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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
3© SAP SE or an SAP affiliate company. All rights reserved.
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
4© 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
5© SAP SE or an SAP affiliate company. All rights reserved.
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
6© 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
7© SAP SE or an SAP affiliate company. All rights reserved.
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
8© SAP SE or an SAP affiliate company. All rights reserved.
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
9© SAP SE or an SAP affiliate company. All rights reserved.
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
10© SAP SE or an SAP affiliate company. All rights reserved.
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)
11© SAP SE or an SAP affiliate company. All rights reserved.
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
12© SAP SE or an SAP affiliate company. All rights reserved.
Time Tabele per Line
13© SAP SE or an SAP affiliate company. All rights reserved.
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
14© SAP SE or an SAP affiliate company. All rights reserved.
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)
15© SAP SE or an SAP affiliate company. All rights reserved.
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
16© SAP SE or an SAP affiliate company. All rights reserved.
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
17© SAP SE or an SAP affiliate company. All rights reserved.
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
18© SAP SE or an SAP affiliate company. All rights reserved.
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
19© SAP SE or an SAP affiliate company. All rights reserved.
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
20© SAP SE or an SAP affiliate company. All rights reserved.
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
21© 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
22© SAP SE or an SAP affiliate company. All rights reserved.
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
23© SAP SE or an SAP affiliate company. All rights reserved.
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]
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
25© SAP SE or an SAP affiliate company. All rights reserved.
© SAP SE or an SAP affiliate company.
All rights reserved.
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In particular, SAP SE or its affiliated companies have no obligation to pursue any course of business outlined in this document or any related
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