RJ IT SAP Training Material

- SAP Planning (APS ~ HSB) -

2019.11
 Mid Term Production Planning Flow

Overview
SD PP
SAP SAP

PO Receipt
FERT HALB FERT, HALB
Sales Order Plan. Order Plan. data Prod. Order
Sales Order Creation Creation Creation
Creation
I/F
Daily/Size/Line
Order date
SAP Adjustment
Master Data
Material HSB Cre-
APS MP I/F ation & Re-
BOM lease
Work Cen-
ter
APS GMES
Routing
Prod ver-
sion LOT Group- P.Card Cre-
Lead-time ing* ation
APS
Line by APS MP Run
Model
Assembly
line Capa.

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 Mid Term Production Planning Flow

Term description
- Lot : A combination of Nike PO + BR, one lot consists of one or more Nike POs and constitutes planned and production orders for each FERT/HALB defined in
SAP.
- Planned order : Plan period created when creating a plan for MPs interfaced to SAP after lot grouping in APS for Nike PO + BR quantities
Standard information of SAP with intervals of 2-3W after manufacturing start date + Standard cost must be prepared / Material ordering criteria
Changes in planning date or quantity occur more frequently than other planning intervals, and APS and SAP exchange daily planning information
for each interval
- Production order : Planned order is replaced with production order, usually 2 ~ 3W from the start date of manufacturing
Criteria for Material Request and Production Performance Processing / Lots in the Production order section are not managed in APS.
- HSB : As a work order unit, HSB is released on D+8 days of working day, and it is used as a basis for Passcard creation and gathering production performance.

Plant Work Center Lot number Nike PO Plant Lot number Work Center Halb Code Planned order Production order
UPSC2 AO4971100UP01 31182726 10729197
3502353043-10 SLM01 AO4971100SL01 31182503 10730643
PHH01 AO4971100PP31 31182097 10730624
3502353043-20 PHH01 AO4971100PP01 31182616 10730632
PHU01 AO4971100PH31 31182095 10730622
3502353714-10 PHU01 AO4971100PH01 31182611 10730631
OSP01 AO4971100OS01 31182285 10730637
3502353933-10 UPL01 AO4971100L013 31182079 10730614
2110 FGAC2 1903220041 UPL01 AO4971100L010 31182075 10730610
3502354518-10 UPL01 AO4971100L009 31182072 10730608
3502354788-10 UPL01 AO4971100L007 31182069 10730603
2110 1903220041
UPL01 AO4971100L005 31182067 10730601
3502354788-40 UPL01 AO4971100L002 31182064 10730600
UPL01 AO4971100L001 31182061 10729199
3502354984-10 FSSC2 AO4971100FS01 31182085 10730620
DMP01 AO4971100DM31 31182601 10730626
CLS01 AO4971100CS34 31182605 10730628
PHM01 AO4971100CP01 31182260 10730633
FGAC2 AO4971-100 31182703 10729196
PHZ01 803590PZ 31182283 10730635
OSR01 803589OR 31182297 10730640
IPZ01 801903IZ 31182608 10730630
 Mid Term Production Planning Flow

ZPPR0240 : Can display Production order belonging to specific LOT

ZPPR0700 : Can display Nike PO belonging to specific LOT

ZPPR0700

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 Production Plan Time Fence

Confirmed two-weeks production including existing stocks based on FGA + 4-weeks plan maintenance
- Confirmed 2 weeks production including this week : No additional production plan can be created due to the section in which PASS Card is issued
- W2 ~ W5 week section planning confirmation : Confirm existing plan with material order section
- W6 ~ W9 : Planning interval for new PO

Ass’y HSB Creation

Production order Planned order
Date and Release

Frozen zone Free zone

W W1 W2 W3 W4 W5 W6 W7 …
MP …
D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D20 … ... … … ... … ... … ... ... … ... … ... … ... …
…

W0 W1 W2
HSB
D0 D1 …….. D6 D7 D8 D9 …….. D13 D14 …….. D20

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 APS MP

APS Master Data

Model Line Capa Style Line Assign

Enter the capa for the past production model by the manufacturing line Enter a manufacturing line for each style to be assigned during past
or the model to be assigned in the future production, and use it as ref- production history or future production, and use it as reference in-
erence information when distributing production quantity per day. formation when assigning an MP manufacturing line.

