PP Capacity Requirements Planning
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`
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`Version
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`SAP-00001994
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`Version
`Prepared for R/3 Release 2.2.
`May 94
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`SAP-00001995
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`Copyrights
`
`@1994 SAP AG. All rights reserved.
`Neither this documentation nor any part of it may be copied or reproduced in any form or by any
`means or translated into another language, without the prior consent of SAP AG.
`
`SAP AG makes no warranties or represenations with respect to the content hereof and specifically
`disclaims any implied warranties of merchantability or fitness for any particular purpose. SAP AG
`assumes no responsibility for any errors that may appear in this document. The information
`contained in this document is subject to change without notice. SAP AG reserves the right to
`make any such changes without obligation to notify any person of such revision or changes. SAP
`AG makes no commitment to keep the information contained herein up to date.
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`SAP-00001996
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`

`
`Introduction
`
`This section offers an overview of the integration of the Capacity Requirements Planning (CRP
`System) within the SAP System, in particular within the Logistics and Project Systems. For the
`sake of simplicity, the system is also often called the "capacity planning" system.
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`SAP-00001997
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`Capacity Planning in the SAP System
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`Capacity planning is an essential part of the R/3 System, which as integrated business software
`covers all business functions of a company. The efficiency of the overall system is achieved by
`using integrated modules which each represent areas of common content.
`The functions of capacity planning are used, among other things, in the following processes and
`applications:
`¯ Production planning and control
`¯ Plant maintenance
`¯ Quality management
`¯ Projects
`All modules are real-time applications, that is, quantities and values are updated directly. As a
`result, the same current data is made available to all users of the system. The following figure
`shows a detailed display of the links between Capacity Planning and the other components of the
`PP system.
`
`Material
`Routing
`Bill of material
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`Material require-
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`SAP-00001998
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`

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`Integration of Capacity Requirements Planning within the R/3
`System
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`Capacities must be planned in different areas of a company. In the SAP System, the module
`Capacity Planning is used for this purpose. A capacity is a resource whose availability is planned
`over time. Unlike other resources in the SAP System, such as material, production resources/tools
`or finances, capacities cannot be stored. A capacity which is not used today may no longer be
`available tomorrow.
`The main elements of capacity planning are:
`¯ Available capacities in work centers and capacity categories
`¯ Capacity requirements resulting from orders and operations
`¯ Operation dates resulting from the scheduling of orders
`
`Orders
`
`Orders form the main element of capacity planning. Orders are created in the SAP System as:
`¯ Planned orders in material requirements planning
`¯ Production orders in production activity control
`¯ Maintenance work orders in maintenance
`¯
`Inspection orders in quality assurance
`¯ Networks maintained for projects
`The orders provide the basic dates for scheduling. The standard values and the quantities in the
`operations of the orders form the basis for scheduling and for calculating capacity requirements.
`
`Available Capacity
`
`In the work center the available capacity is defined by capacity categories. Depending on the kind
`of work center defined, there could be the following capacity categories:
`¯ an individual machine on the shop floor (Production Planning)
`¯ a group of people operating an assembly line (Production Planning)
`¯ a maintenance work center (Plant Maintenance)
`¯ an inspection station in quality assurance (Quality Management)
`¯ a group of engineers maintaining a project (Project System)
`Note
`For more information on the defining of capacities for your work centers, please refer to the guide
`PP Work centers.
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`SAP-00001999
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`

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`Introduction to Capacity Planning
`
`This section gives an overview of the structure of the capacity planning system (CRP System) and
`the various access possibilities.
`Capacity planning consists of the following components:
`¯ View definition (Customizing)
`¯ User interface
`¯ Library of functions
`YJe~LBe3th~tion
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`i ..........
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`SAP-00002000
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`View Definition
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`Different users, depending on their role in the company, need to use different views concerning
`capacity planning:
`¯ The dispatcher needs to find out what is in the order/operation pool for a machine.
`¯ A member of the sales staff wants to get information on the processing status of a customer
`order.
`¯ The plant manager wants to evaluate the capacity load of the work center groups and their staff
`over the coming months.
