Work Center Capacity In Production Planning
Contents What is Capacity?.......................................................................................................................................................4 Role of Capacity in PP: ...............................................................................................................................................4 Integration with Other Business function:................................................................................................................4 Capacity Category: .....................................................................................................................................................5 Work center Capacity: ...............................................................................................................................................5 Available Capacity: .................................................................................................................................................5 Required Capacity...................................................................................................................................................6 Pooled capacity: .....................................................................................................................................................7 Creation of Pooled capacity: ..............................................................................................................................7 Assignment of Pooled capacity: .........................................................................................................................9 Interval of Available capacity: ...............................................................................................................................9 Procedure for creating Interval of available Capacity: ........................................................................................ 10 Shift Definition and Sequences: ......................................................................................................................... 13 Shift Definition:.................................................................................................................................................... 13 Shift Sequences: .................................................................................................................................................. 14 Break definition: .................................................................................................................................................. 15 Use of Shift Sequences in Work center: ......................................................................................................... 16 Individual Capacity: ............................................................................................................................................ 17 Capacity in different Unit of Measure: .................................................................................................................. 20 Capacity – Wok center Hierarchy: .......................................................................................................................... 21 Static Cumulation and Period pattern Key: ......................................................................................................... 22 Dynamic Cumulation: ......................................................................................................................................... 23 Indicators influences Capacity Planning: ............................................................................................................... 25 Relevant to finite scheduling indicator .............................................................................................................. 25 Can be used by several operations indicator ..................................................................................................... 25 Long term planning ............................................................................................................................................. 26
What is Capacity? • • •
Capacity means capability to do certain work. In SAP capacity is closely related with work centers. i.e. Capability of work center/machine to do a certain operations. In general it will be measured in “Time” unit. We can also use other unit of measures which is depends upon business process.
Role of Capacity in PP: In production planning, capacity data in work center is used for calculating 1. Required capacity for an order or Operation 2. Available Capacity of a work center
Integration with Other Business function: Work center is integrate with the below business functions or Modules. 1. Human Resource a. We can assign HR object to work center which will be helpful for determining qualification of an employee. b. Example certain operations which need special skillset like CNC Operator/programmer, we can assign to the work center.
2. Plant Maintenance a. When particular Machine/work center is scheduled in PM order for maintenance activities, its capacity will be locked for production uses.
Capacity Category: • •
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Capacity category used to distinguish various capacity with in a work center. If you want to maintain different capacity for labor and machine in a work center we can define it by means of capacity categories. o Machine Capacity o Labor Capacity. etc. Example Consider a ‘Lathe Machine’ in which requires ‘3 Labors’ to perform the operations and it is available 9 hours per day. In this case, Capacity Category Machine Labor
Available hours
Total No of Capacity hours 9 1 9 Hrs. 9 3 27 Hrs.
Work center Capacity: Available Capacity: • • • • •
In general capacity means ‘Available hours’ of a machine or labor. This available hours excludes Break or halt hours. Assume that a Lathe machine is available in a production plant from 9 AM to 9 PM and there will be a break time of 2 hours for lunch and evening snacks. Now the Capacity of the Lathe machine is calculated as follows. Available Capacity = 12 Hours (Total hours) - 2 Hours (Break) Available Capacity = 10 Hours
Required Capacity • •
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Required capacity is hours required for a work center to produce particular quantity of an assembly. System uses below information to calculate “Required Capacity” for a work center. o Capacity formula: ▪ Capacity formula uses Standard value key Parameters (Work center Basic data screen) o Operation time in Production Order ▪ This uses time defined in routing operation for base quantity. For an example: A process in steel cutting unit uses a machine called “Plasma cutting” in which below standard value parameters: o Setup time o Machine time o Labor time Let say in Routing we have maintained below times for the above parameters o Base Quantity: 120 PCs o Setup time : 30 Mins o Machine time : 90 Mins o Labor time : 90 mins Capacity formula defined for Machine is as follows: Machine time * Quantity to be produced / Base quantity
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When production order for the quantity of 300 PCs is created capacity is calculated as follows. Required Capacity = 90 mins * 300 PCs / 120 PCs Required Capacity =
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225 mins
With “Number of Individual capacity” : o This is number of individual machines available with similar capacity. o When system calculates ‘capacity required ‘it divides the number Individual capacity in formula and when calculates “available capacity” it multiplies number of individual capacity. o Capacity formula defined for Machine is as follows: Machine time * Quantity to be produced / Base quantity * No of splits o o
Required capacity = 90 mins * 300 PCs / 120 PCs * 2 Required capacity = 112.5 mins
Pooled capacity: • • •
Work centers which are having same capacity type can be assigned with Pooled capacity. In this capacity is defined globally and assigned to the all work centers. Example in your organization, let say you have 7 lathe machines with similar capacity.
Creation of Pooled capacity: Pooled capacity cab be created by accessing following menu path.
We can also typing following transaction code. Transaction Code CR11
Description Create capacity
Assignment of Pooled capacity: Once Pooled Capacity is created (in transaction CR11), it can be assigned with work center (In transaction CR01/CR02) in “capacity” tab.
Interval of Available capacity: •
When standard available capacity of a machine need to replace for certain periods, we can use Interval available capacity.
