Multi-level Supply & Demand Matching -sap(1).ppt

Multi-levelSupply&Demand Matching,SCMU5:Demand and Supply Planning,Course Overview Diagram,2,4,1,Demand Planning,Supply Network Planning,Multi-level Supply&Demand Matching,Collaborative Planning,5,Exercise,3,Contents:,CTM,CTM OverviewDemand Prioritization and Supply Distribution CTM Master DataUnconstrained/Constrained CTMReplenishment PoliciesRules-Based CTM,CTM Overview CTM Process Overview,Contents:,CTM Overview,CTM as a Integral Part of the APO,Complements theAPO Supply Network Planningfocus on production planningwith capacity check on activity levelOrder BasedCTM focus on grading production processesHigh-Tech industries(e.g.semiconductor companies)Solution for companieswhich want high customer satisfactionwith many constraints,The CTM Approach,Huge amount of dataeach demand is treated separatelyheuristics versus finding an optimal solutionpull approach based on customer needs downstreamApproachconstraint programminggoal-oriented programming,CTM,Target Days of Supply,Target Days of Supplyforces that demand of following days is fulfilled(covered)by the given supply time-dependent valuesat all levels,Target Days of Supply(TDS),90,100,100,Supply,Demand,100,110,310,190,3,3,3,TDS,2,3,because,90,100,100,Supply,Demand,100,110,310,190,3,3,3,TDS,2,3,+,+,The Input,productavailability dateavailable quantityorigin locationprioritycategory(e.g.near obsolete,normal,.),productdue daterequired quantitydestination locationpriority,categorizedsupplies,prioritizeddemands,1.,2.,3.,4.,5.,6.,7.,8.,9.,10.,11.,The Application Model,categorizedsupplies,prioritizeddemands,1.,2.,3.,4.,5.,6.,7.,8.,9.,10.,11.,Production Master Data,Supply Chain Network,The Solution,categorizedsupplies,prioritizeddemands,1.,2.,3.,4.,5.,6.,7.,8.,9.,10.,11.,Capable-to-Match,multi-site capacity check and check of transportation capabilities,Comparison of SNP Strategies(1),Demand at a location,Dependent demand at loc.,Processing flow,Heuristics:,Optimizer:,CTM:,Capable to Match(CTM),CTM approachDemand prioritizationSupply categorizationSearch strategiesMulti-site planningCTM constraintsProduction resourcesLot sizesDue dates,Synchronous Production and Sourcing,Multi-level synchronous production needs multi-level dynamic order split,107,136,150,107,136,150,107,107,307,336,350,307,336,350,307,307,0,950,350,307,336,350,0,307,Production,Production,Inter-plant transport,200,200,200,200,Inter-plant transport,200,200,200,200,Production,SNP Strategies:A Comparison,Bucket Oriented,Order Oriented,SpeedQualityProd.resourceOther resourceMultilevelCostsPrioritiesQuota arrang.Constraint,Heuristics,Optimizer,CTM,+-2.step,local2.step,local+-+-,-+global+global+material+Creates+,global+-+-location/mat.+,Demand Prioritization,Contents:,Demand Prioritization,CTM Process(Overview),Demand PrioritizationSupply CategorizationCTM EngineCreate CTM Application ModelCTM algorithm,CTM Process,DemandPrioritization,SupplyCategorization,DemandsForecasts(from APO Demand Planning)Sales ordersPrioritization is based on:CategoryDateLocationProductDemand Selection CTM Work Area,PrioritizedDemands,Demands,Demand Prioritization,CTM:Demand Prioritization/Sales order Criteria,CriteriaATP categorydemand due datelocation priorityLocation-specific product priority time-/version-dependent,location-specific product priorityproduct numberlocation numberrequested quantityuser exit,Additional R/3 categories:item category of the sales documentsales document numberorder item numberdate on which the record was addeddelivery priorityconfirmed quantitypercentage of confirmed quantitymaximum number of partial deliveries allowed per itemdelivery groupdelivery date,CategorizedSupplies,Supplies,Excess,Normal,Target,Supply Categorization,Supplies include:Inventory Purchase ordersCategorization is based on supply limits:For each location For each productPre-processing step,Supply Distribution,Contents:,Supply Distribution,Supply Distribution,Distribution of unused,available supply from one location to other locations single-level basis using existing quota arrangements and transportation lanes.UnconstraintOrder-based(pegging can be fixed),CTM Master dataCTM ProfileCTM Planning Strategies,Contents:,Master Data,Master Data for CTM,Product master(location)Lot sizes(minimum/maximum increment)Priority Location masterPriority for locationResourcesSingle activity,multi-activity,bucketMaster data check,Supply chain model Time-phased,product-dependent transportation lanes Transport duration Transport calendar Production Process Model(PPM)PPM time validity PPM lot size validity Operation scrap Material consumption(Input/Output at beginning and end),APO Production Process Model(PPM),planning order,process,PPM summarizes Routing BOM PPM supports operations:set of different process steps modes:alternative production modes for a process step(e.g.manual assembly or automatic assembly)effectivity based on time intervals effectivity based on lot sizes PPM processes will be realized by APO production orders,Input/Output Components,Input Componentsalternative componentsalternatives in timeidentification of“raw