Setupmatrix
The steup matrix is a configuration element used to specify the time
required to switch from producing one product to another or to prepare a
machine from old setup to a new production setup run.
For example Product A, B, C can be produced in same lathe machine but
with different moulds. Product A and C uses same Mould 1 (1hr setup
time), but product B use different mould 2 (2hr setup time). So it means if
the lathe machine has mould 1 installed we can produce product A and C
in single go and if need to produce the product B we need to change the
mould which requires 2 hr.
Let us consider we need to produce the products A, B, C.
Production Sequence 1: A -> B -> C
Setup time = A (1 Hr) + B (2 Hr) + C (1 Hr) = 4 Hr
Production Sequence 2: A -> C -> B
Setup time = A & C (1 Hr) + B (2 Hr) = 3 Hr
If we produce the product in 1st sequence we need to change the moulds
for each production. So it will take 1 he extra setup time. But if we produce
the Products in 2nd sequence then we take 1hr less setup time. So in the
2nd sequence the remaining 1 hr of the machine can be used for
producing another product. So like this we can reduce the setup time and
increase the production time. All these can be done only if we have
production resourse crunch.
Main Part:
Setup matrix Creation methods
1. Automatic creation
2. Manuall creation.
In automatic method characters are mandatory whereas in manuall
method setup group are mandatory. Also manuall method can support
campaign planning
Automatic Setupmatrix creation 1: reference SAP manufactory
For generation the setup matrix automatically, we need to define the class
characters for material based on business and to create it in SAP. Consider
we have 3 materials and which are produced in different forms & pack in
same workcenter 'Lathe' which has 9 different moulds.
Material Character - Bulk Character 2 - Pack
Powerppds Power 1000ML
Ultrapowerppds Ultrapower 500ML
Supremeppds Supreme 750ML
Setup time required for changing moulds in lathe on product change.
Production Production
line A - Bulk line A - Pack
type type
Ultra
Suprem 1 500 750
Power powe
e ltr ml ml
r
Power 0 2 3 1 ltr 0 1 2
Ultra 500
2 0 2 1 0 1
Power ml
Suprem 750
4 3 0 2 1 0
e ml
1 2 3 1 0.5 0.7
So here there will be 90 combinations of setup transistion times.
Process flow
S1. Creation of characteristics and class - CT04, Cl02 - (and moving it to
APO system using CIF See)
2. Maintain setup matrices for characteristic value
/N/SAPAPO/CDPS_CHARMAT.
3. Maintain rules for the generation of setup groups using
/N/SAPAPO/CDPS_GRPRULE. 4. Maintain rules for setup matrix generation
with /N/SAPAPOI/CDPS_MATRULE.
5. Generate the setup matrix based on the specified rule using
/N/SAPAPO/CDPS_MATGEN.
6. After generation, display the setup groups and setup matrices with
/N/SAPAPO/CDPS_SETUP.
7. Creation of PP master data - MM01, CS01, CR01, CA01, C223.
8. Creation of PP order - /n/SAPAPO/RRP3
9. Running heuristics - /n/SAPAPO/CDPS0
Menu Path: SAP Easy Access screen > Logistics > Advanced Planning >
Master Data > Setup Group/Setup Matrix > Generate Setup Matrices.
Characteristics - CT04
Class - CL02
Maintain setup matrix - /SAPAPO/CDPS_CHARMAT
After execution click create to create new entries. Later save it and click
back. Then double click on the line item. Also do it for Packtype.
Transform the setuptime table to below in excel and copy it here.
Do the same for packtype
characteristics
Maintain rules for generationg setup group - /n/SAPAPO/CDPS_GRPRULE
Give the characters inside and seperator as - hypen. We can use up to 6
characters
Maintain rules for generating setup matrices - /N/SAPAPO/CDPS_MATRULE
Give the values which we created before.
Generate setup matrix - /N/SAPAPO/CDPS_MATGEN
Display setup Matrix - /N/SAPAPO/CDPS_SETUP.
We can cross verify the values which we created. Now setup matrix is
created.
Master data.
Created Material Master in mm01 with class characters and dummy BOM
in cs01 with no components.
Check that all characteristics moved to APO system in /N/SAPAPO/MAT1.
CIF is mandatory.
Create Resource - CR01
Inside capacity header click APO resource and change the resource type to
2 - single reosurce. Setup matrix can be created only in single resource
type.
In APO /N/SAPAPO/RES01 maintain the setup matrix which we created.
Routing - CA01 - I am creating as single routing and assigning all the
materials to it.
Created production version in C223 and moved it to ppds via
CURTOADV_CREATE with absolete transfer
/SAPAPO/CURTO_SIMU - Display Production Data Structures
Let us create order in /n/SAPAPO/RRP3. Inside it click edit
button.
Then add the available date and required quantity and save it.
See the changes in production scheduling board - /n/SAPAPO/CDPS0
You can see the setup matrix time has been picked here. Even I mentioned
1 hr in routing it took the time from setup matrix.
