Purpose
Sales and Operational Planning (S&OP) are essential and strategic elements of the ERP Rebuild project design, playing a pivotal role in the overall success of the project. In parallel to this, the Advanced Planning and Scheduling (APS) project is being executed concurrently, utilizing Kinaxis Maestro, a leading software solution, to implement both Demand Planning and Sales and Operational Planning functionalities within the Syensqo system. This document serves as a comprehensive guide, designed to offer an in-depth understanding of the current "As-Is" planning processes, the integration mechanisms, and the overall system landscape associated with the existing Maestro system, all within the scope of the APS project.
Additionally, the document aims to identify and highlight the critical changes required to ensure that the APS system aligns seamlessly with the ERP Rebuild project’s goals and objectives. It outlines the necessary adjustments and modifications needed in the existing system to accommodate these changes. Furthermore, this document provides a detailed vision for the future state of the integration and system landscape, showcasing how the APS and ERP systems will function cohesively after the rebuild is complete. A proposed approach for data cleansing and cutover, aligned with the ERP rebuild design, is also included to ensure smooth data transition and system upgrades.
As-Is
Scope
APS project has the following categories
- Demand Planning
- Supply and Inventory Planning
- Production Planning and Scheduling
- S&OP / IBP
APS project is planned in Drops with each drop delivering enhanced functionality of the above categories. A high level view of the scope of the APS project is below:
Category | Key Elements | Details |
Demand Planning | Demand Planner Process, Ownership, Cadence, Calendar | Standard procedures, defined responsibilities, and schedules for demand planning activities. |
Demand Plan Targets | Establish targets based on historical data, market trends, and business goals. | |
Statistical Forecasts | Use statistical models to generate baseline forecasts from historical data. | |
Consensus Forecasts | Incorporate input from sales, marketing, and operations to refine forecasts. | |
Reporting and Visualization | Use dashboards and reports to track forecast accuracy, trends, and overall performance. | |
Supply & Inventory Planning | Planner Process, Parameters, and Ownership | Establish roles, responsibilities, and parameters for supply and inventory planning. |
Cadence and Calendar | Define schedules for inventory reviews, planning updates, and collaboration. | |
Ability to Define Key Constraints | Identify production, supply chain, or resource limitations. | |
Constraining the Plan | Adjust plans to align with identified constraints. | |
Pegging and Firming the Supply Plan | Match supply to specific demand and finalize orders for stability. | |
View and Act on Supply Exceptions | Identify and address supply-related issues, such as shortages or surpluses. | |
Ending Inventories | Optimize closing inventory levels to minimize costs and risks. | |
Inventory Exceptions | Identify anomalies in inventory data and take corrective action. | |
Periods of Coverage | Ensure adequate inventory levels to cover demand for a specific period. | |
Publishing the Supply Data to ERP | Share finalized supply plans with ERP systems for seamless execution. | |
Reporting and Visualization | Track and analyze inventory and supply performance using dashboards and reports. | |
Production Planning & Scheduling | BOM Substitutions and Alternatives | Manage flexibility in the bill of materials (BOM) to accommodate material shortages or alternatives. |
Master Production Plan | Create a high-level production plan based on demand forecasts and constraints. | |
Enterprise Scheduling | Detailed planning and scheduling of production activities across facilities. | |
S&OP/IBP | Demand and Supply Balancing | Align demand forecasts with supply capabilities while addressing constraints and trade-offs. |
S&OP Dashboard | Centralized platform for tracking KPIs, aligning stakeholders, and facilitating decision-making. |
Below is the split of the functionalities across multiple drops.
Interfaces
Multiple interfaces are required to connect the Maestro system with SAP ECC (ERP Central Component).
These interfaces will facilitate seamless data exchange and integration between ECC and Maestro, supporting critical business processes such as planning, inventory management, order fulfillment, and reporting. They can be categorized into the following:
| Category | Description |
|---|---|
| Enterprise Structure Data | This includes organizational data such as company codes, plants, storage locations, sales organizations, and distribution channels. Ensuring alignment between SAP ECC and Maestro allows for accurate representation of the organizational hierarchy and dependencies. |
| Config Data | Configuration data includes system settings, rule definitions, and organizational configurations like MRP settings, delivery priorities, and planning parameters. This ensures that ECC and Maestro operate with aligned business rules and logic. |
| Master Data | Master data encompasses key foundational data such as material master, customer master, BOM's, Routings etc... It ensures consistent and accurate information flows between SAP ECC and the Maestro system for efficient operations. |
| Transactional Data (Demand / Supply) | This category includes real-time transaction data such as sales orders, purchase orders, demand signals, supply plans, and stock movements. It supports demand & Supply planning, inventory management processes. |
| Planning Results | These are outputs from planning activities, including demand forecasts, production schedules, procurement plans, and ATP (Available-to-Promise) data. Planning results support Maestro's decision-making and strategic planning functions while aligning with ECC data. |
Below is an overview of the interfaces.
Note: ECC is represented as one line and it comprised both the ECC's
Data Sources
System Architecture
To-Be
Scope (Changes) - Meeting online
Interfaces - Based on Scope
Data Sources
System Architecture - Picture (Bhargavi) - Sascha
Integration with key functionalities (PAL/ATP) - Meeting Online
Cutover Approach - Meeting Online
Governance / Resources - Meeting Online with Gab
Governance Model
Responsibilities
Business
Kinaxis
ERP Rebuild