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Oracle APS and GOP – Getting To Automated Sales Order Scheduling. Mark Hopkins, Xilinx, Inc. 1/17/06. Topics. Goals of Our GOP Implementation Where We Are Today How We Did It Lessons Learned. Project Goals. Schedule new sales orders accurately Hit our first commitment

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oracle aps and gop getting to automated sales order scheduling

Oracle APS and GOP – Getting To Automated Sales Order Scheduling

Mark Hopkins, Xilinx, Inc.

1/17/06

Xilinx Confidential

topics
Topics
  • Goals of Our GOP Implementation
  • Where We Are Today
  • How We Did It
  • Lessons Learned

Xilinx Confidential

project goals
Project Goals
  • Schedule new sales orders accurately
    • Hit our first commitment
    • Minimize reschedules
  • Preserve excellent on time delivery performance
  • Manage exceptions, and let the rest happen automatically
    • Reduce planner workload and allow them to focus on model maintenance

Xilinx Confidential

results auto release and on time delivery
Results: Auto Release And On Time Delivery

~13k Line Items per month.

Xilinx Confidential

our planning environment
Our Planning Environment
  • Oracle APS (ASCP and GOP)
  • Oracle ERP
    • Order Management, Purchasing, Financials, HR
  • Custom Systems/Interfaces
    • Item & BOM Based on Matrix and Legacy
    • Forecast
      • Manugistics
      • Home grown Customer Forecast Management System
    • Wafers, Piece Parts, WIP tracking

Xilinx Confidential

what s in production ascp and gop
What’s In Production:ASCP and GOP
  • Monthly / Weekly APS Plan for Wafers and Piece Parts (since April ‘03)
    • EDD
    • Unconstrained Plan
    • Wafer Plan, Piece Parts, Assy, Test, Sort, Bump Capacity
  • Daily Plan for Assembly Releases (since August ‘04)
    • ECC
    • Output is used for all products assembly starts planning
  • Daily Plan for GOP (since August ‘04)
    • ECC
    • Almost 100% of incoming sales orders get schedule dates recommended from GOP

Xilinx Confidential

our model example from our atp plan
Our Model(example from our ATP Plan)

Plan Type:

Cost Based Optimized Plan - HP 64bit Exe

Enforce Material Constrained Plan

Holistic Manufacturing Plan with Project Planning

Time Buckets: 35 days, 10 Weeks

Inputs:

Orgs: 56

Items: 22k

Demands: 19k

BOM's: 17K

Outputs:

Demands: 64k

Supplies: 56k

Pegging: 78k

Res Reqmts: 200k

Xilinx Confidential

terms
Terms
  • GOP / ATP – Global Order Promising / Available To Promise
  • CFD – Current Factory Date (equivalent to Schedule Ship Date in Oracle)
  • OFD – Original Factory Date (the first commit on the sales order)
  • ATP Override – The ability to change the date that GOP was recommending prior to committing to the customer
  • Auto Release – A sales order that books, gets scheduled, and committed to the customer with zero planner intervention

Xilinx Confidential

standard oracle gop process
Standard Oracle GOP Process

Xilinx Confidential

xilinx gates in gop process
Xilinx Gates in GOP Process
  • Is part/whs set up as “auto release?”
    • Yes: does schedule ship date meet auto release criteria
    • No: Does planner agree with Schedule Ship Date?
  • Is calendar date blocked?
  • Is order on hold?
  • Is order unusually large?
  • Do we want to force a particular schedule date to happen (ATP Override?)

Xilinx Confidential

demand management form
Demand Management Form

Xilinx Confidential

getting to 100 auto release
Getting to 100% Auto Release
  • Oracle
    • Need to consider alternate boms, substitute components in ATP/GOP algorithm. Lack of this functionality causes overly conservative commitments. In semiconductor mfg, this is needed to recognize bin downgrades, alternate mask sets.
    • ATP Algorithm needs to recognize that an order due 3 months from now can be satisfied with a wafer start. Allow finished goods to show as available for any new orders.
  • Xilinx
    • Data Maintenance. Specifically sourcing rules, and BOMs.
    • Our current BOM structure does not handle some new products / military scenarios. We are working on a new item/bom management system that will give us this.
    • Lot specific yields for new products.

Xilinx Confidential

lessons learned
Lessons Learned
  • Need a way to validate / build confidence in production data prior to exposing to customers
  • Develop metrics and publish progress
    • We gave prizes to the first planning teams to hit 3 different milestones
  • Need to build planners’ confidence in ATP ‘black box’ by developing an understanding of true problems vs. perceived problems or gross generalizations. Until we could explain each situation (which was a long process), anything that did not fit planners’ mindset was judged as “ATP is wrong.”
  • Incremental fixes / enhancements help zero in on the issues
  • Data maintenance and reporting that identifies data problems is helpful

Xilinx Confidential