Enterprise Systems Optimization Introduction EGN 5623 Enterprise Systems Optimization (Professional MSEM) Fall, 2012

Course Objective Supply chain management (SCM) concepts, modeling, configuration, integration, data transfer, and supply network planning and optimization. With a focus on SAP implementation

SCM Scope Single facility SCM ◦Increased planning capabilities for a single facility ◦ Finite-capacity scheduling Multiple facility SCM ◦Integrated planning for the entire supply chain network ◦ Multiple plants and distribution centers ◦ Multiple vendors ◦ Multiple customers ◦ Multiple transportation options

ERP Operations related to SCM Related ERP Modules ◦Materials Management (MM) and Production Planning (PP) modules ◦ Sales and Operations Planning (SOP) ◦ Forecasting ◦ Master Scheduling ◦ Material Requirements Planning (MRP) ◦ Capacity Requirements Planning (CRP) ◦ Order release and receipt

ERP & SCM Basics (SAP View) SAP ERP: ◦Holds master data for materials, plants, customers, vendors, purchasing information records ◦Holds transactional data (e.g., sales orders, planned orders) ◦Is where plans get executed SAP SCM: ◦Is where “advanced planning” happens ◦Imports master and transactional data from ERP ◦Sends plans back to ERP for execution ERPSCM Core Interface (CIF)

SCM Exercises Plan with GBI v 1.0 ◦Review Master data ◦APO Demand planning ◦Planning in SCM  Supply Network Planning (SNP) Heuristics  Deployment and Transport Load Builder (TLB)  Capable to Match (CTM)

Modules related to ECC and SCM The products and modules involved in the SCM exercises are: ◦ERP (ECC 6.0):  MM,  PP,  SD ◦SCM 7.0:  DP (Demand Planning),  SNP, and  Deployment

Work Flow in SAP SCM

Work Flow for our Exercises

Introduction to SCM and SAP APO Theories & Concepts EGN 5623 Enterprise Systems Optimization (Professional MSEM) Fall, 2012

The APICS-Standard Planning Framework

Intro to Supply Chain Materials ◦Any commodities used directly or indirectly in producing a product or service.  Raw materials, component parts, assemblies, finished goods, and supplies Supply chain ◦Flow of materials through various organizations from the raw material supplier to the finished goods consumer.

Supply Chain Management Definition ◦All management functions related to the flow of materials from the company’s direct suppliers to its direct customers. Functions included: ◦purchasing, traffic, production control, inventory control, warehousing, and shipping. Two alternative names: ◦Materials management ◦Logistics management

Supply Chains Definition Supply Chain – A supply chain is the network of organizations, people, technology, activities, information and resources involved in the production of a product or a service – Includes suppliers, manufacturers, transporters, warehouses, retailers and customers Production System – A manufacturing subsystem that includes all functions required to design, produce, distribute, and service a manufactured product. A Supply Chain consists of one or many production systems that work together in the fulfillment of a customer order Best viewed as a network

Supply Chain for Steel in an Automobile Door MININGCOMPANY Mines iron ore STEELMILL Forms steel ingot STEELCOMPANY Forms sheet metal IronoreSteelingots AUTOMOTIVESUPPLIER Makes door AUTOMOBILEMANUFACTURER Makes automobile CARDEALERSHIP Does preparation Cardoor Car Car FINALCONSUMER Drives automobile Prepared Preparedcar Sheetmetal

Supply Chain Management in a Manufacturing Plant ReceivingandInspectionRawMaterials, Parts, and In-processWare-HousingProductionFinishedGoodsWare-housingInspection,Packaging,AndShipping Suppliers Customers Materials Management PurchasingProductionControl Warehousing and Inventory Control Shipping and Traffic Physical materials flow Information flow

Logistics Logistics usually refers to management of: ◦the movement of materials within the factory ◦the shipment of incoming materials from suppliers ◦the shipment of outgoing products to customers

Movement of Materials within Factories IncomingVehiclesIncomingVehiclesReceivingDockReceivingDockQualityControlQualityControlWarehouseWarehouse WorkCenterWorkCenter Other Work Centers CentersPackagingPackagingFinishedGoodsFinishedGoods ShippingShippingShippingDockShippingDockOutgoingVehiclesOutgoingVehicles The typical locations from/to which material is moved: The typical locations from/to which material is moved:

Shipments To and From Factories l Distribution Resource Planning l Distribution resource planning extends DRP so that the key resources of warehouse space, workers, cash, and vehicles are provided in the correct quantities at the correct times.