** Manage BOM and Work Center information interfaced from SAP to APS.
** There is a Mold Master, but it does not establish MP by using it, but JJ reports the quantity held by each company as a reference information.
** Want to manage the recent last as master information.

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 APS MP

Lot Grouping
Lot grouping by overseas corporate planners for Nike PO information sent from SAP PP to APS
First, for Nike PO of the same style, group into one lot based on the GAC date of the same Buy date.

OA Apply
OA information applied from SAP SD is interfaced to APS, and this information is applied according to lot section
Lot of production order section does not plan in APS, so even if OA information of lot in that section is received in APS, plan is managed
only by APS and OA is applied in SAP by separately.

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 APS MP

MP Production Plan
Production plan of lot grouping and OA applied result is established by referring to master data and history management is di-
vided into versions.
Run engine and release plan through MP Control board

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Planned order
Planned order
: MP daily received from APS is converted into planned order and standard information is checked for standard cost when convert-
ing.
Created Planned order is returned to APS as 'order info'.
: Planned order target

Upper example

Packing Area

완제 Warehouse
D- 2 Day

Upper Embellishment
D- 5 Day No-sew
원자재 Warehouse

Lamination UPN
UL D- 1 Day
UPL D- 4 Day H/F Welding
Upper Stitch- WIP
Upper Cutting UPF U
ing
P
UPC
UPC Screen,Painting UPS D- Day
정포 UPP
Assembling F
Embroidery
FGA G
ROH UPE

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Planned order

Error When Creating Planned Order

ZPPR2020

** Validation check when creating a planned order for the case where routing ST is '0'

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 Short-term production planning flow

Overview
- Definition: The process of planning and sending the quantity by LOT, assembly line, mini-line, and time zone considering the lead time of
semi-finished products based on the confirmed production order.
- Purpose: Provide basic data of Passcard issuance in GMES
- Applying D-8 operation, HSB for daily LOT information of manufacturing date of D+8 days in working day

Mid Term Production Plan PP Short Term Plan

SAP GMES
Sales Order Cre-
ation
D-9 Order Info (HSB)
Prod. Order Creation
LOT Creation (by Work Center)

D-10 WK
Plan Order Creation D-8 Passcard Issue
(by Work Center) Prod. Order Re-
lease Tally sheet Issue
D-8
SAP MM HSB Creation by
Assembly Line
MRP Run D-8 Operation Con-
firm
HSB Release
Purchasing
FERT Confirm
D-10
Goods Receipt

Prod. Execution
Goods Issue
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 Production order

Production order Creation

: If the production order is changed too early than the manufacturing plan date, there is a problem in applying the OA.
Therefore, the production order can be limited to convert the lot below the specified weeks.

- The default setting is to convert production orders up to 3 weeks, but sometimes the production order convert week is
sometimes increased when there is a long holiday such as VJ's Tet holiday.
- Standard cost is also checked when creating a production order

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 Production date adjustment & Lot delete

Production date adjustment

: Function to change the planned date of the lot in SAP, not APS, if the lot status is before HSB I/F.
If the lot is in a planned order section, the lot information to which the planned date change is applied is sent to the APS.
If the lot is in the production order section, SAP has changed the planned date.

Lot delete
: If the lot status is before HSB I/F, you can delete the lot in SAP
This is the effect of deleting a planned order or production order and sending the deleted lot to APS.
Before deleting, check whether there is material request or production performance.

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 Shortage Order

Shortage Order
: Create shortage lot for additional production in case of HALB or FERT defect that is not processed by OS&D during
production
- Order Type : ZST (No additional material order) / ZSH (Need additional material order)
- Lots for which quantity change OA cannot be applied are sometimes registered as shortage for quantity balancing
- In APS, it is not a managed lot and it is usually converted to a production order immediately after registering a shortage order.
- Free input of size, production planning date
- Lot number starts with ‘S’

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 HSB

HSB Definition
The 12 Pair production order is a basis for Passcard issue and work order, and recently applied logic for HSB by Nike PO.

