lot Size Calculation

194

5.8 Determining the Source of Supply

196

5.8.1 Procurement Types

196

5.8.2 Automatic Determination of the Supply Source

198

5.8.3 Interactive Sourcing

200

5.9 Scheduling

202

5.9.1 Scheduling for External Procurement

202

5.9.2 Scheduling for In-House Production

203

5.9.3 Planning Strategy

205

5.9.4 Finiteness Level

211

5.9.5 Alternative Resources

214

5.9.6 Scheduled Planned Orders

215

5.10 Pegging

216

5.10.1 Dynamic Pegging

218

5.10.2 Fixed Pegging

220

5.10.3 Safety Stocks in SAP liveCache

222

5.11 Setup Times in Planning

222

5.12 Product Interchangeability

225

5.13 Executing Planning in SAP ERP

227

5.14 Summary

228

6 Tools to Evaluate and Process Planning

231

6.1 Order Views

231

6.1.1 Entering the Product View

232

6.1.2 Structure of the Product View

232

6.1.3 Using the Product View

234

6.1.4 Customizing the Product View

235

6.2 Product Planning Table

236

6.2.1 Entering the Product Planning Table

237

6.2.2 Structure of the Product Planning Table

238

6.2.3 Using the Product Planning Table

239

6.2.4 Customizing the Product Planning Table

240

6.3 Product Overview

242

6.3.1 Entering the Product Overview

242

6.3.2 Structure of the Product Overview

243

6.3.3 Using the Product Overview

244

6.4 Detailed Scheduling Planning Board

245

6.4.1 Entering the Detailed Scheduling Planning Board

245

6.4.2 Structure of the Detailed Scheduling Planning Board

247

6.4.3 Using the Detailed Scheduling Planning Board

248

6.4.4 Settings for Detailed Scheduling Strategies

252

6.4.5 Support of Interactive Planning with Detailed Scheduling Heuristics

261

6.4.6 Customizing the Detailed Scheduling Planning Board

263

6.5 Resource Planning Table

265

6.5.1 Entering the Resource Planning Table

265

6.5.2 Structure of the Resource Planning Table

265

6.5.3 Using the Resource Planning Table

267

6.5.4 Customizing the Resource Planning Table

267

6.6 PP/DS Optimizer

268

6.6.1 Basics of PP/DS Optimization

268

6.6.2 Entering the Optimizer

269

6.6.3 Structure of the Evaluation View of the Optimizer

270

6.6.4 Parameterization of the Optimizer

271

6.7 Alert Monitor

276

6.7.1 Entering the Alert Monitor

276

6.7.2 Structure of the Alert Monitor

277

6.7.3 Using the Alert Monitor

278

6.7.4 Customizing the Alert Monitor

279

6.8 Summary

280

7 Advanced Processes in SAP APO-PP/DS

283

7.1 Finite Planning with the Planning Run

284

7.1.1 Finite Requirements Planning

284

7.1.2 Finite Planning as Multistep Procedure

285

7.2 Setup-Optimal Sequencing with the PP/DS Optimizer

298

7.2.1 The PP/DS Optimizer as an Interactive Planning Tool

299

7.2.2 Sample Process for Interactive Setup Optimization

299

7.3 Capable-to-Promise

308

7.3.1 Prerequisites for the Capable-to-Promise Procedure

308

7.3.2 Capable-to-Promise Process

309

7.4 Planned Material Flow

317

7.4.1 Fixed Material Flow Using Pegging Available-to-Promise

317

7.4.2 Fixed Material Flow Using the Material Requirements Planning

319

7.4.3 Fixed Material Flow to Support the Optimization

320

7.4.4 Fixed Material Flow to Support the Capable-to-Promise Procedure

322

7.5 Multiresource Planning with the Wave Algorithm

323

7.5.1 Prerequisites for Multiresource Planning

323

7.5.2 Multiresource Planning Process

324

7.5.3 Alternatives to Multiresource Planning

331

7.6 Integration of Variant Configuration

332

7.6.1 Overview of the Procedures with SCM-APO Integration

333

7.6.2 Basic Prerequisites for the Variant Configuration under SCM-APO

336

7.6.3 Scenario 1: Make-to-Order Production with Variant Configuration without Characteristics-Based Forecasting

342

7.6.4 Scenario 2: Make-to-Order Production with Variant Configuration and Characteristics-Based Forecasting

345

7.7 Material Requirements Planning-Based Detailed Scheduling

357

7.8 Summary

360

8 Alternative User Interface for Planning

361

8.1 Planner’s Home Page

361

8.1.1 Introduction to the Planner’s Home Page

361

8.1.2 Technical Prerequisites and Setup Process

362

8.1.3 Organization and Adjustment

363

8.1.4 Applications

365

8.2 Enhanced Product Planning and Side Panels

368

8.2.1 Introduction to Enhanced Product Planning

368

8.2.2 Technical Prerequisites and Setup Process

368

8.2.3 Building Blocks of Enhanced Product Planning

369

8.2.4 Side Panels

370

8.3 Summary

374

Appendices

375

A Transactions and Menu Paths

377

A.1 SAP ERP Core Interface

377

A.2 SAP ERP Customizing

379

A.3 SAP APO-PP/DS Master Data

380

A.4 SAP APO-PP/DS Planning

383

A.5 SAP APO Monitoring

385

A.6 SAP APO Administration

385

A.7 SAP APO Customizing

386

B SAP Notes on SAP APOPP/DS

391

B.1 SAP APO-PP/DS in General

391

B.2 Master Data in General

391

B.3 Production Process Model, Runtime Object, and Production Data Structure

392

B.4 MRP Areas

393

B.5 Product Interchangeability

393

B.6 Integration

394

B.7 Production Planning in General

394

B.8 Production Planning Run, Heuristics, MRP

395

B.9 Product View and Product Planning Table

396

B.10 Pegging

396

B.11 CTP Check, Multilevel ATP Check

397

B.12 Conversion of Orders

397

B.13 Safety Stock

398

B.14 Characteristic Dependent Planning/Block Planning

398

B.15 Special Planning Processes

399

B.16 Detailed Scheduling—Integration

399

B.17 Detailed Scheduling Planning Board

399

B.18 Scheduling

400

B.19 Customer-Specific Heuristics

401

B.20 Optimization

401

B.21 Alert Monitor

402

B.22 Rapid Deployment Solutions

402

B.23 Performance

402

B.24 SAP APO Deployment Options

403

B.25 Planner’s Home Page and Enhanced Product Planning

403

C Heuristics

405

C.1 Heuristics for SAP APO 3.0

405

C.2 New Heuristics Introduced in SAP APO 3.1

408

C.3 New Heuristics Introduced in SAP SCM 4.0

410

C.4 New Heuristics Introduced in SAP SCM 4.1

411

C.5 New Heuristics Introduced in SAP SCM 5.0

412

C.6 New Heuristics Introduced in SAP SCM 5.1

414

C.7 New Heuristics Introduced in SAP SCM 7.0

414

C.8 New Heuristic Introduced in SAP SCM 7.0, EHP1

415

C.9 New Heuristics Introduced in SAP SCM 7.0, EHP2

415

D Abbreviations

417

E The Authors

419