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1、Huawei TechnologiesHuawei APS ProjectSolution Architecture SpecificationFactory PlannerRevision 6.8/ 5-MAR-2003TABLE OF CONTENT PURPOSE7INTRODUCTION7FP Solution Overview7Weekly and Daily FP Runs7TECHNICAL SOLUTION DESIGN8FP Inter-functional Workflows with DP,SCP, and SCC9DP to Forecast Netting, to S
2、&OP, to MP & to FP9MP to FP9FP to MP10FP to SCC10FP to Oracle12FP STATIC MODEL13BOM Definition14Demand and Backlog Management15Demand Prioritization15Supply16Raw Material16Work Orders16WIP Backflushing for Component Inventory16Routing Definition18PCBA Routing18PCBT Routing19ATO assembly Routing20Res
3、ource Definition21Critical Resource Flag:21Alternate Resource:22Pooled Resource23Simultaneous Resource:23Batch Resources24Number of Operators assigned to a task.25Tester definition for Network Product:25Tester definition for Wireless Product:27Additional Notes and Decisions on the resource definitio
4、n in ATO27Resource Calendar Maintenance28Capacity Balancing30EXCLUSIONS AND OUT OF SCOPE REQUIREMENTS32ASSUMPTIONS32FUNCTIONAL SOLUTION DESIGN41ICP Demand411.1 Material assignment according to Demand priority (FP-1)411.2 Plan For Orders With “Enter+Scheduled” Status (FP-2)421.3 Assign higher demand
5、priority if one of its work orders has been released (FP-3)421.4 Material planning for POC forecast (FP-4)441.5 R&D Material Requirement (FP-5)441.6 Account Shipment time to deliver to customer (FP-6)441.7 PTO From The Same Shipset Will Complete Together (FP-7)451.8 Assembly coordinate for (POC and
6、ATO) under PTO (FP-8)461.9 Safety Stock Planning (FP-9)471.10 Operation Level Material Consumption (FP-10)482.0 ICP - Supply492.1 Consume From Inventory Buffers (FP-11)492.2 Alternate Part Function (FP-12)502.3 Engineering Change Order (FP-13)512.4 Coordinate Work Orders For Finished AI And Semifini
7、shed AI (FP-14)522.5 AI Work Order Generated Based On lot sizing rule (FP-15)533.0 Review ICP Results543.1 Check BOM, Supplier Data And Unplanned Orders (FP-16)543.2 Release Work-order with Material shortage (FP-17) Solution postponed543.3 Review late orders and material assignment (FP-18)573.4 WIP
8、Reporting And Planning (FP-19)573.5 Schedule frozen period (FP-20)584.0 Modeling of Capacity604.1 Aggregate Resource Modeling: (FP-21) Requirement Eliminated.604.2 Multiple parallel resource planning (FP-22)614.3 Capacity Balancing Logic (FP-23)624.4 Minimum Utilization Required For Subcontractors M
9、anual Process (FP-24)634.5 Review Capacity Plan (FP-25)634.6 Revise capacity plan (FP-26)645.0 Scheduling655.1 Scheduling Rule (FP-27)655.2 Adjust Schedule (FP-28)666.0 Procurement Recommendation676.1 Consolidate PR Based On Time And Lot Sizing Rule (FP-29)676.2 Procurement Suggestion With Blanket P
10、O Number (FP-30) Not Required686.3 Vendor Allocation (FP-31)686.4 Forecast For VMI Vendors (FP-32)736.5 Delivery Schedule For JIT vendors (FP-33)746.6 Each Factory Building At Shenzhen Should Consume Inventory From Its Own Building First, Output Factory Location For PR For Vendor Delivery Informatio
11、n (FP-34) Solution Postponed757.0 Output Results787.1 Output Production Schedule (FP-35)788.0 Security799.0 Reports (FP-36)819.1 Over Procurement Warning Report82ENHANCEMENTS TO I2 SOFTWARE86Template Customization86Gap Analysis86UI WORKFLOW86CUSTOMIZED REPORTS86User Access & Security87Key Interface
12、and data requirement87PERFORMANCE REQUIREMENTS87APPENDIX A: DEFINITION AND TERMS87APPENDIX B: INBOUND DATA SPECIFICATION88FP SERVER FLAGS SETTING112APPENDIX C: OUTBOUND DATA SPECIFICATION119APPENDIX D: CUSTOM CODE131REVISION HISTORY131MAJOR CHANGES SINCE LAST REVISION133REQUIRED APPROVALS133Terms an
13、d DefinitionAcronymMeaningAIATO Item. AI has a fixed formation, can be assembled according to MRP, can be sold directly, e.g. manufactured board.APSAdvanced Planning & SchedulingATOAssemble To Order Model Item. A product model with production according to order. Sub Item in model list is optional (b
14、oth type and amount), e.g. Product Debugging Mainframe List.BOMBill of material BTOBuild To OrderBTSBuild to StockCAOConstraint Anchor Optimization: FPs algorithm to perform capacity balancing.DFi2 Demand FulfillmentDPi2 Demand PlannerECOEngineering Change Order EDCExpedite, De-expedite, CancelERPEn
15、terprise Resource PlanningFGEnd Product, fixed formation, e.g. ISDN phoneFPi2 Factory PlannerMDSMaster Demand ScheduleICPInfinite Capacity Plan; plan only constraint by materialODSi2 Operational Data StorePOPurchase OrderPOCPTO Option Class. POC is an assembly of items that are directly shipped, the
