Baan Dimension featuresbaansupport.com/docs/baansupport.com_case3.pdfDemand #10 - Width 400 mm...

Dimensions

Philosophy

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Baan Dimension Solutions

DimensionsIndex

n Why an attribute-driven ERP system?

n The basics: product definition & characteristics

n Tracking & Tracing

n Sales

n Production typologies. – Example: Flat Steel Making– Transformation– Multi-level Transformation– Production Typologies. Manufacturing


DimensionsIndex (2)

n Planning

n Valuation Control

n End-to-End Solution


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Why an attribute-driven ERP system?


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Basic Problem

SKU EnvironmentSKU Environment

ItemItem : BULB: BULBOn HandOn Hand : 3 pieces: 3 pieces

InventoryInventory

Dimensional EnvironmentDimensional Environment

ItemItem : Metal: MetalOn HandOn Hand : 100 ton: 100 ton

InventoryInventory

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600 X 500

800 X 600

1000 X 800

SKU Environment:SKU Environment:Identify each sheet size with an item code

Item: HR1010-600x500Item: HR1010-800x600Item: HR1010-1000x800

Dimensional Environment:Dimensional Environment:One item code; Size control by IDno

Item : HR 1010IDno 1012 : L= 600; W= 500IDno 1013 : L= 800; W= 600IDno 1014 : L= 1000; W= 800

Solutions


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600 X 50

800 X 60

1000 X 80

SKU Environment:SKU Environment:Identify each bar size with an item code

Item: MP1010-600x50Item: MP1010-800x60Item: MP1010-1000x80

Dimensional Environment:Dimensional Environment:One item code; Size control by IDno

Item : MP 1010 (Cr40Mo12)IDno 1012 : L= 600; W= 50IDno 1013 : L= 800; W= 60IDno 1014 : L= 1000; W= 80

Solutions


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• Explosion of item codes

• Most items codes are created on a one time customer request

• Only a few items do really bear stock

• Poor inventory overview

• High risk for duplicate item codes

• High risk that production or purchase orders are created while alternatives are available

• MRP will give improper advises (focused on item code)

• Conflict between inventory and financial unit

• Issuing a new item code for each new appearance is cumbersome and time consuming

Consequences of SKU Driven ERP


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The basics: product definition & characteristics


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GradeWidthLengthThicknessEtc.

Grade : 1010 1020Width : 1000 1000Length : 1000 2000Thickness : 1 1

Product Identification

Item1:x

1:z

Standard ProductStandard Product

1:y

Characteristics

CharacteristicSets


Dimensions


Item

IDno #53 1020 1800 1.2 19.000

IDno #31 1020 400 1.2 8.000

IDno #27 1010 2000 1.0 22.000

IDno #12 1010 1000 1.0 14.000

Grade Width Thickness Weight


Dimensions

ItemItem

Product Identification: Data Structure

60’20’1/32’PolishedA.........

SpecsSpecs

Length

WidthThickn.SurfaceQuality……...

HR 1010

IDno 3030


Dimensions


SpecsSpecs

Length


HR 1010 ItemItem

Dimensions:Specs that enableon-line Sorting andQuerying of theInventory Screen


Dimensions


SpecsSpecs

Length


HR 1010ItemItem

60’20’1/32’PolishedA.........

Dimset:

Pre-defines Values of Specs

•Template for Order Entry

•Label for Inventory Displays

60’20’1/32’

SS 1/32[Smalll Sheet, gauge= 1/32]


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Product Identification:Product Hierarchy

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Inventory View Options:n Indexes by item

n Multi level aggregation

n Conversion to any unit

n Direct query management

n Possibility to link images

n Direct link to planned transactions

n Direct link to historical transactions


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Product IdentificationExample: Inventory PresentationExample: Inventory Presentation


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Characteristics

By characteristic the user can specify:n Category (information, design, measure)

n Type (alphanumeric, integer, double, number of decimals, date, etc.)

n Business functions active (purchase, sales, production, etc.)

n Tolerances (absolute, relative, exact, etc.)