Refer to mini-line information managed by master data (input from Stitching Mini line)
Usually one line has three mini-lines and mini-line 99 is the line for shortage order assignment.
Component order is managed by entering mini-line for semi-finished workshop.

HSB Creation Date

Working day based D+8

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 HSB

HSB Creation
Planner creates HSB by manufacturing line

- The system allocates lots by mini-line, but can be adjusted by the user
- User can input by time, size for individual Mini-line and 'Auto. Allocate ’is used to allocate the quantity to each Mini-
line sequentially by size.
- When HSB generation by each manufacturing line is completed, release processing is performed and this information is
sent to GMES.

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 HSB

HSB Example
For VJ lot 1903220041, when HSB is created on the basis with HSB information on May 20 of the planned assembly date, HSB informa-
tion is generated in the same line, mini-line, hour and size with quantity.
Basic Start Date Material Line MINI LINE Prudction hours 12T 8 8T 9 9T 총합계
2019-05-20 AO4971-100 C2 02 1 1 60 0 0 60 121
2019-05-20 AO4971-100 C2 02 2 0 0 0 72 60 132
2019-05-20 AO4971-100 C2 02 3 0 48 72 0 0 120
2019-05-20 AO4971-100 C2 02 4 0 0 0 72 60 132
2019-05-20 AO4971-100 C2 02 5 0 48 72 0 0 120
2019-05-20 AO4971-100 C2 02 6 0 0 72 0 60 132
2019-05-20 AO4971-100 C2 02 7 0 48 84 0 0 132
2019-05-20 AO4971-100 C2 02 8 0 62 0 0 60 122
2019-05-20 AO4971100CP01 C2 02 1 1 60 0 0 60 121
2019-05-20 AO4971100CP01 C2 02 2 0 0 0 72 60 132
2019-05-20 AO4971100CP01 C2 02 3 0 48 72 0 0 120
2019-05-20 AO4971100CP01 C2 02 4 0 0 0 72 60 132
2019-05-20 AO4971100CP01 C2 02 5 0 48 72 0 0 120
2019-05-20 AO4971100CP01 C2 02 6 0 0 72 0 60 132
2019-05-20 AO4971100CP01 C2 02 7 0 48 84 0 0 132
2019-05-20 AO4971100CP01 C2 02 8 0 62 0 0 60 122
2019-05-20 AO4971100CS34 C2 02 1 1 60 0 0 60 121
2019-05-20 AO4971100CS34 C2 02 2 0 0 0 72 60 132
2019-05-20 AO4971100CS34 C2 02 3 0 48 72 0 0 120
2019-05-20 AO4971100CS34 C2 02 4 0 0 0 72 60 132
2019-05-20 AO4971100CS34 C2 02 5 0 48 72 0 0 120
2019-05-20 AO4971100CS34 C2 02 6 0 0 72 0 60 132
2019-05-20 AO4971100CS34 C2 02 7 0 48 84 0 0 132
2019-05-20 AO4971100CS34 C2 02 8 0 62 0 0 60 122
2019-05-20 AO4971100DM31 C2 02 1 1 60 0 0 60 121
2019-05-20 AO4971100DM31 C2 02 2 0 0 0 72 60 132
2019-05-20 AO4971100DM31 C2 02 3 0 48 72 0 0 120
2019-05-20 AO4971100DM31 C2 02 4 0 0 0 72 60 132
2019-05-20 AO4971100DM31 C2 02 5 0 48 72 0 0 120
2019-05-20 AO4971100DM31 C2 02 6 0 0 72 0 60 132
2019-05-20 AO4971100DM31 C2 02 7 0 48 84 0 0 132
2019-05-20 AO4971100DM31 C2 02 8 0 62 0 0 60 122

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