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.

SyWay Project > APS and ERP Rebuild Project Alignment approach > image-2024-12-4_12-18-16-1.png

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

SyWay Project > APS and ERP Rebuild Project Alignment approach > image-2024-12-9_22-47-26-1.png

Below is the detailed list of the interfaces

Kinaxsis Interface	SAP Object Reference	Classification	Group	Description/Reason
Sites	Plants	Enterprise Structure	Core	List of Site/Plant Codes and descriptions (Manual Load Only)
Material Types	Material Types	Config	Core	List of Material Types and descriptions
MRPType	MRPType	Config	Core	List of MRP Types and descriptions
MRPGroup	MRPGroup	Config	Core	List of MRP Groups and descriptions
ProcessOrderTypes	ProcessOrderTypes	Config	Core	List of Process/Work Order Types and descriptions
StorageLocations	StorageLocations	Enterprise Structure	Core	List of Storage Locations and descriptions
MRPAreas	MRPAreas	Config	Core	List of MRP Areas and descriptions
LotSize	LotSize	Config	Core	List of LotSizes and descriptions
SpecialProcKey	SpecialProcKey	Config	Core	List of SpecialProcurementKeys and descriptions
Calendars	Calendars	Config	Core	List of Calendars and dates
SalesOrdertypes	SalesOrdertypes	Config	Core	List of Sales Order Types and descriptions
Purchaseordertype	Purchaseordertype	Config	Core	List of Purchase Order Types and descriptions
UnitOfMeasure	UnitOfMeasure	Config	Core	All the Units of Measure are used in the data
Calendars	Calendars	Config	Core	Includes all Plant, Shipping and Receiving Calender Dates
Parts	Material Plant	Master Data	Master Data	All parts/materials that represent that master index of planning materials
PartConversion	Material Plant / Material / Plant	N/A	Master Data	All parts and any associated part number differences.
PartUOMconversion	Material Plant Alternative UOM	Master Data	Master Data	All Alternate Units of Measure used for the parts/materials for reporting or functionality.
BOM	BOM	Master Data	Master Data	A list of all components, alternatives and substitutions used in the production of an assembly
Forecast			Demand	The current Sales Forecast from published Forecast (Gross Only)
Consensus			Demand	The current Sales Forecast currently active from ERP (Gross and Net)
SalesOrders	SalesOrders	Transactional Data	Demand	All Internal or External Sales Orders that have a remaining open quantity
Delivery	Delivery	Transactional Data	Demand	All Internal or External Sales Orders that on delivery and do not have a post goods issue transaction
Batch	Batch	Transactional Data	Supply	All Batch records with a remaining inventory balance
Onhand	Onhand	Transactional Data	Supply	All Onhand records; blocked, restricted, unrestricted, quality, consigned or material provided to vendor
WorkOrder	WorkOrder	Transactional Data	Supply	All work orders; production or process with a remaining quantity
PurchaseOrder	PurchaseOrder	Transactional Data	Supply	All purchases orders; stock transport, external, consignment or subcontract with a remaining quantity
PurchaseRequitions	PurchaseRequitions	Transactional Data	Supply	All purchases requisitions that have a remaining quantity
FirmPlannedOrders	FirmPlannedOrders	Transactional Data	Supply	All FIRM Planned orders that must respected by Maestro (inside PTF or FIRM Planned)
Tollingallocation		Transactional Data	Supply	All work order; production or process order allocations that have a remaining requirement qty.
WorkOrderAllocation		Transactional Data	Supply	All tolling/subcontract allocations that need to be provided vendor
HistoricalSupplyPurchase	Purchase Order	Transactional Data	Supply	All historical purchase orders receipts. Used for leadtime variability.
CurrencyConversionActual	CurrencyConversionActual.tab	Transactional Data	Core	All currencies used in the data and their respective exchange rates to the USD currency
Customer	Customer	Master Data	Demand	A list of all External and Internal Customers that have open have open Sales Demand or Sales History
DependentAllocation	STO	Transactional Data	Demand	All Internal demand (stock transport) requirements that have a remaining quantity, and originate from a site not in Maestro.
CustomerPrice	Price	Transactional Data	Demand	A list or Sales price for a part/material and Customer specific price.
ConstriantAvailable			Supply	All Constraints used by partsourcing to generate load and their respective available load.
ConstriantPart			Supply	All constraints applied to partsourcing which their constraint, fixed and variable load rates
CurrencyConversionForecast	CurrencyConversion(Forward looking rate)	Transactional Data	Core	All Future currencies used in the data and their respective exchange rates to the system BASE currency
HistoricalCurrencyConversion	CurrencyConversion	Transactional Data	Core	All Historical currencies used in the data and their respective exchange rates to the system BASE currency
SalesOrganization	SalesOrganization	Enterprise Structure	Demand	A list of the Sales Organisations used (if applicable)
HistotricalDemandActuals	Sales Orders	Transactional Data	Demand	A minimum of 2 years of External Sales shipments
HistoricalForecast	Sales Orders	Transactional Data	Demand	A period [typically 12 months] of forecast history, forecast accuracy measurements
HistoricalSupplyMfg	production orders	Transactional Data	Supply	All historical work orders. Used for lead time variability.
MD04		Transactional Data	Validation	This information is intended to be used for validating input data from SAP, and is not intended to be used for planning or decision making in Maestro
	Oppurtunities	Transactional Data	Demand
	End Use (Market)	Transactional Data	Demand
	Routings	Master Data	Supply
	WorkCenters	Master Data	Supply
	Production versions	Master Data	Supply
	PIR (Purchase info record)	Transactional Data	Supply
	Product hierarchy	Master Data	Demand
	Customer Hierarchy	Master Data	Demand
	Planned orders to S/4	Transactional Data	Supply

