Supply Chain Planner Training Guide
Supply Chain Planner Training Guide
TRAINING – SUPPLY,
STOCK, RESOURCES
J U LY 2 0 2 3
COMPANY CONFIDENTIAL
NXP, THE NXP LOGO AND NXP SECURE CONNECTIONS FOR A SMARTER WORLD ARE TRADEMARKS OF NXP B.V. ALL
OTHER PRODUCT OR SERVICE NAMES ARE THE PROPERTY OF THEIR RESPECTIVE OWNERS. © 2020 NXP B.V.
P R O D U C T I O N O R D E R C R E AT I O N
Production orders are requests towards factories to produce a certain item, using a certain supply chain, for a
certain date, in a certain quantity
NL74 - NIJMEGEN NL74 - NIJMEGEN TW70 - KAOHSIUNG TW70 – KAOHSIUNG TW10 – KAOHSIUNG WH PTFP – CONSIGNMENT
RAW WAFER SLDI SLDI CEPT PEP PEP
WI
WI
P
P
WIP
Planner Process
Convert
review order
Planned Subcon sites
Release
Planner order Process Purchase
Convert Convert
creation order order
PL11 (EXCEL)
Planner
Review
COMPANY CONFIDENTIAL 2
W I P, N E W R E L E A S E D , U N R E L E A S E D
COMPANY CONFIDENTIAL 3
R E L E A S E PA R A M E T E R S
• Release Parameters will define whether an operation plan is sent into SAP for further processing
− 7 parameters are controlling the releases via the post-processing in MP-shop
− Only those “Operation plans” that meet the necessary criteria will be “proposed” to PPF for review and release
through SAP ZREVIEW
• Different Release Parameters are maintained on different levels of the master data structure
− Produced Item Location
− Consumed Item Location ITEM LOCATION ITEM LOCATION
(CONSUMED) (PRODUCED)
− Supply Chain
− Seller Product SUPPLY CHAIN SUPPLY CHAIN SUPPLY CHAIN
COMPANY CONFIDENTIAL 4
R E L E A S E PA R A M E T E R S – R E L E A S E F E N C E
• The Release Fence (RF) defines how many days in advance an order is sent to the factory
• All operation plans that have a start date no later than current date + RF will be released (if all other release
conditions are met)
• Current day is always included in the calculation:
− If current day is a Monday and RF is 7 days, then all operation plans with a start date before next Monday (not included)
will be released
• RF is maintained on the consumed item location
Operation plan #1
Operation plan #2
Operation plan #3
Operation plan #4
RELEASE
FENCE
COMPANY CONFIDENTIAL 5
R E L E A S E PA R A M E T E R S – R E L E A S E A G A I N S T S C H E D U L E D R E C E I P T S
• PO Disaggregate splits the operation plan up into parts, where each part equals the quantity of one lot
− In case LP lot-size is 25 wafers and PO Disaggregate is set to TRUE, then the proposal of 100 wafers with the same
start/end date will be split into 4 proposals (25 wafers each)
• The parameter is maintained on the supply chain and is either TRUE or FALSE
• Maximum number of splits that can be done to a single operation plan is 999
• Example: Operational plan quantity = 27500 units with an LP lotsize of 25 units -> Proposals: 999x25 units + 1x2525 units
PG ComponentItem ComponentItemDesc ComponentSiteID ProdItem ProdItemDesc ProdSiteID PO_Disaggregate ProductionOrderID PlannedStartDate PlannedCompDate StartQty EndQty
ADA 340000136774 T0733521C3B/SLDB 0010042435@E212 340000136772 8KMZ710V4AE/SLDI E212 N 126125 27-Mar-23 15-May-23 71 71
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 50286 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948714 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948715 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948716 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948717 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948718 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948719 21-Mar-23 18-Apr-23 25 25
ADA 340000240614 T2910V2A RRR-LIL/SLPD 0000832398@E028 340000240615 T2910V2A 002-LIL/SLDI E028 Y 948720 21-Mar-23 18-Apr-23 25 25
COMPANY CONFIDENTIAL 7
R E L E A S E PA R A M E T E R S – R E L E A S E B L O C K
• Release Block (RB) prevents operation plans from being released into SAP even if all other parameters are met
− Parameter set to „TRUE” means that the proposal will never be „New released” even if it is within release fence while
capacity and components are planned herefore the release block is especially useful for
COMPANY CONFIDENTIAL 8
