Supply Chain Design

SOLUTION DESIGN

Acme Corporation

Supply Chain Material Planning

Author: Bryan Baker

Creation Date: June 2, 2004

Last Updated: July 14, 2007

Document Ref: BP.080-SCP

Version: DRAFT 1A

Approvals:

See Appendix Note: All approvals will be maintained electronically

and attached to the end of this document.

Solution Design Doc Ref: TBP.080-SCPT

July 14, 2007

Document Control

Change Record

Date Author Version Change Reference

02-Jun-04 Bryan Baker Draft 1a No Previous Document

Reviewers

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2 Project Manager

3

4

Note To Holders:

If you receive an electronic copy of this document and print it out, please write your

name on the equivalent of the cover page, for document control purposes.

If you receive a hard copy of this document, please write your name on the front cover,

for document control purposes.

TSupply Chain Material PlanningT Document Control ii

File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

Solution Design Doc Ref: TBP.080-SCPT

July 14, 2007

Contents

Document Control ii

Descriptive Overview of Acme Corporation Planning 1

Design Assumptions 1

Key Business Processes Listing & Description 2

Key Business Process - Setup Information 1

Requirement Essay - Setup Information 1

Solution Components - Setup Information 1

Key Business Process - Forecasting/Demand Management 5

Requirement Essay - Forecasting/Demand Management 5

Solution Components - Forecasting/Demand Management 5

Process Flow Diagrams - Forecasting/Demand Management 7

Key Business Process - Material Planning 8

Requirement Essay - Material Planning 8

Solution Components - Material Planning 8

Process Flow Diagrams - Material Planning 11

Key Business Process - Capacity Planning 12

Requirement Essay - Capacity Planning 12

Solution Components - Capacity Planning 12

Process Flow Diagrams - Capacity Planning 14

Key Business Process - Kanban Planning/Replenishment 15

Requirement Essay - Kanban Planning/Replenishment 15

Solution Components - Kanban Planning/Replenishment 15

Process Flow Diagrams - Kanban Planning/Replenishment 17

Open and Closed Issues for this Deliverable 18

Open Issues 18

Closed Issues 18

Email Approvals 19

TSupply Chain Material PlanningT Document Control iii

File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

Solution Design Doc Ref: TBP.080-SCPT

July 14, 2007

Descriptive Overview of Acme Corporation Planning

Acme is a Lean Manufacturing company and uses Kanban or Pull sequencing extensively in their production operations. The Acme Planning Group

currently prepares a single forecast to drive i2 Factory Planner, which is used in parallel with the Kanban system. The number of Kanban cards in use

is checked manually on a monthly basis and adjusted accordingly.

Design Assumptions

Proposed solution assumes the following:

Legacy Systems i2, Excel Spreadsheets

The design will provide an alternative to the current planning process. This alternative will eliminate the need to maintain the i2 legacy

system and manually manipulate data in Excel Spreadsheets.

Current Process

Currently the Acme Planning Group prepares a rolling 52 week forecast external to the i2 Factory Planner system. This information is a

compilation of marketing data and sales history extracted through a SQL Script from the Oracle Order Management module. This

compiled demand data is loaded into i2 Factory Planner. i2 Factory Planner prepares an unconstrained MRP plan. This plan is used as

a management tool in conjunction with the Kanban card system.

The production areas use Kanban cards to replenish the majority of all material requirements. The number of Kanban cards necessary

to meet demand is adjusted monthly. Historical material transaction data is extracted and combined with forecast information. Then

this data is manually massaged and fed into a spreadsheet, which uses a Kanban sizing formula to recommend the appropriate number

of Kanban cards. Kanban cards are then added or removed from the production area as necessary to bring the number of active Kanban

cards into agreement with the sizing calculation.

