2608 SAP Planning and Scheduling Workshop (1)

Orange County Convention Center Orlando, Florida | May 15-18, 2011SAP Planning & Scheduling Workshop Gus McIntosh Ben Mansi ] [ Learning Points  Understand the capabilities of SAP and how you can use them to support an effective planning & scheduling process.  Explore non standard SAP PM options for scheduling and how they can support your requirements.  Better understanding of key tools and approaches that can be deployed to provide the basis for measuring planning and scheduling performance improvement. Real Experience. Real Advantage. 2 [ Agenda  Planning in SAP  Task Lists  BOM  Work Order Planning  Scheduling  Dates  Capacities  Capacity Evaluation  Planning Board  Project Systems  MRS  PMX Real Experience. Real Advantage. .[ Planning in SAP  Task List Overview  Task List Details  Structures / functions  Supporting Maintenance Plans / One Time Work     Bill of Materials Work Order Planning Tools to Support Work Planning List Edit Reports Real Experience. Real Advantage.  Simplifies the Work Order Planning process  Task List “TL” Types:  General (can be used on multiple objects) (TL Type “A”)  Functional Location (associated with FLocs) (TL Type “T”)  Equipment (associated with specific Equipment item) (TL Type “E”)  The type of Task List created will depend on the objective of the plan /and related Technical Object  General TL can be configured Real Experience.  Predefined list of Work activities that contain Work Group. Work Description. Duration. Services. Number of Workers and associated Material Items. identify the required Resources (Labor. Skill. . Real Advantage. Materials.[ Task List Overview  Task Lists describe the sequence of individual maintenance activities to be performed.  Task Lists are „building blocks‟ of Maintenance Plans. Special tools) and related procedures. [ Task List Overview Usage Regular maintenance (PM‟s. PdM‟s. Real Advantage. Duration. Maintenance and Service Planners Reliability Engineers . servicing & inspection) Major maintenance Activities (planned repairs. Total Work Material components (Stock / non-stock w/BOM) Special Tools/drawings/equipment (PRT‟s) Craft / Specialists / Qualifications / Contractors To standardize work processes Why? To plan maintenance orders more effectively To create maintenance plans more quickly Who? Real Experience. Overhauls) Work steps (operation) Contents Long text (Std Text) instructions Maintenance work centers # Resources. .[ Task List Overview Work Order Maintenance Plan & Schedule Maintenance Item Maintenance Item Object List Object List Lists of: Functional Location Equipment Item data Planning data Task List data Maint . Real Advantage. Plan data Location/account assign Maintenance Strategy Task List Overview Maintenance Task List Tools Services Components Labor Maintenance Task List Operation Operation Operation Operation Operation Sub-Operation Operation Sub-Operation Long Text Standard Text Real Experience. [ Task List Overview . Real Advantage.Use in work order Leverage one or more Task List‟s for planning work orders Task List (Turbine 1000) Equipment (Turbine – 1000) Operation #1 Operation #2 Operation #3 Operation #1 Operation #2 Real Experience. . . Real Advantage.[ Task List Task List Header Operation Sub-operation Material Production Resources/Tools Maintenance Package Example of FL Task List Group and Group Counter numbers can be internally or externally maintained Header defines default Work Center Real Experience. .[ Task List – Use in Preventive Maintenance Task List Header Operation Sub-operation Material Production Resources/Tools Maintenance Package Standard / Long Text Object Dependencies User Defined Fields Control Key (Internal. External. Services) Classification Real Experience. Real Advantage. 2. Real Advantage.14.6.5. Header data settings common across plants Real Experience.3.15 General settings typically common across plants Internal processing settings typically common across plants External processing (operation Services) defaults can cause the need for multiple profiles by plant.7. .13.[ Task List Profile TL Profile Parameter ID “PIN” – Sets default in IA01. .[ Task List Structure Task List Overview Header TL Group w/multiple Counters Alpha/numeric Operation details copied onto Work Order Work Center & System Condition are defaults for TL Operations Mat‟l BOM populated on Gen TL makes items available Operation Overview Real Experience. Real Advantage. . Real Advantage.[ Task List Structure – Package Allocation Options Only applicable if used in Strategy Plan Defines applicably frequency per Task / Operation This option has limited view of package text. This option has better view of package text but more screens Real Experience. .[ Task List Structure – Internal Processing Internal Processing Detail Resources provided from internal Work Centers Work requirements define resource forecast when associated with Maintenance Plan Real Experience. Real Advantage. Real Advantage.[ Components – Show Operation Assembly Options  General Task Lists. Assembly (Material) BOM‟s can be used to display part requirements Assemblies are useful on work order operation assembly field for planning Parameter ID: PM_TREE_INACTIVE = X Non-stock assignment – Only through a BOM Real Experience. . [ Task List Structure .Components From selected Operation •Component Overview •Setting of 1 results in order setting: •Use to activate on order Standard(S) BOM for freely assigned parts Real Experience. . Real Advantage. . Real Advantage.Relationships Finish to Finish Finish to Start Start to Finish Start to Start Operation Relationship Real Experience.[ Task List Structure . [ Task List Structure .Relationships Standard FS relationship applies based on Operation # Relationships can be applied They are copied onto Work Order Network graphic is easiest way to maintain relations Real Experience. Real Advantage. . Real Advantage.