n Transformable yes/no

n Multiple lingual descriptions and predefined choices


Dimensions

Data by IDno Object

ItemWarehouse / LocationCharacteristics (SPECs)Purchase / Production OrderSupplierPurchase / Production PriceReceipt DateSupplier IDno and Main IDnoCost ComponentsImageTextPlanned TransactionsHistorical Transactions

IDno

IDno : 555Item : A402Warehouse : MMPLocation : L1-H23-2Char: Grade : AChar: Thickness : 1.0 mmChar: Width : 1.000 mmChar: Inn Diam. : 300 mmWeight : 19.500 kgPurchase Order : 260023Supplier : Mill LTDReceipt Date : 12-09-2006Purchase Price : 39.000 EUR

IDno


Dimensions

DiscreteDiscrete•• 1 IDno = x (approx.) identical pieces1 IDno = x (approx.) identical pieces

Non DiscreteNon Discrete•• 1 IDno = 1 unique piece1 IDno = 1 unique piece

IDno

IDno

IDno

IDno

Identification Methods


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Tracking & Tracing


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Planned Planned TransactionsTransactions

HistoricalHistoricalTransactionsTransactions

Tracking and Tracing


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Transaction InformationTransaction Information• Item code• Warehouse• Planned Characteristics• On Order / Alloc. Info• Order number • Supplier / Customer • Purch. / Prod. / Sales Price• Receipt / Delivery Date• Descriptions • Remarks• Text

Tracking

Planned Planned TransactionsTransactions


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Tracing

Transaction Information• Item code• Warehouse / Location• Actual Characteristics• Quantity Received/Delivered• Order number • Supplier / Customer • Purch. / Prod. / Sales Price• Receipt / Delivery Date• Descriptions • Remarks• Text

HistoricalHistoricalTransactionsTransactions


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Tracing

Graphic traceabilitywith link to session:sales order;production order;transformation order;purchase order;Idno data.


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Sales


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Order Entry

What is important:What is important:n Order entry based on characteristics

n Inventory, planned receipts and demands visible and sorted by characteristics

n Possibility to:– Sell from inventory (on hand and planned receipts)– Slot demand automatically in production Block– Purchase / Produce on demand

n Possibility to merge demands to– Inventory available – Planned receipts

n Sales and purchase prices based on characteristics


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Order Entry


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Price Control

Base Price• From/To date• To Quantity• Quantity Unit

• From/To Date• To Quantity• Quantity Unit• Derived Spec• Amount, Percentage, Formula

Discounts by:• Base Price• Characteristics

• From/To Date• Base Price and/or Spec• Quantity Unit• Derived Spec• Amount, Percentage, Formula

Item

Surcharges by:• Base Price• Characteristics


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Production typologiesExample: Flat Steel Making


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n Manufacturing (SFC)– Final product is made up of other products – BOM / Formula driven

n Transformation (TRO)– Transformation of characteristics– Relationship between input / output material is often

order-specific

Production Typologies


Dimensions

Raw

Iron

Process

OperationsOperations

MaterialsMaterials

Process


MaterialsMaterials

Process


MaterialsMaterialsSteel Slabs Hot Rolled

Coils

Production TypologiesIron Making, Steel Making, Slab Casting, Hot Rolling

Process


Manufacturing

Transformation


Dimensions

RawMaterials

Process


RawIron

Production TypologiesIron Making


Dimensions

Production TypologiesIron Making

Iron OreIron Ore


PROCESS IDno

IDno

IDno Cast #1

Cast #2

Cast #3

LimestoneLimestone

CoalCoal


Dimensions

Process


MaterialsMaterials

Process


MaterialsMaterials

Process


MaterialsMaterialsRaw

Iron

Steel Slabs Hot Rolled

Coils

Production TypologiesSteel Making, Iron Casting, Hot Rolling


Dimensions


MaterialsMaterials

PROCESS IDnoIDno

Production TypologiesSteel Making, Iron Casting, Hot Rolling


Dimensions


MaterialsMaterials

Process

Hot Rolled

Coil

Cold Rolled

Coil

Production TypologiesCold Rolling


Dimensions

Production TypologiesCold Rolling


MaterialsMaterials

PROCESS IDnoIDno


Dimensions


MaterialsMaterials

Process

Master CoilSlit Coil

Slit Coil


MaterialsMaterials

Process

SheetSlit Coil

Production TypologiesSlitting & Cutting


Dimensions


MaterialsMaterials

PROCESS IDno

IDno

IDno

IDno

Sales Demand

Sales Demand

Inventory

Production TypologiesSlitting & Cutting


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Production typologiesTransformation