material”Output componentsco-productspossibility to model bin splitsno explicit head material for processes,R,R,R,R,co-products,processes,Resources,Single-Activity Resources time-continuous available capacity for one activity Multi-Activity Resources time-continuous available capacity for multiple activities Bucket Resources time intervals available capacity per time interval,Transportation Lanes,Transport Lanes directed between two locations time-phased product-dependent transport time transport calendar,May 2000 1 2 3 4 5 6 7 8 91011121314151617181920212223232526272829303031,CTM Profile,Define all settings necessary for a CTM run in this profile:Planning area and periodPlanning strategiesSequence for demand prioritizationCategorization of supplies by limit,CTM Planning Strategies,Define the following strategies in the CTM profile:Planning methodPlanning areaScheduling directionPegging typeSearch strategy,CTM Planning Method,The planning method determines which orders will be included in the CTM run based on the pegging relationships in the order netOptions include:Plan unpegged orders onlyPlan all orders except those in fixed pegging relationshipsReplan all ordersPlanning areas:Model CTM work area,Fixed Pegging,Dynamic Pegging,Steps for CTM runConstrained/Unconstrained CTM,Contents:,Constrained/Unconstrained CTM,Selection of the Process Flow,Alternatives for processes production plants transport lanesSupply NetworkConstraints restrictions of production sites(determination of qualified sites),In many business scenarios,a complex Supply Chain Network of alternative flows is built out of the huge amount of decision alternatives.,Restricted Supply Chain Network,.but can be reduced by Supply Network Constraints,Steps for a CTM Run,1.Create Master Data*2.Create a supply chain model*3.Define CTM profile*4.Maintain CTM time stream*5.Define planning data6.Define planning method,7.Determine search strategy*8.Prioritize demand9.Define limits for supply categories10.Categorize supplyStart planning run*Mandatory setup,Supply Constraints and Capacity Constraints,t,Demand,no capacity,no supply,Success,notfulfilled,notfulfilled,fulfilled,Concurrent Capacity Requirement Planning andMaterial Requirement Planning,t,Determination of the Solution Tree,Search By tree exploration Using backtrackingConstraint PropagationTruncation of the search tree to reduce the search spaceConstraints Supply Capacity,Customer Order,t,Partial Shipment,max:3 days,t,Partial Satisfaction,Partial ShipmentA demand can be partially satisfiedin time(late demand)Time frame can be specified Partial SatisfactionA demand can only be partially satisfied Early DeliveryMaximum number of days canbe specified,Constraints,Constraint Programming and Scheduling,Constraint programming usingILOGs C+Solver Library constraints on time quantity capacities goals declarative approachScheduling usingILOGs C+Scheduler Libraryscheduling module based on Solver,constraint modelbasic search goals,CTM applicationmodel,strategies,CTM layers,CTM Results,CategorizedSupplies,PrioritizedDemands,Capable to Match,Multi-site capacity and transportation capability check,Supply Chain Viewer,Tracebility of the result supports the analysis and understanding of the result Fixed pegging Guarantees a relationship to the initial demand Over timeRetains relationships to important orders Demand-dependente.g.for important customers/orders Fixed pegging versus dynamic peggingdynamic pegging optimizes if changes occur CTM Viewer only for display purpose,APO Plan Monitor,ComparisonOver timeOver versionsDefine key figure profilesChoose from predefined key figures Use formulas to define further key figuresUse ranges and formulas to define scoresCombine score of different key figures to define an overall quality indicator,Key Figures,Scores,Formulas,Search StrategyLate demand StrategyPartial Shipment/Partial SatisfactionTarget days of supplySafety Stock,Contents:,Replenishment Policies,Late Demand Strategies,Domino effectplanning immediately withpostponed due datepossible result:each postponed demand can influence the due date of the next demand Airline reservationshift to the end of the demand list,1.,2.,3.,4.,t,domino effect,1.,2.,3.,4.,airline reservation,t,5.,Safety Stock,Safety stock replenishmentExplicit time-dependent valuesAt all levelsResult of the new safety stock planning can be usedTime-dependent strategy for decreasing safety stock(interval planning),Rule-Based CTM OverviewProduct/Plant SubstitutionDown Binning,Contents:,Rule-Based CTM,Rule-Based CTM,Demand-dependent multi-level Supply demand match How to influence the CTM search during a planning run applying demand-dependent rules including constraints Substitutions from stock,Supply Chain Network,“Rule-Based CTM allows a better control of the supply chain”,Down Binning,Down binningto fulfill a demand for a low quality product,it is allowed to use products of a higher qualityby special substitution PPMs which avoid production on lower levelsusing explicit substitution rules,500MHz,550MHz,600MHz,500MHz,1000,50%,30%,20%,500MHz,600MHz,500,300,500,300,100,60,40,100,