[ Task List Structure .Relationships Relationship data copied from Task List onto Work Order Order scheduled with basic start of 01/31/2007 Real Experience. . [ Task List Structure . .Relationships With offset Real Experience. Real Advantage. [ Task List Structure .Relationships Real Experience. Real Advantage. . Items and Plans Strategy plans MUST have a task list or will not schedule plan “Error”. .Supporting Maintenance Plans Task Lists applied in same way to Strategy. Real Experience. Real Advantage.[ Task Lists . Single Cycle or Multiple Counter Plans Strategy Plans must have same Strategy on Task List. .[ Task Lists .Supporting Reactive / One Time Work / Overhauls Using existing Task List to plan Work Order Choose all or specific Operations Choose all or specific Work Centers Real Experience. Real Advantage. Supporting Reactive / One Time Work / Overhauls Using Task List to plan Work Order – Or setup as Manual call Real Experience.[ Task Lists . . Real Advantage. PRT planning.[ Operations & Sub operations Can use sub operations to plan multiple resources on same task list operation     No component. . Real Advantage. External Services No date scheduling specific to sub operation No Relationships and Constraints Defined at superior Operation level On Work Order can adjust start and end times using offset Capacity requirement defined for sub operations Included within capacity loading Available within Planning Table for Dispatch Enter confirmations at sub operation level Real Experience. Real Advantage.[ Procedures and Long Text Apply Long text using standard text key Apply text directly to Operation  Cut / Paste  Upload Real Experience. . Hardware Real Experience. Real Advantage. .[ Planners and MRO – Inventory and Purchasing  Components:     Stock material Non-stock Material Text Item Document Coupling Equipment (Pump) Impeller Bearing/Gasket Assembly Bearing Gasket Misc. 0075” Bearing 123456 879444 Real Experience. RDC COLUMN MIXER RDC MIXER RAFFINATE BOOSTER PARAFIN STRIPPER BOOT WATER Plant BPU Unit Equipment Service M6833 P1677 P4283 P9614 10003857 BOM TOLUENE COLUMN REFLUX PUMP P-9614 PUMP Equipment BOM BILL OF MATERIALS FOR P-9614 Pump Shaft 1.020” X .EAST EXT.[ Bill of Materials US01 Aromatics ACU . Real Advantage.East M1118 CHEMICAL SUPER PLANT AROMATICS AROMATICS CATALYTIC UNIT . . Real Advantage.[ Bill of Materials Equipment BOM Example Real Experience. . Real Advantage.[ Bill of Materials Equipment BOM Construction type BOM Equipment  Equipment  Equipment  Equipment  Construction type Mat 1 Mat 2 Mat 3 Mat 6 Mat 20 Mat 7 Mat 10 Mat 11 Real Experience. . . Real Advantage.[ Bill of Materials – Construction Type Equipment BOM BOM Items Construction Type / Material BOM Real Experience. [ Bill of Materials – Construction Type Construction Type / Material BOM assigned to General Task List General Task List is made available as ref. object to related Equipment Real Experience. Real Advantage. [ Work Order Planning Can establish default calculation method:    Calculate Work Calculate Duration Calculate Manually All Internal Labor planned with reference to an Activity Type Holds Cost Rate Is used to calculate Plan and Actual labor cost Manual planning of Operations Similar structures / functions as for Task List Real Experience. Real Advantage. [ Work Order Planning Select from BOM or add manually Real Experience. Real Advantage. Real Advantage. .[ Work Order Planning Material Requirement Date set by Operations Start Can adjust with Offset Real Experience. Real Advantage.[ Work Order Planning Unplanned Service Requirement  Overall limit set Planned Service  Need defined in terms of detailed Service Items referencing a Contract / Service Master Real Experience. . Real Advantage.[ Codes To Support Work Planning  Tools to help Planner manage the work  Priority & Risk codes  Equipment Criticality (ABC)  Equipment Availability (System Condition. Revisions)  User Status to support control. MOC….  To further support Parts status  Routinely a review of work orders should be made so that  Priority work orders are being planned first  Common Locations of multiple work orders can be reviewed Real Experience. workflow and reporting  „In Planning‟ or equivalent  Review in field  Waiting on Engineering. . [ Codes To Support Work Planning System Condition – use to identify operational state for required intervention Revision code – options for use  Define turnarounds / outages / shutdowns  Apply target basic dates  Tagging / Grouping  Basic Work Order scheduling Real Experience. . Real Advantage. Real Advantage.g.[ Consider different PM Priorities There needs to be a way to identify PM‟s that can be scheduled anytime. E. See Priority “0” Assignment is across all plants by Order Types Real Experience. certain inspections. . .Coordination with Production The Reservation by PM is part of the integration with Production Planning at the work center level. Real Advantage. This field can be used to identify if the work can be performed while the equipment is in operation (like certain inspections. Real Experience. It can be part of the “ready to work” criteria in selecting orders for scheduling. vibration analysis.[ Operating Condition . testing) or if the equipment must be taken out of operation. Real Advantage.[ Operating Condition – Where Used – Order Header Real Experience. . Real Experience.