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[ 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.
[ 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
Contents
Long text (Std Text) instructions Maintenance work centers # Resources, Duration, Total Work Material components (Stock / non-stock w/BOM) Special Tools/drawings/equipment (PRTs) Craft / Specialists / Qualifications / Contractors To standardize work processes
Why?
Who?
Real Experience. Real Advantage.
Maintenance Task List Tools Services Components Labor Maintenance Task List Operation Operation Operation Operation Operation Sub-Operation Operation Sub-Operation Long Text Standard Text
- Use in work order Leverage one or more Task Lists for planning work orders
Task List (Turbine 1000)
Operation #1
Operation #2 Operation #3 Operation #1 Operation #2
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. Real Advantage.
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
Internal processing settings typically common across plants External processing (operation Services) defaults can cause the need for multiple profiles by plant. Header data settings common across plants
Work Center & System Condition are defaults for TL Operations Matl BOM populated on Gen TL makes items available Operation Overview
This option has better view of package text but more screens
Component Overview
Operation Relationship
Strategy Plans must have same Strategy on Task List, Items and Plans Strategy plans MUST have a task list or will not schedule plan Error.
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
Apply Long text using standard text key Apply text directly to Operation
Cut / Paste Upload
Impeller
Bearing/Gasket Assembly
Bearing
Gasket
Misc. Hardware
[ Bill of Materials
US01
Aromatics ACU - East M1118
CHEMICAL SUPER PLANT AROMATICS AROMATICS CATALYTIC UNIT - EAST EXT. RDC COLUMN MIXER RDC MIXER RAFFINATE BOOSTER PARAFIN STRIPPER BOOT WATER
Plant
BPU Unit Equipment Service
M6833
P1677 P4283 P9614 10003857 BOM
123456 879444
[ Bill of Materials
Equipment BOM Example
[ Bill of Materials
Equipment BOM Construction type BOM
Equipment
Equipment
Equipment
Equipment
Mat 7
Mat 10 Mat 11
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.
All Internal Labor planned with reference to an Activity Type Holds Cost Rate Is used to calculate Plan and Actual labor cost
Planned Service
Need defined in terms of detailed Service Items referencing a Contract / Service Master
This field can be used to identify if the work can be performed while the equipment is in operation (like certain inspections, vibration analysis, testing) or if the equipment must be taken out of operation.
It can be part of the ready to work criteria in selecting orders for scheduling.
Maintenance Item (partial screen below) Setting the Operating Condition on the Maintenance Item will default to the work order header.
Informational User Statuses No numbering, Multiple active, Can be automatically set, Transaction controls, Position controlled, Authorization controllable
Real Experience. Real Advantage.
Statuses can be: Sequentially numbered and activated/deactivated, Sequence control Single activation Authorization controllable
Real Experience. Real Advantage.
In this example, the status INP (In Process) is automatically set when a work order is printed or reprinted. The status INP is removed when the order is TECOd.
Note: User statuses are available for notifications, orders, equipment, functional locations, serial numbers, IBase,
[ Plant Sections
Used in List Edit displays work locations. Augments functional location for some users.
[ Planner Groups
Planner Group Tables One table for flocs, equipment, 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. Work center is another common approach.
Real Experience. Real Advantage.
Planner group maintained on floc or equipment will default to notification or order unless user maintains personal defaults.
Real Experience. Real Advantage.
The problem is the indicator is buried on the Control tab. GUIxT is a good solution.
Planned: All preventive maintenance orders and other work orders that require planner intervention before the job is started.
What if no parts and the operation is estimated/planned? Do KPIs exclude PMs?
Unplanned: Work that is not immediate and handed to a craft to troubleshoot and plan themselves. No previous planner intervention.
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
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
Column layouts can be adjusted and saved as user specific variant Can Sort on columns and filter data, e.g. 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.g. Release Work Order
Real Experience. Real Advantage.
[ 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 - Ready to Schedule? Scheduling Options: Capacity Leveling (Tabular Planning Table) Publish the Schedule Schedule Compliance Reporting
Execution Process
Prepare to Schedule
Scheduling Direction
Basic Start Op. 010 4hrs Op. 020 4hrs Op. 030 6hrs Op. 040 4hrs
Schedule Finish
040
[ Scheduling Types
Typically there are no reasons to change standard SAP Scheduling Type settings. The with Time indicator allows input of times against basic start and end dates as shown below.
[ Scheduling Types
The with Time indicator allows input of times against basic start and end dates as shown below.
[ Scheduling Types
3 Only Capacity Requirements
All Operation Dates / Times set from Basic dates
[ Scheduling Parameters
Defined in configuration & control how dates are calculated Defined for Plant / Order Type
[ 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. This ensures clean start and finish times without SAP calculations in fractions of hours. Shift Order: Switch on to exclude confirmed actual dates and times from recalculation of schedule e.g. if work was not completed and need to adjust schedule dates to another time in future.