R E L E A S E PA R A M E T E R S – R E L E A S E C O - P R O D U C T
• A co-product is a product that is produced besides the wanted main product according to a predefined split
− Co-products are either desired or undesired by-products of the production process (e.g. waste is an undesired by-product)
− Example: the factory tries to produce 100 processors of 2 Ghz. Due to the nature of the production process of semi-conductors, the
output results in a variety:
70 processors of 2.0 Ghz – main product with target speed
20 processors of 1.8 Ghz – lower speed but can still be sold to the market, is a desired co-product, does not get scrapped
10 processors of 1.6 Ghz – lower speed but can still be sold to the market, is a desired co-product, does not get scrapped
Release Co Product = True Release Co Product = False
Released 2.0, 1.8, 1.6 Ghz 2 Ghz
Unreleased 1.8 and 1.6 Ghz
COMPANY CONFIDENTIAL 9
R E L E A S E PA R A M E T E R S – C O D P
• Upstream of the CODP, operation plans will be released if they are pegged to the following demand types:
− forecast demand
− order demand
− safety stock requirements
• Downstream of the CODP, operation plans will be only released for:
− sales order demand
− safety stock requirements* Downstream of CODP
*Operation plans for Seller Specific Safety Stock (SSSS) downstream of CODP are never released since SSSS is inserted (and treated) in the system as a forecast (but with different
demand priority) while OP’s pegged to safety stock are actually pegged to so-called ‘excess stock’ and are always released
COMPANY CONFIDENTIAL 10
R E L E A S E PA R A M E T E R S – M A I N TA I N I N G C O D P
• Note, The DODP (Default Order Decoupling Point) of the Item-Location is NOT used in the MP-Shop release
logic, it is only used in determination of the default CODP for a supply chain
• CODP is used in MP-Shop and the Forecast Netting process as well
− Changes of the CODP are reflected MP-Shop everyday while only once a week in the FX process
COMPANY CONFIDENTIAL 11
R E L E A S E PA R A M E T E R S – F L E X I B L E L O C AT I O N R E L E A S E
• The Flexible Location Release defines on which day(s) an order is sent to the factory and only on these
specific days will the operation plans released into SAP (if all other release conditions are met as well)
− MPSHOP checks the release pattern on the consuming buffer of a supply chain and releases operation plans only in
case the current day allows so
• JDA MDM has been adapted to
provide flexibility of maintaining
release days either at item
location level or at location
level
• Item Location level releases:
−Release Fence UOM = 'Everyday’: all operation plans consuming from that specific buffer will be released
−Release Fence UOM = ‚Mo/Tu/We...’: OP’s will get released on the specific day indicated in the UOM
−Release Fence UOM = ‚NoRelease’: no OP’s consuming from that buffer are released
COMPANY CONFIDENTIAL 12
R E L E A S E PA R A M E T E R S – F L E X I B L E L O C AT I O N R E L E A S E
• Location level release pattern is maintained per engine and location via the Location Release menu in MDM UI
− Release Fence UOM = ‚LocRelease’ or blank: the corresponding Location Release Calendar is used
OP’s will only be released the Plan Current day is one of the days for which the location release is set to YES in MDM UI
In case no days are defined to be released (i.e, location release is set to 'No' for all days) then MPSHOP will not release and Dynamic
Expiration fence becomes 7 days and hence all forecast for that seller product will not be expired incase of factory or PPF shutdowns
In case location release is set to “Yes” for one or more days, but there’s no overlap with plan release days, then Dynamic Expiration fence
becomes 7 days
In case there is no record for the plant in Location Release Calendar , then it is treated as release on all days (i.e. Mo /Tu/We/Th/Fr)
COMPANY CONFIDENTIAL 13
STOCK MANAGEMENT – SAFETY STOCK
• Safety stock is additional buffer of material that is maintained to mitigate risk of stockouts due to uncertainties in
supply, demand or manufacturing yield and that adds flexibility to the operations
• Customer Program contracts define an agreed volume of safety stock that must be maintained by NXP for that
