Implementation Guide for the mySAP SCM APO Trim Optimization Interface / the Interface for industry-specific optimization in mySAP SCM

Introduction The interface for industry-specific optimization is not just an interface to exchange data. The characteristics of the underlying concept and of the optimization process itself would influence the total system design and setup. Therefore this implementation guide will give you a detailed insight which setups are possible and what the impact on the system will be.

The Business Process Production Planning with Trim Optimization

The Optimization Problem and Process The following description is related to the paper industry but the principles can be adapted to any other industry with cutting optimization problems such as metals, wood and textiles. Basically the trim optimization problem is to cut rolls out off reels in the most efficient way. The problem occurs either because reels normally have standard sizes whereas the rolls have custom sizes. Or the mix of required standard sizes varies in a hard to predict manner, whereas the constraints for producing reels require a stable and predictable product mix for the reels. The trim optimizer has to find a solution how to cut the rolls from the reels considering the below mentioned objectives and constraints.

© SAP AG 2005, mySAP SCM APO Trim Optimization Interface / Ingo Schill / 5

The Trim Optimization Problem

Cutting1 Cutting2

Reels from Paper Machine

12

3 45

A B

Trim Loss

Objective:minimize trim loss

Constraints:Run length, wind direction, tolerances, min/max width,..

Customer orders:Cut Rolls(length, width, CoreType, …)Objective:

reduce numberof knife changes, keep orders together, etc.

Find an optimal way to cut rolls/ sheets from reels considering customer or process specific constraints.

Picture 1: The trim optimization problem

Objectives of TRIM optimization in paper cutting operations • Reduce knife changes

• Produce demands connected • Reduce TRIM loss • Obey manufacturing constraints e.g. run length, wind direction, maximum knife

positions… Based on the trim optimization problem, objectives and constraints it becomes clear that the optimization task belongs to production planning. That means that the optimization task needs to be integrated into the overall production planning and detailed scheduling process. First of all, the production planning process starts with the creation of demands (e.g. sales orders, purchase requisitions, secondary demands, etc.) followed by a material requirements planning. The next step is the trim optimization, which should take place shortly before the execution horizon is reached. Compared to material requirements planning, which will be executed several times, the trim optimization makes only sense to be executed once. Every additional or reduced order influences the trim optimization result heavily; therefore it should be done if the order situation on the optimized resource will not change anymore. Post TRIM a final material requirements planning run based on the trim result together with a detailed scheduling run will be executed, before the production plan will be converted and released for production.

Characteristics of a Trim Sheet / Trim Sheet Order The result of a trim optimization run is a so called trim sheet or cut sheet. The characteristics of this trim sheet, which drive the trim sheet order design in SAP is that the structure is not known a priori. That means that the actual number of sets and patterns, number and characteristics of output components and the output component itself is not determined before or even similar from trim sheet to trim sheet. That is all a result of the trim optimization. In a planning environment the actual trim sheet is represented as a trim sheet order. The common setup of this trim sheet order, as of today, is that one operation will reflect a logical pattern. And one output component will represent one roll position within that pattern with its characteristics, quantity and order number. A trim sheet will be characterized by sets, logical and physical patterns. A set is defined as a horizontal arrangement of rolls across the width of the jumbo, which are produced exactly once. If the same set is produced multiple times this is called a pattern. Patterns can be divided in logical and physical once. Logical patterns are a group of sets, where the knife position and the order assignment on the roll positions are identical. Physical patterns are a group of sets, where only the knife positions are identical, the order assignments are irrelevant. The common representation of a trim sheet is by logical patterns.

