DSM Integration Architecture V2.4

8/13/2019 DSM Integration Architecture V2.4

1/131

Project Sunrise / BR 1

2009 i2 Technologies, PROPRIETARY and CONFIDENTIAL Page 1 of 131

Sony Corp.

PROJECT SUNRISE

BUSINESS RELEASE 1

DSMINTEGRATION DESIGN

SPECIFICATION

REVISION 2.4/01-MAR-2010


2/131

Project Sunrise / BR 1


TABLE OF CONTENTS

0. INTRODUCTION............................................................................................... 30.1. PURPOSE: ............................................................................................. 30.2. CONTEXT ................................................................................................ 30.3. SCOPE.................................................................................................... 30.4. WHAT THIS DOCUMENT ADDRESSES............................................................ 30.5. WHAT THIS DOCUMENT DOES NOT ADDRESS................................................. 3

1. OVERVIEW ....................................................................................................... 42. E2E WORK FLOWS........................................................................................... 4

2.1. DATA FROM EXTERNAL SYSTEMS............................................................. 92.1.1. Top Level................................................................................................................. 92.1.2. Modeling of Items (ItemMaster, Item Group Master, Item Group Detail,ItemSiteMaster) .........................................................................................................18162.1.3. Modeling of Network (Site Master, Supplier Master, Customer Master, BODs).......28252.1.4. Modeling of Manufacturing Network (BOM, Routing / Operation, Item BOM

Routing) ...................................................................................................................43402.1.5. Modeling Capacities and Constraints (Resource Master, Resource

Calendar, Resource Calendars.................................................................................... 612.1.6 Modeling Demand (Sales Master, Sales Order Master, Sales Order Line,

Product Master) .......................................................................................................83812.1.7 Modeling Time Periods .........................................................................................85812.1.8 Modeling Business Rules (ItemSiteRepPolicy, Planning Parameters)Error! Bookmark not defin

2.1.9Modeling Stock (Inventory, Intransitshipments, Distribution Order Header,Distribution Order Lines, Production Orders) ........................................................8782

2.2MASTER DATA COMING THROUGH NON-KEY UI.........................................107882.3DATA COMING BY INTERFACING WITH OTHER I2SYSTEM............................10788

2.3.5 Demand Planning ...........................................................................................107882.3.6 Forecast Netting .............................................................................................10788

2.4OUTPUTS FROM DSM ...........................................................................120882.5EXCEPTION /ERROR HANDLING...............................................................12888

Data Loading Mode and Frequency .................................................................................128883 APPENDIX ...............................................................................................12989

3.1BLUE FILE DATA AND INTERFACE FREQUENCY............................................129893.2LIST OF ABBREVIATIONS........................................................................12989

4 REVISION HISTORY...............................................................................129895 MAJOR CHANGES SINCE LAST REVISION ............................................129906 REQUIRED APPROVALS .........................................................................13090


3/131

i2 Project Methodology Project Sunrise / BR 1


0.INTRODUCTION

0.1.PURPOSE:

Integration Design Specification defines the data mapping and data workflow issues thatwould arise in integration of the i2 Demand Planning solution with all other systems.

The task of Integration Design involves the following:

Data mapping

Timing, workflow control and performance issues

Data conversion, validation and error trapping/handling

The document covers integration between individual i2 modules, specification of data acrossthese modules and the details of extracting this data from external systems (e.g. extractingdata from a staging database to Demand Planning) and the necessary logic to transform datafrom source to destination format.

The document also includes the details of data workflows (e.g. an overall system diagramdetailing the individual modules and their interaction) and details of timing (e.g. frequency ofdata exchange and transformation) and performance (e.g. expected duration of each exchangeor transformation). The data conversion and mapping logic, procedures for validating data,trapping and handling errors are also dealt with in this document.

0.2.CONTEXT

As the integration workflows are designed to support the designed solution, this document goesin tandem with the solution design document.

0.3.SCOPE

The scope of this document is a complete overview of all integration related topics for SonyDemand Supply Management (DSM) solution as part of Sony Sunrise project. It thus gives anoverview of all involved systems, tools and technologies used and the relationships andinterdependencies of the modules involved.

0.4.WHAT THIS DOCUMENT ADDRESSES

This document is designed to capture the technical details of the various data flows andintegration touch-points for the applications and systems being implemented as a part of theDemand Supply Management (DSM) Planning implementation as part of Sony Sunrise project.

0.5.WHAT THIS DOCUMENT DOES NOT ADDRESS

This document does not address the following:

The integration architecture components and functions which are common across thetracks. These are defined in the overall integration architecture specification document


4/131



The features / functionality description and the addressed business challenges. These areaddressed as part of corresponding Solution Architecture / design documents.

1.OVERVIEW

This document provides an overview of different interfaces to DSM and will serve as referencesource as part of this. For each interface the following information is provided with appropriatecontext.

