Integrated Production Optimization & Detailed Planning in S/4HANA (SAP PP/DS & ePP/DS)
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 configuration. 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 is the strategic standard solution for production planning in S/4HANA and the ideal complement for Integrated Business Planning in the cloud.
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
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