Representing a Trim Sheet in SAP APO and SAP R/ 3

The Template PPM/PDS (APO)

In general each PPM/PDS can be used as a template PDS. But in order to be able to select the PPM/PDS for the creation of the trim sheet automatically, the PDS must have type T. PPM/PDS of type T are not considered during source determination. This defined template PPM/PDS contains input nodes and one or more operations with activities (for example, winding or slitting) with one or more output nodes each. But, based on the characteristics of the trim sheet / trim sheet order the template PPM/PDS looks similar to SuperBOM and SuperRouting. It has to contain all possible input and output components, which could appear together in one order. Also the number of operation for winding or sheeting needs to represent the maximum possible number (depending if an operation will represent a logical, physical cut pattern or sets). The order based on the template PPM/PDS is created by deleting operations and activities and copying output nodes to respective operations. In general it would also be possible to copy operations as well. But in the case that the number of operations exceeds the number of operations defined in the PPM/PDS integration issues would occur with SAP R/3 (SAP ERP). Contrary to other PPM/PDS types, a template PPM/PDS cannot be used to create an order directly in the system. Instead, the attributes of the order structure (operations, input and output nodes etc.) must be specified during order creation, based on a template PPM/PDS. There are no APO internal processes or functions which are able to create an order based on a template PPM/PDS. Such orders can only be created by using the BAPI ManufacturingOrderAPS.CreateFromTemplate The creation of template PPMs/PDSs make use of the standard master data setup for PPMs/PDSs via the CIF. The issue now is to identify which production version on the R/3 side should be transferred as PPM of type “P” for production and which one should be transferred as PPM/PDS of type “T” template for TRIM. The easiest way to solve this issue without development effort in the CIF itself is to follow a naming convention and using the user exit EXIT_/SAPAPO/SAPLCIF_PPM_001 in the inbound interface for PPMs in APO. For the PDS the BADI /SAPAPO/CURTO_CREATE exist to create PDS structure with type T. The naming convention has to be applied for all identifiers of production versions if all products which should be transferred as PPMs of type “T”. Example coding: Name of production version contains string “TPPM”. The plan usage is changed to “T” for template. LOOP AT IT_CIF_PLAN.

IF IT_CIF_PLAN-EXT_PLANNR+11(4) = 'TPPM'. MOVE 'T' TO IT_CIF_PLAN-PL_USAGE. ENDIF. MODIFY IT_CIF_PLAN. For template PDS functionality works similar to the PPM functionality, also the BAPI is the same.

Trim Sheet Order (APO) The ManufacturingOrderAPS.CreateFromTemplate BAPI must be used in order to create orders with reference to a template PPM. For this document these kinds of orders will be called trim sheet orders. Trim sheet orders in APO are not of a special order type. These are usual APO planned orders in the first phase and production orders after they have been transferred to R/3. After creation, the status of the order is automatically set to “input fix”, “output fix”. And the so called SAP application setting of the order shows “Trim Optimization Interface”, that indicates that the BAPI and the template PPM/PDS was used to create the order. The SAP application setting is used by some functions in APO PP/DS to control, what can be done with an object. In the case of a trim sheet order it is prohibited to change input or output components nor operations. As SAP APO does not provide any functionality to further optimize or even show the trim result in an appropriate manner, this behavior is intended not to destroy the optimized result. Only date changes are allowed, that means you can move the order on the planning board. Additionally, an order that was created using a template PPM/PDS cannot be reexploded in the APO system because the order structure was also transferred when the order was created. This information is no longer available in the APO system at the time of reexplosion. As already mentioned the common setup of this trim sheet order, as of today, is that one operation will reflect a logical pattern. Each output node assigned to an operation represents the group of identical rolls at the roll position. The quantity of the output node is the sum of all rolls. The disadvantage of this solution is that the number of rolls cannot be seen directly rather would be stored within a characteristics of output node. The number of sets, number of patterns and roll position would also be stored within characteristics of the output node. Basically there is also a second possibility, create one output node for each roll and each operation represent only one set. This solution gives a much better transparency. The disadvantage is possibility to end up with a huge number of line items and operations. In any case the outputs are basically independent from each other. That means each roll or output could have its own quantity, its own configuration and its own accounting information.