System Architecture

High-Level Architecture: Integration of Kinaxis with Existing SAP ECC Systems

The integration of the Kinaxis system with the existing SAP ECC systems will involve two distinct Kinaxis instances to support different business needs and geographical requirements:

Kinaxis US:
- This instance will primarily serve the composites GBU (Global Business Unit).
- It will facilitate compliance with export control regulations, specifically ITAR (International Traffic in Arms Regulations), ensuring all ITAR-related processes are managed effectively.
- Hosting Location: This instance will be hosted in the United States to meet ITAR compliance requirements and regional data governance standards.
Kinaxis ROW (Rest of the World):
- This instance will support the other GBUs, including Aroma, Novecare, TS, O&G (Oil & Gas), and Specialty Polymers.
- The ROW instance will manage planning, supply chain, and operational data for these GBUs while aligning with the broader strategic goals.
- Hosting Location: This instance will be hosted in Europe, ensuring efficient regional operations and compliance with European data protection standards.

Both instances will integrate with the existing ECC systems to enable real-time planning, supply chain visibility, and data sharing across multiple GBUs while adhering to regional compliance and operational requirements.

SyWay Project > APS and ERP Rebuild Project Alignment approach > image-2024-12-9_22-53-49-1.png

To-Be

Changes in Scope

A comprehensive analysis has been conducted on the functionalities and data structures based on the scope of the APS project and the conceptual design from the ERP Rebuild initiative. The analysis has identified a range of changes that will be necessary to align with the project goals and future-state processes

Functionality

The following topics are identified as potentially requiring changes during the ERP Rebuild project. Note that the below table represents only the functionalities that require a change. Total list of all the functionalities can be found in the attachments.

Area	Key Topics	Current Design	Changes Required (ERP Rebuild)	Change Description	Change complexity
Demand Planning	Demand forecast unit definition	Packed Material + Ship-to / Sales area Lowest level where we collect the data (Sales order) and where we can enter forecast.	Yes	Packed Material(SKU) + Sold to + Ship To + Sales Area	High
Demand Planning	Hierarchy definition	Several hierarchies required to facilitate the data entry (forecast entry at aggregated level with automatic disaggregation at lowest level) and analysis.	Yes	Changes are in the data section. Depending on the hierarchy the corresponding functionality also has to change (Aggregation and disaggregation logic definitions might change)	High
Demand Planning	Estimated Time of Arrival (ETA) vs Departure (ETD)	Forecast are entered at ETA level and needs to be converted to ETD for the supply part but also for the revenue projection. AI team support requested to get the most accurate supply offset and financial offset	Yes	The logic to calcuation ETD from ETA or vice versa will change and the data will be have to be consumed from S/4 instead	Medium
Demand Planning	Disaggregation		Yes	Based on the changes in the data modes / hierarchies	High
Demand Planning	Achievable demand	Once the demand consensus published, we can then get back from the SP part, the achievable demand. (= when Consensus demand can not be reached) This information is shown in the DP, the demand team needs to review with the sales team and make adjustments if possible	Yes	Extra contstrains from S/4 will have to be taken into account ex: Maintenance plans	Medium
Demand Planning	Allocation	In progress: When there is no option to meet the demand, the allocation process is triggered = Volume allocated to customer - Control of the allocated volume at sales order entry in SAP for SPP.	Yes	PAL Integration	High
Supply Planning	Netting / Forecast consumption	Reconciliation between order book and forecasts. Including Demand time fence (when do we consider that a non ordered forecast should be ignored ?) and spreading (from a monthly forecast to weekly/daily net demand).	Yes	Order types / Item categories / other critieria to exclude Sales Orders	Medium
Supply Planning	Distribution network	Escalation of the demand to the distribution sites and upstream to the production plants Including cross-systems transfers (WP1 <-> PF1) flows.	Yes	Intercompany / China flow will have to be adopted	High
Supply Planning	Buffer sizing and positioning	Proactive dimensioning of inventories. Setting up differentiated targets. Simulation of Safety stock adjustments (impact on inventory projection and service level). Inventory projection. (in qty and in value) Inventory analysis (IQR)	Yes	Demand driven buffer sizing will be required	Medium
Supply Planning	Firming the plan	Monitoring the execution of / derives from the plan : Live view on gap between Operational plan and S&OP. Operational planning decisions (what sourcing decision to launch ?).	Yes	Purchase requisitions instead of planned orders	High
Inventory Planning	Including Tolling & Consignment		Yes	Vendor consignment planning to be included	Medium

Data

The following topics are identified as potentially requiring changes during the ERP Rebuild project. Note that the below table represents only the functionalities that require a change. Total list of all the data elements can be found in the attachments.

