Exploring the Usage of Optimization in SAP S/4HANA PP/DS

Objective

After completing this lesson, you will be able to explain the usage of optimization in SAP S/4HANA PP/DS

Principles and Procedures of Optimization in SAP S/4HANA PP/DS

Optimization uses an objective function to evaluate a schedule (that is, the dates or sequence and resource assignment of operations and activities).

The objective function is the sum of differently weighted times and costs that are especially critical for planning. During optimization, the system tries to reduce the value of the objective function, that is, find a schedule in which the different times and costs – based on their weighting – are as small as possible.

The graphic contains 3 charts illustrating the weighting of optimization parameters.

This example shows the following:

  • The top chart (1) shows the order status after the production planning run. The setup times are not optimized and accumulate again each time due to a product change on a resource.

  • The middle chart (2) shows the result with the optimized setup times.

  • The third chart (3) shows a curve of the effects of adherence to deadlines against setup times between the two previous schedule examples.

The graphic outlines an example of the complexity of optimization problems.

When optimizing orders / operations, even "more minor" scheduling problems are complex.

Optimization Algorithm for Detailed Scheduling

To get a good solution within a limited processing time, algorithms are needed that reduce the complexity of scheduling problems. How suitable an optimization algorithm is in finding a good solution, depends on the scheduling problem.

The following optimization algorithm is used for the detailed scheduling optimization:

Genetic Algorithm: This procedure is suitable for planning problems for which the planner can find a feasible solution, but not a good solution. A typical use for this algorithm is to establish an optimal sequence based on the setup of operations.

Note

There used to be support in the DS optimizer for an algorithm called Constraint Propagation. This has however been discontinued by SAP.

The optimization algorithm and weighting of optimization criteria you use to obtain good solutions is dependent on the scheduling situation and the company goals. You decide on the quality of the solutions by setting the processing time for the optimization. The rules of thumb are as follows:

  • The more time you have, the better the solution will be.

  • The more extensive and complex the problem is, the more time you require.

How to Use the Optimizer in SAP S/4HANA PP/DS

DemoStart Demo

Use the PP/DS Optimizer

ExerciseStart Exercise

Steps

  1. Check the assignment of the setup-matrix to your resource WT-X##_1010_001 and to your resource WT-N##_1010_001.

    1. Navigate to your resources using transaction /N/SAPAPO/RES01, or using the menu path: Logistics→ Advanced Planning→ Master Data→ Resource→ Resource.

    2. Enter your resource WT-X##_1010_001 in plant 1010 in planning version S4224MPPDS and choose Enter (on your keyboard).

    3. Navigate to the Time-Cont. Capacity view.

    4. Check / maintain the value PAINT SHOP for the setup matrix.

    5. Save you changes, and repeat this process for the second resource (WT-N##_1010_001).

    6. Save your changes again and leave the transaction.

  2. Check/assign the correct Setup group category and the correct Setup group key to your finished products according to the settings in the following table:

    Setup group category/Setup group Key

    ProductSetup group categorySetup group key
    T-F2##1 (Color)20 (Yellow)
    T-F3##1 (Color)30 (Green)
    T-F4##1 (Color)40 (Blue)

    1. Start transaction CA02, or choose the menu path: Logistics → Production → Master Data → Routings  → Routings  → Standard Routings  → Change .

    2. Enter your finished product T-F2## in plant 1010.

    3. Select operation 0030 and choose Detail.

    4. Scroll down to the segment General data and assign the keys from the table above.

    5. Save your changes.

    6. Repeat the process for your finished products T-F3## and T-F4##.

    7. Save your changes once again and leave the transaction.

  3. Transfer the PDS for Advanced Planning using the following parameters:

    Settings for the PDS Transfer

      
    Planning Version in APOS4224MPPDS
    MaterialT-F2##, T-F3##, T-F4##, T-S1##, T-S2##
    Plant1010
    Production Version0001
    Transfer ModeAbsolute Transfer

    1. Start the transaction /NCURTOADV_CREATE (PDS Transfer (PP/DS)), or use the menu path: Logistics → Production → Master Data → PDS for Advanced Planning → CURTOADV_CREATE - PDS Transfer (PP/DS).

    2. Execute the transaction using the parameters from the table above.

    3. Leave the transaction when you are done.

  4. Open the Product View and enter the following data:

    Planning version:S424MPPDS
    Product:T-F4##
    Location:1010 (Trsp.

    Enter the three requirements for 30 pieces each (one by one!) for product T-F4## (use a minus sign to indicate it is a requirement), and once all three requirements have been created, generate the planned orders by executing the product heuristic. Repeat these steps for the other two products T-F2## and T-F3##. Save your changes.

    1. Navigate to the menu path: Logistics → Advanced Planning → Production Planning → Interactive Production Planning → /SAPAPO/RRP3 - Product View.