Analyzing Shipping Decisions The “Transportation Problem” ◦Problem involves shipping a product from several sources (ex. factories) with limited supply to several destinations (ex. warehouses) with demand to be satisfied ◦Per-unit cost of shipping from each source to each destination is specified ◦Optimal solution minimizes total shipping cost and specifies the quantity of product to be shipped from each source to each destination

Warehousing Definition ◦Warehousing is the management of materials while they are in storage. ◦Viewed as distribution center (DC) Warehousing activities: ◦Accounting ◦Ordering ◦Storing ◦Dispersing

Warehousing Record keeping within warehousing requires a stock record for each item that is carried in inventories. The individual item is called a stock- keeping unit (SKU). Stock records are running accounts that show: ◦On-hand balance ◦Receipts and expected receipts ◦Disbursements, promises, and allocations

Common Supply Chain Processes

Common Time Horizons for SCM Processes

Level of Detail and Time Horizon for SAP APO Modules

SCM Processes in SAP APO Modules

SAP APO System Structure and Integration with SAP ERP

Characteristics of the SC Network Each node may consist of a production system of its own Links in the network represent a business relationship between two nodes e.g. transportation of a product between two nodes The number of levels in a supply chain varies and depends on the complexity of the product Flows can skip levels by that: Supplier ships direct to DC Manufacturer ships directly to customer The decoupling point is the shift occurs from make-to-stock to make-to-order The decoupling point is not fixed to one level of the supply chain and is influenced by postponement strategies (e.g. Dell)

Characteristics of the SC Network Multiple Products, each with possibly different Bills of Material and multiple configurations Multiple Suppliers for raw materials, parts or subassemblies Multiple Subcontractors Multiple Plants possibly containing a wide variety of equipments Multiple Warehouses – Distribution centers, local, regional and factory warehouses Different means of Transportation (air, sea, rail, FTL, LTL) either leased, owned or contracted Different information systems and communication channels People with various skills at all levels of the organization

Example of Costs and Revenues in the Supply Chain Costs – Production and purchasing costs – Setup or changeover costs – Transportation and handling costs – Hiring and firing costs – Overtime costs – Inventory costs – Promotional and advertising costs – Renting and leasing costs – Subcontracting costs – Overhead – Capital investments and depreciation – Taxes and duties Revenue – Customer is the only source of revenue From sale of products, spare parts, materials or service

Example of Constraints Productivity constraints Equipment capacity constraints Labour availability Technological constraints Inventory constraints Purchasing, manufacturing and distribution lead times Demand uncertainties and seasonalities Service requirements Budget Regulations and other constraints

Categories and Attributes of a Supply Chain - Reproduced from Fleischmann B., Meyr H, Hierarchy and Advanced Planning Systems, Handbooks in OR and MS, Chapter 9, Elsevier, 2003, pp

Types of Production Systems 1. Pure Inventory Systems – Simplest form of logistic system – Only procurement activities with no production or complex distribution processes – Example: wholesale or retail operations where items are purchased 2. Continuous production Systems – Manufacturing of a few families of technologically related products in large quantities – Example: Assembly lines or fabrication lines 3. Intermittent production Systems – Batch production of many products which share several processing centers 4. Project based systems – Production of a unique complex product such as a ship or a bridge

Production Strategies Make to Stock ◦Production is based on forecasted amounts for stocked items Make to Order ◦Production of a product is made for a customer order in the quantity specified by the order

2. Hierarchical Planning Hierarchical planning was first introduced by Robert Anthony in 1965* as a three level management framework that consists of: – Strategic or long-term planning – Tactical planning (or management control) for mid-term planning – Operational planning for short term planning The results of one each level are considered as an inputs to the lower level planning Effective implementation and control of the plans requires: – An execution layer that captures the events as they occur – Feedback loops at all levels * R.N. Anthony, Planning and Control Systems: A Framework for Analysis, Cambridge. Mass., 1965