Trim Sheet Order / Multi line item Order (R/3) As opposed to SAP APO in SAP ERP the trim sheet order is an individual order type. The trim sheet order type will make use of co-product functionality which means on the other hand that similar prerequisites and behaviors are true for the trim sheet order. Since IS-MP 46C1 (the Industry Solution Mill Products is an add-on to R/3 release 4.6c) orders can be created in SAP ERP (formerly SAP R/3) with multiple line items. Each line item has an individual quantity, individual configuration and maybe an individual accounting. That means such an order does not belong to an individual customer segment. Even more it is not necessary that a line item for a configurable material has an assignment to a customer order at all. It is possible to produce configurable materials for unrestricted stock. The only prerequisite is that the material has to be batch managed.

The costs of such an order are distributed between the line items according to a special settlement rule which is also available within the Industry Solution. (See Settlement Rules)

The Interface to an external (Trim) Optimization Tool

Prerequisites The usage of PP-SFC is mandatory; the template PPM/PDS concept is not available with PP-PI orders (process orders) Use of the Industry Solution Discrete Industry Mill Products (DIMP) Material is managed in batchesUse of characteristics-dependent planning (CDP) in SAP APO is mandatory for all inputs and outputs. CDP configuration setting is checked when a template PPM/PDS is transferred from the ERP system to the APO system.

TOI Related OSS Notes 578872 – Node collection of the trim optimization interface 578863 – Defining PPM template in APO 688946 – Starting planning run automatically 628681 – Takeover of APO position numbers 362208 – Create deallocated orders in APO

Master Data For modeling the paper making process the usage of characteristics (variant configuration) to describe the various product and process parameters is very common. Even, if a company has only standard products and would for whatever reason not need characteristics (i.e. all planning relevant characteristics can be derived by the material name), for the trim optimization system it would be mandatory to use characteristics. There have to be characteristic values associated with the orders to be trimmed, for instance providing trim related input parameters, like diameter, width, etc. In general the download of master data needs to be triggered by the trim optimizations system. A change management is not available; therefore the trim optimizer needs to download master data on a periodical basis, to ensure synchronization with the APO system.

Material Master Data As already mentioned we are dealing with a co-product environment. Therefore, materials that are the outcome of the trim process have to be co-products (the co-product indicator must be activated in the material master (MRP 2 area) within an SAP ERP system). Additionally equivalence numbers have to be maintained (see Cost Settlement / Settlement Rules). If you need to change the duration or capacity consumption parameters for modes or resources, the output components must have the same units of measure. The units of measure are checked when a template PPM/PDS is transferred from the ERP system to the APO system.

Production Versions for the trimmable products/materials Materials/products, for which the trim optimization should be carried out, need to have two production versions assigned. One for the initial planning run and one for the creation of the trim sheet order. Within APO both master data models the PPMs and the PDS (only since SCM 5.0) can be used. In this case, the creation of the master data could be done via transfer from the SAP ERP system.

PPM/PDS for initial planning run The set of routing/BOM (PPM/PDS) does not be special in any case to normal production versions. Also no limitations in regards to usable standard functionality exist. The PPM/PDS for the initial planning run would be needed during CTP or production planning to create initial orders. These orders act as the input for the trim optimization package, later on. Only one thing in regards to the trim process needs to be considered, the modeling of expected trim loss already within the initial PPM/PDS. Due to the trim optimization problem, each trim solution will contain trim waste. If you do not model expected trim waste in the initial PPM/PDS as well, you will always have a quantity and capacity deviation. In order to minimize this deviation between the initial order and the trim order it is recommended to model expected trim loss in the PPM/PDS for initial planning, as well. This can only be an assumption but nevertheless increases the accuracy of the initial plan.

Template PPM/PDS The so called template PPM/PDS is necessary to create a trim sheet order by the trim optimization package. Some issues have already been covered in earlier chapters. Some modeling issues are described below. For setting up the template PPM/PDS in a paper making scenario a fundamental decision has to be made. Should the paper machine and winder be modeled in one or in separate BOM levels? Beside this fundamental decision both options do have one thing in common: The winding or cutting operations are always the last operations in the routing, which means, that a material level has to follow the trim operation. In other words there needs to be an output material after the TRIM operation. The following description for the modeling of components and operations are valid for single and separate MRP levels.