[ Operating Condition – Where Used Order / Task List Operations The importance at the operation level is knowing in IW37N whether the equipment needs to be shutdown or in operation Maintenance Item (partial screen below) Setting the Operating Condition on the Maintenance Item will default to the work order header. . Real Advantage. [ Codes To Support Work Planning User Status to support process / workflow Control related – single option Information – multiple selection Real Experience. Real Advantage. [ User Statuses – Informational for Process Used for process and backlog/fore log management, general information Informational User Statuses No numbering, Multiple active, Can be automatically set, Transaction controls, Position controlled, Authorization controllable Real Experience. Real Advantage. [ User Statuses – Sequentially Controlled Used for process control and backlog/fore log management Statuses can be: Sequentially numbered and activated/deactivated, Sequence control Single activation Authorization controllable Real Experience. Real Advantage. the status INP (In Process) is automatically set when a work order is printed or reprinted. . Real Advantage. Real Experience.[ Status Transaction Controlled In this example. The status INP is removed when the order is TECO‟d. [ User Status Assignments Assignment is at the order type and operation level Note: User statuses are available for notifications. serial numbers. . equipment. Real Experience. orders. Real Advantage. IBase. functional locations. Real Advantage.[ Codes To Support Work Planning ABC Indicator for Criticality Real Experience. . Examples Used in List Edit displays to prioritize work Real Experience. .[ ABC Indicator . Real Advantage. Real Experience. Real Advantage. . Augments functional location for some users.[ Plant Sections Used in List Edit displays work locations. notifications/orders One table for task lists Planner groups for orders is the number one means of denoting ownership of the order from a planning perspective.[ Planner Groups Planner Group Tables One table for flocs. Real Experience. . Real Advantage. equipment. Work center is another common approach. Real Experience.[ Planner Group Use Planner Grp On Notification Planner Grp On Order Planner group maintained on floc or equipment will default to notification or order unless user maintains personal defaults. . Real Advantage. The problem is the indicator is buried on the Control tab.[ Planning Indicator – Good KPI but bad location The Planning indicator provides nice out of the box reporting. Real Experience. Real Advantage. GUIxT is a good solution. .  Planned: All preventive maintenance orders and other work orders that require planner intervention before the job is started.Definition Important: Understood and agreed upon definition used consistently.  Immediate: Break in work that is not planned. . Real Advantage.[ Planning indicator .  Other solutions besides the planning indicator Real Experience.  What if no parts and the operation is estimated/planned?  Do KPI‟s exclude PM‟s?  Unplanned: Work that is not immediate and handed to a craft to troubleshoot and plan themselves. No previous planner intervention. Real Advantage. .[ Codes To Support Work Planning User Defined Fields Available within Planning Table Real Experience. Real Advantage. .[ Default Settings on work order Real Experience. Real Advantage.[ Default Settings on work order Real Experience. . .[ Materials Planning – Release By setting at Operation level to „Immediately‟ all Reservations or Requisitions associated available for further processing Setting can also be made at Component level Early Release of Material Requirements puts in process without need to fully Release the Work Order for execution   Generates Purchase Requisition and initiates Procurement process Stock Reservation established When and why would you release materials early?  Where there is a long lead item and need exists to place purchase order Default value is configurable Real Experience. Real Advantage. .[ List Edit Reports Real Experience. Real Advantage. [ Materials Availability Material Availability can be checked at any time from within the Work Order A Material Availability Report is also available that can provide status across multiple Work Orders Availability Report also includes for Non Stock items where planned Goods Receipt dates are compared to Operation Earliest Start dates Real Experience. Real Advantage. . . Real Advantage.[ Availability Checking Control Real Experience. . Real Advantage.7 SP EA_APPL 200) Real Experience.[ Manage Planning Activities .List Edits SAP List Edit function facilitates review of and adjustment of Work Orders  IW38 – Order Header  IW37 – Order Operations  IW37N – Order Header & Operations (Require 4. by Status (System and User) Select single or multiple Work Orders and drill down to individual objects in Change mode Can carry out functions collectively e.List Edits Column layouts can be adjusted and saved as user specific variant Can Sort on columns and filter data.g. e. Real Advantage. Release Work Order Real Experience. .[ Manage Planning Activities .g. [ Periodic Maintenance Schedule  General industry acknowledgement of need for an effective scheduling process ensuring:  Most important work is being executed  It is being worked at the optimal time  Execution is undertaken employing the most appropriate and available resources  Cost of execution is reduced  Most top performing Maintenance Organizations establish a Weekly Schedule and measure compliance against it. .  Schedule requires involvement and agreement from all involved departments particularly Production and Maintenance. Real Experience. Real Advantage. .[ Weekly Scheduling in SAP  Objectives:  Outline the use of standard SAP Capacity Leveling and Evaluation functions to support creation of Weekly Maintenance Schedule  Identify options and approaches that work best  Keeping it simple  Consider shortfalls in functionality  Touch on approaches without use of Capacity Leveling Real Experience. Real Advantage. labor resource estimates (number of people and man hours) and durations  Material Requirements  Criticality and Priority  Work Categorization (e.[ Prerequisites to Periodic Scheduling process  An effective SAP planning process that defines and prioritizes work  A maintenance backlog accurately represented in SAP in terms of:  Work activity. Project. . etc. Real Advantage. Preventive. Corrective.g.)  