Data Object Type	Data Object	Current Design	Source	Direction	Changes Required (ERP Rebuild)	Impact	Change Description	Change complexity
Master data	Customers	Sold to , Ship To	SAP	To Maestro	Yes	Additional Combinations	All Business Partners	Medium
Transactional Data	Sales Orders		SAP	To Maestro	Yes	Additional attributes	Extra attributes ( Incoterm / Transportation mode etc..)	Medium
Transactional Data	Pricing Conditions		SAP	To Maestro	Yes	Additional Combinations	Access sequences might change / Future prices source might change	Medium
Master data	End Use (Market)		SAP	To Maestro	Yes	Different source / definition	To be consolidated with the customer / CMIR	Medium
	GBU		SAP	To Maestro	TBD
Master data	Parts <> Material x plant	Units, Calendars, Leadtimes (MRP views), Archetype (SHS), Purch group / MRP controllers (resp.)	SAP	To Maestro	Yes	Different source / definition	Material fields are going to change - MDS will determine the impact	High
Master data	Workcenters	selected by type for time being focussing on Machines/process lines	SAP	To Maestro	Yes	Additional attributes	Shifts / Times / usage % will have to consumed from work centers	High
Master data	Routings		SAP	To Maestro	New			High
Master data	PIR (Purchase info record)		SAP	To Maestro	Yes	Additional Combinations	Vendor consignment PIR to be included	Low
Master data	Special procurement Key		Derived	To Maestro	Yes	Different source / definition	Should come from S/4	Medium
Transactional Data	PR		SAP	To Maestro	Yes	Additional Combinations	Document types / additional fields / Status	Low
Transactional Data	PO		SAP	To Maestro	Yes	Additional Combinations	Document types / additional fields / Status	Low
Transactional Data	Deliveries (Sales Order)		SAP	To Maestro	Yes	Additional Combinations	Document types / additional fields / Status	Low
Transactional Data	Planned / process / production orders		SAP	To Maestro	Yes	Additional Combinations	Document types / additional fields / Status	Low
N/A	Source lists		Maestro	To Maestro	To be deleted		To be replaced with the functionality from Quota
Master data	Quotas		Maestro	To Maestro	Yes	Additional Combinations	Should come from S/4	Medium
N/A	Transfers between SAP systems		Maestro	To Maestro	Yes	Different source / definition	Information will come from S/4 - To use combination of SPK and Quota	Medium
Transactional Data	Costing (excluding internal margins)		External File	To Maestro	Yes	Different source / definition	Should come from S/4	High
Master data	Resource hierarchies		External data / derivation based on rules	To Maestro	TBD
Transactional Data	Purchasing lead time		External data / derivation based on rules	To Maestro	Yes	Different source / definition	Should come from S/4	Low
Master data	Calendars (Factory)		External data / derivation based on rules	To Maestro	Yes	Additional Combinations	Should come from S/4	Low
Master data	Geographic regions		External data / derivation based on rules	To Maestro	Yes	Different source / definition	Should come from S/4	Low
Transactional Data	Inspection Lot			To Maestro	New			Medium
Master data	Product hierarchy			To Maestro	New		Should come from S/4	Medium
Master data	Customer Hierarchy			To Maestro	Yes	Different source / definition	Should come from S/4	Medium
Master data	Profit Center hierarchy			To Maestro	New		Should come from S/4	Medium
Transactional Data	Customer material info record			To Maestro	New		Should come from S/4	Medium
Master data	Customer lead time fence			To Maestro	New		Lead time can be managed in Maestro and sent nack to SAP or vice versa.Master slave relationship TBD based on the design	Medium
Master data	Safety Stock			To SAP	New			Low
Master data	Safety period			To SAP	New			Low
Master data	Lead Times			To SAP	New			Low
Transactional Data	Planned orders		Kinaxis	To SAP	Yes	Additional Combinations	Document types / additional fields / Status	Low
Transactional Data	Purchase Requisitions		Kinaxis	To SAP	New			High
Transactional Data	Planned Idependent Requirements			To SAP	New			High

Interfaces

System Architecture

Time Phased System Diagram - Prep Bhargavi - Meeting Online

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