[ 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
[ Assign Revisions
Select Orders and assign Revision dates
Can apply direct on Work Order Header or collectively through IW38 or IW37N
Factory Calendar
Employee HR Assignment
SAP HR
[ Factory Calendar
Defines working days & Holidays
Can be used to group Work Centers in Capacity Planning Required if assigning Shifts Required if executing finite scheduling
(9 * 0.9) * 3 = 24.3
(9 * 1.2) * 3 = 32.4
[ 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
[ Capacity Versions
Can apply different Versions of available capacity on Work Order Header
HR assignment
[ Capacity Evaluation
[ Capacity Evaluation
Work Center Work Center
Standard Overview
Output to Printer
Export to Excel
Real Experience. 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 Evaluation
Select via overall profiles Configured to meet specific reporting needs Evaluation periods Period Display e.g. Day, week, Month Data selection options Filters Exceptions Can use Wildcard * in selection Selection by status of Order
Provides a breakdown of each requirement period in an Order Operation list form. Layout can be configured to meet specific needs Does not use ALV technology Can download to Excel etc.
Establish layouts to sort by Criticality, Priority, Order Type, Basic dates, etc. 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
[ Materials Availability
Can navigate between IW37N and Planning Table using selection to determine Orders to be included.
Call up Planning Board directly Select by Work Center Can refine selection further e.g. Revision Recommend finalizing schedule using direct access to ensure all requirements accounted for
Define weekly schedule by assigning (Dispatching) work Adjust dates within table to balance resources with work requirements
Month
Field values and layout can be configured Not ALV technology so somewhat limited 15 fields maximum
A new operation first appears on Capacity Planning Table as a Pooled Capacity Requirement. The scheduled date of the operation is from Order
Period
Total Reqts
Op Op text
FL
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
8 5 8 4 2 8 1 45
Selected Work Requirements mapped to defined Work Center capacity based on Operation Dates
Dispatched Operation
Total Reqts
Op Op text
FL
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
3. Select All Work Order Operations CM25) 4. Click Dispatch Button 5. Click Save Button
[ 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
[ Assignment to Individuals
[ Assignment to Individuals
[ Assignment to Individuals
[ Assignment to Individuals
[ Assignment to Individuals
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
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). 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
Week 02 02
# of Scheduled Orders 3 2 5
# of Compliant Orders 2 1 3
Can enhance scheduling capability through use of PS Planning board Project environment - Shutdowns / Turnarounds
[ PS and PM Overview
Project Definition WBS Structure
PROJECT
PS
Network Activity
PM
PM Orders
[ PS and PM Overview
Project Definition WBS Structure
PROJECT
PS
Network Activity
Good practice to design / adopt coding mask(s) to ensure consistent numbering / identification of WBS Elements Capital or Expense Budget / Organizational Responsibility Phase, Stage, Event Major Resource Area
145
Framework / defaults for all objects in project -Organizational -Overall Dates -Control settings
146
148
[ Project Copying
149
PS
Plan Dates
S F
PM
S PM Orders F
Real Experience. Real Advantage.
Networks / Activities
The network / activity relationship is remarkably similar to the order operation relationship.
Note: each activity within a network can be assigned a different WBS element if different from the parent.
Activities within same Network can be linked to different WBS Multiple Network can be included within project
153
154
155
WBS Element
WBS Element
156
WBS Element
Network Activity
157
159
161
162
164
169
170
[ 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
cProjects
Request WebUI
technically based on PS
Manager View
(Web UI based)
Employee View
(Web UI based)
(summary)
MRS support RP structure to identify an organization hierarchy pertinent to Resource Planning, or the standard Org Management Structure can be used. 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. MRS requires a linkage of a Work Center to one node in the RP structure via the HRMS linkage. MRS planning board uses the PM Work Order Operations Work Center to identify what resource should be shown. Capacity Data of work center is only used when scheduling on work center level is done (Scheduling in PM/CS and PS, and in the MRS Demand View). It is not taken into account when scheduling is done on individual level. (MRS Resource View) MRS can enforce a 1-to-1 relationship between the MRS assignments and the PM Order operations. Thus if multiple assignments are created for an operation, new operations will be created during Back Integration.
Employee
[ Functional Overview
Demand Gantt
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)
In the work center view a possibility is provided to drill down from work center level to resource level. 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.
[ Scheduler Workplace
[ Terms
Demands Resources Organizational unit Resource node Position Person Resource planner Capacitive scheduling
[ Demand
Order
MRS
Operation Demand
Operation
Demand
Operation
Demand
Plant
Technical Services
Pipe Fitters
Millwrights
Machine Shop
Plant
Technical Services
Pipe Fitters
Millwrights
Machine Shop
Pipefitter
Millwright
Machinist
Qualifications, scales, qualification catalogs, and qualification matrixes Employee and requirements profiles Tools (as equipment or material)
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
Link A 061 LA
HR record/person
PO10
Organizational Unit
Real Experience. Real Advantage.
Link A 008 P
Center
Link A 061 LA
Work Center
(ZMRS)
Technical Services
Piperfitter
Seen as Resources
4343 John Wayne 4555 Mark Scott
WC_4343
[ Schedule to Resource
[ Demand layout
[ Resource layout
No relationship:
Assign resource(s) to operation in Requirements Assignment tab Cannot display assignments in List Edit
Data Flow:
Work order data Updated Dates
Updated Employee Assignments
Detailed Dispatching
[ IT Overview
The Vesta Integration is developed as a Microsoft Excel Add-In It uses standard SAP BAPIs to interface with SAP The add-on honors all SAP and Microsoft security mechanisms
SAP
Vesta Integration Addon
MS Excel
BAPIs and RFCs
[ 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, 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
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