Proposed Solution

Acme Corporation will use both the Oracle Supply Chain Planning and Oracle Kanban Planning functionality. The rolling 52 week forecast

will continue to be prepared externally and will be imported using the Open Forecast Entries Application Program Interface (API), which is a

standard Oracle API. Forecast and Sales Order information will be loaded into a Master Demand Schedule (MDS), which will be loaded

into the Acme Materials Requirements Planning (MRP) Plan. The MRP Planner Workbench will be utilized for the release of Discrete Jobs

and Purchase Requisitions for non-Kanban items. Kanban items will be planned as a part of the planning process but orders will not be

released through the Planner Workbench. The Kanban Planner will be run monthly, or as necessary, using the same MDS information

feeding MRP to calculate the appropriate number of Kanban cards needed in the production area. Cards will be adjusted manually as

necessary.

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Key Business Processes Listing & Description

Process ID Process Title Description of Process Owner Notes

SETUP Setup Information Specific Setups necessary for Planning Planning

FCST Forecasting/Demand Management Create Statement of Demand Planning

MRP Material Planning Material Requirements Planning Planning/Purchasing

CRP Capacity Requirements Planning Capacity Requirements Planning Planning

KANBAN Kanban Planning Kanban Planning and Replenishment Planning/Purchasing

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Key Business Process - Setup Information

`

Requirement Essay - Setup Information

The functionality of the Oracle 11i Supply Chain Module is based mainly upon the arrangement of the setups within the Oracle

Manufacturing System. Setup information currently in place from Acme s Phase I implementation may need to be changed in

order for the Supply Chain Planning application to achieve the desired result. There is a large degree of flexibility within the

setups themselves. Many of the setups can be determined at a later date, but there are a few that will be necessary to mention at

this time. These specific setups will determine the use of areas that may merge with other modules such as Item Attributes and

BOM/Routing information.

Solution Components - Setup Information

Solution Technique

There are many setup parameters within the Oracle 11i Supply Chain Planning module. Only a few specific areas will be

documented at this time.

SETUP.01 The following system setups will be as follows:

1) Profile Options There are numerous Planning Profile Options that will control various aspects of the planning

process. Refer to the Supply Chain Planning Setup Document for specific profile settings.

2) Planning Parameters Default information used when a new plan is created. This information includes flags for

time fence control, inventory netting options and material scheduling methods. Settings for these parameters

will be determined during CRP1. Some settings may be for future use and will be reviewed during CRP1.

3) Planning Manager The Planning Manager controls a continuous background process that periodically activates

for all organizations. It differs from a normal process in that you need to start it only once. This will be set to run

every 30 seconds as per the default.

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

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SETUP.02 Item attributes define how an Item will act within the system. Supply Chain Planning uses a variety of

attributes to enable Items to behave as directed within the MRP Plan. These attributes are Item specific, meaning that the

settings for one Item can be different for another Item within the same Inventory Organization. The main Planning

Attributes that will be utilized are as follows:

Planner Codes (Already set and in use.)

Order Modifiers (Will experiment with settings during CRP1.)

Planning Method (Will be set using templates.)

Forecast Control (Will be set using templates.)

Pegging (Will be set using templates.)

Planning Time Fence (Will be set using templates.)

Release Time Fence (Will be set using templates.)

Some of these attributes, such as Planner Codes, were populated during Phase I, and the current settings will be used

without change. Other settings fall into two broad groupings, MRP items and Kanban items. These attributes will be set

using item attribute templates. Two templates will be created, one for MRP and one for Kanban items. These templates

will be applied using the Open Item Interface in Update mode. Refer to the setup document for specific setting for each

template

SETUP.03 Forecasts will continue to be developed external to the Oracle system. However, this forecast information

must be imported to a Forecast Set/Forecast within Oracle. Therefore, the Forecast Set and Forecast must be defined in

Oracle. The Open Forecast Interface API will be used to automate importing the external forecast into the defined

Forecast.