`
`Profiles
`
`To meet these different requirements, profiles can be set up via the customizing of the CRP
`system, which define the views. Relevant values necessary for the configuration of a particular
`profile are, for example, the planning interval, the period split, the order types, the work centers or
`the capacity categories to be selected in capacity planning for a particular view.
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`SAP-00002001
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`User Interface
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`The results of capacity planning are presented in tabular form as lists or in graphic form. The
`following graphics types are available:
`¯ Hierarchy graphics for the display of work center hierarchies
`¯ Capacity load displays in vertical (column) or horizontal bar form
`¯
`Input/output diagrams for orders in line form
`¯ Gantt chart for the display of the date situation
`¯ Planning tables for the dispatching of orders/operations to the work centers (for Release 3.0)
`The interface to Microsoft EXCEL enables you to transfer the evaluated CRP data to a PC. The
`functions of MS-EXCEL can be used there for further calculations and the editing of presentations.
`
`Customizing
`
`The selection of fields appearing on lists, the sorting and grouping of these fields can be
`determined via user-specific settings in Customizing (see ~e~!ngs).
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`SAP-00002002
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`KLibrary of Functions
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`Within the framework of capacity planning, the CRP system provides the different PP applications
`with specific functions. These functions can either be called up automatically from the applications
`by the system or can be activated by the user via menus.
`In the current Release this library of functions includes:
`¯ The evaluation of the available capacity at the work center, with the possibility of cumulating the
`available capacity using work center hierarchies and of managing different versions of the
`available capacity
`¯ Scheduling of production order operations with time elements, work center formulas, distribution
`functions and reduction measures (for example, splitting, overlapping)
`¯ Calculation of capacity requirements to be distributed over the duration of the operation via a
`distribution function
`¯ Load analysis of the capacity requirements of planned and production orders by means of
`various groupings, sortings and cumulation types.
`Various other functions are planned for the future:
`¯ Sequencing for capacity leveling in bottlenecks
`¯ Planning strategies for dispatching of orders
`¯ The integration of optimization procedures for capacity leveling
`¯ Simulation of different operating statuses for available capacity and order dispatching
`¯ Capacity scheduling which checks the available capacity during lead time scheduling
`¯ Splitting of orders and operations into several partial lots and the allocation of these partial lots
`to different work centers
`¯ The combining of orders and nesting of operations from different orders so that the production
`process can be optimized
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`SAP-00002003
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`Data Flow
`Using such basic R/3 data as material masters, routings and work centers, as well as via planning
`and production orders, a data base is created which can represent the available capacity and the
`capacity requirements.
`The available capacity specifies the output of a capacity per workday. A capacity is always
`allocated to at least one work center.
`The capacity requirements specify the output that individual orders require of a capacity at a
`particular time. The capacity requirements are calculated during lead time scheduling.
`In the capacity evaluations, these requirements can now be compared with the available capacity:
`¯ The percentage capacity load as well as the free capacity per work center is calculated in the
`standard overview.
`¯ The capacity detail list displays per work center and period which orders are responsible for the
`capacity requirements.
`In the variable overview, you can display various types of data used in capacity planning in the
`form of a list. The layout of the list is user-defined.
`Via these three evaluation forms and the corresponding graphics, the CRP system represents a
`very flexible tool for carrying out capacity evaluations.
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`¯
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`SAP-00002004
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`Basic Elements of Capacity Planning
`
`This section gives an overview of:
`¯ how the available capacity of a work center is specified
`¯ how the start and finish dates of the operations are determined for scheduling
`¯ how capacity requirements are generated
`¯ how the reduction of capacity loads is carried out
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`SAP-00002005
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`Available Capacity
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`Definition
`
`The available capacity refers to the available output of a capacity in a certain period. The available
`capacity is determined through (see the figure below):
`¯ Work start and finish times
`¯ Break length
`¯ Efficiency rate (utilization) of the capacity
`¯ Number of the individual capacities of which the capacity consists
`Via the capacity, the working/operating time and the daily available capacity are stored for each
`work center. The available capacity can be defined both for one work center and for all work
`centers together.
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`The capacity requirements of the operations in the order are calculated for capacity planning and
`compared with the available capacity defined in the work center. You must define the capacity
`required, the capacity categories and the available capacity for each work center.