Resource group / Work Center capacity information maintained to reflect:  Standard Working Times  Weekly available capacity Real Experience. [ Scheduling in SAP  SAP Date Scheduling  Relationships & Constraints  Revisions  Manage Work Center Capacities  Standard / Intervals / Versions  Calculation from HR Employees / Work Center Hierarchies  Capacity Evaluation  Work Orders . Real Advantage. .Ready to Schedule?  Scheduling Options:  Capacity Leveling (Tabular Planning Table)  Publish the Schedule  Schedule Compliance Reporting Real Experience. [ „Typical‟ Scheduling Process Manage Employees & Schedules (HR) Maintain Shifts & Availability Manage Remaining Work Execution Process Preventive & Predictive Process Evaluate Requirements v Capacity Manage Work Center Capacity Manage Daily Work Assignment Manage Work ready to be Scheduled Prepare to Schedule Define Weekly Schedule Finalize Weekly Schedule Communicate Weekly Schedule Work Planning Process Hold Planning Meetings Real Experience. Real Advantage. . 030 6hrs Op. 010 4hrs Op. 040 4hrs Time Window for Work Work Order Basic Start Date Schedule Start 010 Start date Start time Finish date Finish time Duration (hours) People involved Work Work Order Operation 020 030 Schedule Finish 040 12/13/2007 7:00 12/13/2007 11:00 4 2 8 12/13/2007 11:00 12/13/2007 15:00 4 1 4 12/13/2007 15:00 12/14/2007 12:00 6 2 12 12/14/2007 12:00 12/14/2007 16:00 4 2 8 Times constrained by Work Center operating time Real Experience. Real Advantage.[ SAP Date Scheduling  Adopt a scheduling direction – Forwards or Backwards  Duration and Work Center standard work times drive Work Order schedule date calculation WO Scheduled Dates Adjusted Scheduling Direction Basic Start Op. 020 4hrs Op. . [ SAP Date Scheduling Real Experience. . Real Advantage. . Real Experience. The „with Time‟ indicator allows input of times against basic start and end dates as shown below.[ Scheduling Types   Typically there are no reasons to change standard SAP Scheduling Type settings. Real Advantage. .[ Scheduling Types  The „with Time‟ indicator allows input of times against basic start and end dates as shown below. Real Advantage. Real Experience. [ Scheduling Types  3 – Only Capacity Requirements All Operation Dates / Times set from Basic dates Real Experience. . Real Advantage. .[ Scheduling Parameters  Defined in configuration & control how dates are calculated  Defined for Plant / Order Type Real Experience. Real Advantage. Real Experience. .[ Scheduling Parameters  Options for Date Adjustment  Do you want to adjust or retail Basic Dates?  Are Material Requirement dates to be driven by Order Start or Operation Start?    Automatic Scheduling: switch on to ensure dates are always re-calculated when Order processed / saved Scheduling with breaks: Consider excluding breaks from Work Center operating times. Real Advantage. if work was not completed and need to adjust schedule dates to another time in future. Shift Order: Switch on to exclude confirmed actual dates and times from recalculation of schedule e.g. This ensures „clean‟ start and finish times without SAP calculations in fractions of hours. [ Work Order Relationships & Constraints Real Experience. Real Advantage. [ Work Order Relationships & Constraints  Typically no need for complex relationships and constraints  Adopt simple and standard approach to use of dates  Operation start and stop dates / times are driven by WC Operating time  You want to have a process where you adjust Order dates (start or finish) and let system calculate scheduled dates Real Experience. Real Advantage. [ Revisions     Transaction OIOB used to define Revisions Revisions can be used to define Maintenance Periods etc. Change Basic Start / End Dates Can adjust Revision dates and collectively re-apply Real Experience. Real Advantage. Real Advantage.[ Assign Revisions Select Orders and assign Revision dates  Can apply direct on Work Order Header or collectively through IW38 or IW37N Real Experience. . .[ Manage Work Center Capacities  Can access & maintain from capacities from within both Evaluation & Leveling  Changes to calculations are immediately reflected on Table / Reports  If change from Planning Table will only become permanent when Save on exit Work Center Capacity Capacity values are not stored in SAP – dynamically calculated Viewed in reference to a Factory Calendar Capacity Planner Group Factory Calendar Employee HR Assignment SAP HR Standard Available Capacity Versions Intervals of Available Capacity 3 aspects can be taken into account:  Standard Capacity  Intervals & Shifts  Versions Real Experience. Real Advantage. Real Advantage.[ Factory Calendar  Defines working days & Holidays Real Experience. . . Real Advantage.[ Standard Work Center Capacity  Defined on WC Capacity Header screen Can be used to group Work Centers in Capacity Planning Required if assigning Shifts Required if executing finite scheduling Real Experience. . Capacities * Operating Time (Operating Time is adjusted by Utilization) Real Experience. Real Advantage.[ Standard Work Center Capacity  For each Work Center you establish a standard available capacity and working times that reference a specific Factory Calendar  Factory Calendar (defines working days / non working (including holidays) days.  Breaks can be defined that are deducted from available operating time  For typical routine maintenance scenarios it is recommended to exclude breaks and adjust start and finish dates to reflect normal available work time  The standard capacity is applied to all the working days defined within Factory Calendar  For non working days the capacity is set to zero.  As previously notes the working times influence how schedule dates are calculated on the Work Order Work Center Capacity = Number of Ind. 2) * 3 = 32.4 Real Experience. 1 hr Breaks = 9 (9 * 1.0) * 3 = 27 (9 * 0.0) * 2 = 20 10 hrs. Real Advantage.[ Standard Work Center Capacity  Calculation examples: Operating Time = Calculated Work Time * Utilization 10 hrs.9) * 3 = 24. No Breaks = 10 (10 * 1.3 (9 * 1. . Real Advantage.