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Orange County Convention Center Orlando, Florida | May 15-18, 2011

SAP 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.

[ 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.

[ Task List Overview


Task Lists describe the sequence of individual maintenance activities to be performed, identify the required Resources (Labor, Materials, Services, Special tools) and related procedures. Predefined list of Work activities that contain Work Group, Skill, Work Description, Duration, Number of Workers and associated Material Items. Task Lists are building blocks of Maintenance Plans. 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. Real Advantage.

[ Task List Overview


Usage
Regular maintenance (PMs, PdMs, servicing & inspection) Major maintenance Activities (planned repairs, Overhauls) Work steps (operation)

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?

To plan maintenance orders more effectively


To create maintenance plans more quickly

Who?
Real Experience. Real Advantage.

Maintenance and Service Planners


Reliability Engineers

[ 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 . 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. Real Advantage.

[ Task List Overview

- Use in work order Leverage one or more Task Lists 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. Real Advantage.

[ 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.

[ Task List Profile


TL Profile Parameter ID PIN Sets default in IA01,2,3,5,6,7,13,14,15

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. Header data settings common across plants

Real Experience. Real Advantage.

[ 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 Matl BOM populated on Gen TL makes items available Operation Overview

Real Experience. 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. Real Advantage.

[ 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.

[ Components Show Operation Assembly Options


General Task Lists, Assembly (Material) BOMs 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. Real Advantage.

[ 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.

[ Task List Structure - Relationships

Finish to Finish Finish to Start Start to Finish Start to Start

Operation Relationship

Real Experience. Real Advantage.

[ 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.

[ Task List Structure - Relationships


Relationship data copied from Task List onto Work Order Order scheduled with basic start of 01/31/2007

Real Experience. Real Advantage.

[ Task List Structure - Relationships


With offset

Real Experience. Real Advantage.

[ Task List Structure - Relationships

Real Experience. Real Advantage.

[ Task Lists - Supporting Maintenance Plans


Task Lists applied in same way to Strategy, Single Cycle or Multiple Counter Plans

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.

Real Experience. Real Advantage.

[ 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.

[ Task Lists - Supporting Reactive / One Time Work / Overhauls


Using Task List to plan Work Order Or setup as Manual call

Real Experience. Real Advantage.

[ Operations & Sub operations


Can use sub operations to plan multiple resources on same task list operation
No component, PRT planning, 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. 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. Hardware

Real Experience. Real Advantage.

[ 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

TOLUENE COLUMN REFLUX PUMP


P-9614 PUMP Equipment BOM

BILL OF MATERIALS FOR P-9614 Pump Shaft 1.020 X .0075 Bearing

123456 879444

Real Experience. 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. Real Advantage.

[ 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.

[ 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, workflow and reporting In Planning or equivalent Review in field Waiting on Engineering, 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. Real Advantage.

[ 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.

[ Consider different PM Priorities


There needs to be a way to identify PMs that can be scheduled anytime. E.g. certain inspections. See Priority 0

Assignment is across all plants by Order Types

Real Experience. Real Advantage.

[ Operating Condition - Coordination with Production


The Reservation by PM is part of the integration with Production Planning at the work center level.

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.

Real Experience. Real Advantage.

[ Operating Condition Where Used Order Header

Real Experience. Real Advantage.

[ 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 Experience. 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.

[ Status Transaction Controlled

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.

Real Experience. Real Advantage.

[ User Status Assignments


Assignment is at the order type and operation level

Note: User statuses are available for notifications, orders, equipment, functional locations, serial numbers, IBase,

Real Experience. Real Advantage.

Codes To Support Work Planning

ABC Indicator for Criticality

Real Experience. Real Advantage.

[ ABC Indicator - Examples


Used in List Edit displays to prioritize work

Real Experience. Real Advantage.

[ Plant Sections
Used in List Edit displays work locations. Augments functional location for some users.

Real Experience. Real Advantage.

[ 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 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 Experience. Real Advantage.

[ Planning Indicator Good KPI but bad location


The Planning indicator provides nice out of the box reporting.

The problem is the indicator is buried on the Control tab. GUIxT is a good solution.

Real Experience. Real Advantage.

[ Planning indicator - Definition


Important: Understood and agreed upon definition used consistently.

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.

Immediate: Break in work that is not planned.


Other solutions besides the planning indicator
Real Experience. 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. Real Advantage.

[ 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.

[ Availability Checking Control

Real Experience. Real Advantage.

[ 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 4.7 SP EA_APPL 200)

Real Experience. Real Advantage.

[ Manage Planning Activities - List Edits

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.

[ 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.

[ 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, labor resource estimates (number of people and man hours) and durations Material Requirements Criticality and Priority Work Categorization (e.g. Preventive, Corrective, Project, etc.)

Resource group / Work Center capacity information maintained to reflect:


Standard Working Times Weekly available capacity
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

Real Experience. Real Advantage.

[ 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.

[ 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. 010 4hrs Op. 020 4hrs Op. 030 6hrs 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

Real Experience. Real Advantage.

[ 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.

Real Experience. Real Advantage.

[ Scheduling Types
The with Time indicator allows input of times against basic start and end dates as shown below.