Modeling components Basically, for the modeling of components within the template PPM/PDS nothing special needs to be considered. Although, I would like to mention that the BOM for the template PPM should be a SuperBOM (aka MaximumBOM) that is commonly used in the paper industry. For example, you have a configurable product with five material variants. Only 2 or maximum 3 of these 5 material variants will be in a trim sheet together. The template PPM/PDS, which is set up for the configurable material, needs to contain all 6 material numbers as components. That gives you the advantage that all possible combinations of the 6 materials are covered by only one PPM/PDS.

The second thing to consider is that you are in a co-product environment (see Material Master Data). That requires the maintenance of all possible input components as well as all possible output components within the BOM. The output co-products have to be maintained as components with a negative quantity to differentiate them as output. From a performance point of view you should not exceed 250 components. Therefore it would be possible to group materials based on logical parameters rather following strictly one template PPM per configurable material as well. But in this case the template PPM determination by the trim package becomes more complicated. Details on assigning components to operations see “Modeling of operations”. Our recommendation is to assign the master output to the last operation and the inputs to the first operation. When the TRIM order is created the optimization tool deletes the operations between the first and the last which are not needed and assigns the additional input and output nodes to the remaining operations.

Modeling of operations The BAPI CreateFromTemplate basically allows the external system to copy/replicate operations and activities defined in the template PPM/PDS. But orders created using this feature cannot be transferred back into R/3 at the moment, because R/3 is not able to process new operations in orders coming from APO due to mapping problems with the operation number and activity number between ERP and APO. Therefore, it is only possible to delete operations and to use the chosen operations exactly one time. The same is valid for the activities. That would mean the template PPM/PDS is a maximum routing. That means the routing needs to contain the maximum number of operations which are possible in reality. The best practice setup for the operations is one operation normally will represent one logical cut pattern. But also one operation could represent a set or even a physical pattern.

Only simple serial start/end relationships between activities are allowed. This means that parallel arrangements and "loops" to previous activities are not permitted. When copying activities and operations from a template PPM/PDS, the relationships to the predecessor activities are also copied. If the template PPM/PDS activity has no predecessor activity, a standard relationship (END-START) is created in the order. If you do not want this to be the case, you can define a "dummy" predecessor in the template PPM/PDS, so that this relationship can be used instead. The standard behavior of the CIF is to assign input components to the first operation and output components to the last operation. That is fully sufficient even we will have output components assigned to each operation within a trim sheet order. But the BAPI and the template PPM/PDS is capable to copy components an assign it to the right operations where the input is consumed or the output is produced. Also a common setup is that, the trimming operations are normally the last operations in the routing; because currently a trim package deletes operations without knowledge if the operation is a trim operation or not. That means after the trimming operation a BOM level has to be defined. In general, the concept of the template PPM allows having non-trimming operations before and after the actual trim operations. But in this case the trim optimization package needs to evaluate the template PPM/PDS structure very carefully and a logic for the order creation based needs to be very sophisticated. Up to now, this has not been realized by any known trim package provider.

Modeling of MRP levels As already mentioned, after the trimmed resource a MRP level needs to be introduced in any case. Following, the outlined concepts for modeling of MRP levels for a PM and a winder is only an example. They are also valid correspondingly to other routings like for instance coater and sheet cutter or shearing and cut-to-length lines in metals.