[ Standard Work Center Capacity  Calculation examples: Work Center factory calendar defined as 7 work days / week Non working holidays defined on 12/25 and 1/1 Available capacity 45 hours per day Real Experience. . .[ Intervals & Shifts   Standard capacity can be further refined by adding Intervals Different capacities can be set for individual days or periods of time In this example no intervals yet exist Indicates standard capacity Real Experience. Real Advantage. Real Experience.[ Intervals & Shifts In this example interval added Note: Interval operating times also impact Order date scheduling. . Real Advantage. [ Intervals & Shifts  Monday 21st Holiday per Factory Calendar ----. Real Advantage. .5 Day Interval-- Real Experience.7 Day Cycle --------. . Real Experience. Real Advantage.[ Intervals & Shifts To add an interval 1 (default) or 7 days are applicable cycles Although 7 day cycle only first 5 days applicable to Interval. 5 Day Interval-- Real Experience.[ Intervals & Shifts  Monday 21st Holiday over ridden by Interval ----.7 Day Cycle --------. Real Advantage. . . Real Advantage.[ Intervals & Shifts Real Experience. .[ Intervals & Shifts  Can reference and apply shifts defined within HR Real Experience. Real Advantage. Real Advantage.[ Intervals & Shifts  Can apply shift sequence and define capacity by shift Real Experience. . [ Capacity Versions Can have multiple Versions of available capacity within Work Center 3 Standard delivered versions Can add your own versions Can change active Versions when evaluating capacity or leveling (scheduling) Intervals are associated with specific versions Real Experience. Real Advantage. . Real Experience. Real Advantage.[ Capacity Versions Can apply different Versions of available capacity on Work Order Header Schedule dates reflect defined versions. . Real Advantage. .  Configuration setting on Evaluation Profile  Not possible within Evaluation  Cumulate Capacity based on employees assigned to Work Center Capacity  HR assignment Real Experience.[ Employee Assignment & Capacity Calculation  Within Capacity Leveling it is possible to calculate available capacity based on individual work schedules maintained within HR Master Records. . Real Advantage.[ Employee Assignment & Capacity Calculation Real Experience. [ Employee Assignment and Capacity Calculation Capacity leveling reflects HR Schedule of employees Work Center Capacity is ignored Real Experience. . Real Advantage. Real Advantage. .[ Capacity Evaluation Easy to configure reporting function to further support scheduling process Real Experience. [ Capacity Evaluation Work Center Work Center Standard Overview Change Work Order Output to Printer Export to Excel Real Experience. Real Advantage. . Real Advantage.[ Capacity Evaluation Work Center Work Center Change Capacity Detailed Capacity List Can branch to Capacity Planning Table & Dispatch work (Prepare Schedule) – Changes update reports Dispatch Work Change Work Order Capacity & Work Order changes dynamically update reports Capacity Planning Table Real Experience. . [ Capacity Evaluation Select via overall profiles Configured to meet specific reporting needs  Evaluation periods  Period Display  e. Real Advantage. week. . Month  Data selection options  Filters  Exceptions Can use Wildcard * in selection Selection by status of Order Real Experience.g. Day. .[ Capacity Evaluation – Standard Overview The Standard Overview report  comparison of requirements compared to available capacity Can adjust profile settings „on the fly‟ Real Experience. Real Advantage. Real Advantage.[ Capacity Evaluation – Standard Overview Differing intervals to be evaluated Time period definition Applied Capacity Version Can filter display based on loading Real Experience. . .[ Capacity Evaluation – Standard Overview Graphic views available Real Experience. Real Advantage. Real Advantage.[ Capacity Evaluation – Standard Overview Real Experience. . Real Advantage. Layout can be configured to meet specific needs Does not use ALV technology Can download to Excel etc.[ Capacity Evaluation – Detailed List Provides a breakdown of each requirement period in an Order Operation list form. . Real Experience. Real Advantage. .[ Work Orders .Ready to Schedule? Real Experience. Real Advantage. Priority. Order Type. Basic dates. . etc.[ List Edit . System & User Status to select and identify readiness for scheduling Drill down to adjust Work Order plan and status data Use Revision functionality  Collective assignment & update of Basic Dates Direct Access to Material Availability report for selected Order / Operations Real Experience.Used to manage backlog    Establish layouts to sort by Criticality. Real Advantage. Manage Backlog Manage dates / apply Revisions Check Materials Availability Publish Weekly Schedule Monitor execution status Real Experience. .[ Order & Operations List  Single screen combining Order Header and Operation data.  Can define and save both selection parameters and layouts to meet specific Scheduler processing functions. Real Advantage. .[ Order & Operation List – Schedule Overview Schedule Overview (Gantt) Real Experience. Real Advantage. .[ Order & Operation List – Materials Availability Materials Availability Report Real Experience. . Real Advantage.[ Materials Availability Real Experience. [ Capacity Planning Table  Using Planning Table to create the Weekly Schedule  Review work requirements against capacity  Manipulate capacity & requirements  Dispatch operations requirements to specific work days  Recommend use of CM25 Variable Capacity Planning Table  Dispatching work moves an operation onto a particular day and changes Operation system status (to DSPT). Real Advantage.  Two dispatching options:  Manual  Finite (using a dispatch strategy). . Real Experience.  This day may or may not be the same as how it was originally planned / scheduled in the work order. .g.