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For example a work center which has standard available capacity of 8 hours per day. But from the date 20-June to 28-June due to higher demand, company want to run the machine for 16 hours. In this case we can define the Interval of capacity for these periods as 16 hours.
Procedure for creating Interval of available Capacity: •
Go to Capacity header of a work center.
1. Click on
Again Click on
Now press enter
Here you can find the from the period 20-June to 28 June(Interval of capacity) available capacity is 16 hours whereas rest of days it is 8 hours(Standard Available capacity).
Shift Definition and Sequences: Shift Definition: •
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The following Parameters are maintained in “shift Definition”. ✓ Validity Period of a Shift (Start date and End date) ✓ Start time and end time. Example: ✓ A company operate with 2 shifts ✓ “A” Shift ---- 06 AM to 14 PM ✓ “B” Shift ----- 14 PM to 22 PM Shift definition will be maintained as follows:
Shift definition in SAP is part Customization activity which can defined in transaction “OP4A”
Shift Sequences: The sequences of the shifts are defined in this.
Break definition: Here we can define the break time for each shifts and assign them to Shift definition later.
Use of Shift Sequences in Work center: • • •
This shift timing and breaks will be used at the time of Capacity and scheduling calculations. By default system schedules the break time is distributed equally over the working hours. When we want system to uses exact break time for scheduling defined in shift the following settings are required. o Order type scheduling parameter we need to maintain the indicator “Scheduling with Break”
Note: This topic will be discussed in details in “Production Order” tutorial.
Individual Capacity: • •
Individual capacity in SAP used for detailed capacity requirement planning. This can be explained with below example o Let say you have, Lathe Machines A and B o Machine A is available from 06:00:00 to 17:00:00 Hours o Whereas Machine B is available from 06:00:00 to 22:00:00 Hours o Possible way of Mapping in SAP for this scenario is ▪ Create 2 work centers with different capacity ▪ Create only one work center but number of individual capacity need to be created inside work center capacity.
Select each Item and click on Machine “A”
Machine “B” Capacity
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When we create Production Order, which Individual capacity we are going to use to perform the operation will be assigned.
Capacity in different Unit of Measure: • • • •
In general, capacity is defined in unit “Hour”. But there may be a case, different UOM can also be maintained. UOM may be Cubic Meter (M3) or KG or TON etc. For an example, let’s consider a casting Industry where casting is formed from molten metal from furnace. Here furnace capacity can also defined in “TON”. But the relation between TONs and Hours must be maintained in the capacity work center capacity. This will be used to evaluate the capacity in TONs also.
Capacity – Wok center Hierarchy: • • •
Capacity can be cumulated by means of work center Hierarchy. Hierarchy work center’s available capacities are cumulated and to its superior work center. There are 2 types of cumulation available in SAP
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o Dynamic Cumulation o Static Cumulation Dynamic cumulation is used to cumulate both “Available Capacity” and “Required capacity” whereas Static cumulation cumulates “available capacity”os a hierarch work centers by manually.
Static Cumulation and Period pattern Key: • •
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In static cumulation, Available capacity cumulation is calculated using “Period Pattern key “defined. Period pattern key is used for o Cumulating available capacity o Displaying available capacity. In static Cumulation, Cumulated available capacity of a superior node will not be changed automatically when there is a change in the available capacity of a subordinate work center. So we must cumulate available capacity periodically. Definition of Period pattern key is part of IMG activity using transaction OP11. Example, o When you want to cumulate available capacity as 3 segments in time axis. o First segment, Cumulate next 7 days available capacity o Second segment, Cumulate next 3 weeks from last period of segment 1. o Third segment, cumulate 1 month available capacity from last period of segment 2.
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Work center Hierarchy for the above diagram is.
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Here available capacity of A and B work center are cumulated in higher hierarchy. i.e. cumulated available capacity is displayed in available capacity C. Period Pattern Key creation is part of IMG activity in transaction OP11.
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Periods in Period pattern key may be Work days, calendar days, Week, Month or year.
Dynamic Cumulation: • •
In dynamic cumulation, System cumulates the “available capacities” and the “capacity requirements” for all capacity categories of the work centers specified in hierarchy. This is defined in Option profile of “Over all profile” which is part of IMG activity for the case of “Available capacity “cumulation. (Transaction OPA3)
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This is defined in Evaluation profile of “Over all profile” which is part of IMG activity for the case of “Required capacity “cumulation. (Transaction OPD0)
Indicators influences Capacity Planning: Relevant to finite scheduling indicator • • • •
When this Indicator is activated system consider the existing capacity load while calculating available capacity. Let say Machine ‘A’ which available capacity is “8” hours. It was scheduled for an order on 10-July for 4 hours 30 mins. When new order is created for this machine on same date, system will propose only remaining hours (3 hours 30 mins)
Can be used by several operations indicator • • • •
When this Indicator is activated in work center, that particular work center capacity can be utilized by more than one operations. This allows system consume the available capacity for other production orders. For example, let say you defined a storage tank as work center in a chemical industry. When 2 production order try to use this storage tank to fill the finished chemical, system will only allow When this indicator is activated.
Long term planning • •
When this Indicator is activated, this work center can also be used to calculate capacity requirement of Long term Planning. Note: Long term planning in SAP also called simulation MRP where we can upload demand simulation to calculate required raw materials and capacity for assembly/sub assembly.