Real Experience. Real Advantage.

[ 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.

[ 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.

Real Experience. Real Advantage.

[ 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.

[ Assign Revisions
Select Orders and assign Revision dates

Can apply direct on Work Order Header or collectively through IW38 or IW37N

Real Experience. Real Advantage.

[ 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.

[ 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. 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. Capacities * Operating Time (Operating Time is adjusted by Utilization)
Real Experience. Real Advantage.

[ Standard Work Center Capacity


Calculation examples:
Operating Time = Calculated Work Time * Utilization

10 hrs, No Breaks = 10 (10 * 1.0) * 2 = 20

10 hrs, 1 hr Breaks = 9 (9 * 1.0) * 3 = 27

(9 * 0.9) * 3 = 24.3

(9 * 1.2) * 3 = 32.4

Real Experience. 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. Real Advantage.

[ 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.

[ Intervals & Shifts


In this example interval added

Note: Interval operating times also impact Order date scheduling.


Real Experience. Real Advantage.

[ Intervals & Shifts

Monday 21st Holiday per Factory Calendar

----- 7 Day Cycle --------- 5 Day Interval--

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.

Real Experience. Real Advantage.

[ Intervals & Shifts

Monday 21st Holiday over ridden by Interval

----- 7 Day Cycle --------- 5 Day Interval--

Real Experience. Real Advantage.

[ Intervals & Shifts

Real Experience. Real Advantage.

[ Intervals & Shifts


Can reference and apply shifts defined within HR

Real Experience. Real Advantage.

[ Intervals & Shifts


Can apply shift sequence and define capacity by shift

Real Experience. Real Advantage.

[ 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.

[ Capacity Versions
Can apply different Versions of available capacity on Work Order Header

Schedule dates reflect defined versions.

Real Experience. Real Advantage.

[ Employee Assignment & Capacity Calculation


Within Capacity Leveling it is possible to calculate available capacity based on individual work schedules maintained within HR Master Records. Configuration setting on Evaluation Profile Not possible within Evaluation Cumulate Capacity based on employees assigned to Work Center Capacity

HR assignment

Real Experience. Real Advantage.

[ Employee Assignment & Capacity Calculation

Real Experience. Real Advantage.

[ Employee Assignment and Capacity Calculation


Capacity leveling reflects HR Schedule of employees

Work Center Capacity is ignored

Real Experience. Real Advantage.

[ Capacity Evaluation

Easy to configure reporting function to further support scheduling process

Real Experience. Real Advantage.

[ Capacity Evaluation
Work Center Work Center
Standard Overview

Change Work Order

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 Planning Table

Real Experience. Real Advantage.

[ 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

Real Experience. Real Advantage.

[ 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.

[ Capacity Evaluation Standard Overview


Differing intervals to be evaluated Time period definition Applied Capacity Version Can filter display based on loading

Real Experience. Real Advantage.

[ Capacity Evaluation Standard Overview

Graphic views available


Real Experience. Real Advantage.

[ Capacity Evaluation Standard Overview

Real Experience. Real Advantage.

[ Capacity Evaluation Detailed List

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.

Real Experience. Real Advantage.

[ Work Orders - Ready to Schedule?

Real Experience. Real Advantage.

[ List Edit - Used to manage backlog

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

Real Experience. Real Advantage.

[ 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.

Manage Backlog Manage dates / apply Revisions

Check Materials Availability Publish Weekly Schedule

Monitor execution status

Real Experience. 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. Real Advantage.

[ 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). This day may or may not be the same as how it was originally planned / scheduled in the work order. Two dispatching options: Manual Finite (using a dispatch strategy).

Real Experience. Real Advantage.

[ Getting to Planning Table

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

Real Experience. Real Advantage.

[ Getting to Planning Table

Can change time settings before execute.

Can further filter requireme nts data.

Real Experience. Real Advantage.

[ Time Profile Settings


Todays date = 1/24/2008

Backlog Orders show yesterday

Backlog Orders show today


Real Experience. Real Advantage.

[ Tabular Planning Table Overview


Capacity details available / scheduled

Work List details


Configure layout, selection rules, 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.

[ 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. Real Advantage.

[ 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.

[ Tabular Planning Table Pooled Requirements


MECH

A new operation first appears on Capacity Planning Table as a Pooled Capacity Requirement. 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.Cap Dispatched Pool/Rqmts

Total Reqts

# 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. 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. Real Advantage.

[ Tabular Planning Table Schedule Process (Dispatch)


MECH

Operation Start & Finish Dates

Dispatched Operation

Period Avail.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 Reqts

# 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. Real Advantage.

[ Tabular Planning Table Schedule Process (Dispatch)


Select Order Operations and click button

Status of DSPT applied Pool requirements committed and become Scheduled.

Real Experience. Real Advantage.

[ Tabular Planning Table Schedule Process (Dispatch)


Example of completed Weekly Schedule in Planning Board

Real Experience. Real Advantage.

[ 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. GoTo Planning Board

3. Select All Work Order Operations CM25) 4. Click Dispatch Button 5. Click Save Button

Real Experience. 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. Real Advantage.

