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Oracle APS and GOP – Getting To Automated Sales Order Scheduling

Oracle APS and GOP – Getting To Automated Sales Order Scheduling. Mark Hopkins, Xilinx, Inc. 8/23/06. Topics. Goals of Our GOP Implementation Where We Are Today How We Did It Lessons Learned. Project Goals. Schedule new sales orders accurately Hit our first commitment

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Oracle APS and GOP – Getting To Automated Sales Order Scheduling

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  1. Oracle APS and GOP – Getting To Automated Sales Order Scheduling Mark Hopkins, Xilinx, Inc. 8/23/06 Xilinx Confidential

  2. Topics • Goals of Our GOP Implementation • Where We Are Today • How We Did It • Lessons Learned Xilinx Confidential

  3. Project Goals • Schedule new sales orders accurately • Hit our first commitment • Minimize reschedules • Preserve excellent on time delivery performance • Manage exceptions, and let the rest happen automatically • Reduce planner workload and allow them to focus on model maintenance Xilinx Confidential

  4. Results: Auto Release And On Time Delivery ~13k Line Items per month. Xilinx Confidential

  5. Our Planning Environment • Oracle APS (ASCP and GOP) • Oracle ERP • Order Management, Purchasing, Financials, HR • Custom Systems/Interfaces • Item & BOM Based on Matrix and Legacy • Forecast • Manugistics • Home grown Customer Forecast Management System • Wafers, Piece Parts, WIP tracking Xilinx Confidential

  6. What’s In Production:ASCP and GOP • Monthly / Weekly APS Plan for Wafers and Piece Parts (since April ‘03) • EDD • Unconstrained Plan • Wafer Plan, Piece Parts, Assy, Test, Sort, Bump Capacity • Daily Plan for Assembly Releases (since August ‘04) • ECC • Output is used for all products assembly starts planning • Daily Plan for GOP (since August ‘04) • ECC • Almost 100% of incoming sales orders get schedule dates recommended from GOP Xilinx Confidential

  7. Our Model(example from our ATP Plan) Plan Type: Cost Based Optimized Plan - HP 64bit Exe Enforce Material Constrained Plan Holistic Manufacturing Plan with Project Planning Time Buckets: 35 days, 10 Weeks Inputs: Orgs: 56 Items: 22k Demands: 19k BOM's: 17K Outputs: Demands: 64k Supplies: 56k Pegging: 78k Res Reqmts: 200k Xilinx Confidential

  8. Terms • GOP / ATP – Global Order Promising / Available To Promise • CFD – Current Factory Date (equivalent to Schedule Ship Date in Oracle) • OFD – Original Factory Date (the first commit on the sales order) • ATP Override – The ability to change the date that GOP was recommending prior to committing to the customer • Auto Release – A sales order that books, gets scheduled, and committed to the customer with zero planner intervention Xilinx Confidential

  9. Standard Oracle GOP Process Xilinx Confidential

  10. Xilinx Gates in GOP Process • Is part/whs set up as “auto release?” • Yes: does schedule ship date meet auto release criteria • No: Does planner agree with Schedule Ship Date? • Is calendar date blocked? • Is order on hold? • Is order unusually large? • Do we want to force a particular schedule date to happen (ATP Override?) Xilinx Confidential

  11. Demand Management Form Xilinx Confidential

  12. Getting to 100% Auto Release • Oracle • Need to consider alternate boms, substitute components in ATP/GOP algorithm. Lack of this functionality causes overly conservative commitments. In semiconductor mfg, this is needed to recognize bin downgrades, alternate mask sets. • ATP Algorithm needs to recognize that an order due 3 months from now can be satisfied with a wafer start. Allow finished goods to show as available for any new orders. • Xilinx • Data Maintenance. Specifically sourcing rules, and BOMs. • Our current BOM structure does not handle some new products / military scenarios. We are working on a new item/bom management system that will give us this. • Lot specific yields for new products. Xilinx Confidential

  13. Lessons Learned • Need a way to validate / build confidence in production data prior to exposing to customers • Develop metrics and publish progress • We gave prizes to the first planning teams to hit 3 different milestones • Need to build planners’ confidence in ATP ‘black box’ by developing an understanding of true problems vs. perceived problems or gross generalizations. Until we could explain each situation (which was a long process), anything that did not fit planners’ mindset was judged as “ATP is wrong.” • Incremental fixes / enhancements help zero in on the issues • Data maintenance and reporting that identifies data problems is helpful Xilinx Confidential

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