Automotive Consulting Solution. Lean Manufacturing Planning & Control (LMPC)

Transcription

1 Automotive Consulting Solution Lean Manufacturing Planning & Control (LMPC)

2 Agenda 1. Benefit for the Customer 2. Description of the Function 3. The Function in the System 4. Technical Information 2

3 Customer Benefit Solution Proven solutions/services of SAP Automotive Consulting Solutions already running productive at several customers Solutions and documentation are available in German and English Cost 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 Prompt implementation possible Defined timeframe for implementation 3

4 Agenda 1. Benefit for the Customer 2. Description of the Function 3. The Function in the System 4. Technical Information 4

5 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 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) 5

6 Agenda 1. Benefit for the Customer 2. Description of the Function 3. The Function in the System 4. Technical Information 6

7 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 7

8 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 8

9 Leveling How does it look & feel? selection of levelling-relevant materials definition of steps to be performed selection of levelling period parameterization of levelling algorithm via user interface 9

10 production line 1 Free capacity (for orders with date) Free capacity (for orders with date) 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 production Fertigu group for ngsgrup 1-n pe materials definition start - end per productio n group (block) Definition of Production Schedule line time monday tuesday wednesday thursday friday saturday sunday 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 material A material B material C & D material A material B material C & D material E material F material G Planned Maintenance 10

11 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 11

12 Time Tabele per Line 12

13 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 13

14 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) 14

15 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 15

16 Planning Table Look & Feel Capacity view Visualization of order sequence Stock level view Alerts, e.g. for buffer level, constraints not met, etc. All relevant data available (> 900 columns in ALV-Grid) flexible & adjustable menus and buttons Sequencing according to different criteria (e.g. setup matrix) 16

17 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 17

18 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 18

19 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 19

20 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 20

21 Agenda 1. Benefit for the Customer 2. Description of the Function 3. The Function in the System 4. Technical Information 21

22 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 22

23 Source of Information Internet Overview-, Detail- and Customer presentations - distribution list Signing up through mario.rebitzer@sap.com OSS-System Notes (Search term: Automotive Consulting Solutions) 23

24 Thank you! Mario Rebitzer Platinum Consultant Industry Area Automotive SAP Deutschland SE & Co. KG Hasso-Plattner-Ring Walldorf, Germany M +49/ S +49/ E mario.rebitzer@sap.com

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