[ Assignment to Individuals

Real Experience. Real Advantage.

[ Assignment to Individuals

Real Experience. Real Advantage.

[ 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.

[ 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. Real Advantage.

[ 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). 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. Real Advantage.

SAP Project System (PS)

Real Experience. 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. Real Advantage.

[ 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, Stage, Event Major Resource Area

Real Experience. Real Advantage.

145

[ Project Definition Example

Framework / defaults for all objects in project -Organizational -Overall Dates -Control settings

Real Experience. Real Advantage.

146

Creating a project and associating WBS elements


The first step is to create a project and create/assign WBS element values to the project. This transaction is of great use in creating both the Project and the WBS elements.

Real Experience. Real Advantage.

[ Project WBS Structure Example

Real Experience. Real Advantage.

148

[ Project Copying

Real Experience. Real Advantage.

149

[ 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. Real Advantage.

Networks / Activities
The network / activity relationship is remarkably similar to the order operation relationship.

Real Experience. Real Advantage.

Network finer points continued


There are durations, relationships, intervals. If the network is linked to another, then its dates will move when the master network reschedules.

Note: each activity within a network can be assigned a different WBS element if different from the parent.

Real Experience. 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.

153

[ Network Activity Relationships


Network Order Network Activity

Real Experience. Real Advantage.

154

[ Project Date Planning & Scheduling

Top Down or Bottom Up Date Planning

Scheduled / Calculated Dates

Real Experience. Real Advantage.

155

[ 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

Rescheduling the project


Have the option of rescheduling network only, networks and orders, or just orders. Pulls off the basic start date of the master network and then reassigns basic and scheduled start dates of all orders. Transaction gives warning messages for orders unable to schedule and why.

Real Experience. Real Advantage.

[ 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.

159

Linking maintenance orders to networks


Once this link is made, the order schedule and basic dates will mirror the networks activity dates. Additionally, the order will begin showing up in PS networks as a network object as well. NOTE: Network assignment are made at the order level and not the operation level. It is imperative that the planning of the order operations is sound because moving individual operations is not possible.

Real Experience. Real Advantage.

[ PM Work Order to Project Assignment

Real Experience. Real Advantage.

161

[ PM Work Order to Project Assignment

Real Experience. Real Advantage.

162

Overview and reporting in PS Networks

Real Experience. Real Advantage.

[ Project Date and Work Planning Reports

Real Experience. Real Advantage.

164

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. Real Advantage.

More on Project Info Systems (CN41) -- Graphics


Network Diagram These charts show durations, relationships, float and critical path (red) for the networks

Real Experience. Real Advantage.

More on Project Info Systems (CN41) -- Graphics


This is a Gantt view of the same network diagram.

Real Experience. Real Advantage.

[ Example Report Work & Schedule Data

Real Experience. Real Advantage.

169

[ Standard Exports MS Project

Real Experience. Real Advantage.

170

SAP Multi Resource Scheduling (MRS)

Real Experience. Real Advantage.

[ 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.

[ 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. Real Advantage.

[ Work Center / Resource Planning Structure

(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.

Real Experience. Real Advantage.

Master Data for Qualifications: Overview


Demand Qualification Matrices

Qualification Catalogues Requirements Profile

Employee

Employee Profile Skill Level

Real Experience. Real Advantage.

[ Functional Overview

Demand Gantt

Work Center Gantt Work Center Capacity Alert Monitor


Real Experience. Real Advantage.

[ Functions in Demand Gantt chart


Flexible selection of relevant orders and networks in entry screen
E.g. 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.

[ Details about work center dispatching

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.

Real Experience. Real Advantage.

[ Details about absolute Capacity Utilization

Real Experience. Real Advantage.

[ Scheduler Workplace

Real Experience. Real Advantage.

[ Terms
Demands Resources Organizational unit Resource node Position Person Resource planner Capacitive scheduling

Real Experience. Real Advantage.

[ 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.

[ 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. Real Advantage.

Master Data Resource planning structure:


Human Resources (HR or BP record) Resource availability data Organizational unit/Work center Resource planner

Qualifications, scales, qualification catalogs, and qualification matrixes Employee and requirements profiles Tools (as equipment or material)

Real Experience. Real Advantage.

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. Real Advantage.

Link A 008 P

Center

Link A 061 LA

Work Center
(ZMRS)

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.

PIPE Pipefitter 1223

Piperfitter

Seen as Resources
4343 John Wayne 4555 Mark Scott

WC_4343

Written back to operation when Resource is scheduled.


Real Experience. Real Advantage.

John Wayne WC_4555 Mark Scott

[ Schedule to Work Center

Real Experience. Real Advantage.

[ Schedule to Resource

Real Experience. Real Advantage.

[ Demand layout

Real Experience. Real Advantage.

[ Resource layout

Real Experience. 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. Real Advantage.

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.

[ 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

Real Experience. Real Advantage.

[ 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

Real Experience. Real Advantage.

210

Thank you for participating.


Please remember to complete and return your evaluation form following this session. For ongoing education in this area of focus, visit www.asug.com. SESSION CODE: 36245

Real Experience. Real Advantage.

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