`
`Capacity Categories
`
`To every work center, you can allocate several capacities which are distinguished by means of their
`capacity category. A capacity category can occur only once per work center. However, capacities of
`different work centers can have the same capacity category. In particular, this is important for the
`cumulation of available capacity and requirements via a hierarchy.
`
`Available Capacity
`
`For every capacity, you can specify in the work center an available capacity varying over time. You
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`SAP-00002006
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`can use any units of measure and intervals of available capacity here. You can also define several
`versions of available capacity.
`For the definition of available capacity, you have to maintain the following data in the capacity
`header:
`¯ the factory calendar which is the basis of the availabile capacity
`¯ the number of the active version of available capacity
`¯ the base unit of measure of the available capacity
`If you do not enter a factory calendar, the calendar which is predefined for the plant is valid.
`Note
`If the capacity is used as the basis of scheduling, the base unit of measure of the capacity must
`have the dimension "time".
`
`Standard Available Capacity
`
`The standard available capacity is always valid if no interval of available capacity is defined. To
`define the standard available capacity, you have to maintain the following data in the header of the
`capacity (work center):
`¯ Start and finish time of the shift
`¯ Break length
`¯ Efficiency (utilization) rate of the capacity
`¯ The number of individual capacities of which the capacity planner group consists such as the
`number of machines or persons
`Using the above data, the system calculates the working/operating time of the capacity in the unit
`"hours" and the available capacity in the base unit of measurement of the capacity. The validity
`period of the standard available capacity is unlimited.
`Available capacities deviating from the standard available capacity are identified by a version
`number. For capacity planning, the active version is always used.
`If you have specified validity periods for the available capacity, this is referred to in the SAP System
`as an interval of available capacityinterval of available capacity. Thus, an interval of available
`capacity is an available capacity with a specific validity period.
`
`Shift Sequences
`
`For the definition of an interval of available capacity, you can also access shift sequences managed
`centrally. This simplifies the adjustment of available capacities if not individual availabilities but
`only the shift sequence itself must be changed. In the shift sequence, typical sequences of shifts
`are defined for all work centers for a certain period.
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`SAP-00002007
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`Shift definition
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`Shift Definition
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`In a shift definition, start, finish and break times of a shift are specified for all work centers using this
`shift.
`Shift definitions simplify making changes to the available capacity. If, for example, the working
`hours change in a shop floor area it is not necessary to change the available capacity at all the
`work centers involved if you are using shift definitions. You just have to adapt the corresponding
`shift definition. As a result, all available capacities which refer to the shift definition are changed
`automatically.
`You will find additional information on maintaining capacities and available capacities at work
`centers in the guide PP Work Centers.
`
`Work Center Hierarchy
`
`Work centers can be grouped together in a so-called work center hierarchy. Every hierarchy must
`have a name, which you have to assign when creating the hierarchy. A work center can be
`contained in several hierarchies (see the figure below).
`With work center hierarchies, it is possible to cumulate the available capacity and the capacity
`requirements from subordinate work centers in work centers of the higher hierarchy levels. The
`available capacity maintained for a hierarchy work center is made up of the total of the available
`capacities of the subordinate work centers.
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`SAP-00002008
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`Cumulation of Available Capacity
`
`If no available capacity was maintained for a hierarchy work center, it must be cumulated via the
`hierarchy. The two cumulation options, static and dynamic, are described below.
`Cumulation of the available capacity is useful for planning purposes if the available capacity for the
`subordinate work centers is maintained. From this, the available capacity of the higher-level work
`center can be derived. However, it is also possible to maintain the available capacity directly in the
`higher-level work center.
`There are two possibilities of cumulation:
`¯ The available capacity has already been cumulated when maintaining the capacity (static).
`See PP Work Centers for this.
`¯ The available capacity is not cumulated until the capacity planning run (dynamic). For further
`information on this see ~.tj..o...n..s...
`Note
`If you want quick processing, static cumulation is recommended. However, the available capacity of
`the higher-level work center does not change automatically if the available capacity of a
`subordinate work center changes. During dynamic cumulation, the current available capacity of the
`subordinate work centers is always used.
