Strategic component planning

Central, global planning of Global Common Data (GCD) via several systems with different models at ZF Friedrichshafen

To the Quick Facts

Implementation highlights

Long-term capacity overview for the next five years
Global planning of all purchased part requirements through multi-level, cross-site explosion of bill of material levels
Expansion to include strategic capacity planning (GCP) as a central, integrated and harmonized system for capacity planning

Use of the results by downstream areas such as purchasing, logistics, work preparation and production

Challenge

Aggregation of the required purchased parts across approx. 60 different locations with several ERP systems
Calculation of the expected purchase volume per material and supplier based on a 5-year forecast
Consideration of intercompany relationships between plants
Consideration of multi-level subcontracting
Different master data in each plant, supplier numbers must be consolidated to a unique supplier ID
Forecast and planning of projects with reference BOMs
High data volume with approx. 60 million procurement proposals in the planning horizon
Identification of the causative primary requirements, project probabilities, etc. starting from the purchased part or supplier and subsequent characteristic-based planning (CDP in CTM)

CONSILIO successfully supported us in implementing global planning across multiple systems with different master data models and merging them into a central APO.

Tobias Werberich, Global Material & Capacity Planner PL Suspension Technology ZF Friedrichshafen AG

Project Goals

Global planning of all purchase & in-house requirements through multi-level, multi-site resolution of all BOM levels.
Traceability of the use of purchased parts in customer requirements for risk assessment, e. g. in case of supplier failure
Simulation (what-if) of the impact on component requirements in the event of changes to customer or primary requirements
Extension to include strategic capacity planning (GCP) as a central, integrated and harmonized system for capacity planning and a long-term capacity overview for the next five years
Planning of supplier capacities on capacity families
Use of results by downstream areas such as purchasing, logistics, AV, manufacturing, etc.

Conclusion

Global planning across several systems with different master data models and merging in a central APO were successfully implemented
Sufficient effort should be calculated for the preparation or correction of master data and the harmonization of the interface (CIF mapping)
Due to the high data volume and despite the associated longer runtime of the planning chain, SAP APO was successfully used in this use case
The corresponding effort for job control should be planned for restarting after terminations, individual package formation and the prevention of load peaks
The procedure is technically demanding from a CTM point of view, but has proven itself through the right technical interventions and enhancements

ZF Friedrichshafen GmbH & CO. KG

Industry: Automotive
Business area: In the four technology fields of vehicle motion control, integrated safety, automated driving and electric mobility, ZF offers comprehensive solutions for established vehicle manufacturers and for newly emerging providers of transport and mobility services.

Locations: 260 in 41 countries
Web: www.zf.com
Consulting partners: CONSILIO GmbH