16、 materials will be directly shipped without testing if OE selects materials in POC option class list. e.g. complete set of installation parts.PRPurchase Requisition (recommendation)PTOPick To Order, which contains both ATO (Assemble To Order) and other non assembly material, e.g. B SwitchROIRapid Op
17、timized IntegrationSC Supply ChainSCCi2 Supply Chain CollaborationSCMSupply Chain ManagementSCPi2 Supply Chain PlannerTMAPI / i2APITradeMatrix Application Program Interface, synonymous with i2API.WOWork orderPurposeThis document describes the solution architecture for FP, to be used by Huawei to do
18、factory planning and scheduling. The document is a complete description of the software functions/ features that would be used to address the business requirements identified through the Business Analysis Document. IntroductionFP Solution OverviewAs a module in the APS solution, FP performs material
19、 and capacity planning, as well as factory scheduling for Huawei. FP plans for all demands in Huawei, including customer orders, forecasts, R&D, as well as internal demands. The implementation is planned to go live in May, 2003. The organization involved in the scope of this implementation is Huawei
20、s factory in ShenZhen for all the product divisions. This implementation will enable the Huawei ShenZhen factory to: Perform material requirement forecast planning for all non-critical procured parts for 12 months that is the planning horizon for Demand Planner. Plan for capacity constraint producti
21、on plan over a three-months horizon Generate production schedule for 3 days Improve demand due date performance by reviewing early warning of late orders, and material and capacity shortage Have visibility into material supply and demand pegging Have visibility of the entire supply chain from shipse
22、t, to PTO, to ATO, to AI, and to raw material. Technical Solution DesignMP runs daily and assigns due dates for forecast demands. Oracle is the system of record for sales orders after they first go through DF algorithm. DF assigns a promise date for each sales order if it can be fulfilled by invento
23、ry or WIP. On the supply side, FP will first consume inventory and WIP. Then FP consumes PO with its expected arrival time and committed PR from SC to meet demands. Outside the vendor leadtime, FP will make PR without quantity limitation. Buyers will only use FPs PR for non-critical components. The
24、PR for critical components will come from MP. After FP generates the production schedule for the next day, the schedule will be outputted to Oracle. The longer-term production plan of a few weeks will be sent to MP and others for their future visibility. Interfaces must be developed to link data. Al
25、l FP input and output data will integrate with other i2 modules and HW systems through ODS.FP Inter-functional Workflows with SCP and SCC,The following is the diagram for the APS integration:Forecast Netting to FPOutputs to FPData OutputDescription1.Forecast for Level III. Level III for all non-SCP
26、parts.MP to FPEveryday MP outputs the constrained Make To Stock production plan for critical material. The build plan only includes those used to meet forecast demands. The non- critical material forecast come from the Forecast Netting DF engine on daily basis. To keep that supply and demand consist
27、ent when feeding from MP to FP, the build plan and procurement plan (within 6 month) should be read to FP. The procurement from MP (within 6 months) is used in FP as additional PR after ERPs existing PO/PR.MP Outputs to FPData OutputDescription1.Build plan for forecast For FP PP engine, the MPs plan
28、 of (0-3) months will be fed to PP.For FP MRP engine, S&Ops build plan from 7-12 months will also be read as forecast in addition to 0-6 build plan from MP. 2.Supply of MP planned parts.For both the PP and MRP engine, only the procurement plan from MP from (0-6 month) is required to be read into FP
29、as supply. FP can create supply for critical material after use up those procurement plan.FP to SCCThe main purpose of the FP to SCC workflow is to communicate procurement forecast generated for non-critical items. This forecast is the net requirement (net of PO), and constraint by procurement leadt
30、ime. Based on a feasible material and capacity plan, weekly FP outputs PR suggestion for all its planned parts to SCC for collaboration once a week. FP also outputs JIT/VMI pull signal based on the near term production schedule. And after each FPs daily run, exceptions such as material shortage and
31、expedition recommendations are handled manually outside SCC. The exception PO EDC reports are output from both the MRP and PP engines. Only the PROC for non-critical parts will be sent to SCC as forecast. They will be processed further according to whether they are JIT/VMI/normal . OutputsData Requi