`
`Cumulation of Requirements
`
`Work center hierarchies are used to judge the load of a group of work centers. For this the work
`centers must be grouped together into a hierarchy. A special evaluation work center is at the peak
`of the hierarchy. By cumulating the available and required capacities for this work center, the load
`of the entire work center group can be displayed (see the figure below).
`Note
`Only the capacities available and required of the same category are cumulated together.
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`SAP-00002009
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`SAP-00002010
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`

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`Scheduling
`
`Introduction
`
`The R/3 logistics system has different forms of scheduling:
`¯
`In material requirements planning, the basic dates of a planned order are calculated for every
`BOM level, for which the in-house production times in the material master are used. The
`planning accuracy is carried out to the day.
`
`Requirements planning
`
`Backward scheduling
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`4
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`Date requi red
`Product
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`Variable-size parts
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`Product
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`Assembly
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`Material master
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`’lqme required for
`in- plant producti on
`
`Float before
`production
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`Execution
`time
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`FI oat after
`production
`
`In Sales and Distribution, the basic dates of the sales order such as the packaging/lading date,
`transport date, scheduled shipping date are calculated. The desired delivery date specified by
`the customer is used for this, in order to carry out backward scheduling.
`The scheduling type used in capacity planning, the subject of this manual, starts with the basic
`dates that were calculated either in material requirements planning or entered manually by the
`user. The orders to be scheduled here are planned orders, production orders, maintenance
`orders and networks.
`
`Elements of Scheduling
`
`SAP-00002011
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`

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`The main elements of scheduling are the following
`¯ Operations which describe the individual processing steps in an order
`¯ Relationships which specify the sequence in which the operations should be carried out.
`
`Elements of scheduling for planned and production orders
`
`I
`
`I
`t forming execution time
`
`Every operation in planned and production orders is divided into operation segments (see the figure
`below):
`¯ Queue time
`¯ Setup time
`¯ Processing time
`¯ Teardown time
`¯ Wait time
`Dates are calculated for all the above operation segments.
`Relationships are created automatically by the system. The operations with ascending numbers are
`linked by relationships for each operation sequence in the order. The relationships between the
`operation sequences must be maintained explicitly.
`For planned and production orders, the duration of the relationships is represented by the move
`time.
`In planned and production orders, the floats before and after production are taken into account. The
`float before production is between the basic start date and the first operation, the float after
`production between the finish date of the last operation and the order finish date.
`
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`Scheduling elements of networks/maintenance orders
`
`The acitivities/operations of networks and maintenance orders are not divided into segments, as for
`the planned and production order.
`For networks, relationships must be maintained explicitly (see the figure below). For maintenance
`
`SAP-00002012
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`orders, the relationships are generated by the system, as for planned/production orders.
`D2a~ys 20 Work
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`Durations
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`Activity
`
`¯ -~ Relationship
`
`Durations of planned and production orders
`
`For the production order, the duration of the operation segments setup, processing, teardown is
`calculated by entering the standard values of the operation into the work center formulas.
`You can maintain the queue time individually for every operation or for the work center as a whole.
`You can maintain the move time individually for each operation or define it in the move time matrix
`in Customizing via the location group.
`The required wait time is an individual value which you can maintain per operation.
`You can maintain the delivery time for externally processed operations individually for every
`operation.
`
`Durations of networks/maintenance orders
`
`For a network activity and maintenance operation, the duration of the operations is calculated using
`a formula from the work center, if the duration of the operation has been entered into the formula.
`If no formula exists in the work center, the duration of the operation is the manually entered
`duration.
`You can maintain the duration of relationships in the network individually.
`
`Working/Operating Time
`
`The duration of the operations or the time intervals of the relationships are distributed for
`scheduling over a time axis. Every element of scheduling (operation or relationship), can have its
`own duration and working/operating time.
`The working/operating time specifies how long the work takes. The term working time is used for
`labor, the term operating time for machines. Since it is not always clear what is involved, the
`compound designation working/operating time is used here.
`The calendar used contains the workdays and the public holidays. At the work center, the
`working/operating time per workday can be specified, including start/finish times of work/breaks.
