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Rough-Cut Capacity Planning in SCM EIN 5346 Logistics Engineering (MSEM, Professional) Fall, 2013. Rough-Cut Capacity Planning in SCM Theories & Concepts. Material programs Supplier selection Cooperation. Plant location Production systems - Subcontractors.

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Rough cut capacity planning in scm ein 5346 logistics engineering msem professional fall 2013

Rough-Cut Capacity Planning in SCM EIN 5346 Logistics Engineering(MSEM, Professional)Fall, 2013


Rough cut capacity planning in scm theories concepts

Rough-Cut Capacity Planning in SCMTheories & Concepts


Hierarchical planning framework review

  • Plant location

  • Production systems- Subcontractors

  • Physical distribution structure- Transportation strategy

  • Product program- Strategic sales planning

Long term

  • - 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

Hierarchical Planning Framework (review)

Short term

EXECUTION

Flow of goods

Information

Feedback



Production process review

  • Requirements for Production Planning:

    • to meet the demand

    • to consider the resource capacities and the material availabilities

    • to improve utilisation of the resources

    • to lower the setup time

    • to minimize the stock, and

    • to minimize the work in process (WIP)

    • to improve stability of the plan

Production Process (review)


Rough cut capacity planning

  • The main goal in rough-cut capacity planning is to identify where overloading or under-loading of production capacity occurs and revise the MPS as required.

  • Overloading means that too much production of products has been planned in the facility and insufficient capacity exists to produce planned quantities of products required in MPS.

  • Under-loading means that not enough production of products has been planned to fully load the facility.

Rough-cut Capacity Planning


Rough-Cut Capacity Planning in APO-SNP where overloading or under-loading of production capacity occurs and revise the MPS as required.


Order life cycle for make to stock
Order Life Cycle for Make-to-Stock where overloading or under-loading of production capacity occurs and revise the MPS as required.


Order life cycle for make to order
Order Life Cycle for Make-to-Order where overloading or under-loading of production capacity occurs and revise the MPS as required.


Forecast consumption mode and horizon
Forecast Consumption Mode and Horizon where overloading or under-loading of production capacity occurs and revise the MPS as required.

(Backword consumption of 4 days and a forward consumption of 3 days)


Transactional data for transferring

  • Starting from a demand plan, SNP checks the resource capacities and delivers a medium/long-term plan for the estimated sales volumes.

  • The plan includes the quantities to be transported between locations (e.g., DC-customer, or plant-DC) and the quantities to be produced (and procured), taking available capacity into consideration.

  • SNP creates planned orders, purchase requisitions, and stock transfers that can be transferred directly to the connected OLTP systems.

Transactional Data for Transferring


Capacity levelling

  • Capacity leveling supports the following resource categories:

    • Production resources

    • Transportation resources

  • Capacity levelling supports the following resource types:

    • Bucket resources

    • Single-mixed resources

    • Multi-mixed resources

    • Transportation resources

Capacity Levelling


Capacity levelling1

  • The planner can use the following methods to adjust the plan:

  • Backward scheduling of the capacity load to fulfill demand using high priorities without due date violations. This rescheduling does not create any orders in the production horizon.

  • Forward scheduling of the capacity load for lower priority demand and use of demand priorities to minimize due date violations

  • A combination of backward and forward scheduling of the capacity load.

Capacity Levelling


Capacity levelling profile

  • The main settings in the capacity leveling profile are scheduling direction, prioritization, and method.

  • Scheduling Direction controls whether Forward, Backward or Combined scheduling is used.

  • Prioritization for the heuristic run defines how leveling determines the sequence of orders. The two possible choices for prioritization (to be sorted by ascending or descending order) are

    • by order size or

    • by product priority.

  • The three Method choices are

    • Heuristic,

    • Optimizer or

    • Badi (Business Aided-in).

Capacity Levelling Profile


Time based capacity levelling
Time-based Capacity Levelling scheduling direction, prioritization, and method.


Capacity levelling2
Capacity Levelling scheduling direction, prioritization, and method.


Heuristics based capacity levelling

  • Heuristic-based capacity leveling compares, period by period, the capacity load on a resource with the requested load, either from the beginning or from the end of the planning horizon – depending on which scheduling direction is selected (forward or backward scheduling).

  • If the resource is found overloaded, the system first selects all the activities or orders that cause the overload in this period. It then sorts these orders according to the priority that is defined and shifts orders or partial orders, one by one into subsequent or previous periods until the required maximum resource utilization is reached.

Heuristics-based Capacity Levelling


Heuristics based capacity levelling1

  • For forward scheduling, the system moves the orders so far that the first activity using the resource to be leveled only begins after the overloaded period.

  • For backward scheduling, the system moves the orders so far that the last activity using the resource to be leveled actually ends before the overloaded period.

  • The system takes the lot sizes and rounding values defined in the master data into account when moving the orders.

Heuristics-based Capacity Levelling




Period factor
Period Factor Heuristic




Heuristics based capacity levelling2

  • Only orders that cause overloads are changed. Heuristic

  • This proves advantageous when a lot of orders exist but only some of them overload the resource.

  • Prioritization is done by product or by product quantity.

  • Select “Capacity Leveling” from the menu to balance the required work loads.