Data flow diagram: each interface is described using a data flow diagram to visualize thedependencies between the various components involved in the mappings.

Specification of Inbound data: This provides a summary of the logic/scripts for extracting datafrom Data hub and providing it in the correct format.

Specification of Outbound data: This provides a summary of the logic/scripts for moving datafrom DSM and providing it in the correct format.

Pre-processing and Post-processing& Data Mapping Logic: defines, if the data needs to beconverted on import or export from the module, what methods and technologies will beinvolved and specifies the before & after forms of the data. The logic how datahub data ordata from other systems is mapped to DSM is specified in the appropriate section of thisdocument.

Data Exchange Method or Protocol Used: Describe in detail what methods will be employed totransfer the data to and from the i2 solution. This may include technologies such as FTP, JDBC,flat-files, and methods such as database-to-database transfers etc.

Data Load, Timing & Other Considerationsdefine how frequently will the data need ismodified or refreshed within the system, what is the size of the data and what is the timetaken import & export data from the i2 solution.

Error Trapping/Handlingspecifies how will the errors in the data mapping process beidentified and eliminated. There are different areas, where a consistent error handling needsto be done.

2.E2E WORK FLOWS

The following section provides an overview how the data is transferred around the entiresolution. It also depicts how the data gets transformed using rules to populate the outputstaging / fixed schema needed for different planning engines. Currently the document focuseson the area which is marked in red. This gets updated in the successive phases.


5/131



Diagram1: End to end Architecture

A section of the above diagram is further expanded to highlight data movement from Sonysystems to Staging area


6/131



Sony

Source

Systems

Netchan

ge

Table

Outbound Tables

Inbound

Table

Excel Upload Non key UIs

Transaction Table

Blue Files

Master Data

Master data will be

provided as full load on

the Weekly basis and

Net-change on the

daily basis

BF

tables

Blue files needs to be

achieved before the

data is loaded from

Sony to the local

system

Data Hub

ABPP Weblogic

I2 file

system

DMZ

Master

Table

Blue Files: Blue Files represents the agreed data format protocol to get master / transactiondata from Sony systems. Each of these have a fixed layout that contain different columns, datatype, length along with which parts of the data represents primary / NOT NULL information.This data will be transferred from the Sony file system (DMZ) to the i2 file system using FTPprotocol over secure internet. For an entity, data in blue file layout can be fetched though

multiple physical interfaces. So, for a blue file layout, there can be one or more physicalinterfaces. Data coming through each interface is given with a distinct file name. SQL loader isused to load data from blue files into the staging tables.

Data Hub: On collecting data from multiple source systems, Data Hub acts as centralrepository needed for planning. Different activities like data cleansing, creation of additionaldata needed for planning is done here. Taking this as source, data is populated to DSM planningengine. Similarly, the output from planning engine is written to hub before being fed todifferent reports built. Effectively, all data transformations needed to prepare data in theappropriate format for the i2 engines have to be done in data hub. Data hub is powered by i2sAgile Business Process Platform (ABPP). It provides database layer to store the require data,User Interface to perform different operations and application server to facilitaterequest/response mechanism.

1. User Interface: - All non-key UIs are built leveraging this infrastructure. Using theunderlying security framework, role based access control is provided for different UIelements

2. Database :- To facilitate data movement through net-change / full load mechanism,and also to ensure the smooth data transfer, different database entities can logicallybe grouped as


7/131



Inbound tables: The Inbound tables are where data from external systems cominginto ABPP is staged.

Master tables: The Master tables contain the correct and validated data in ABPP.

Netchange tables: The Netchange tables hold the delta between the inbound dataand the Master data for the static data. Transactional data do not go under the Net

change process.

Error tables: Error tables contain the records that get rejected during the dataload due to bad or inconsistent data.

Outbound tables: The outbound tables are a database snapshot of the Mastertables. This is the placeholder from which data is extracted and sent todownstream applications such as I2 ODS and Demand Planning.

Transaction tables: Transaction tables do not have any net-change logic associatedand is typically used to store entities such as orders or forecasts.

3. Application Server: - All requests sent to facilitate different operations are served byweb services exposed through this application server. The requests can include theones coming through user interface operations or request/response operations to

engines.

4. Naming convention for blue files: - This section contains this naming convention usedfor blue files. This is to be filled

E2E Example: It is a standard process/workflow in the ABPP product in which data movementhappens from the staging IN tables to NC or Net Change tables and then to the master i.e. MSTtables. Any error while loading is captured in the ERR or error tables.

