Oracle%20APS%20and%20GOP%20

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Oracle APS and GOP Getting To Automated Sales
Order Scheduling

• Mark Hopkins, Xilinx, Inc.
• 8/23/06

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Topics

• Goals of Our GOP Implementation
• Where We Are Today
• How We Did It
• Lessons Learned

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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

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Results Auto Release And On Time Delivery
13k Line Items per month.
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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

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Whats In ProductionASCP 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

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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
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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

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Standard Oracle GOP Process
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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?)

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Demand Management Form
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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.

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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