Heuristics-based Capacity Levelling


Benefits of snp with scm

  • The benefits of Supply Network Planning with SAP SCM are as follows:

  • Cross-plant medium-term rough-cut planning

  • Cross-plant optimization of resource utilization

    • Simultaneous planning of procurement, production and distribution

    • Simultaneous material planning and finite capacity scheduling of production, storage, and transportation resources

  • Planning of critical components and bottleneck resources

  • Prioritization of demands and receipts

  • Collaborative supply planning over the Internet

Benefits of SNP with SCM



Operation research or

  • Operation research refers to the application of quantitative methods and techniques to business problems in order to best utilize a company’s resources.

  • OR is used by many leading companies in recent years to optimize their limited resources in order to maximize their profits or minimize their costs.

  • Linear programming (LP) is one of the most important tools of operation research.

Operation Research (OR)


Linear programming lp1

  • Five common types of LP problems: quantitative methods and techniques to business problems in order to best utilize a company’s resources.

    • Product mixed

    • Ingredient mix

    • Transportation

    • Production plan

    • Assignment

Linear Programming (LP)


Five common types of lp problems
Five common types of LP problems quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Five common types of lp problems1
Five common types of LP problems quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Steps in formulating lp problems

  • Define the objective quantitative methods and techniques to business problems in order to best utilize a company’s resources.

  • Define the decision variables

  • Write the mathematical function for the objective (objective function)

  • Write a one- or two-word description of each constraints

  • Write the right-hand side (RHS) of each constraint, including the unit of measure.

  • Write<=, =, or >= for each equation

  • Write all the decision variables on the left-hand side of each constraints

  • Write the coefficient for each decision variable in each constraint.

Steps in Formulating LP Problems


Formulating lp
Formulating LP quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Formulating lp1
Formulating LP quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Formulation lp
Formulation LP quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Formulation of problem
Formulation of Problem quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Objective and constraints
Objective and Constraints quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Steps in graphical solution method
Steps in Graphical Solution Method quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Graphical solution
Graphical Solution quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Graphical solution1
Graphical Solution quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Graphical solution2
Graphical Solution quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Graphical solution3
Graphical Solution quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Transportation network problem
Transportation (Network) Problem quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Requirement assumption
Requirement Assumption quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Feasible solutions property
Feasible Solutions Property quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Cost assumption
Cost Assumption quantitative methods and techniques to business problems in order to best utilize a company’s resources.


Parameter table for transportation problem

Supply quantitative methods and techniques to business problems in order to best utilize a company’s resources.

S1

S2

.

Sm

Parameter Table for Transportation Problem


Transportation problem model

  • Any problems (whether involving transportation or not) fits the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.

  • The objective is to minimize the total cost of distributing the units. All the parameters of the model are included in this parameter table.

Transportation Problem Model


Objective function constraints
Objective Function & Constraints the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.


Rough cut planning in scm sap implementation

Rough-Cut Planning in SCM the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.SAP Implementation


Planning book and views
Planning Book and Views the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.


Capacity check view
Capacity Check view the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.

Now switch to the CAPACITY CHECK view. In the Selection profile

section double click on ## RESOURCES. Double click on the work center (plant ##A1). Switch the TB Profile to 12MONTH. We appear to have enough capacity in the work center at the aggregated monthly level.

Now change the TB Profile to 180 DAYS. We are overloaded in the first couple days as SCM has tried to produce all that is needed to satisfy safety stock in those days.


Key figures and category group in snp standard planning book
Key Figures and Category Group in SNP Standard Planning Book the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.


Hw 6 exercises due date 11 30 13
HW 6: Exercises: the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.(Due date: 11/30/13)

1 Setup Transactional Data Transfer between SCM and ERP

  • Maintain integration settings in SCM system

    • Maintain distribution definitions in SCM system

    • Maintain Objects specifics settings in SCM system

    • Define transfer of SNP orders in SCM system

  • Create integration model for transactional data in SAP ERP system

    • Create and activate integration model for planned orders and production orders in SAP ERP system

    • Create and activate integration model for purchase orders and purchase requisitions in SAP ERP system

    • Define transfer of SNP orders in SCM system

      2. Supply Chain Modeling

  • Global Bike Company (GBC) Supply Chain

  • Transactional data used in supply chain planning

    • Interactive SNP planning

    • Selection profile

    • Review forecast values for production


2. Please solve the following LP problem. the model for a transportation problem if it can be described completely in term of a parameter table like Table 8.5 and it satisfies both the requirements assumption and cost assumption.

Objective: Min Z = 10,000 X1 + 15,000 X2

S.T. X1 + 2X2 >= 4

X 1+ X2 >= 2.5

1) Draw a graph

2) Plot the constraint function

3) Outline the feasible solution

4) Circle the optimal solution point.


3. The Green Up Fertilizer Company ships fertilizer from three manufacturing plants to four distribution centers (DC). The shipping cost per truckload of fertilizer from each plant to each DC is:

PlantDistribution Center (DC)

ABCD

1 $464 $513 $654 $867

2 $352 $416 $690 $791

3 $995 $682 $388 $685

Plant 1 has a monthly capacity of 75 truckload, Plant 2 has a monthly capacity of 125 truckload, and the Plant 3 has a monthly capacity of 100 truckload. The monthly DC demand is A = 80 truckload, B = 65 truckload, C = 70 truckload, and D = 85 truckload. Please formulate an LP problem to determine how much truckload of fertilizer should be shipped from each plant to each DC per month to minimize monthly shipping cost.

1) Define the objective.

2) Define the decision variables.

3) Write the mathematical function for the objective.

4) Write the constraints.

5) Solve the LP problem


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