specific customer
• Demand and supply variations
− Unexpected decreased or late supply
− Unexpected increased or early demand
• Safety stock types:
− Fixed (Static safety stock)
− TimePhasedUser
− TimePhasedIP
NL74 - NIJMEGEN NL74 - NIJMEGEN TW70 - KAOHSIUNG TW70 – KAOHSIUNG TW10 – KAOHSIUNG WH PTFP – CONSIGNMENT
RAW WAFER SLDI SLDI CEPT PEP PEP
SS = INFINITE* SS = FIXED (0) SS = FIXED (0) SS = FIXED (100.000) SS = TPIP (2WKS) SS = TPIP (3WKS)
*Infinite safety stock type only applies to SLSI and SLEP item locations, where it is automatically set and can not be changed by the users COMPANY CONFIDENTIAL 14
STOCK MANAGEMENT – SAFETY STOCK TYPES
QUANTITY
TIME
QUANTITY
150.000 PCS
• Start date of a period must be a Monday 100.000 PCS
TIME
COMPANY CONFIDENTIAL 15
STOCK MANAGEMENT – SAFETY STOCK TYPES
Time Phased IP
• SS Coverage = the number of weeks of
average demand that should be covered
• Look Ahead = the number of weeks to
considered when calculate the average weekly
demand
• Tail off = defines the horizon on which the
dynamic safety stock should be calculated
• Based on the planned demand for non-CP
customer locations
• For CSW locations the calculation is done
based on the latest DP Constrained Final
Forecast
COMPANY CONFIDENTIAL 16
STOCK MANAGEMENT – SAFETY STOCK PRIORITIES
• The Safety Stock Priority indicates the relative importance of the item location in safety stock calculations, with
respect to the importance of other item locations within the supply path
− CSW’s are usually set to priority „Highest” to ensure that our contractual obligations with our customers are fulfilled
− Business is responsible for defining the importance of SS buffers within the supply path
• SS Priority values:
− Lowest
− Low
− Medium
− High
− Highest
NL74 - NIJMEGEN NL74 - NIJMEGEN TW70 - KAOHSIUNG TW70 – KAOHSIUNG TW10 – KAOHSIUNG WH PTFP – CONSIGNMENT
RAW WAFER SLDI SLDI CEPT PEP PEP
SS PRIO = LOW SS PRIO = LOW SS PRIO = MEDIUM SS PRIO = HIGH SS PRIO = HIGHER SS PRIO = HIGHEST
COMPANY CONFIDENTIAL 17
STOCK MANAGEMENT – MAXIMUM ON HAND (MOH)
COMPANY CONFIDENTIAL 18
STOCK MANAGEMENT – MOH TYPES
Both Fixed and TimePhasedUser MOH types will always adapt to the SS setting of the item location, only
difference is that with the TPU setup user can set different MOH values within the horizon via a calendar
SS = 100.000 PCS
TIME
COMPANY CONFIDENTIAL 19
STOCK MANAGEMENT – MOH CONSTRAINT
• Max on Hand Constraint determines how important it is to stay within the boundaries of the defined MOH
value
− The more the plan violates the MOH constraints, the more „penalty points” the engine gets, thus the engine will push
additional material from higher constraint to lower constraint MOH’s
• MOH Constraint values:
− Highest
− Higher
− Medium
− Low Highest Higher High Medium Low Lower Lowest XLow XXLow XXXLow
− Xlow SLSI/SLEP Infinite, MOH Constraint = Blank, MOH Qty = Blank
SLxx
− XXLow CExx
− XXXLow ICxx
PEP@IWH
PEP@GDC
PEP@CSW
*General guideline for MOH Constraint setup within the supply path. User needs to consider business requirements/agreements
(e.g. not allowing additional stock of SFG at subcon sites might require MOH „Highest” Constraint value
COMPANY CONFIDENTIAL 20
S T O C K M A N A G E M E N T – C O D P R E L AT I O N
• CODP determines what manufacturing orders are released towards the sites.
− Operation plans upstream of the CODP will be released against customer orders, customer forecast and safety stock
− Operation plans downstream of the CODP will only be released if they are against customer orders and safety stock
• CODP is also used in Forecast Netting process -> Forecasted demand downstream of CODP is expired
• Setting CODP at different stages will reflect the business strategy. Some examples:
− Make to forecast
− Make to order
− Customized products
• When defining the CODP, business needs to consider (amongst other aspects) the risk of idle stock and the service level to
customers
Downstream of CODP
COMPANY CONFIDENTIAL 21
STOCK MANAGEMENT – BUILD TO ORDER VS. ASSEMBLE TO ORDER
• Build to order modell - Risk to build product based upon forecast (custom product, high cost etc.)