SETUP.04 Sales Orders and/or Forecast information will be loaded into a Master Demand Schedule (MDS) to create an

aggregated statement of demand. The load of the MDS will be done automatically on a nightly basis. This process

should be monitored and a designated individual(s) contacted in case of error or warning. This process must complete

before using the MDS for Kanban sizing and prior to launching the MRP Plan.

SETUP.05 A single specific Material Requirements Planning (MRP) Plan will be used for execution. However,

additional plans may be created for simulation. This Plan will launch on a nightly basis, following the loading of the

MDS. This launch must be planned for a specified time frame, as yet to be determined, to ensure optimum resourse

usage. This launch will be an automatic process but will need to be monitored. A designated individual(s) should be

notified if the Plan completes with any errors or warnings.

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

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SETUP. 06 The Oracle Kanban Planner Workbench will be tested to compare the calculated Kanban sizing result to the

existing legacy method. The same MDS used for MRP will be used, but Pull Sequences may need to be defined for

additional items. Today Purchased Items are the only items with Pull Sequences defined. Items needing to generate

work orders will need Pull Sequences defined as being sourced from Production . The full list of these Production

Kanban items is yet to be determined.

Process Steps

Process Step Name Description Business Process Solution

Step # Type

SETUP.01 System Setups Initial settings Profile settings, Planning Parameters and M

starting the Planning Manager

SETUP.02 Item Specific attribute information Set item attribute settings necessary to allow M

Attributes/ for planned items Oracle 11i Supply Chain Planning to function as

Safety Stock required. Set safety stock parameters.

SETUP.03 Forecast Define forecast and populate Forecast anticipated Sales Orders. Set forecast M

data entry level, bucket and consumption parameters.

SETUP.04 Master Define and Load the MDS Define and Load MDS to create an aggregated M

Demand statement of demand.

Schedule

(MDS)

SETUP.05 Material Define/Run Material Define and Run the Material Requirements Plan. M

Requirements Requirements Plan

Plan

SETUP.06 Kanban Pull Define Additional Kanban Define Additional Kanban Pull Sequences for M

Sequences Pull Sequences Make Items.

C = Custom, M = Mapped, W = Workaround, G = GAP

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

Solution Design Doc Ref: TBP.080-SCPT

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Reengineering Opportunity

Currently historical information is used along with forecast information to calculate Kanban sizes. Need to determine if the forecast

information feeding the MDS will provide similar or more accurate sizing. This would simplify the Kanban sizing process.

Interfaces

The Open Forecast Interface API will be used to automate importing the external forecast into the defined Forecast.

Open Item Interface may be used to update item attributes using the API in Update mode and applying templates to the

appropriate items.

Assumptions

None

Responsibility

The initial setup information listed above will be the responsibility of the Planning Team prior to go-live.

The Interfaces mentioned above will need to be added to the IT Task list for Phase 2.

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

Solution Design Doc Ref: TBP.080-SCPT

July 14, 2007

Key Business Process - Forecasting/Demand Management

Requirement Essay - Forecasting/Demand Management

The Forecast is a statement of anticipated demand. This demand may be for top level, make or buy, finished good items or

sub-assemblies sold as service parts. As Sales Orders are received they must replace the forecast through consumption. The

forecast will be developed external to Oracle. It will be a 52 week rolling forecast and will be updated monthly. Acme needs

to be able to import this forecast into the Oracle Supply Chain Planning System. It may be necessary at certain times to

modify the forecast for specific items manually in the planning system between updates.

The Master Demand Schedule (MDS) is unique to Oracle. This tool allows multiple forecasts/demand streams to be

combined. The Oracle MRP process requires Forecast information to be aggregated into an MDS for use in the planning

process. Acme will define a single MDS for production use. The information in the MDS must be reloaded whenever the

forecast is updated and prior to using the MDS in the planning process.