[ Getting to Planning Table  Can navigate between IW37N and Planning Table using selection to determine Orders to be included. Revision Recommend finalizing schedule using direct access to ensure all requirements accounted for Real Experience. Call up Planning Board directly Select by Work Center Can refine selection further e. Real Advantage. Real Experience. Can further filter requireme nts data. .[ Getting to Planning Table  Can change time settings before execute. Real Advantage. .[ Time Profile Settings Today‟s date = 1/24/2008  Backlog Orders show yesterday Backlog Orders show today Real Experience. Real Advantage. selection rules.[ Tabular Planning Table Overview Capacity details – available / scheduled Work List details Configure layout. time periods of table to meet specific company needs and scheduling timeframes Can Maintain Capacity and Order details directly from table  View work requirements by period Define weekly schedule by assigning (Dispatching) work Adjust dates within table to balance resources with work requirements Real Experience. . Real Advantage. Real Advantage. .[ Tabular Planning Table Views For weekly schedule recommend daily view Weekly or Monthly views can be used for longer term planning / scheduling Week Month Real Experience. [ Tabular Planning Table  Requirements Section of Planning Table Field values and layout can be configured Not ALV technology – so somewhat limited 15 fields maximum Real Experience. Real Advantage. . Cap Dispatched Pool/Rqmts Total Req‟ts # P A OT S Start Time Order Op Op text FL Capacity Requirements from Work Order Operations 6 Hrs 12 Hrs 8 Hrs 4 Hrs 1 1 1 1 PM03 0 01/22/2008 07:00 816542 0010 Op 1 PM03 0 01/22/2008 07:00 816542 0020 Op 2 PM03 0 01/22/2008 07:00 816542 0030 Op 3 PM03 0 01/22/2008 07:00 816542 0040 Op 4 Planning Table Requirements are assigned independent of the remaining available capacity Configure to calculate remaining available capacity as the difference between available resources and work already dispatched Real Experience.  The scheduled date of the operation is from Order Period 12/11/07 24 Hrs 6 Hrs 18 Hrs 12/12/07 24 Hrs 12 Hrs 8 Hrs 12/13/07 24 Hrs 0 Hrs 4 Hrs Daily Capacity of Work Center Avail. . Real Advantage.[ Tabular Planning Table – Pooled Requirements MECH  A new operation first appears on Capacity Planning Table as a Pooled Capacity Requirement. Real Advantage.[ Tabular Planning Table – Pooled Requirements Daily Capacity of Work Center 8 1 Initial system distribution of hours based on Operation dates  45 Work Hours planned for 8/27 Capacity Requirements from Work Order Operations 8 5 8 4 2 8 1 45  Selected Work Requirements mapped to defined Work Center capacity based on Operation Dates Real Experience. . [ Tabular Planning Table – Schedule Process (Dispatch) MECH Operation Start & Finish Dates Dispatched Operation Period Avail. Real Advantage.Cap Dispatched Pool/Rqmts 12/11/07 24 Hrs 24 Hrs 0 Hrs 12/12/07 24 Hrs 20 Hrs 0 Hrs 12/13/07 24 Hrs 4 Hrs 0 Hrs Total Req’ts # P A OT S Start Time Order Op Op text FL 6 Hrs 12 Hrs 8 Hrs 4 Hrs 1 1 1 1 PM03 0 01/22/2008 07:00 816542 0010 Op 1 PM03 0 01/22/2008 07:00 816542 0020 Op 2 PM03 0 01/22/2008 07:00 816542 0030 Op 3 PM03 0 01/22/2008 07:00 816542 0040 Op 4 DSPT DSPT DSPT DSPT Planning Table Real Experience. . [ Tabular Planning Table – Schedule Process (Dispatch)  Select Order Operations and click button Status of DSPT applied „Pool‟ requirements committed and become „Scheduled‟. Real Advantage. Real Experience. . Real Advantage.[ Tabular Planning Table – Schedule Process (Dispatch)  Example of completed Weekly Schedule in Planning Board Real Experience. . Click Dispatch Button 5. GoTo Planning Board 3.[ Weekly Schedule Creation using IW37n & Planning Table  If Work Order dates already defined within weekly period you can set the Schedule in 5 simple steps: 1. Select required Order Operations (IW37N) 2. . Real Advantage. Click Save Button Real Experience. Select All Work Order Operations CM25) 4. Real Advantage. .[ Assignment to Individuals  SAP Capacity Planning Table (Capacity Leveling) can be used to assign / dispatch to individual people  Work can be assigned to individual employees defined in HR module  Work times are driven by work schedule in HR  Process is called Split Assignment  Split Dispatched Operations to individual persons  Split Assignments are presented in CATS Work list for each individual Real Experience. .[ Assignment to Individuals Real Experience. Real Advantage. Real Advantage. .[ Assignment to Individuals Real Experience. [ Assignment to Individuals Real Experience. Real Advantage. . [ Assignment to Individuals Real Experience. Real Advantage. [ Assignment to Individuals Real Experience. Real Advantage. [ Publish the Schedule Example of Weekly Schedule Real Experience. Real Advantage. . Real Advantage.[ Publish the Schedule Example of Weekly Schedule (CM07 Report) Real Experience. Real Advantage.[ Publish the Schedule After Dispatch refresh of IW37N updates status and dates ready for publishing Selection variants and layouts defined to meet schedule publishing requirements Variety of publishing methods Real Experience. . Real Advantage. .[ Publish the Schedule Example of Weekly Schedule (IW37 Report) Real Experience. .[ Some publish in Excel – down load from List Edit Real Experience. Real Advantage. .[ Schedule Compliance Report    Standard SAP does not readily support this reporting requirement  No history of schedule or date status at point of time  Required changes impact Work Order data Straightforward report to develop in SAP (Abap) or in BI (preferred). Real Advantage. Advantages of BI:  Maintain compliance specific history over time  Technology readily support analysis within and across organizations  Use Dashboard to effective compare results and drive improved performance Year 2007 2007 Week 02 02 Plant ABCD ABCD Planner Work Grp Center PG1 A PG1 B Sum PG1 # of Scheduled Orders 3 2 5 # of Compliant Orders 2 1 3 % Compliant 67% 50% 60% Real Experience. Real Advantage.