`The following rule applies:
`¯
`If the time unit of the duration is smaller than the unit "day", the working/operating time per
`
`SAP-00002013
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`

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`¯
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`workday is used.
`If the time unit of the duration is greater or equal to the unit "day", scheduling to the day is
`carried out on the basis of the valid calendar.
`
`Calendar
`
`The calendar from the work center applies; if none is defined in the work center, the calendar from
`the operation / the relationship applies; if no calendar is specified there either, the Gregorian
`calendar is used.
`
`Working/Operating Time per Workday
`
`Working/operating time must be defined for the capacity category specified on the scheduling
`screen in the work center. If no working/operating time per workday is defined, the system uses a
`working/operating time from 00:00 to 24:00.
`
`How is Scheduling carried out?
`
`The principles of scheduling, their main forms and additional functions are explained below.
`For the scheduling of networks, the operations are listed according to their rank. The start activities
`(operations without predecessors) have the lowest rank. The target activities (operations without
`successors) have the highest rank. All successors of an operation have a higher rank than the
`operation itself. All operations are scheduled according to the rank.
`Starting from the start or finish date of the order, the calculated duration is distributed on the time
`axis, making use of the corresponding working/operating time for every operation, and start and
`finish dates are calculated. Forward scheduling starts with the order start date. Backward
`scheduling starts with the order finish date.
`The time intervals between the operations are scheduled via the relationships. All time intervals of
`the relationships are considered as minimum time intervals.
`
`Control Key
`
`Only the operations having a control key for capacity planning can be scheduled. Operations not
`scheduled have the duration 0 and receive as start and finish date the date of the preceding
`operation (for forward scheduling) or the start date of the following operation (for backward
`scheduling).
`
`Rules for Calculating the Dates
`
`If scheduled dates/times are the start of a shift, the work finish time or midnight, the following rules
`apply:
`Start times are set at the start of shift or 00.00 hours.
`Finish times are set at the work finish time or 24.00 hours (midnight).
`If an operation with the duration zero falls on one of these dates, the following special rule
`applies:
`
`during forward scheduling, start and finish times are set at the work finish time or 24.00
`hours.
`during backward scheduling, start and finish times are set at the start of a shift or 00.00
`hours.
`This is necessary so that the finish times are not before the start times.
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`SAP-00002014
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`

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`Reduction of Overall Lead Time
`
`If the dates calculated for scheduling are not within the start and finish dates, the system attempts
`to reduce the lead time step by step.
`You can assign a reduction strategy to every operation. With this strategy you can specify
`¯ how many reduction levels may be carried out for an operation
`¯ which reductions are carried out at every level
`
`Reduction measures for planned/production orders
`
`The following process-related reduction measures are possible:
`Reduction of the queue time
`Per reduction level, you can specify the percentage by which the queue time should be reduced.
`However, the minimum queue time must be observed.
`Reduction of execution time through splitting
`The splitting of an operation over several persons or machines causes a reduction of the
`execution time.
`Reduction of the lead time through overlapping
`The overall lead time of the order is shortened by the overlapped production of operations.
`Reduction of move time
`Move time can be reduced to the minimum move time.
`If you also want to reduce the order floats (floats before and after production), you can specify
`this in Customizing for each plant, order type and planner group. In this case, you can specify
`the percentage by which the floats should be reduced for each reduction level.
`You can find more information about overlapping and splitting routings in the PP Routing guide.
`
`¯
`
`Reduction in networks and maintenance orders
`
`In the network, the operation duration is reduced by a percentage for each reduction level. The
`minimum duration must be observed in this case.
`No reduction measures are possible for maintenance orders.
`
`Scheduling Partially Confirmed Operations
`
`There are two possibilities of scheduling partially confirmed operations:
`¯ Partially confirmed operations - the partially confirmed operation is scheduled forwards from the
`actual finish date. Only the remaining duration is regarded as a duration.
`The remaining duration of an operation is calculated according to the following formula:
`Remaining quantity = original quantity - actual quantity
`To calculate the duration of the operation segments, the remaining quantity and the forecast
`values or standard values must be entered into the formula if no forecast values were
`confirmed.