Separate MRP levels for PM and Winder This model, where you will have two MRP levels, one for the PM and one for the winder, is also called the split model. The advantages of the split model are the trim optimization package does not have to deal with paper machine (non-winder) orders / operations which are no cutting operations. Also a re-assignment of winder orders to blocks is possible without changing the PM orders. The disadvantage would be to cover the following scenario. We have several PMs in one mill, where each PM can only supply one specific winder. Both machines basically are capable to manufacture similar grades of paper. That would mean that you have to ensure during production planning that if an order is scheduled on a winder the PM order for the supply is connected to the right winder order. This scenario is difficult because of the necessity to have an inter-order mode coupling (a reel from a PM can only be processed at a defined winder or group of winders). To ensure this a solution via user exit has to be implemented. (See note 362208 for the user exit)

Single MPR levels for PM and Winder The only difference to the split model is that the first operation will be the PM operation followed by the winder operations as explained. Disadvantages of the single set up appear mainly for the trim optimization package. At the single case, the trim optimization package has to deal with production stages and planning related information, for which it is not directly responsible. The external trim optimization package needs to be able to identify which operation(s) belong to the paper machine and which operations belong to the winder, for instance.

BAPI ManufacturingOrderAPS.CreateFromTemplate This BAPI ManufacturingOrderAPS with the method CreateFromTemplate must be used in order to create manufacturing orders with reference to a template PPM/PDS. For this scenario these kinds of orders can be called trim sheet orders. Because a template PPM/PDS only serves as a template, the concrete attributes of the order (like operations, activities, components, and so on) must be transferred by the external system when the order is created. The BAPI is available since APO 4.0. And with the SCM 5.0 release the BAPI ManufacturingOrderAPS.CreateFromTemplate is officially released. Also available since SCM

5.0 is the BAPI for the use with Product Data Structure (PDS). Therefore the BAPI has a field for the PDS name. A detailed documentation about the BAPI itself can be accessed via the BAPI explorer.

Cost Settlement / Settlement rules To ensure that the cost settlement will be done on a item level the default distribution rule of the order type-dependent parameters has to be set to “PP5” (ProductionFullSettlement(Mill)). This distribution rule settles the cost of the production to the order items, proportionally to the planned quantities of the items. Example: Order 4711 Item: 10 Roll Quantity 500 lb Item: 20 Roll Quantity 700 lb Total production cost: 2400 $ Settled Cost per item: Item: 10 Cost: 1000$ Item: 20 Cost: 1400$ From mySAP ERP 2005 the cost settlement based on actual posted quantities is possible. Therefore the distribution rule PP6 is available with mySAP ERP 2005. In earlier releases, the PP6 is not available by default. But it is possible to make this functionality available via a downgrade, which will be a custom development project. Additionally, within the material master data the settlement rules and equivalence numbers for co-products have to be maintained out of technical reasons but there is no need to maintain realistic figures. The multi line item order used within SAP for Mill Products is an enhancement of standard co-product functionality in SAP ERP. The standard co-product order calculates the quantity for the order items based on the quantity of the main product. Therefore the system checks if the appropriate settlement rule exists. This behavior is also true for the SAP for Mill Products multi line item order even the order item quantities are independent from each other and no quantity calculation based on the settlement rules is executed. To learn how to setup and maintain settlement rules please consult the SAP ERP documentation. The valid settlement rule is determined by the header product of the production order. That means that a settlement rule needs to be maintained in each product master, which could become a header product in a trim order (basically every product). As the combination and the appearance of products in a trim sheet order are not predetermined, this means that each product master on the trim level needs a settlement rule. This ends up in a huge maintenance effort. This effort could be saved, for instance, if the trim optimizer would always use a specific material (the configurable material for example) and creates a dummy header output node with a very small quantity (0,001 kg for example) which will be ignored during production planning and execution later on. In this case the settlement rule would only be set up and maintained once for

the configurable material (or a limited number depending on the number of configurable products).