[ Schedule Compliance Report  Requirements of Report:  „Snapshot of scheduled work (DSPT) for week n+1 (day/time at end of week n)  „Snapshot of completion status (as defined) for week n+1 (day/time at start of week n+2)  Comparison of schedule v completion Real Experience. . [ SAP Project System (PS) Real Experience. . Real Advantage. Real Advantage. .[ Use of SAP Project Systems SAP Project System (PS)  Can enhance scheduling capability through use of PS Planning board  Project environment .Shutdowns / Turnarounds Real Experience. . Real Advantage.[ PS and PM Overview Project Definition WBS Structure PROJECT PS Network Activity PM PM Orders Real Experience. Real Advantage.[ PS and PM Overview Project Definition WBS Structure PROJECT PS Network Activity Real Experience. . [ Project Coding Mask Level 1 Level 3 Level 2 Good practice to design / adopt coding mask(s) to ensure consistent numbering / identification of WBS Elements • Capital or Expense • Budget / Organizational Responsibility • Phase. 145 . Stage. Event • Major Resource Area Real Experience. Real Advantage. 146 .[ Project Definition Example Framework / defaults for all objects in project -Organizational -Overall Dates -Control settings Real Experience. Real Advantage. [ Creating a project and associating WBS elements  The first step is to create a project and create/assign WBS element values to the project. .  Real Experience. This transaction is of great use in creating both the Project and the WBS elements. Real Advantage. 148 .[ Project WBS Structure Example Real Experience. Real Advantage. 149 .[ Project Copying Real Experience. Real Advantage. . Real Advantage.[ Plan and Schedule Dates Project Definition WBS Structure PROJECT PS Plan Dates S F S Network Activity F Plan Milestones PM S PM Orders F Real Experience. [ Networks / Activities  The network / activity relationship is remarkably similar to the order operation relationship. Real Experience. Real Advantage. . relationships.   Note: each activity within a network can be assigned a different WBS element if different from the parent. Real Experience. then its dates will move when the master network reschedules. . intervals. Real Advantage. If the network is linked to another.[ Network finer points continued  There are durations. 153 . Real Advantage.[ Network Activity Example • Activities within same Network can be linked to different WBS • Multiple Network can be included within project Real Experience. Real Advantage.[ Network Activity Relationships Network Order Network Activity Real Experience. 154 . [ Project Date Planning & Scheduling Top Down or Bottom Up Date Planning Scheduled / Calculated Dates Real Experience. 155 . Real Advantage. [ Can Relate Across Network Orders and WBS WBS Element WBS Element Real Experience. Real Advantage. 156 . [ Gantt View of Plan WBS Element Network Activity Real Experience. Real Advantage. 157 .   Real Experience.[ Rescheduling the project  Have the option of rescheduling network only. networks and orders. . Pulls off the basic start date of the master network and then reassigns basic and scheduled start dates of all orders. Real Advantage. Transaction gives warning messages for orders unable to schedule and why. or just orders. 159 .[ PM Work Order to Project Assignment Work Order Additional Data Tab Work Order to WBS Work Order to Network Activity WBS or Activity Dates applied to Work Order Real Experience. Real Advantage. Additionally. It is imperative that the planning of the order operations is sound because moving individual operations is not possible. the order schedule and basic dates will mirror the networks activity dates. . Real Advantage.[ Linking maintenance orders to networks  Once this link is made. NOTE: Network assignment are made at the order level and not the operation level. the order will begin showing up in PS networks as a „network‟ object as well.   Real Experience. Real Advantage.[ PM Work Order to Project Assignment Real Experience. 161 . Real Advantage. 162 .[ PM Work Order to Project Assignment Real Experience. . Real Advantage.[ Overview and reporting in PS Networks Real Experience. Real Advantage.[ Project Date and Work Planning Reports Real Experience. 164 . Real Advantage. .[ More on Project Info Systems (CN41)  Allows the user to set up which fields are displayed and how this may look in a graphical extract. Real Experience. Real Advantage. .[ More on Project Info Systems (CN41) Real Experience. float and critical path (red) for the networks Real Experience.Graphics   Network Diagram These charts show durations.[ More on Project Info Systems (CN41) -. Real Advantage. relationships. . Real Experience.[ More on Project Info Systems (CN41) -. Real Advantage. .Graphics  This is a Gantt view of the same network diagram. 169 . Real Advantage.[ Example Report – Work & Schedule Data Real Experience. 170 . Real Advantage.[ Standard Exports – MS Project Real Experience. Real Advantage.[ SAP Multi Resource Scheduling (MRS) Real Experience. . [ What is MRS?  A “Multi Resource Scheduling” tool  View the status of resource planning  Assign suitable employees and tools to requirements (demands) from different areas  Transfer data to and from systems which manage personnel resources and tools Real Experience. . Real Advantage. Real Advantage. .[ MRS Scenario Overview Demands Plant Maintenance Order/ Service Order Project System Network cProjects Request WebUI technically based on PS Planning and Scheduling Manager View (Web UI based) Capacity Management Graphical Planning Board (SAP GUI based) Employee View (Web UI based) Real Experience. new operations will be created during Back Integration. or the standard Org Management Structure can be used.  Capacity Data of work center is only used when scheduling on work center level is done (Scheduling in PM/CS and PS. It is not taken into account when scheduling is done on individual level. .  