Solution Components - Forecasting/Demand Management

Solution Technique

Acme will develop a single forecast to drive production. This forecast will be a compilation of history from Oracle Order

Management information, the current forecast and pricing information. The forecast will be prepared in MS Access and forecast

entries will be analyzed for both quantity and dollar amount discrepancies. A single Forecast Set/Forecast will be created for

production use. Forecast entries will be by item number. Acme does not feel the need to forecast at a more ganular level (i.e.

Item-Customer) at this time. When the forecast anaysis is complete the finished forecast will be loaded into the Oracle Supply

Chain Planning System via the Open Forecast Interface API. Maintenance of the Forecast Sets/Forecasts will be done on a

monthly basis.

FCST.01 Often it will be necessary to modify forecast information on an item before time for regeneration of the

Forecast. In these situations the Planning Department will need to modify the forecast manually.

FCST.02 After Forecast information is modified it will be necessary for this updated information to be passed to

the MDS. This can be done on a nightly basis as part of the planning process or it can be done manually as needed.

Shipped Sales Orders will decrement the MDS accordingly to remove the demand from the planning process. It

may be necessary at times to review this information.

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

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Process Steps

Process Step Name Description Business Process Solution

Step # Type

FCST.01 Maintain Update Forecasts as needed Forecasts updated with Item information for M

Forecast consumption.

FCST.02 Maintain MDS Load/Copy/Merge MDS Reload MDS with updated information. M

C = Custom, M = Mapped, W = Workaround, G = GAP

Reengineering Opportunity

None noted at this time.

Interfaces

Open Forecast Interface API will be used to automate importing the external Forecast into the defined Forecast.

Assumptions

None

Responsibility

Forecast Set/Forecast creation will be the responsibility of the Implementation team during system setups. Additional

Forecast Set/Forecasts will be created as needed by the Planning Department.

Forecast maintenance will be the responsibility of the Planning Department, based on input from the Sales

Department/Customers.

The Load/Copy/Merge of the MDS will be an automated process that will run every evening, to be completed prior to

the launch of the MRP Plan.

The Planning Group will check the concurrent request list each morning to ensure no errors occurred.

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

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Process Flow Diagrams - Forecasting/Demand Management

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

Solution Design Doc Ref: TBP.080-SCPT

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Key Business Process - Material Planning

Requirement Essay - Material Planning

The Acme Production MRP Plan will be utilized to plan for the replenishment of Finished Goods, Subassemblies and Raw

Materials. However, Acme makes broad use of Kanban replenishment and Kanban items will not be replenished from the

Oracle MRP Planner Workbench. While Demand and Supply information for Kanban items is visible on the MRP Planner

Workbench, they will not be released from the workbench.

Solution Components - Material Planning

Solution Technique

Material requirements are visible for items within the Oracle Supply Chain Planner Workbench based on numerous Plan Options.

The Planner Workbench provides a broad spectrum of information for the Planner.

MRP.01 The ability to query information within the Workbench is the same for all Items, Make or Buy. The

Planners will use the tools presented to them to make proper choices for execution within the MRP Plan. The tools

available to them will be the Planners Workbench, as well as the Reports that are made accessible.

1) Planned Orders for items are suggestions from the Workbench for potential Requisitions or Work Orders. The

suggested quantity needed, receipt date necessary for inventory, sourcing information, and the demand

associated to the Planned Order are among the pieces of information visible within the Workbench. This

information is useful to determine the execution necessary for each Planned Order.

MRP.02 Execution in the Workbench will be at the Planners discretion. The Planner will use the information available

to determine if the Planned Order will be released, or firmed for future release. Changes may be made to the Planned

Order prior to releasing, to ensure the correct dates and quantities exist on the new Requisition or Work Order being

creating. If a Planned Order does not exist for the Item, a new unscheduled Planned Order can be added for release.