    2. Enter planning version S424MPPDS, product T-F4## and location 1010.

    3. Create the first requirement. Select Create Order and create the first requirement for product T-F4##, using the Avail/Reqmt Date and enter/select Monday in two weeks and enter a Rec./Reqmts Qty of -30. Choose Enter (on your keyboard) to create the order. You can enter the dates of the following two requirements of 30 pieces directly using the selection help and also enter the quantity directly.

    4. Once all three requirements have been created, enter the Product View once again. Go to Change mode, execute the Product Heuristic and Save your planning results.

    5. Repeat the previous steps a) to d) also for your products T-F2## and T-F3##.

  5. Open the Detailed Scheduling Planning Board (variable view) from the Interactive Production Planning menu. Use the following parameters:

    General settings

      
    Overall Profile:SAP001
    Plng VersionS4224MPPDS
    Time Profile:SAP001
    Work AreaS42XX

    Profile settings

      
    Resource ChartDisplayed
    Product ChartDisplayed
    Operations ChartDisplayed
    Current ModeX - Select Any Mode
    Alert ProfilePPDS-##

    Hint

    You can use the button Profiles... to hide the charts that you do not need for this exercise.

    Add your alternative resource WT-N##_1010_001 to the work area.

    Start the transaction and familiarize yourself with the scenario. The planned orders are colored like the finish product color. You can see capacity overloads on the paint shop WT-X##_1010_001. Add the Resource Utilization as a chart. Stay in the Detailed Scheduling Planning Board.

    1. Open the Detailed Scheduling Planning Board - Variable View using transaction /SAPAPO/CDPS0, or use the menu path: Logistics → Advanced Planning → Production Planning → Interactive Production Planning → Detailed Scheduling → Detailed Scheduling Planning Board - Variable View.

    2. Choose Profiles... and change the settings using the values given in the table above. Confirm your settings by choosing Adopt.

    3. Enter the data and choose Execute (F8).

    4. Select the paint shop WT-X##_1010_001 in the Resources Chart and use the right mouse button to add the Resource Load as a Chart.

    5. Stay on this screen for the next step.

  6. Use the heuristic Plan Sequence Manually for the bottleneck resource WT-X##_1010_001 to create an order sequence that is optimal in terms of setup. This means: T-F2## (Yellow), then T-F3## (Green), and finally T-F4## (Blue). Are you seeing any delays? Look at the network view of the orders. Stay on this screen for the next step.

    1. Select the bottleneck resource WT-X##_1010_001 in the upper-middle window (Resources Chart).

    2. Choose the menu path: Functions → Heuristics → Schedule Sequence Manually. The orders are displayed.

    3. Choose Swap Pages to move the orders to the clipboard.

    4. Select the column Product Number and choose Sort in Ascending Order.

    5. Select all orders and choose again Swap Pages.

    6. Execute planning by choosing Schedule (F8). You now receive an order sequence that is optimal in terms of setup. The capacity overload has been leveled.

    7. Are you seeing any delays? Select the three products T-F2## (Yellow), T-F3## (Green), and T-F4## (Blue), and choose Extras → Network View - Orders → Display as a Dialog Box. Any green triangles you can see symbolize planned independent requirements that are linked to the planned orders using the green lines in the chart (pegging edges). You might see some planned orders whose entry is to the right of the requirement date. If that is the case, then there are delays. Close the Network View: Orders pop-up screen again, and stay on this screen.

  7. Make sure that nothing is selected in the Detailed Scheduling Planning Board and that all relevant resources are visible in the Resources Chart. Start the PP/DS Optimizer with the predefined time specifications. Choose the Optimization Profile, maintain an End of Horizon of today + 3 months, and set a maximum run time of 10 seconds. Save the optimization profile and execute a first optimization run. Toggle between displaying absolute and weighted values. What's the difference? Has the planning result changed? Stay on this screen.

    1. Make sure that nothing is selected in the Detailed Scheduling Planning Board and start the PP/DS Optimizer using the button Optimize.... Maintain the end horizon and, once again, choose Optimize....

    2. Choose the button Optimization Profile and enter a Maximum Runtime of 10 seconds. Save the profile and choose Copy to close the pop-up screen.

    3. Choose the button Start Optimization Run.

    4. After the optimization run, switch back to the Optimization tab page and switch between absolute and weighted values. The weighted values are multiplied by the defined weights. Therefore, you do not see any delays here.

    5. Has the planning result changed? This depends. Analyze the screen. Stay on this screen.

  8. Start optimization again, but now with a focus on the reduction of delays. For example, set a weight of 1 for the maximum delay costs and a weight of 2 for the total delay costs. If there are still delays, you can further increase these weights. Once you are done, return to the Detailed Scheduling Planning Board.

    1. Choose the button Optimization Profile and enter a weight of 1 for the maximum delay costs and a weight of 2 for the total delay costs. Save the profile and copy the settings.

    2. Choose Start Optimization Run.

    3. After the optimization run, switch back to the Optimization tab page and switch between absolute and weighted values. The result could be that the setup times have increased, and the delays have been reduced. If there are still delays, you can further increase the relative weights. Use the Back button to return to the Detailed Scheduling Planning Board.

  9. Leave the transaction without saving (choose Close).

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