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APO-PPS-PLE: Heuristics in Production Planning and Detailed Scheduling ( RELNAPO_30A_SP1_PPS-PLE2 )

APO-PPS-PLE: Heuristics in Production Planning and Detailed Scheduling ( RELNAPO_30A_SP1_PPS-PLE2 )

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APO-PPS-PLE: Heuristics in Production Planning and Detailed Scheduling

Use

As of Release 3.0A (First Customer Shipment and Support Package 1), the functions for planning with heuristics in Production Planning and Detailed Scheduling have been extensively enhanced. The following functions are now available:

  • Several standard heuristics are provided by SAP in areas such as production planning, detailed scheduling, repetitive manufacturing, model mix planning and so on.
  • SAP provides several algorithms with which you are able to define your own heuristics. You are also able to use your own algorithms to define heuristics.
  • Heuristics can be performed automatically when automatic planning is triggered in PP/DS.
  • Heuristics can be performed during a planning run.
  • Heuristics can be executed during interactive planning. You are able to define which heuristics are to appear in the interactive planning menus.
  • You are able to define planning packages in order to plan products together using the same heuristic.
  • You are able to execute the planning run in simulation mode.

These functions are explained in more detail in the respective sections.

Note: In Release 2.0A, two types of background planning were available:

  • Mass scheduling
  • Product planning run

These are no longer available in Release 3.0A. These have been replaced by the Production planning run.

Standard Heuristics

A heuristic is a planning function that executes planning for selected objects (depending on the focus of planning: products, orders, operations, resources or line networks) using a particular planning procedure (algorithm). SAP provides a number of standard algorithms (also referred to as function modules) to solve specific planning tasks. For each algorithm, you are able to vary the settings, thereby defining different heuristics using the same algorithm.

The following standard heuristics are available in Release 3.0A:

Heuristics for Detailed Scheduling: (Focus of Planning: Resources and Operations)

  • SAP001: Schedule sequence (based on algorithm /SAPAPO/HEUR_PLAN_SEQUENCE)
You use this heuristic in the detailed scheduling (DS) planning board to determine the sequence in which selected scheduled operations are to be rescheduled. This heuristic was available in Release 2.0A.
  • SAP002: Remove backlog (based on algorithm /SAPAPO/HEUR_RESOLVE_BACKLOG)
You can use this heuristic in the DS planning board and in the production planning run to resolve the backlog on selected resources, that is, to reschedule operations that are before the current date/time. This heuristic was available in Release 2.0A.
  • SAP003: Manually schedule sequence (based on algorithm /SAPAPO/HEUR_PLAN _SEQUENCE_MAN)
You use this heuristic in the DS planning board to manually determine the exact sequence in which selected scheduled operations are to be rescheduled.
Note: This heuristic cannot be used in the production planning run.
  • SAP004: Minimize lead time (based on algorithm /SAPAPO/HEUR_REDUCE_LEADTIME)
You can use this heuristic in the DS planning board and in the production planning run to reduce the lead time of orders that have operations on selected resources.
  • SAP005: Scheduling deallocated operations (based on algorithm /SAPAPO/HEUR_DISPATCH)
With this heuristic, you can reschedule the selected deallocated operations.

For more information, see the Release Information on New Heuristics in Detailed Scheduling.

Heuristics for Production Planning (Focus of Planning: Products)