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MRP.03 The same Exception messages are visible within the Workbench for both Make and Buy Items. The Make

Item messages are associated to Discrete Jobs/Repetitive Schedules only. The Buy Item messages can be associated

to both Requisitions as well as Purchase Orders. Not all of the messages require execution. The reasoning behind the

Exception message is not always readily available. Research is sometimes necessary to understand the reasoning

behind the message. This information will be an integral part of training. Some are for use as reference information

only. The most common messages monitored are:

Reschedule Out Move the Requisition/Purchase Order receipt date or the Discrete Job completion date

out

Reschedule In Move the Requisition/Purchase Order receipt date or the Discrete Job completion date in

Cancel Cancel the Requisition/Purchase Order or Discrete Job.

Orders with Compressed Days The completion date is in the future, but the start date is in the past (there

is not enough lead time to complete this order expedite).

1) The Planner may not be able to execute all of the Exception messages from the Workbench. If a Requisition

still exits and has not been converted to a Purchase Order, the exception execution can be performed. If the

Exception message is against a Purchase Order instead, the changes must be done within the Purchase Order

itself and not from the Workbench.

2) There will also be occasions when a Discrete Job will need to be updated, as in the Exception messages above.

After release the only changes allowed from the Planner Workbench are date changes. These changes will be

made to enable the scheduling process.

3) There may also be times when the Bill of Material requirements for the Discrete Job may need to be changed.

This is necessary not only for Inventory control, but also for the Workbench to plan for the correct materials.

This will be discussed in the Work In Process Solution Design Document.

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Process Steps

Process Step Name Description Business Process Solution Type

Step #

MRP.01 View View Planned Orders, Determine what execution is necessary. M

Workbench/Reports Exception messages, and

Reports

MRP.02 Workbench Release of Planned Creation of Work Orders and M

Execution Orders Requisitions from the Workbench.

MRP.03 Planning Exception Take Action on Exception Release Exceptions from the M

Maintenance Messages Workbench/Communicate changes

with Purchasing, Order Management.

C = Custom, M = Mapped, W = Workaround, G = GAP

Reengineering Opportunity

None noted at this time.

Interfaces

None noted at this time.

Assumptions

None

Responsibility

Releases/Reschedules of Requisitions and Work Orders will be the responsibility of the Planners.

Updates necessary to the Purchase Orders will be managed by the Purchasing Department.

The Planning Group will check the concurrent request list each morning to ensure no errors occurred.

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Process Flow Diagrams - Material Planning

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Key Business Process - Capacity Planning

Requirement Essay - Capacity Planning

Acme is currently unable to make use of Oracle Capacity Requirements Planning due to the lack of system routings.

Routings are being added to the system information in Phase 2 and the associated Resources will be used in Capacity

Planning.

Solution Components - Capacity Planning

Solution Technique

MRP tries to validate and plan for the availability of material. As this information is generated the capacity load placed on the

resources listed within the routings is calculated. Oracle Capacity Planning allows the planner to view this information

compared to the availablility of each resource within each planning bucket. Planning exception messages such as Late order due to

resource shortage and Resource Overloaded are available to highlight capacity overloads and aid the planner.

Process Steps

Process Step Name Description Business Process Solution Type

Step #

CRP.01 View Capacity View Capacity View Capacity loading/availability M

Information loading/availability. for key resources.

CRP.02 Adjust Adjust work orders accordingly. Adjust work orders according to M

operations available capacity.

C = Custom, M = Mapped, W = Workaround, G = GAP

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Reengineering Opportunity

None noted at this time.

Interfaces

None noted at this time.

Assumptions

Departments, resources and routings must be created and the appropriate shifts must be applied to the relevant resources within

each department to allow Capacity Planning to report on this information.

Responsibility

The Documentation Group will be responsible for defining departments and routings.

The Cost Accounting Group will be responsible for defining resources.

