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Leverage the classic production planning scenario in ERP with Model Mix Planning and Sequencing in SCM APO  

Model Mix Planning and Sequencing are functionalities that are available as part of the Automotive OEM scenario “Make to order for OEMs”.

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These functionalities are used in a repetitive production environment with the goal to optimize the usage of the production lines when you are producing configurable products in high volume.

Model Mix Planning and Sequencing as standard solutions are only available for a master data setup based on iPPE.

However, a lot of customers do not want use the iPPE bill of material (PVS), routing (ACT – Process Structure) and Factory Layout (FLO) for various reasons and prefer staying with the classic bill of material (BOM) and the classic routing.

Nevertheless they might have the need to optimize their production and build a sequence for the transfer to their Manufacturing Execution System (MES).

For these customers I would like to highlight the possibility to do production planning in ERP based on the classic data model and to combine this scenario with Model Mix Planning and Sequencing on a “lean” iPPE data model in SCM APO.

This “lean iPPE” scenario  is successfully in use by a big German OEM for several years.

A shortened version of the customer process has been implemented in the IDES system landscape and can be accessed under the name of “Assembly planning in repetitive manufacturing”. 

The following pictures show the required master data and the system setup:

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In SCM APO you will have to create manually an iPPE PVS header, an iPPE routing with at least one activity and an iPPE production line structure (FLO) that should only be as detailed as needed.

For the production lines you have to specify details like the base rate and takt time in the APO resource master.

For the Model Mix Planning and Sequencing you need to define restrictions based on the characteristics of the vehicle. Also you need to define the procedure profile for the Model Mix Planning where you specify the algorithm that is used to get the optimal model mix based on the given restrictions and the available resources. 

After you have created manually these required master data objects in APO you can transfer the classes and characteristics as well as the configurable material (KMAT) from ERP with the help of the SAP Core Interface (CIF).

Additionally you have to transfer your vehicle orders as well via CIF.

With these prerequisites you can built up the following process in the system: 

  1. Get customer requirements for a configured vehicle
  2. Transfer the requirements to SCM APO
  3. Do a Model Mix Planning to create planned orders and assign them to a daily or shift bucket based on predefined restrictions
  4. Send created planned orders to ERP
  5. Eventually do a planning of the vehicle sequence based on the defined restrictions
  6. Eventually transfer the determined optimal sequence to your MES system
  7. Continue the production planning process in ERP including the BOM explosion.
  8. With the final backflush also the planned order in SCM APO will be deleted.

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To combine the process of a production planning based on the classic BOM and the classic routing in ERP with Model Mix Planning and Sequencing based on IPPE master data you need to implement User-Exit EXIT_SAPLCORD_004 and BADI Z_RRP_SRC_EXIT.  

Please be aware that ERP can only take into account daily requirements. Only APO can take into account subdaily requirements and can do a subdaily production planning.

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4 Comments

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  1. Nicole Pompejus Post author
    Ashok,
    Thanks for your interest in this solution. First of all I would like to highlight that in the Automotive planning scenario with iPPE you do not transfer the PDS from ERP but you transfer your master data from ERP to APO via CIF and then create the PDS in APO.
    Concerning your other questions: It is true that in this specific scenario you do not have the components of the KMAT in APO as the BOM explosion is done in ERP. In APO you only do an assignment of your configured orders to time slots on your iPPE production line taking into account certain restrictions that are defined on characteristic value level. All the planning functions that would include a BOM explosion in APO are not covered by this process. I hope this answers your question.
    Regards
    Nicole
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  2. Thomas Rask
    Dear Nicole,

    Thankls for a very interesting scenario description. I am wondering if this set-up would as well work in a scenario where you do not run repetitive manufacturing in the ERP system, i.e. using normal planned and production orders?

    We have a case where, for certain reasons, it is not desired to implement REM, but the production is still a tact-based line so the MMP features would be of great help.

    Do you know if this would be a possible option?

    Best Regards,
    Thomas

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    1. Nicole Pompejus Post author
      Hi Thomas,

      yes, this can also work with normal production orders. The only problem is that in this scenario you have to take care of the synchronization between the production orders in ERP and the planned orders in APO by yourself ,e.g. with additional coding (if you use repetitive in ERP and APO the synchronization happens automatically). We have customers who have done this already successfully. It makes the scenario a little bit more complicated but it is feasible.
      Best regards
      Nicole

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  3. Thomas Wright

    Hi Nicole,

    Great post, but I can’t find a demo script entitled “Assembly planning in repetitive manufacturing”… can you share, perhaps attached here?

    Thanks

    Tom

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