Taking the example of ITEMMASTER table in ABPP schema, if data is in the following format inIN_ITEMMASTER:

IN_ITEMASTER

CATEGORY ENTERPRISE ITEM ITEMDESC

TV SONY KDL26EX302S SONYTV1

TV SONY KDL32EX302R SONYTV2

TV SONY KDL26EX302T SONYTV5

DI ICDSX850 SONYTVCOMPONENT

After running e2e, data as visible in the different tables will be as follows:

Data from the IN tables will be moved to NC where it is compared with the existing data in MSTtable and the SYS_NC_TYPE field updated accordingly. The NC table will hold those recordswhich are mismatched between the IN and MST tables with appropriate SYS_NC_TYPE status. Ifit is a new record (new Primary Key), the SYS_ NC_TYPE is updated as INSERT and for the sameprimary key but different non-key fields, the SYS_NC TYPE will be written as UPDATE. In theexample below, the item code KDL26EX302T already exists in the MST_ITEMMASTER table, butits description has changed and hence the SYS_NC_TYPE is UPDATE.There is a record for item


8/131



KDL26EX301R which exists in the old MST_ITEMMASTER table but has not come in the freshextract and hence itsSYS_ NC_TYPE=DELETE

NC_ITEMMASTER

CATEGORY ENTERPRISE ITEM ITEMDESC SYS_NC_TYPE

TV SONY KDL26EX302S SONYTV1 INSERT

TV SONY KDL32EX302R SONYTV2 INSERT

TV SONY KDL26EX302T SONYTV5 UPDATE

Parts SONY KDL26EX301R SONYTV4 DELETE

Thus, e2e will load the data into the MST tables according to the SYS_NC_TYPE column in theNC tables. SYS_ENT_STATE field in the MST tables will give the status of the record as towhether it is an ACTIVE record to be sent to downstream applications or inactive in which case

the SYS_ENT_STATE= DELETED.

MST_ITEMMASTER Before e2e is run

CATEGORY ENTERPRISE ITEM ITEMDESC SYS_ENT_STATE

TV SONY KDL26EX302T SONYTV3 ACTIVE

Parts SONY KDL26EX301R SONYTV4 ACTIVE

MST_ITEMMASTER After e2e is run

CATEGORY ENTERPRISE ITEM ITEMDESC SYS_ENT_STATE

Parts SONY KDL26EX302S SONYTV1 ACTIVE

Parts SONY KDL32EX302R SONYTV2 ACTIVE

Parts SONY KDL26EX302T SONYTV5 ACTIVE

Parts SONY KDL26EX301R SONYTV4 DELETED

While inserting these records, if any error is encountered, it is entered into the ERR or errortables as shown below. Any violation in constraints, Primary Key, Foreign Key etc will beentered in the ERR tables of ABPP. In the example below, the record for itemICDSX850 hasbeen rejected as the length of data exceeds the column length.

ERR_ITEMMASTER

CATERGORY

ENTERPRISE

ITEM

ITEMDESC

SYS_ERROR_ID

SYS_ERR_CODE

SYS_ERROR_TIME

SYS_ERR_SVRTY

SYS_NC_TYPE


9/131



DIICDSX850

SONYTVCOMPONENT ERR_0002

ORA-0000_Referential IntegrityViolated

01/10/201009:29:07 ERROR INSERT

2.1. DATA FROM EXTERNAL SYSTEMS

2.1.1. Top Level

Definition: - The tables listed in this section are necessary tables to construct thesupply chain in the engine. Inputs from external systems are not needed to populatethese tables.

For populating these top level tables, there will be a PL/SQL procedure whichpopulates IN_* tables. From there on, data is moved to master tables through regulare2e workflow.

1. Instance Master(IM):- This table is internally used by i2 data structures to identify

different planning engine instances and its related data. No data is needed fromexternals systems. Using the BITPOSITION value presented in this table, engine iscalculated. Effectively all each instance of an application will have an uniqueengine id, and adaptors (software programs that read data from DB tables andconstruct appropriate models in transient memory) read data based on engine id.

BLUE_FILE_FIELD IF_TBL_FIELD FIXED_SCHEMA_FIELD DATA_MAPPING_LOGIC REMARKS

IM.INSTANCEID GPSI Fixed value

IM.BITPOSITION 1 Fixed Value

IM.APPLICATIONNAME SCP

2. EnterpriseMaster(EM):- This is used to define the independent business entity/ Toconstruct the supply chain model, two top level table forms the foundation. Theyare EnterpriseMaster and SupplyChainMaster. EnterpriseMaster contains informationabout the enterprise.


EM.ENTERPRISE SONY Fixed Value

EM.ENGINEID 2 Computedvalue based

on bitposition

Going forward, all the tables will have columns enterprise and engine_id. Toavoid repetition, these columns are not included for each table.


10/131



3. SupplychainMaster(SCM):- For a given enterprise, each supply chain is identifiedwith a distinct id. This table contains details related to supply chain.