32、redDescriptionSource of Data1.Non-critical material forecast. 0-2 months form the daily PP engine. 3-12 months from weekly MRP engine. FPFP exception message to Procurement DepartmentFP outputs PO EDC reports from both the PP and MRP engine with different plan ID in the same ODS. For both Expedite a
33、nd De-expedite, message from the PP engine will override the ones from the MRP engine. Only the cancel message from MRP engine should be used. Filtering criteria specified by procurement departement will be used to process the exception messages in the procurementplan outputted by both PP and MRP en
34、gines. One assumption made here is that when MP creates additional procurement outside its 1/3 leadtime, they will become PR/PO in ERP. FP treats the new MP generated PR same as PO/PR from ERP, and will generate EDC expection message againt them.FP to OracleFP outputs planning results back to Oracle
35、 to make the data consistent between Oracle and FP. After FP outputs planning results to ODS, ROI will populate the corresponding tables in Oracle. They are:1. Create AI work orders2. Write plan start time (PST), and resources assignment3. Write material assignment for all work orders4. Update the s
36、hipset completion date. ROI adds the transportation time to the FP shipset before writing to the Oracle ERP table.5. PR recommendation.The output tables used to write to Oracle are summarize as below. OutputsWrite to OracleData OutputLogic1.AI work orders ManufacturingPlanProductionorderid (= new AI
37、 Work order ID) ItemQtyproducedPlannedstartdate = between (today, today+2)PlannedcompletiondateBomid = (AI BomID)Routingid = (AI routingID)2Update all start time (PST), and resources assignment for all work ordersOperationPlanProductionorderid = AI or ATO WOOperationseqResourcenameIsalternateresourc
38、eNumberofunitsIsscheduled = 1Plannedstartdate = between (current, current + 2 days)Plannedenddate3material assignment for all work ordersSupplyDemandPegPlanDemandorderid (= AI or ATO WIP)=productionorderidSupplyorderid (PO, PR)Serialnum (Inv buffer)Item (raw material)Qtyallocated (quantity assigned)
39、Demandtype (=MFG)Demandpst between (currentday, currentday +2)4shipset completion dateShipment Plansalesorderid +solinenum (Shipset demand ID)Plannedavaildate (FP planned end date)Item (shipset item)Customerid 5PR suggestionProcurement Planorderid + orderlinenumItemQtyplannedPlanneddeliverydateRecom
40、mendedsupplieridOrdertype = (PROC)Poreleasedate= between (current day, current day+7)MessagepstMessagelpstPP and MRP FP RunsFP PP engine is responsible for production planning for 3 months horizon. To generate material forecast for non-critical material, PP engine outputs material requirement for th
41、e first 2 months, and the MRP engine outputs the next 10 months (3 to 12). This is used to generate exception report for buyers to expedite material and create PR. The production plan and scheduling is also performed from this engine. These PR recommendations will be sent to Oracle, reviewed by plan
42、ners and buyers before releasing. The confirmed PR and PO are the material supply for the daily FP runs.EnginePP MRP Responsible forPR generation + FCST within 2 monthsFCST greater than 2 monthsBucket3 months that starts with 14 daily buckets, followed by 13 weekly buckets. 12 months that starts wit
43、h 13 weekly buckets, and then followed by 9 monthly buckets. change reqModel featureOperation-level material consumptionYesspec fileBackflushed inventoryYesengine idBackflushed demandsYesengine idProcurement leadtimeYesspec fileProcurement lot sizingNospec fileManufacturing order lot sizingNospec fi
44、leFull routing, alt. Resource, simultaneous resourceOne fixed routing? No alt. Simul. Resourcesspec fileAlternate routingNoAlternate part. Yesspec fileBOM, routing, part effectivityYesVendor allocationYesCAO, schedulingNoworkflowFrozen period, schedule restorationNospec fileIA_POST_PROCESSINGNoflagR
45、esource_data_fileStatic filespec fileSafety stock for critical and non-critical partsYesOutput all output tableOutput only the procurement_record and PO_edc_record in procurementplan tableSpec fileFP Static ModelThe following shows the static model representation of FP. SO1_SS1 is the top produced p
46、art, and C1 and C2 are the raw material in the BOM. The routing is also shown in the model. BOM DefinitionFP generates material requirement based on exploding BOM. The Oracle multiple level and phantom BOM will be converted to one level BOM for ATO, and another level BOM for AI. The drawing below illustrates how a shipset BOM is represented in FP. In addition to the relationship between the produced part and its primary components, FP BOM also contains alternate parts and ECO. The draw
