Integrated Production Optimization & Detailed Planning
in S/4HANA
The traditional ERP system from SAP offers the classic MRP approach with separate capacity planning for production planning.
In most cases, several iterations are necessary to arrive at a capacity-coordinated production plan. In today's world, and especially with multi-stage production, this is hardly feasible manually. The high effort in terms of costs, integration and IT support often prevented medium-sized companies from additionally operating an external advanced planning system. However, due to limited possibilities for finite planning, production planning in the ERP comes up with results that cannot be implemented in production. Excel and other tools are used, transparency is lost due to lack of integration into the ERP.
The integrated detailed planning SAP embedded PP/DS provides a production and detailed planning solution with many advantages for planners:
Coordinated, smoothed and feasible production plans across plants and scheduling levels; reduction of lead time in the entire production chain; setup-optimized planning and optimal capacity utilization. All production constraints such as machine, personnel, production resource/tool capacities and availability are taken into account simultaneously.As a decisive innovation, SAP ePP/DS is technically fully integrated in S/4HANA and thus enables a seamless transition from detailed production planning to production execution. In S/4HANA installations, PP/DS is already technically included and can be easily activated via customizing. Master data such as material masters, work centers can be selectively activated for detailed planning and optimization by setting an indicator. This enables successive use of PP/DS.
Benefits of production planning
With the help of SAP embedded PP/DS, typical production planning goals can be achieved more easily:
- Optimal ability to provide information regarding the capacity utilization situation and adherence to schedules
- High adherence to delivery dates with regard to customer requirements
- Reduction of setup times and setup costs through setup optimization
- Optimal utilization of machinery and equipment
- Consideration of further restrictions such as production resources/tools, personnel qualification, etc.
- Flexible handling of exceptions, for example delays of a raw material or the failure of a plant
SAP PP/DS functionalities
- Scheduling of requirements at precise times
- Just-in-time processes
- exact transport planning
- Fixed and dynamic pegging across multiple demand levels
- Integrated, multi-level planning of quantities and capacities such as:
- Machines
- Staff
- Tools etc.
- Reduction of inventories across all disposition levels
- Specially defined (both standard and custom) ages help to detect and actively counteract exceptions. For example, shortage/surplus or capacity bottlenecks
- Observation of all capacity bottlenecks and corresponding rescheduling or adjustments to the production program
- Attention to material availability across all stages
- If there is no availability, the orders are postponed accordingly
- Material consumption is determined according to all requirements
- Requirements from the individual customer segment such as KES or higher production orders
- Preplanner or higher production orders
- Based on customer-specific requirements, demand maps can be created with the help of proprietary heuristics.
- Orders can be feasibly scheduled taking into account the capacity situation and depending on tool availability as well as other restrictions
- Presentation of capacity utilization by means of comprehensive analyses and Fiori apps
- Capacity bottlenecks are identified and can be actively counteracted
- Infinite and finite resource planning options
- Use of powerful heuristics and optimization algorithms
- Schedule optimization based on different functions:
- Minimize delay costs
- Reduce setup costs
- Reduce mode costs
- Take advantage of greatly simplified master and transaction data management
- Prioritization and rescheduling of orders as well as consideration and reduction of buffers in orders
- Avoidance of rescheduling or new planning in the event of minor deviations in deadlines and quantities
- Machine and plant-dependent setup time optimization as well as scheduling of orders on alternative plants and machines
- Early notification of dispatchers in the event of exceptional situations such as deadline violations and capacity overloads
- Multi-level order relationships (pegging):
- Establishing relationships between demand and procurement elements through pegging
- Relationships can be considered even if requirements shift across all BOM levels and components
- Increase in productivity and adherence to deadlines and thus also your competitiveness
- Solutions implemented in PP/DS on ERP can be transferred to SAP S/4HANA in the event of a future changeover
- Unlock your opportunities and synergies for value creation, information flow and collaboration with all participants in the supply chain with us
- Design and implementation of detailed planning and optimization solutions
- Identify current solutions and trends for dealing with increasing complexity
- Creation of agile and interlocked business processes
- Creation of feasible, optimized production plans taking into account capacity and material availability as well as technical restrictions and business management criteria
- Optimization of plant utilization, set-up times and shortening of throughput times
Detailed production planning with SAP PP/DS in a large bakery
Fresh production constantly presented us at Harry-Brot with new challenges, so we needed a planning tool that would enable us to quickly and easily adopt and implement the changed demand situation. How did we solve this? What challenges did we encounter? In my presentation, I would like to introduce the detailed planning board and its adaptations. Furthermore, the heuristics we use with their challenges and solutions. Last but not least, I would like to give an insight into the planning of recursive materials. Speaker: Martin Reintsch, Process Coordinator Production - Production Systems, Operational Plant and Material Planning, Harry-Brot
What motivated the long-established German company Rudolf Group to switch to S/4HANA with a greenfield approach?
In this Expert Talk, Rudolf Group, a specialist in textile and specialty chemicals, shows how the integration of the entire company into S/4HANA and the switch to embedded PP/DS for production planning and EWM for warehouse management has resulted in greater process automation, fewer individual applications and better networking of the company divisions.
Best practices PP/DS as a project accelerator for an S/4HANA greenfield template
Learn more about the procedure and the challenges of the S/4 greenfield implementation with Embedded PP/DS. The Schunk Group in Heuchelheim creates a global template for S/4HANA and uses SAP and the CONSILIO best practice solution as a project accelerator.
Speaker: Holger Feldmann, Head of Process and Logistics Optimization & Head of Central Maintenance, Schunk Group
SCM EXPERT TALK ON PROCESS & PLANNING OPTIMIZATION WITH PP/DS AND IBP
CONSILIO is an expert in SAP S/4HANA conversion and supply chain management process and planning optimization with SAP PP/DS and SAP IBP solutions in the automotive, manufacturing and process industries.
SAP PP/DS is the strategic standard solution for production planning in S/4HANA and the ideal complement for Integrated Business Planning in the cloud.
CONSILIO ADD-ON "FINITE PLANNING WITH MACHINES AND TOOLS"
Manufacturing companies need to optimize the utilization of their production facilities in order to be able to offer products competitively on the market. This presents many with major challenges! For this purpose, we will show you our solution for finite planning of machines and tools with SAP planning tools.
ADVANCED PLANNING AND OPTIMIZATION IN S/4HANA
With the features for detailed planning, S/4HANA users not only benefit from improved requirements planning through the MRP Live material planning run, but can also perform finite capacity planning using automated heuristics or optimizations. At the same time, in S/4, the master and transaction data management of a classic ERP/SCM system landscape can be drastically simplified through integration into one system.
SAP IBP AND PP/DS: INTERACTION OF ROUGH AND DETAILED PLANNING
Well-coordinated rough and detailed planning processes for supply chain and production are essential for the sustainable success of manufacturing companies. In this webinar, we will show you various approaches to linking the two SAP solutions in a meaningful way.
Our services for you
- Our experts develop an individual detailed planning concept tailored to your application and support you in its implementation
- We optimize your detailed planning while taking into account deadlines, set-up times and overloads
- Together with your employees, we carry out readiness projects to prepare processes and data for migration
- CONSILIO will work with you to create an individual roadmap in which all the necessary steps are presented in a comprehensible manner.
- We execute the migration of data from an already connected supply chain management system into your embedded PP/DS
- Existing customer programs are adapted by us for S/4HANA
