lean manufacturing planning & control (lmpc)sapidp/011000358700001066112013e/... · proven...

Automotive Consulting SolutionLean Manufacturing – Planning & Control (LMPC)

2© SAP SE or an SAP affiliate company. All rights reserved.

Agenda

1. Benefit for the Customer

2. Description of the Function

3. The Function in the System

4. Technical Information


Customer Benefit

Proven solutions/services of SAP Automotive Consulting

Solutions already running productive at several customers

Solutions and documentation are available in German and English

Prompt implementation possible

Defined timeframe for implementation

Exact calculation of implementation cost. Implementation for fixed price

6 months of free follow up care operations for bug corrections starting at

the date of installation within the development landscape. Afterwards

chargeable consulting support starts

No additional ongoing costs (i.e. maintenance cost)

Time

Cost

Solution


Agenda






The ACS combines and integrates two approaches:

1. Production planning cockpit with many enhancements

2. Integration of Lean Manufacturing functions (e.g. Heijunka and Kanban)

Motivation

Enhancement of SAP ERP production planning

Centralization and integration of interrelated functions (Cockpit)

Support of classic production planning & control

Solution for planning and control of repetitive and discrete production orders,

process orders (PP-PI), PM and PS

Thorough integration of Heijunka processes and SAP eKanban

Transparency through visualization. Easy to use due to flexible customization,

according to user‘s requirements

Flexible and easy to enhance with further customer-specific function modules


Agenda






Function Overview

Lean Manufacturing / Heijunka

Leveling (Heijunka)

Production Schedule – Rhythm Wheel

Simulation of Heijunka-Plan und EPEI - Calculation

Integration of MRP / Detailed Scheduling and Kanban


Leveling (Heijunka)

Challenge:

Demands of manufacturing goods vary over

time and result in inefficiencies:

Bull-Whip Effect

Fluctuations on lower levels of BOM

Efficient use of capacities is not possible

causes short term ad-hoc reaction

instead of long term optimization

Solution:

Leveling of replenishment items enables

production to be more smooth and efficient

Fluctuations on lower levels of BOM are

leveled as well

Minimization of Bull-Whip-Effect and stock

levels


Leveling – How does it look & feel?

selection of

levelling period

selection of

levelling-relevant

materials

parameterization of

levelling algorithm via

user interface

definition of steps to be

performed


Production Schedule – Rhythm Wheel

New master data: production schedule assigned to production line and production groups

(blocks), comprising 1-n materials

Assembly groups can be assigned per plant and production line, entering start / end time

per day

Changeover times can be minimized in advance, using the ideal sequence of materials

Definition of Production Schedule

line time monday tuesday wednesday thursday friday saturday sunday

pro

du

ctio

n li

ne

1

06:00

07:00

08:00

material A

Free

cap

acit

y(f

or

ord

ers

wit

h d

ate) material A

Free

cap

acit

y(f

or

ord

ers

wit

h d

ate) material E

09:00

10:00material F

11:00

material B material B12:00material G

13:00

14:00material

C & Dmaterial

C & DPlanned

Maintenance15:00

16:00

17:00

18:00

19:00

20:00

21:00

22:00

Fertigu

ngsgrup

pe

production

group for

1-n

materials

definition

start - end

per

productio

n group

(block)


Creation of Production Schedules

1: Creation of assembly groups

2: Definition of blocks – assignment of production groups per weekday

3: Definition of start / end-times and planning restrictions


Time Tabele per Line


Simulation of Heijunka-Plan und EPEI - Calculation

Visualization of capacity usage per production block

Calculation of EPEI per production block

Adjustments of start / end times enables iterative optimization

Feasibility check and optimization of the production resp. Heijunka schedule


Integration of MRP / Detailed Scheduling and Kanban

MRP & detailed scheduling enables production optimization in advance

Check and observance of restrictions (e.g. capacity available) ensured

Empty Kanbans (Pull) are linked to orders visually

This function integrates the two worlds – push & pull, and shows the deviation

between production plan and real consumption

Order

confirmed with

empty Kanban

Not yet

confirmed

Additional

Call-of (empty

Kanban)


Planning Table – Functions and Features in a nutshell

Enhancement of graphical planning table through ALV grid, with access to all

relevant data

(> 900 data columns, extendable according to customer‘s needs)

Additional chart to visualize capacity usage and stock over time

Many ways to sequence and reschedule orders

Refresh und Save planning table without having to leave the transaction

Menus and buttons to call other transactions and functions (can be adapted

flexibly

& and extended according to customer‘s needs)

Production schedule for sub daily partition of available capacity

Visualization of alerts and conflicts , e.g. if delivery date is exceeded etc.

Solution can be adapted very flexible via customer specific functions and

enhancements


Planning Table – Look & Feel

Capacity

view

flexible &

adjustable

menus and

buttons

All relevant data

available (> 900

columns in ALV-Grid)

Alerts, e.g. for

buffer level,

constraints not

met, etc.

Visualization

of order

sequence

Sequencing

according to

different criteria (e.g.

setup matrix)

Stock level

view


Function ALV-Grid & Buttons

Buttons and underlying functions can be changed easily and adapted to different users

needs – examples:

Build production blocks (planning according to production schedule)

Capacity & availability check

Mass conversion planned orders to production / process orders

Create PM-order

Release order / activity

Build order pool

Consideration of customer specific scheduling / sequencing logic

Rows / data fields can be coloured according to values comprised

Alerts, showing e.g. if delivery date is exceeded or ok

Buttons can be

adjusted

according to

user‘s needs in

user profile


Scheduling & Sequencing

Diverse scheduling functions (planned & production orders)

Production blocks (according to prod. schedule)

Order pools (bundling of orders)

Free production scheduling

Order sequencing e.g. according to sort sequence in ALV grid (acc. to any

of the columns available)

Very easy way to sequence orders

More than 900 columns available in ALV-Grid

Comfortable re-planning function (drag & drop / up & down buttons)

Usage of up to 4 strategy profiles possible

Use of different planning logics to schedule different groups of materials

possible


Visualization

Visualization:

Graphical Chart to visualize capacity usage and stock level

Visualization and display of manufacturing conflicts (availability of

components,

tools & resources, etc.)

Visualization of dates, e.g. delivery date

Individualization & Ergonomics:

Handling and calling other transactions via integrated buttons , e.g.:

conversion of orders, availability check

Adjustable menus and buttons according

to individual user‘s needs

Adjustable Menus

with e.g. mouse

click right


Other enhancements

MRP-run per production line

Display of planning table on two screens

(e.g. graphical part separately from data (ALV-grid))

Further transaction calls / functional enhancements via customer specific

enhancements

Solution specific authorization concept


Agenda






Technical Information

Available for SAP ERP ECC 6.0

Activation of automotive industrialized solution in SAP ERP System not

necessary

Technical installation is possible remotely

Modification-free

Delivery in Z-namespace


Source of Information

OSS-System

Notes (Search term: Automotive Consulting Solutions)

Internet

Overview-, Detail- and Customer presentations

http://www.sap.com/acs

Email - distribution list

Signing up through [email protected]

http://www.sap.com/acs

Thank you!

Ferenc Gulyássy

Business Processes Senior Consultant SCM

SCM Consulting

SAP Deutschland SE & Co. KG

Hasso-Plattner-Ring 7

69190 Walldorf, Germany

M +49/ 15116810060

E [email protected]


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