  • SAP_PP_001: Planning with standard lots (based on algorithm /SAPAPO/HEU_PLAN_STANDARDLOTS)
You can use this heuristic to generate new receipt elements to cover products requirements, taking into account the lot-sizing parameters maintained in the Product Master.
  • SAP_PP_002: Planning with standard lots + dialog box (based on algorithm /SAPAPO/HEU_PLAN_STANDARDLOTS)
This heuristic is based on the same algorithm as heuristic SAP_PP_001. The only difference being is that a dialog box appears in which you can interactively change the lot-sizing parameters to be used for planning.
  • SAP_PP_003: Planning deficits (based on algorithm /SAPAPO/HEU_PLAN_DEFICITS)
You use this heuristic to plan just the shortages and to reduce surpluses. Dynamic pegging relationships are taken into account with this heuristic.
  • SAP_PP_004: Part period balancing procedure (based on algorithm /SAPAPO/HEU_PART_PERIOD)
You can use this heuristic to optimize setup and storage costs when calculating the lot size. Starting from the product shortage date, consecutive requirements quantities continue to be collected in a lot until total storage costs exceed the setup costs. Lot-sizing parameters are taken into account during this procedure.
  • SAP_PP_005: Purchase order quantity optimization (based on algorithm /SAPAPO/HEU_PUR_PLANNING)
You use this heuristic to optimize purchase order quantities while taking requirements, storage costs and vendors into account. The system considers the different delivery periods and discount levels of the vendors and determines the unit costs for each vendor while also considering the storage costs. Lot sizes are formed according to the optimum discount levels and unit costs.
  • SAP_PP_006: Periodic procedure for 3 horizons (based on algorithm /SAPAPO/HEU_PEGID_PERIODIC_LOT)
With this heuristic, you are able to define three planning horizons within which a different lot-sizing procedure can be used. You are able to choose between a procedure with lot-for-lot order quantities or various period lot sizes.
  • SAP_PP_007: Move requirements to receipts (based on algorithm /SAPAPO/HEU_MIN_PEG_GIV_SUPPLY)
You use this heuristic to reschedule all requirements to allow them to be covered by receipts. This heuristic only considers dependent requirements from stock transfer and in-house production. Planned independent requirements and sales orders are not considered by the heuristic.
  • SAP_MRP_001: Product planning run using low-level coding (based on algorithm /SAPAPO/HEU_MRP_PLANNING)
You use this heuristic to plan products according to the heuristic defined in the Product Master for each product. The heuristic is carried out for the top level product using low-level coding, that means if a component is not available on time, the top order is not rescheduled. The components that are defined as being planned automatically (both immediately or in planning run) are then planned using the heuristic defined in the Product Master. If you have not defined a heuristic for a product in the Product Master, the APO System uses the default heuristic you have entered for the Product heuristic in Customizing for Production Planning and Detailed Scheduling, under Global Settings -> Maintain Global Parameters and Defaults.
Components that are defined as being planned manually (both with and without check) are not taken into account during the production planning run. The ATP check for components planned manually with check is not carried out.
  • SAP_MRP_002: Product heuristic (based on algorithm /SAPAPO/PROD_PLANNING)
You use the product heuristic to plan products according to the heuristic defined in the Product Master for each product. The heuristic is carried out for the top level product. Components that are defined as being planned automatically and immediately are planned using a simple lot-sizing heuristic. The planning with this heuristic is carried out according to multi-level logic, that is, if a component is not available on time, the top level order is rescheduled. For the components that are defined as being planned automatically in the planning run, planning file entries are created. The product heuristic can be executed in interactive planning and during the production planning run. If you have not defined a heuristic for a product in the Product Master, the APO System uses the default heuristic you have entered for the Product heuristic in Customizing for Production Planning and Detailed Scheduling, under Global Settings -> Maintain Global Parameters and Defaults.
The ATP check is carried out for components that are defined as being planned manually with check.

Heuristics for Repetitive Manufacturing (Focus of Planning: Resources/Line Networks/Products)

  • SAPREM: Multi-resource planning (uniform) (based on algorithm /SAPAPO/REM_HEUR_TEMPLATE)
You use this heuristic to generate planned orders for requirement taking into account the available resource capacity for each period. The heuristic distributes the planned orders evenly between all resources. If there is no capacity in the period, the planned order is placed in the previous period. If the resources in this period are also fully loaded, no planned orders are created.
  • SAPREM2: Multi-resource planning (primary resource) (based on algorithm /SAPAPO/REM_HEUR_WAVE)
You use this heuristic to generate planned orders for requirement taking into account the available resource capacity for each period. The heuristic firstly attempts to load a primary resource 100% and then the secondary resources. If not alternative resources are available, the resources from the previous period are loaded. If the first period is fully loaded, the orders are distributed to the resource in the subsequent period.