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Process Flow Diagrams - Capacity Planning

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File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

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Key Business Process - Kanban Planning/Replenishment

Requirement Essay - Kanban Planning/Replenishment

Acme uses Kanban cards extensively in their operations. The number of Kanban cards in service for each item is reviewed

monthly to determine if adjustments are necessary. Currently this is a manual, external process. Data including usage for

the last three months for each item, along with Sales Order shipments and issues to WIP, is combined to yield a statement of

anticipated demand. This information along with lead time and Kanban container sizing information is then used to

calculate the optimum number of Kanban cards for each item. Lastly, the number of Kanban cards in service for each item is

adjusted to match the calculated optimum number.

Kanban cards needing replenishment for purchased items are replenished using Oracle purchasing requisitions which are

converted into purchasing orders. This process is standard Oracle functionality and is being utilized today. Kanban cards

needing replenishment for manufactured items need to have work orders created in the system for tracking. Currently this is

a manual process in Oracle.

Solution Components - Kanban Planning/Replenishment

Solution Technique

Oracle Kanban Planner Workbench allows the same forecasting information being developed for MRP to be used to calculate

the optimum number of Kanban cards in service. This demand is exploded from level to level through the BOM structure

thus eliminating the need to include historical usage and issues to WIP in the demand information. This dependent demand

data is used in the Oracle Kanban sizing calculation. (Note: Oracle does not use independent demand in the Kanban sizing

calculation. Therefore, Acme will not use the Oracle Kanban calculation to calculate the number of Kanban cards for Top

Model items. The Oracle Kanban calculation will be used to calculate the number of Kanban cards for subassemblies only.)

Once the optimum number of cards has been calculated for each item Oracle will help adjust the number of cards necessary

in the system to meet optimum numbers. Pulling excess Kanban cards or creating additional Kanban cards is a manual

process.

In practice, as Kanban cards need to be replenished, the Oracle Kanban replenishment functionality will allow purchase

requisitions and work orders to be created by clicking on the Replenish button in the system. Pull Sequences are defined as

either Supplier or Production to tell the Oracle system the method of replenishment.

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Process Steps

Proce Step Name Description Business Process Solution Type

ss

Step #

KB.01 Kanban Calculate Kanban size Use the Kanban Planner Workbench to check M

Planning Kanban size based on new demand

information.

KB.02 Replenish Release orders to replenish Generate purchase requisitions and work M

Kanbans Kanbans orders to replenish Kanban needs.

C = Custom, M = Mapped, W = Workaround, G = GA

Reengineering Opportunity

Use Oracle Kanban Planner Workbench to calculate the optimum number of Kanban cards for each item on a monthly basis,

instead of the current detailed manual process.

Interfaces

None noted at this time.

Assumptions

None.

Responsibility

Pull sequences for purchased items will be the responsibility of Purchasing.

Pull sequences for make items will be the responsibility of Planning.

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Process Flow Diagrams - Kanban Planning/Replenishment

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Open and Closed Issues for this Deliverable

Open Issues

ID Issue Resolution Responsibility Target Date Impact Date

Closed Issues

ID Issue Resolution Responsibility Target Date Impact Date

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Email Approvals

From: Sent: Tue 6/22/2004 12:01

Wile E. Coyote [********@****.***]

PM

To: William Bryan Baker

Cc:

Subject: Re: Planning Solution Design Document

Attachments:

View As Web Page

Bryan,

I approve the Supply Chain Material Planning document, Version Draft 1A,

dated 6/17/2004 for the Oracle Manufacturing Phase 2 Implementation, with

the understanding that the design may be modified, as processes are refined

through testing.

Wile E. Coyote

TSupply Chain Material PlanningT Email Approvals 19 of 28

File Ref: Solution Design-SCP.DOC (v. DRAFT 1A )

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July 14, 2007

From: Sent: Fri 6/25/2004 11:55

R. Runner [*******@****.***]

AM

To: William Bryan Baker

Cc:

Subject: Re: Planning Solution Design Document

Attachments:

View As Web Page

Bryan,

I approve the Planning Solution Design Document

R. Runner

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Process Flow Diagrams Production Use Flows

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