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Transformation Slitting

1.050 mm600 mm

300 mm100 mm

Jumbo Roll

ScissorsBar

SlitRoll

ScrapSlit-Scissors


MaterialsMaterials

Process


Dimensions

Inventory Coil #1 Inventory Coil #2 Inventory Coil #3

Demand #10 - Width 400 mm Thickness 1 mm Total Length 2.800 m



1.020 m920 m1.050 m

1.05

0 m

m



MaterialsMaterials

Process


Dimensions


Inventory Coil #1



Dimensions

1000 mm

Knife

1200 mm 1200 mm 1200 mm

Converting / Packaging Sheet Cutting


MaterialsMaterials

Process


Dimensions


140 sheets210 sheets250 sheets

210 m252 m300 m

Demand: 600 Sheets of 1000 x 1200 x 1 mm

1.00

0 m

m

Transformation Cut to Length


MaterialsMaterials

Process


Dimensions

Production typologiesMulti-level Transformation


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Master Coils

Slit Coil

Sheets

Slit Plan

Sales Order 1 Sales Order 3

MP

S o

rM

PS

or

Blo

ckB

lock

--S

ched

ulin

gS

ched

ulin

g

Dem

and

driv

enD

eman

d dr

iven

mul

ti le

vel T

RO

mul

ti le

vel T

RO

SLS

SLSSales Order 2

Opt

imiz

edO

ptim

ized

TRO

TRO

Logistical Process Example


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Master Coil Slit Coil Sheet

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Production TypologiesMulti Level Transformation


Dimensions

No InventoryInventory


Demand

Sales Order EntrySales Order Entry


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Inventory


Main TRO


MaterialsMaterials

Process


MaterialsMaterials

Process

DemandDemand

Production Orders GenerationProduction Orders Generation


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Inventory



MaterialsMaterials

Process


MaterialsMaterials

Process

Demand

Production Order ExecutionProduction Order ExecutionMain TRO


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Transformation (TRO)Traceability


MaterialsMaterials

Process


MaterialsMaterials

Process


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Production typologiesManufacturing


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• The Length and Width are inherited via a formula • The Grade, Finish and Thickness are directly inherited

SalesGrade, Finish, ThicknessLength, Width, HeightQuantity

Production order

Grade, FinishLength, Width, ThicknessCutting, Bending, Welding

BOX

SHEET

ManufacturingExample Inheritance (1)


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DemandProduct : A401Width : 1000 mmLength : 5000 mColor : Red

Product : A401Width : 1000 mmLength : 5000 m

20 KG


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DemandProduct : A401Width : 1000 mmLength : 5000 mColor : Red

Product : A401Width : 1000 mmLength : 5000 m

20 KG

5300 m

21.2 kg

5300 m


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ManufacturingSupport to Engineering


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ManufacturingSupport to Material Planning


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Planning


DimensionsProduction planning board


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Valuation Control


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Purchase price

Purchase price differenceAfter receipt goods

Purchase price differenceAfter receipt invoice

Valuation Control Purchase

IDno


Dimensions

Valuation Control Production


MaterialsMaterials

PROCESS

Base Material Value(Actual)

ActualActualProduct Product ValueValue

Operations Value

(Estimated or Actual)

Added MaterialsValue

(Fixed or Actual)

Added Value


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n Value inheritance from in going IDnos to outgoing IDnos

n Value distribution for added Materials and Operations costs on primary unit

Valuation Control Value Distribution - Example


MaterialsMaterials

PROCESS

Sales Demand

Sales Demand

Inventory

Sales Demand

Inventory


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To Scrap IDno(fixed value)

Total Value to output IDno’s

Total Valuedirect into Finance

Value difference to output IDno’s

Value difference direct into Finance

Direct Process(as stock transaction)

Scrap

Valuation Control Production Scrap Processing


Dimensions

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