− Set CODP at Raw Wafer to expire forecast within full cycle time of the supply path and to avoid releasing any operation pegged to forecast
− Set MOH = 0 at all buffers to not allow excess stock
Downstream of CODP
CODP
RAW WAFER SLDI SLDI CEPT PEP
• Assemble to order modell – Aim to have buffer at die bank to better service customer in shorter LT or to fully load Wafer Test
− Set CODP at Die Bank to expire forecast within Assy/FT LT horizon and allow diffusion/WT starts based upon forecast or sales orders, while
only allowing Assy/FT based upon sales orders
− Set MOH qty at diebank to allow for excess stock Downstream of
Upstream of CODP CODP CODP
COMPANY CONFIDENTIAL 22
R E S O U R C E M A N A G E M E N T – C A PA C I T Y
• Resources in MDM represent the capacity groups that are needed during the manufacturing process
• Generic resources are created and maintained exclusively by the Factory Planner.
• Considering capacity, resources can be:
− Finite: the planned capacity utilization can never exceed the upper capacity limit
− Infinite: the planned capacity utilization never check the upper capacity limit
• Note, in case a resource is set to be infinite, it is recommended not to have a capacity calendars as this could cause
inconsistencies in planning (engine might treat the resource as a finite and consider the values assigned in the capacity
calendar
• Any resource that does not have a capacity calendar assigned to it is treated as an infinite resource
• Capacity is time-critical, if it is not used in the defined time period (daily/weekly/monthly buckets) it will „expire”
COMPANY CONFIDENTIAL 23
R E S O U R C E M A N A G E M E N T – D ATA S T R U C T U R E
Operation X
BOR X
Resource@TH70
COMPANY CONFIDENTIAL 24
R E S O U R C E PA R A M E T E R S ( N X P 1 ) – R E TA I N A L L O C AT I O N F E N C E ( R A F ) , F L E X I B L E F E N C E ( F F )
• Retain Allocation Fence for finite resources determines in which period a hard constraint applies to it’s capacities
• Within retain allocation fence - The capacity statements in child PG’s and the parent PG are hard constraints
• Between retain allocation fence and flexible fence - Only the Parent PG capacity statements are hard constraints
• Outside flexible fence - Only Parent PG capacity statements are soft constraints
NXP1
COMPANY CONFIDENTIAL 25
R E S O U R C E PA R A M E T E R S – R E TA I N A L L O C AT I O N F E N C E , F L E X I B L E F E N C E
• The Flexible Fence determines what period (UoM: weeks) a resource is treated as finite
− The different type of engines have separate Flex Fence settings
Flexible Fence 1 is used in the Request engines
Flexible Fence 2 is used in the Finite engines
Flexible Fence 3 is used in the Back-end Unconstrained engines
...
• CXI: Based on the Finite engine result, CXI calculates the allocated capacity from a resource to the child PG’s using that
resource (Based on capacity loading on resources as pegged to items in that child PG)
• CXII: Overwrites PG capacity calendars in JDA MDM with the new allocations from CXI
− Within the RAF the CXII module is disabled, so the resource capacity calendars are not touched in this horizon
• FF settings, CX block and other resource related parameters are attributes of PDQ551
− Note, RAF is called RELEASE_FENCE in PDQ551 but this is not to be mistaken with the item location’s Release Fence setting
COMPANY CONFIDENTIAL 26
RESOURCE MANAGEMENT – UNDERUTILIZED, OVERLOADED
• In case PPF finds underutilization or overload on a resource they need to allign with the Business Planning (BP) team
− Overload is not possible in a finite engine, unless it is outside FF2
− Overload on a resource will be pushed out if the resource is set to finite and will be planned by the engine at the earliest possible date where
there is capacity available (will be included in the „planned late” values)
COMPANY CONFIDENTIAL 27
RESOURCE MANAGEMENT – PL10
• PL10 (both the generic report and the cube version) shows the load and the produced quantities per resource/buffer combination
− A distinction is made between Work-in-Progress, New released and unreleased load and produced quantities
− Per resource also the capacity total load, the total produced quantities and the utilization are shown
• New available capacity: The upper capacity limit, the result of the CXI calculation at the end of weekend run
− New Avbl Capacity is only shown on TOTAL view and will not be assigned on 12nc + resource level
• Available Capacity: Capacity available on the resource per PG
− Sourced from MDM capacity calendars at every start of an engine run
• New Release Load / WIP Load / Unreleased Load : The start quantities
• New Released QtyProduced / WIP QtyProduced / Unreleased QtyProduced : The produced (outs) quantities
COMPANY CONFIDENTIAL 28
NXP, THE NXP LOGO AND NXP SECURE CONNECTIONS FOR A SMARTER WORLD ARE TRADEMARKS OF NXP B.V. ALL OTHER PRODUCT OR SERVICE NAMES ARE THE PROPERTY OF THEIR RESPECTIVE OWNERS. © 2020 NXP B.V.