This segment from our 551 page SAP Production Planning manual is being made available as a sample of our training manuals. Please contact
[email protected] if you have any SAP training needs, or visit www.ERPtips.com for more information. Written by Alexis DeStaffany Parker Published by Klee Associates, Inc. Copyright Klee Associates, Inc., 2008, 2010
Production Order Scheduling The scheduling of production orders is performed based on the production dates; and the capacity requirements are calculated for all operations within an order. The most important parameter in production order scheduling is the scheduling type. The following options exist for scheduling types:
Forward scheduling – schedules the order forward using the basic start date or the scheduled start date while including all operations and times to determine the finish date.
Backward scheduling – schedules the order backward using the basic finish date or the scheduled finish date while including all operation and times to determine the start date.
Scheduling today – schedules the order forward using today's date while including all operations and times to determine the finish date.
Capacity requirements only – schedules the order based on capacity requirements only.
The scheduling type is defined in the scheduling parameters for production orders. The scheduling parameters in the production order define the detailed scheduling of an order; they determine adjustment of the dates in the production order and the scheduling type in the direction assigned and reduction characteristics.
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Production Order Scheduling Parameters In this section, we review the production order scheduling parameters available in configuration of production orders. From the IMG, select the menu path: Production Shop Floor Control Operations Scheduling Define Scheduling Parameters for Production Orders.
Since production orders are scheduled using the routing during detailed scheduling, the selection ID is not an available field for entry. Capacity requirements are generated for this production order type as assigned in the parameters.
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The following table describes the sections of the scheduling parameters. Section Adjust Scheduling
Scheduling Control for detailed scheduling
Requirements date determination for components
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Use The dates are adjusted in lead-time scheduling based on the following options:
Basic dates are adjusted and the dependent requirements are adjusted based on the dates of the operation start date.
Basic dates are adjusted and the dependent requirements are adjusted based on the dates of the order start date.
Basic dates are not adjusted and the dependent requirements are adjusted based on the dates of the operation start date.
Basic dates are not adjusted and the dependent requirements are adjusted based on the dates of the order start date.
The following are key options for the scheduling in detailed scheduling:
Start in the past – the number of days that the start date can be in the past in scheduling
Automatic scheduling – reschedules the order automatically in the production order each time a scheduling change is made.
Automatic Log – displays the scheduling log each time a scheduling change is made and the order is rescheduled.
Scheduling allowed for breaks – used if the break time is a set break for scheduling.
Scheduling based on production dates – used if the production dates are used instead of the basic dates.
Shift order – if confirmations exist on an order, the confirmed dates are not taken into account in rescheduling.
The operation segment is defined for the components with a positive requirement quantity. Latest staging date defines whether the latest date or earliest scheduled date is selected in scheduling.
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Date Scheduling Scheduling for production occurs at both the production order and operation level during scheduling. In this section, we review both the scheduling procedures and the key date components within the scheduling for the order and the operation.
Production Order The highest level of scheduling is production order scheduling. The following diagram displays scheduling dates and components used in the scheduling the production order.
As seen in the diagram, the difference between the order dates and the production dates is the float, which is defined in the scheduling margin key. In addition, the finish date calculation accounts for any safety time defined for the material in the material master. The operations are included from the beginning of production to the end of production; these dates are calculated based on the operation components. Once the order is completed in production, the goods receipt processing time is added to determine the availability date of the product.
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Operation During production order scheduling, the operations are scheduled in the order using the dates defined in the operation. The following diagram displays the dates evaluated in the operation scheduling.
Operation scheduling takes into account the scheduling of all the times required for queue, setup, process, teardown, wait and move in each operation. The difference in the earliest start and latest start is the queue time; in the latest start and the earliest finish date, it is the setup and process time; and the difference is the teardown and waits time in the earliest finish date.
Interoperation Times The time to transition the material in the queue, wait and move is the interoperation time. In the routing, the interoperation times can be defined.
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The following table describes the sections in the Interoperation times view of the operation in the routing. Section Interoperation times
Description The following are the key fields in the Interoperation times section:
Reduction strategy – defines how the system reduces lead time by reduction procedures when the lead time exceeds the amount of available time. The reduction strategy is covered in detail in the reduction strategy section of this manual.
Wait time – the amount of time a material can wait between the one operation and the next.
Queue time – the time a material waits at an operation before production starts.
Move time – time required to move a material from one operation to another.
This maintenance is at the routing level, so the routing matrix allows for this information to be stored in configuration and assigned to the work center.
Creation of Location Group to Assign the Move Time Matrix to a Work Center From the IMG, select the menu path: Production Shop Floor Control Operations Scheduling Define Move Time Matrix. 1. Select the
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button to add a new location group.
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2. Select enter on the keyboard to add the location group; highlight the added location group; and double click on the folder.
3. Select the
button to add the times.
4. Enter the move times and dates for the move times.
Scheduling View of the Routing The Scheduling View of the Routing setting adds the move time to the production order during scheduling if the location group is assigned in the routing.
Splitting and Overlapping Splitting and overlapping procedures are used to reduce lead time in the operations. Splitting reduces the duration of processing, and overlapping reduces the duration of lead time. Splitting allows for the operation to be split into multiple operations within the order. The following diagram displays the logical operations in splitting.
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The splits are determined based on the number of splits defined in the routing.
The following table describes the Splitting view of the operation in the routing. Section Splitting
Description The key fields in the Splitting section are:
Required splitting – this indicator is set if the operation must be split for scheduling.
Number of splits – the number of splits that can be determined when dividing lots during scheduling.
Minimum processing time – the processing time should always be above this amount during splitting.
Overlapping is defined by the operations overlapping between one another during production. The following diagram displays overlapping in relation to other operations.
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The overlapping requirements are determined based on the overlapping parameters defined in the routing.
The following table describes the sections in the Overlap view of the operation in the routing. Section Overlapping
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Description The key fields in the overlapping section are:
Required overlapping – overlapping of the operation is required if this flag is set on the routing.
Optional overlapping – overlapping of the operation is optional.
Continuous flow prod – overlapping should always occur to provide a continuous flow of production.
No overlapping – overlapping of production is not allowed.
Minimum overlap time – the shortest amount of time two operations should overlap for greatest efficiency.
Minimum send-ahead Qty – the smallest amount of the material that must be sent to the next operation during overlapping.
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Reduction Reduction is the process of reducing the lead time required to produce a product when the time allotted is less than the available time. In reduction, the system reduces the queue and move time to the minimum and performs splitting and overlapping of operations. There are two main options for configuring the reduction process during scheduling – the reduction strategy and the scheduling profile.
Reduction Strategy From the IMG, select the menu path: Production Shop Floor Control Operations Scheduling Define Reduction Strategies.
The reduction strategy defines how reduction is performed based on the reduction level. The reduction in the queue time is the first reduction parameter and then the transport (move), overlaps and splits are determined and used to reduce the lead times.
Scheduling Profile From the IMG, select the menu path: Production Shop Floor Control Operations Scheduling Define Scheduling Parameters for Production Orders.
The reduction type defines which operations are reduced. The maximum reduction level defines the level used in the reduction strategy.
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