Quantity Calculation Rule For each individual operation, the CALC_OPERATION_QUANTITY method from the /SAPAPO/TMPLPPM_CREA BADI is called to calculate the operation quantity. There, the operations quantity can be determined individually for each operation and can then be returned to the order generation. <SPACE> (Blank) The quantity does not have an effect on the operation quantity of the order. The indicator must be set to a value that is not <SPACE> for at least one component. Otherwise, the operation quantity would have the value '0' (zero) and this is not permitted. A Operation quantity is set on the basis of the main component of the order. The operation quantity for all operations then corresponds to the quantity of the main component. This fixed value can only be set for the main component. In this case, for all other components the fixed value <SPACE> must be used. This is the standard way of determining operation quantity that is also used in SAP R/3. B The quantity is added to the operation quantity. That means that the sum of all components with this fixed value results in the operation quantity. If this fixed value is used, only the fixed values <SPACE> or 'B' can be used for all other components. This fixed value can be used for both input and output components. However, within an order this fixed value can only be used by either Input OR output components. That is, both input and output components cannot be used together in one order to determine the operation quantity. The operation quantity is the same for all operations. This fixed value is useful if, for example, the operation quantity needs to be the same as the total of certain input or output components, but the operation quantity does not correspond to the main component quantity. C You use the method CHG_OPR_QUAN_RULE from BAdI /SAPAPO/TEMPLPPM_CREA to determine the operation quantity of one or more operations in an order. The method CALC_OPERATION_QUANTITY of the BADI /SAPAPO/TMPLPPM_CREA is called for each individual operation to calculate the operation quantity. The operation quantity can be determined there individually for each individual operation and returned to the order generation. Flagging with this attribute assumes implementation of the method CALC_OPERATION_QUANTITY. You can only flag the main output component in the order structure with C. If you flag another component with C, this leads to an error in order generation.

Modeling of Scrap within the Trim Sheet Order Because of the fact, that within a trim sheet order each cutting operation has its own quantity, the normal scrap calculation mechanism doesn’t work. Actually, the scrap calculation within the

template PPM is deactivated. Scrap values are ignored when a template PDS/PPM is transferred from the ERP system to the APO system. Therefore, it can either be mapped as part of the quantity specified for the input/output component (which includes scrap anyway). Or we recommended to model scrap as a separate output material. In this case there are various modeling possibilities. At first scrap can be defined as a special product. There should never be a demand for this product. The disadvantage of this solution is that the trim optimization package needs to know somehow which of the products in the template PPM should be used for the scrap product. Available solutions like naming conventions or separately maintained tables in the trim package are quite cumbersome and not really safe. A more generic way is to classify all scrap products with a special scrap class. In this case, the scrap material is recognized by the optimizer through the class. Secondly there can be a specific characteristic indicating the scrap product. But this requires that the user always adds this characteristic to all classes which are assigned to trimmable products. And the only way to get the information across to the trim optimizer would be to define the scrap product as a product variant and set a specific value for the scrap characteristic. The trim package would than need to read the product master records plus their configuration of all products defined as outputs in the template PPM. The third approach is to use any product in the PPM and create an output node for scrap with this product. In order to mark this node as scrap and in order to prevent that the scrap is used by a demand, the flag IGNORE_PEGGING must be set by the trim package, which can be done with a parameter in the CreateFromTemplate BAPI. Modeling of trim loss with the normal material number plus indicator “not relevant for pegging” is not a complete solution. The material is still visible for ATP checks (if the material is a sellable material).

The trim optimization process Up to now, only modeling and setup alternatives for master data and system customizing are discussed but the overall production planning business process with integrated trim optimization was neglected so far. The production planning process could start as usual with a Capable-to-Promise ATP-Check (CTP) or the execution of a production planning heuristic within SAP APO. If we assume, that we will have a paper machine in any case that is block planned, some block adjustments and replanning steps may be performed as well. So far the process is not specific due to the trim optimization integration. The specifics of the process start about 2-5 days before the execution of the actual plan. Due to a continuously changing order situation on the trimmed resources, it is preferable to execute the trim optimization as close as possible before production execution (means the conversion or release of planned orders to production orders). To make sure that the order situation will not change during the trim optimization the blocks on the paper machine get fixed. No new orders can be scheduled to the block. This is an effective way to fix the winder orders as well, as usually trim optimization packages are choosing the orders to be trimmed via the paper machine orders within one or several similar blocks.

