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Norbert Kytka, Headquarters PlattlingContact
Make to stock and Make to order strategies are transparent to MES CAT. The production order describes the input materials and the output materials, as well as the associated stock locations. The decision about production strategy is taken before the production order is released to the shop floor. Checks for ATP, CTP, product availability, stock strategies and so on are already passed, when the customer order is accepted (for example in a SAP SCM APO environment). MES CAT must execute the order in manufacturing and so there shouldn’t be any degree of freedom to change this at production time. MES CAT confirms the fulfillment of the order and the material flow is controlled by the ERP setup.
Lot membership of orders is decided in the planning process. MES CAT works on existing production orders. They are fixed to a production lot and can’t be reassigned without interferences in the existing production plan and schedule. Grouping orders to a lot mainly decides the utilization of production capacity and will be the result of an ATP, gATP or CTP check. Therefor we do not offer lot grouping for production orders inside MES CAT.
MES CAT offers a data acquisition step related to energy consumptions. In granularity, this can be a variety of volumetric flow rates per logistic unit (handling unit). Their aggregation is later based on the assignment to the production order, sales order or any time-based relation. The acquisition can be automated as described earlier.
The reporting is matter of SAP ERP or BW.
Scheduling, altering the time line of a work center, reducing capacity while in expensive time zones of energy consumption and even decisions spanning the whole production chain or interferences with parallel value chains, must be planning related issues. All these aspects are either cost or consumption driven and thereby they change the punctual operations.
Example: running less sheeter capacity in night shift to reduce electrical power consumption is a change in the work center availability profile. Running a “thin to thick” campaign sequence on one paper machine crossing a “thick to thin” campaign sequence on the other to reduce energy consumption peaks from drying equipment is also at least a production planning issue. But it has impact to the sales and forecast processes as well.
On shop floor, there is execution and confirmation. MES CAT does what is planned, it confirms what is consumed and what came out of the production step.
Did you plan energy as a component in the bill of material? Then the confirmative postings bring to you the consumption. This requires points of measure in the appropriate granularity for all kind of energy components. (Gas for drying hoods, electricity for infrared heating in the final dryer section, steam consumption per jumbo reel…)
In many cases this is reported in the PLC data stream. MES CAT will map this to your SAP setup (for example as machine level measures, based on QM functionality.
Handling of unscheduled orders
All production orders in an SAP ERP environment are scheduled at least by their basic date. Coming from a CTP or gATP planning system, the timeline is available from the detailed scheduling.
Unscheduled orders come in as customer orders. They may override existing priorities in planning. But as soon as they are released production orders they get a schedule and this might mess up the current production sequence.
This is a matter of organizational definition and business rules. The MES system should not support procedures destabilizing a well-planned utilization. It simply handles the given production plan from SAP PP and APO.
Finite scheduling and finite planning will happen in the PP layer. This function is part of the SAP SCM APO- PP/DS. Due to T.CONs strategy, strictly using existing SAP functions, we recommend to find a setup for these requirements in merging MES CAT and the APO features. Our solution extension is compatible with any planning result provided by SAP APO and ERP.
MES CAT has the capabilities to work with MOP structured production orders created in ERP by converting the APO scheduled planned orders.
The detailed planning board is made available role based on shop floor level using the SAP NetWeaver Portal.