Professional Documents
Culture Documents
Who is Entegris?
Core competency: Materials Integrity Management Core markets: Semiconductor, Data Storage, Life Sciences, Fuel Cell Core products: Silicon wafer carriers, wafer shippers, disk shippers, fluid handling Fiscal year 2003 revenue approx. $245M
Manufacturing Locations
DCs
Customers
SAP landscape
Went live on SAP R/3 4.0B in August 1998 (MM,PP,FI,CO,SD,HR) Upgraded to 4.6C in August 2001 R/3 currently implemented at all major facilities outside of Japan Licensed mySAP suite in 2002 Outsourced hardware maintenance for SAP systems in spring 2003.
Importance of Planning
Semiconductor has traditionally been Entegris largest market. Semiconductor market has historically been subject to rapid and significant changes in demand. Failure to anticipate upturns leads to high level of expedites, long lead times, and loss of market share Failure to anticipate downturns leads to excess inventory and capacity
No experience with R/3 Sales & Operations Planning functionality or budget for investigating it No business push for consistent practices and tools
Project goals
Define one global forecasting/demand planning process based on industry best practices to apply for all Entegris facilities/product lines. Implement tools within the SAP environment to enable the realization of the global demand planning process. Match inventory to customer demand Reduce lead times by reducing schedule disruption
Bristlecone Services
Consulting Services
SC Opportunity Assessment SC Network Strategy SC Process benchmarking SCOR framework SC Business Process Improvement SAP APO Implementation Meta-app development SCM-PLM SCM-CRM
Packaged Solutions
plannerDATM SAP APO Value Accelerators Model Validator Planning Results Analyzer
Managed Services
APO Help Desk Planning Expert On Call
Highest number of successful APO implementations Supply Chain domain expertise that spans several industry verticals
Drivers:
Demand Plan Accuracy Improved Supply Planning Capabilities
Where,When, How Much to produce
Deliverables:
Value matrix
Data Analysis
Capacity planning was done once a year Three manufacturing strategies were prevalent, though not formally used:
50% Made-to-Stock 35% Made-to-Order 15% Assemble-to-Order
Total 2001 Inventory 2002 24.3 2.13 11.34 0.13 3.8 3.35
60 nished Goods P 40 M 20 -
Entegris
# Calculated based on assuming customer service requirements, an improvement in forecast accuracy and reduction in supply variability all for made to stock products
Root Cause
1. 2. Inaccurate forecast Lack of Formal Demand Planning & Supply Planning Processes Lack of Planning System
APO Enabler
Demand Planning Supply Planning
3.
Root Cause
1. 2. Inaccurate forecast Lack of Formal Demand Planning & Supply Planning Processes Lack of Planning System
APO Enabler
Demand Planning Supply Planning
3.
Future Potential (based on further improvement in forecast accuracy, reduction in manufacturing batch sizes and reduction in planning cycle times)
Joan Ellison Project Leader and Sr. Business Analyst, IT Entegris, Inc
Forecast Process
Blueprinting determined we needed to develop two forecasting processes in APO.
Monthly Forecast - by Product Managers
System generated forecast that is adjusted by the Product Manager. The Adjusted PM Forecast is reviewed in a Monthly Consensus Meeting and finalized. The Consensus Forecast is then moved to R/3 as Independent Requirements.
Forecast Process
Blueprinting determined we needed to develop two forecasting processes in APO.
Weekly Forecast by Logistics Managers
Customer forecast is what drives this process. The Logistics Manager gets forecasts from a select group of customers who we have established contracts with. This Customer Forecast can be adjusted by the Logistics Manager. The Adjusted Logistics Forecast is moved to R/3.
Forecast Process
Blueprinting determined we needed a way to identify the products that were to be forecasted in APO Developed the Forecast Tier / Manufacturing Strategy relationship based on revenue. Tier 1 = 80% revenue + Tier 2 = 95% revenue + Tier 3 = 100%
Assemble-to-order Build-to-Ord
1 9
BW BW Production Production
11
APO APO Development Development
6 2
APO APO QA QA APO APO Production Production
10
R/3 R/3 Development Development
8
R/3 R/3 QA QA
5
R/3 R/3 Production Production
Key Figures
Sales order history quantity Invoiced sales Previous consensus forecast Actual sales order bookings Batch statistical forecast Product Manager adjustments Adjusted Product Manager forecast Sales forecast Adjusted Logistics forecast Consensus forecast
Key Figures
Sales order history quantity Previous Logistics forecast Actual sales order bookings Adjusted Product Manager forecast Batch statistical forecast Customer Forecast Logistics adjustments Adjusted Logistics forecast
BW
APOODSSF Invoiced History Sales Org 1000
APO
Historical Revenue & Units (BUoM)
Units Conversion
Hist Revenue Hist inv. Sales (BUoM) (ZV_EA)
Converted Units
Hist Revenue Hist inv. Sales (BUoM) Hist inv. Sales (EA) (APOASPFV)
Converted Units
Hist Revenue Hist inv. Sales (BUoM) Hist inv. Sales (EA) (ZFV_BW_EA)
Reports
ASP (EA)
(MATNRASP5)
Forecast Versions
Sales History Version Units (APOFVER)
Version Units
Sales Changes
Profit Center changes (ZFV_PC)
BW
APO
Historical Revenue
A
BW Revenue
Revenue BW Revenue History (ZQ_SALES)
BW Structures
Sales History Consensus Revenue Final Revenue
APO Revenue
Revenue APO (ZQ_APO_SA)
APO Units
Consensus Units
Consensus Units + + (ZQ_BW_F)
A
APO Info Cube
Sales history (ZQ_IC)
Frontend Data
Sales Unit Forecast (ZQ_FRONT)
Future direction
Stabilize APO-BW data transfer Continue to work towards targeted inventory and lead time reductions Investigate/prepare for APO Supply Network Planning
Thank You For Attending! Please remember to complete and return your evaluation form following this session. Mike_beller@entegris.com Joan_ellison@entegris.com Chandra.mohan@bcone.com
Session Code: 710