Afterwards the trim optimization process will be performed. The capabilities here depend on the used trim optimization package of course. If a satisfying result is achieved, the trim solution will be released back into APO and creates the trim sheet order. The scheduling should be done infinite. At this point in time it is very important, with which date and time the trim sheet order is created. To determine the right date and time of the trim sheet order you have to determine the following: First, the order situation on the trimmed resource shows the initial orders from the CTP or planning run and additionally the trim sheet order infinitely scheduled on the same resource. That means actually at this point in time we have an overproduction/overload on the resource. Secondly, the used planning direction (forward, or backward scheduling) together with the planning heuristic (e.g. CTP) and if a connected resource (most likely the paper machine) is block planned is important. Now it is obvious that the next step takes care of the overproduction. Therefore, after the creation of the trim sheet order in APO a set of planning and detail scheduling heuristics needs to be executed. Bearing in mind the date and time of the TRIM sheet order, the first step of the planning set is to replan all products on the trimmed resource affected by the new trim orders to get rid of the overproduction. Due to the fact, that the trim sheet order is created with output fix indicator a standard production planning heuristic like planning of standard lots could be used. The heuristic will delete the unfixed initial planned orders and keep the fixed trim orders. Mainly needed in a split scenario, the second step is to replan the upstream resource(s) to adjust the supply quantity to the exact demand of the trim sheet order. Because the trim package may have changed the requirement quantities compared to the initial orders. Next step is a rescheduling heuristic, this would be necessary, for instance, if the trim sheet order is created in deallocated mode or if you would like to close a time gap between the paper machine and winder order. If the resources are scheduled with bucket finite capacity in the previous steps we recommend using rescheduling heuristic to schedule the activities time-continuously as a next step. This set of planning heuristics is ideally executed directly after creation of the trim sheet order and should be also triggered by the external trim package. Since SCM 5.0 a BAPI to trigger a planning run is available otherwise please see note 688946 (Starting planning run automatically). Example settings for a background planning run in the paper industry: Step Function/Heuristic Scheduling

Mode Planning direction

Objects Selection Criteria

01 Planning of Standard Lots

Infinite or search for bucket with free capacity

Backward + reverse

Products All products on the winder resource which are affected by the TRIM result

02 Planning of Standard Lots

Infinite or search for bucket with free capacity

Backward + reverse

Products All products which are dependent demands of the trim sheet

orders 03 Reschedule Find slot Forward Resources Paper

machine (resource upstream from trimmed resource)

04 Rescheduling: Bottom Up

Infinite or search for bucket with free capacity

Forward Resources Paper machine (resource upstream from trimmed resource)

05 Reschedule Find slot Forward Resources Winder (trimmed resource)

Especially if you are using block planning on a resource affected by the planning set some pitfalls need to be considered. First, if you have fixed the block prior to the trim optimization, you have to unfix the block before you will be able to replan/reschedule the block planned resource. Additionally, if you are going to trim a block at once and would like to adjust the supplying paper machine order to the increased paper demand of the trim sheet order (additional trim waste has to be considered) as well, it might happen that the block on the paper machine is too small for the order requirement. Operations cannot be scheduled, even not in deallocated mode, if the block capacity is overloaded. This situation has to be solved organizationally by the planner, who has to manually change the block size and reschedule the order accordingly. The combination of block planning in CTP and the setting schedule components and supplies to the block limits rather the exact time continuous dates could cause an unintended behavior, for instance, if a trim sheet order is created initially time wise overlapping to the supplying block. In this case the supplying order and elements are available only at the end of the block which would be to late, as the trim sheet order already starts earlier. Therefore the system would look for a former block to reschedule the supplying order to that one, if possible.

Cross Plan Trim Cross-plant trim optimization is not supported. Even if a trim optimization package would be able to do a cross plant optimization, APO PP/DS and the necessary update into the R/3 sales order do not allow the correct handling in the standard mySAP business suite. A custom development project can solve the issue.