`After the first partial completion confirmation, the duration for the setup is set to zero. The
`duration for teardown time is only set to zero at the time of final confirmation.
`Indicator for shifting an order- A control parameter for scheduling can be set via Customizing
`in the case of partial completion confirmations. This ensures that the order is shifted to a new
`date, that is, the actual dates of the operations are no longer taken into account. The system
`
`¯
`
`SAP-00002015
`
`

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`then calculates with the remaining duration of the operations, starting from the basic dates of the
`order.
`
`Scheduling Log
`
`If there are errors in scheduling (such as dates not specified in a calendar) or incomplete data
`(such as no working/operating time maintained at the work center for scheduling), the scheduling
`run is, however not interrupted. The errors are written to a scheduling log and the order is
`scheduled in spite of incomplete data. The log can be evaluated afterwards to analyze and
`eliminate the errors.
`
`SAP-00002016
`
`

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`Capacity Requirements
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`Calculation of Capacity Requirements
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`The calculation of the capacity required to produce a material in an operation is carried out within
`the framework of scheduling. For this, the capacity overview screen (work center) contains a
`formula for calculating the capacity requirements of an operation for each of the three main
`operation segments (setup, processing and teardown) as well as for networks/maintenance orders.
`If you do not specify one of these formulas, no capacity requirements are calculated for the
`operation segment in question or for networks/maintenance orders.
`These formulas, which you can maintain within Customizing (see ~, are made
`up of formula parameters. These can in turn be, for example, standard values of the operation,
`work center constants or values for production resources/tools (see the figure below).
`If you use formulas with parameters which refer to standard values, you must set the standard
`values of the individual operations either in the routing or in the production order. If the formula for
`the operation segment "processing" contains, for example, the machine time as a parameter, you
`have to specify the duration of the machine time for a base unit of measure. Capacity requirements
`can only be calculated if values exist for the different formula parameters.
`Please note that the requirements of the operation segments are not considered individually, but
`only as total requirements defined for an operation/activity.
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`4 Work center L J Operation L
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`Formula key
`Formula constants
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`Formulas
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`Standard values
`Setup time
`Processing time
`Teardown time
`Number of splits
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`I Set up I Process Tear down
`tCapacity requirements
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`Distribution of Capacity Requirements
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`For scheduling, the capacity requirements are calculated for the individual operation segments,
`making use of the formulas from the work center. However, in this case no statement can be
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`SAP-00002017
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`made about how the requirements are distributed over the operation duration. For capacity
`planning this is done according to a distribution key set for each capacity category via the period
`split set there. Furthermore, the operation segments are not processed separately. All requirements
`are distributed over the entire operation duration.
`How requirements are actually distributed over the duration of the operation depends on the
`capacity category. The labor capacity of a tooling operator is needed fully at the beginning of the
`operation, whereas the transport capacity may only be needed at the end for conveying the created
`material. The machine capacity, on the other hand, is used continuously over the entire period,
`whereas the machine operator only needs to check the status of processing every four hours.
`You can maintain the distribution key (for controlling the different types of distribution) separately
`for each capacity on the capacity screen of the work center for work orders and
`networks/maintenance orders. However, you can also maintain the distribution key for networks
`and maintenance orders in the activity/operation itself. If no distribution keys are specified in the
`work center or in the operation for a capacity category, you can also do this during capacity
`planning (see ~).
`A distribution key consists of a distribution strategy and a distribution function. All three objects,
`explained below, are maintained in Customizing.
`The distribution strategy defines the dispatch date type, the basis of distribution (calendar, etc.)
`and the type of distribution.
`With the dispatch date type, you can control whether the capacity requirements are to be
`distributed between the earliest or the latest dates of an operation.
`The type of distribution specifies how the basic values of the distribution function are interpreted.
`These basic values can either be the starting/end points of a distribution curve (distribution
`according to function), or else they are distributed discretely according to specific points in time.
`With the basis of distribution, you can determine whether distribution should be carried out
`according to the Gregorian calendar, according to a factory calendar or according to the
`working/operating time.
`The distribution function consists of a series of basic values which contain a duration value in
`percent in each case and a requirements value in percent. The duration value in percent defines a
`date within the duration of an operation. The requir