MRS requires a linkage of a Work Center to one node in the RP structure via the HRMS linkage. Real Experience. Thus if multiple assignments are created for an operation. Real Advantage.  Org Management transactions can link a MRS planner to parts of the structure and MRS transactions can be used to have the default work areas be identified in MRS.[ Work Center / Resource Planning Structure (summary)  MRS support RP structure to identify an organization hierarchy pertinent to Resource Planning. and in the MRS Demand View). (MRS Resource View)  MRS can enforce a 1-to-1 relationship between the MRS assignments and the PM Order operations.  MRS planning board uses the PM Work Order Operation‟s Work Center to identify what resource should be shown. . Real Advantage.[ Master Data for Qualifications: Overview Demand Qualification Matrices Qualification Catalogues Requirements Profile Employee Employee Profile Skill Level Real Experience. [ Functional Overview Demand Gantt Work Center Gantt Work Center Capacity Alert Monitor Real Experience. Real Advantage. . usage of Order List (IW38)  Simultaneous planning of PM/CS orders and PS networks  Display of relationships between order operations (also across orders)  Graphical shifting of operation dates via Drag&Drop  Re-Scheduling of orders  Simulation possible (only after pressing “Save” the data is written to the data base)  Undo / Redo function  Dispatching of orders to Work Center Gantt chart Real Experience. Real Advantage.[ Functions in Demand Gantt chart  Flexible selection of relevant orders and networks in entry screen  E.g. . .[ Details about work center dispatching In the work center view a possibility is provided to drill down from work center level to resource level. Real Advantage.  Real Experience. For this purpose the resources of the work centers can be displayed with their assignments and availabilities.  Via drag and drop the operations can be planned from work center level to resource level. .[ Details about absolute Capacity Utilization Real Experience. Real Advantage. .[ Scheduler Workplace Real Experience. Real Advantage. Real Advantage.[ Terms         Demands Resources Organizational unit Resource node Position Person Resource planner Capacitive scheduling Real Experience. . [ Demand Order MRS Operation Demand Operation Demand Operation Demand Real Experience. Real Advantage. . .[ Organizational Units with Positions Organization Unit Plant Technical Services Pipe Fitters Millwrights Machine Shop Note: Organizational Unit = Resource Node Real Experience. Real Advantage. Real Advantage. .[ Organizational Units with Positions Organization Unit Position Plant Technical Services Pipe Fitters Millwrights Machine Shop Pipefitter Millwright Machinist Note: A Person is assigned to a Position Real Experience. and qualification matrixes  Employee and requirements profiles  Tools (as equipment or material) Real Experience. Real Advantage. . qualification catalogs. scales.[ Master Data  Resource planning structure:     Human Resources (HR or BP record) Resource availability data Organizational unit/Work center Resource planner  Qualifications. Real Advantage. Link A 008 P Center Link A 061 LA Work Center (ZMRS) .[ HR to ERP Relationship HR PO10 Daily batch job HRMS Link Logistics IR02 Organizational Unit PO10 Work Center (0005) Organizational Unit PPOME Resource Planner PO13 Position PA30 Link A 008 P PO01 Work center with resource planning node Work center of technician IR01 Work Center (ZMRS) HR record/person Daily batch job HR Work Center HR Work Link A 061 LA HR record/person PO10 Organizational Unit Real Experience. [ Another view of the relationships Plant Resource Planner Organization Unit Maintenance Work Center Position Technician Work Center Person Technical Services Technical Services Kahn Ellis Piperfitter 1223 Used when work initially planned in operation. Real Experience. PIPE Pipefitter 1223 Piperfitter Seen as Resources 4343 John Wayne 4555 Mark Scott WC_4343 Written back to operation when Resource is scheduled. Real Advantage. John Wayne WC_4555 Mark Scott . .[ Schedule to Work Center Real Experience. Real Advantage. [ Schedule to Resource Real Experience. . Real Advantage. Real Advantage. .[ Demand layout Real Experience. [ Resource layout Real Experience. . Real Advantage. Real Advantage.[ 1:1 assignment relationship versus no relationship  1:1 relationship:  Cause additional operation to be created per resource assigned  Assign “technician” work center representing resource to operation  No relationship:  Assign resource(s) to operation in Requirements Assignment tab  Cannot display assignments in List Edit Real Experience. . [ Vesta Plant Maintenance Excel Integration (PMX) Real Experience. . Real Advantage. [ Standard product functionality Data Flow: Work order data Updated Dates Updated Employee Assignments Sheet filled with Activities Detailed Dispatching Real Experience. Real Advantage. . . Real Advantage.[ IT Overview  The Vesta Integration is developed as a Microsoft Excel Add-In  It uses standard SAP BAPI‟s to interface with SAP  The add-on honors all SAP and Microsoft security mechanisms SAP Vesta Integration Addon MS Excel BAPI’s and RFC’s Real Experience. Real Advantage. 210 . manage and prioritize work  Awareness of non core SAP PM options that can further enhance & support scheduling  Understanding of how PS can expand scheduling capability Real Experience.[ Key Learnings  Understand core SAP planning functions and tools  How to develop and manage a maintenance schedule in SAP     Use of and impact of dates Codes to support the process How to define and manage capacities Assess. com. . SESSION CODE: 36245 ] Real Experience. Please remember to complete and return your evaluation form following this session. Real Advantage. visit www. For ongoing education in this area of focus.asug.[  Thank you for participating.