For first order the setup time 2 hr as the switch is from material empty to
Power 1000ML For 2nd order its 0 hr as the switch is happening between
the power 1000ml to power 1000ml. Same can be seen is setpmatrix -
/n/SAPAPO/CDPS_SETUP
Let us create order for other material.
Let us schedule it and see the difference in planning board
Below the switch is between power 1000ml and ultrapower 500ml
material. so the 1st setup time is 3hr and the second switch is between
ultrapower and ultrapower. so the setup time is 0 hr.
Manual Setup matrix creation 2:
Manual Setup Matrix are mostly used for process industries. Consider
below 3 materials are produced and are grouped under below setup
groups. Transistion times are given below.
Setup
Product SETUPGRP1 SETUPGRP2 SETUPGRP3
groups
MATLATHE01 SETUPGRP1 6 2 3
MATLATHE02 SETUPGRP2 2 0 3
MATLATHE03 SETUPGRP3 3 3 0
Process flow
1. Creation of setup groups - OP43
2. Moving setupgroups to APO logical system using CFM1 and CFM2
3. Display setup groups in APO using /n/SAPAPO/CDPSC6 - Maintain Setup
Groups
4. Create the setup matrix using /n/SAPAPO/CDPSC7
5. After Creation, display the setup groups and setup matrices with
/N/SAPAPO/CDPS_SETUP.
6. Creation of PP master data - MM01, CS01, CR01, CA01, C223.
7. Assign the setupgroups to recipes in C202
8. Assign the setupmatrix to Resource in /n/SAPAPO/RES01
6. Creation of PP order - /n/SAPAPO/RRP3
7. Running heuristics - /n/SAPAPO/CDPS0
Configuration:
Create Setup Group 1: OP43 or Path - SIMG - Production Planning for
Process Industries - Master Data - Master Recipe - Data for Operations and
Phases - Define Setup Groups and Setup Group Categories
Inside it create a setup group key
After creating setupgroups in ECC we need to create integeration model in
CFM1 to create these setupgroups in APO logical system. You can add
plant in general selection also in addition to setup groups. Here you can
uncheck the objects if you have issue.
In next popup screen click No.
Later click Generate it
Activate the integeration Model in CFM2 by clicking activate and start.
Keep the CFM1, OP43, CT04 and CL02 tcodes closed to avoid data locks. At
a time only one model can be activated.
After activation the setup groups will be populated to APO logical system
and seen in tcode /SAPAPO/CDPSC6 - Maintain Setup Groups .
Master data:
Create Setup Matrix in - /n/SAPAPO/CDPSC7
Create setupmatrix and save it. later go back and double click it
Later give the combination manually inside and save it.
The same can be displayed in /SAPAPO/CDPS_SETUP - Display Setup
Matrix
Now create the master data like material master, BOM, Recipe, PDS. Here
additional step is we need to assign the setupmatrix to recipe at operation
level for each material. You can add only to setup operations in recipe.
Double click on operation No 0020 to maintain the setup group.
For MATLATHE02
Assign the setup matrix in /n/SAPAPO/RES01
Move the PDS and check it whether it has all the phase and setupgroup.
Now create orders in /n/SAPAPO/RRP3. Click edit button, give date, order
quantity and save it for all three materials.
Detailed scheduling Board Results
Having issue in PDS. Will update the pics later. As per above method the
setup matrix to be utilized for process orders.
Assumptions in PPDS vs Reality
Previously in ECC Mrp Type XO was used to run advanced planning and the
materials with XO will not be planned in MRP.
But now in HANA the MRP will plan the mateirals with MRP type XO. But
MRP live parameters in MD01N will not be for ePPDS materials. Because of
this ePPDS production order scheduling dates were modified by MRP and
planned orders created for eppds BOM components. To overcome this
remove scheduling in planned order parameters (OPU5) and use basic
date scheduling in MD01N. All BOM materials above eppds material to be
set active for ppds. Planning procedures to be maintained accordingly in
SIMG - Advanced planning - Maintain Planning procedure. Scope Limitaion
in material master to be set accordingly.
Note: /n/SAPAPO/CCR is used to solve scheduling discrepencies.
Scope Limitation in Advanced planning view of material master
Note: Blank - PPDS Entire scope
Some additional data regarding class in ECC vs APO.
Class Characters in APO are used for below.
Shelf Life Planning, Campaign Planning, Setup Matrix, Alternative Mode
Resource Scheduling, Detailed Scheduling with characters, Characteristic
dependent planning CDP, Variant configuration. Integeration Model should
be set in CFM1 to move class characters from ECC to APO logical system
Class type in ppds vs ECC
Class Type ECC APO
Variant Configuration 300 400
Batch Class 023 230
Material Class 001 001
Work center Assignment 019 019
No Integration Model required for data flow
Required only Organization area in use
In workcenter CR02 - More - Extra - Classification - Class type 019 can be
added for Alternate mode resource schdeuling.
Configs to add class charactes in ECC and PPDS
SIMG - Logistics general - Batch management - Batch valuation - Update
standard characteristics , to create default ppds charactersitcs
SIMG - Advanced planning - basic settings - Settings for data transfer, To
move batch master to ppds
Conclusion: I hope this may help someone. Please mention if there are
mistakes.