Hierarchical Planning Framework Procurement Production DistributionSales Long term -Material programs - Supplier selection - Cooperation - Plant location - Production systems - Subcontractors - Physical distribution structure - Transportation strategy - Product program - Strategic sales planning -- Personnel training -- Contracts -- Material Requirements Planning -- Master production Scheduling -- Capacity planning-- Distribution planning-- Mid-term sales planning Mid term -- Personnel scheduling -- Material ordering -- lot-sizing - operations scheduling - shop floor control - Warehouse replenishment - Transportation planning-- Mid-term sales planning Short term EXECUTION InformationFeedback Flow of goods

Differentiating Factors by Planning Levels Factor- LevelStrategicTacticalOperational PurposeSupply chain design, resource acquisition Planning resource utilization Operation scheduling and execution Implementation instruments Policies, objectives, capital investment BudgetsSchedules, procedures and reports Planning horizonLong: 3-5 yearsMedium: 6-18 months Short: daily, weekly, monthly ScopeBroad corporate level Medium plant level Short floor level Level of Management TopMiddleLow Frequency of re-planning Low: every few years Medium: monthly or quarterly High: weekly, daily or as required Source of information Largely externalExternal and internalLargely internal Level of aggregation - product data - time High Product families years Medium Product groups Month Low individual products continuous Degree of uncertainty HighMediumLow Degree of riskHighMediumLow

Introduction to SCM and SAP APO SAP Implementation EGN 5623 Enterprise Systems Optimization (Professional MSEM) Fall, 2012 Introduction to SCM and SAP APO SAP Implementation EGN 5623 Enterprise Systems Optimization (Professional MSEM) Fall, 2012

SAP Business Suite SAP NetWeaver SAP SCM SAP PLM SAPSRM SAP CRM SAP ECC

Planning with SAP ERP & SCM SAP ECC ERP SAP SCM (includes SAP BW) Core Interface (CIF) Demand Planning Supply Network Planning and optimization Production Planning with capacity considerations ATP CTP Detailed Scheduling Deployment Transportation planning Vehicle routing and scheduling Mater data Materials Locations Partner Plants Info records Transactional data Customer orders Production orders Purchasing orders Execution Basic Components of SAP SCM

Planning at Supply Chain Level SAP ECC 1 SAP SCM SAP ECC 2 SAP ECC n Core Interface - Each SAP ECC component covers one or more locations In the network - Planning may be done centrally

SAP SCM Functionality THEORY AND PRACTICE OF ADVANCED PLANNER AND OPTIMIZER IN SUPPLY CHAIN DOMAIN by Sam Bansal

SAP SCM Modules THEORY AND PRACTICE OF ADVANCED PLANNER AND OPTIMIZER IN SUPPLY CHAIN DOMAIN by Sam Bansal

Two planning Scenarios for SAP SCM Alternative Scenario Base Scenario

Cost-Based Optimization Cost or price driven Mixed integer programming Must define all sourcing, production, transportation, inventory costs and constraints

Supply Planning Tasks and Output for SCM Tasks – Identify sources for finished products – Plan and consider safety levels in any location – Distribute production over plants – Choose production resources in plants – Explode bill of materials in plants – Identify sources for supply of raw materials and components Outputs – Purchase requisitions – Stock transport purchase requisition – Planned production orders

SAP APO Architecture

SAP Access through SAPGUI SAPGUI Download The latest SAP GUI release posted on Chico web server User = sap; Password = sapgui4me. This GUI works on Windows 7 systems, as well as Vista and Windows XP.

SAPGUI Download Instruction

SAPGUI Setup SAP SCM

SAP ERP/SCM Clients, Userid, Password SAP SCM Client: 600 Userid: fiu-101 to fiu-130 Initial password: SAP4US

Exercises: Overview of SCM (APO) Master Data 1) Location master data in APO 2) Transportation lanes in APO 3) Product master data in APO 4) Resource master in APO 5) Production Process Model in APO 6) Quota Arrangement in APO 7) External Procurement Relationships in APO