Heuristic for Model Mix Planning (Focus of Planning: Resources/Line Networks)

  • SAP_MMP_01: Model Mix Planning (based on algorithm /SAPAPO/SEQ_MODELMIX_RUN_01)
You use this heuristic to optimize the sequence of configurable products while taking into account any restrictions. You are able to define three planning horizons in which you can use different procedures. The procedures include:
  • Genetic algorithm

  • Equal distribution process

  • Percentage of smoothing

You can find all standard heuristics in Customizing for Production Planning and Detailed Scheduling, under Heuristics ->Maintain Heuristics.

Defining Your Own Heuristics

In APO, you are able to define your own heuristics using the algorithms provided by SAP. You can define heuristics in Customizing for Production Planning and Detailed Scheduling, under Heuristics -> Maintain Heuristics, by entering the algorithm provided by SAP and defining the settings as required.

You are also able to use your own algorithms to create heuristics provided that you integrated the algorithm into the APO System.

Heuristics in Automatic Planning

In Release 2.0A, the method of planning used to plan products during automatic planning was the same for all products. As of Release 3.0A, you are able to define a heuristic at product-location level that is to be used for automatic planning. In the PP/DS tab of the Product Master, you can define which heuristic is to be used to plan the product. If the Automatic planning immediately indicator has been set for the product, the heuristic is executed automatically for the product every time a change relevant to planning is made.

As of Release 3.0A, you can set the Automatic planning in planning run indicator for a product. In this case, the system generates a planning file entry for the product every time a change relevant to planning is made. The products are then planned during the next net change planning run using the heuristic defined in the Product Master (if you enter the product heuristic on the initial screen of the production planning run).

Heuristics in a Planning Run

As of Release 3.0A, you can execute heuristics during a production planning run. If you have selected the Automatic planning in planning run indicator for a product, you plan only the products that have undergone a change relevant to planning and for which a planning file entry has been created by setting the Planning file entry created indicator on the initial screen. If you do not select this indicator, a regenerative planning run will be performed, thereby planning all products in the selection.

If the products are to be planned according to the heuristic maintained in the Product Master, you use the Product Heuristic. You may, however, perform a net change planning run using a different heuristic.

It is also possible to execute several heuristics on the same products in one planning run. The heuristics are executed in the sequence you enter them in the initial screen. An example of this could be that you perform the SAP001 Schedule sequence heuristic to improve the resource loading and then perform the SAP_PP_007 Move requirements to receipts heuristic to reschedule the top level orders accordingly.

Heuristics in Interactive Planning

You are able to define which heuristics appear in the interactive planning menus of the:

  • Order view screens
  • DS Planning board
  • Product planning table

You do this by defining a heuristic profile containing the relevant heuristics in Customizing for Production Planning and Detailed Scheduling, and then by entering the appropriate heuristic profile in the overall profile for the screens. You are then able to start the heuristics in interactive planning by accessing them from the menu.

In the interactive planning screens, you can plan the product according to the heuristic defined in the Product Master by using the Product heuristic function, or you can choose another heuristic and vary the parameters for this heuristic by using the Variable heuristic function. The variable heuristic also allows you to select components for the products that are also to be planned with the heuristic.

Planning Run in Simulation Mode

You are able to execute a production planning run and save the results in a simulation version. This allows to decide at a later point in time whether you merge the simulation into the operative planning version.

Effects on Customizing

You create/maintain heuristics in Customizing for Production Planning and Detailed Scheduling, under Heuristics -> Maintain Heuristics.

You create/maintain heuristic profiles that are used to control which heuristics are displayed in the menus of interactive planning in Customizing for Production Planning and Detailed Scheduling, under Heuristics -> Maintain Heuristics Profiles. You then enter the appropriate heuristic profile in the desired overall profile of the order view, DS planning board and the product planning table.

You enter the default product heuristic that is to be used to plan all products for which no heuristic has been defined in the Product Master, in Customizing for Production Planning and Detailed Scheduling, in the IMG activity Maintain Global Settings and Defaults.

See also

Release information: New Heuristics in Detailed Scheduling






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