SM.SUPPLYCHAINID SONY_TV Fixed Value

EM.SUPPLYCHAINDESC Sony TV SupplyChain

Fixed value todescribe

4. OrganizationMaster(OM):- This table defines different organizations in anenterprise. An organization is a logical grouping of one or more business entities. Italso includes the sales and marketing entities that are used in creating the salesand supply plans.


OM.ORGANIZATIONID SONY_TV Fixed Value

OM.ORGANIZATIONTYPE Manufacturing A fixed keyword asrecognized bySCP engine

5. Plan Master(PM):- This table defines various plans in the supply chain along withdifferent plan specific attributes such as start date, end date, current dateetc.,. There will be only one plan stored for one supply chain. This information ispopulated for each planning run


PM.PLANID PlanDate(YYYYMMDD)_S/N

PM.EFFSTARTDATE

PM.EFFENDDATE

PM.CURRENTDATE

In Sony, the planning cadence follows the cycle of Wednesday Tuesday. For each week,entries in this table are filled using the following logic.

PlanIDArrive using the logicEffstartdateThis represents the plan start date. When running this routine to fill the

values, arrive at the system date, and from this, arrive at the week to which the currentsystem date belongs to. The start date of the current week (Which is always the Monday) willbe the plan start date.


11/131



Effenddate This represents the plan end date. GPSIs plan horizon is 52 weeks. So, ifthe current week is Week 10, the last week will be W10 of next year. So, the plan end date ispopulated with end date of W10 of next year.

6. OrganizationSiteRelation(OSR):- Defines the relationship between organization andsites. This is a table that is internally populated by considering the site information

given through interface M006. Details around this are in Site Master section.

BLUE_FILE_FIELD IF_TBL_FIELD FIXED_SCHEMA_FIELD LOGIC REMARKS

OSR.ORGANZATIONID SONY_TV Fixed value as created inorganizationmaster above

DSM-M006.SiteCode

OSR.SITEID This site id holds areferential integrity withSiteMaster.SiteId defineabove

7. Calendar Master (CM):- Calendars are used to represent continuous time in JulianCalendar. These calendars can be associated with various entities in the schema todefine the time pattern that describe the behavior. Different types of calendarsused in Sonys solution are

1. Site Working Calendar: This is used to represent whether a particular siteis working for a week or not. The Blue file (IFLayout_DSM-M007_Calendar_Master) from Sony will give us the dates on which aparticular site is not working and the calendar is derived from this input:

Populating Calendar Master:

BLUE_FILE_FIELD

IF_TBL_FIELD

FIXED_SCHEMA_FIELD LOGIC REMARKS

IFLayout_DSM-M009_Item_Site_Master.Site Code

CM.CALENDARNAME Get the list of alldistinct sites wheresite type in (SupplierSites, Virtual Sites,Sony Plant, Other


12/131



IFLayout_DSM-M006_Site_Maste.SiteType

Plants, SKD Plants)and createSiteCalendar asWC_Site Code

Populating CalendarDetail:

BLUE_FILE_FIELD IF_TBL_FIELD

FIXED_SCHEMA_FIELD

LOGIC REMARKS

IFLayout_DSM-M009_Item_Site_Master.SiteCode

CD.CALENDARNAME

Same logic used to create Sitecalendar in Calendar Master

For each site,different calendarentries will becreated having thepattern sequenceas the effectivestart date of the

week in YYYYMMDDformat. Hence ifthere are 52weeks, then therewill be 52 entrieswhere the patternsequence for eachentry will be thestart date of eachweek in YYYYMMDDformat

CD.PATTERNSE

Q

For the first record get the

starting date of the week inwhich thePlanMaster.CurrentDate falls inYYYYMMDD format.Subsequent records will havethe start date of the followingweeks for next 52 weeks

Eg.

(Rec 1)20100201

(Rec 2)20100208

CD.EFFSTARTDATE

For the first record get thestarting date of the week inwhich thePlanMaster.CurrentDatefalls .Subsequent records will

have the start date of thefollowing weeks for next 52weeks

Eg.

(Rec 1)02-01-2010

(Rec 2)02-08-2010

CD.EFFENDDATE

CD.EFFSTARTDATE+7 Eg.

(Rec 1)02-08-2010

(Rec 2)02-15-2010


13/131



CD.PRIORITY 1

CD.PATTERNNAME

EVERYDAY Hardcoded value

Populating CalendarBasedAttribute:


FIXED_SCHEMA_FIELD

LOGIC REMARKS

CD.CALENDARNAME

Same logic used to create theCalendar Name above

CD.PATTERNSEQ Same logic as used inCalendar Pattern Detail

ATTRIBUTE WORKING Hardcodedvalue

VALUE 1. Match the site codeused to create theCalendarname withthe Site code inIFLayout_DSM-M008_Site_Calendar_Master where SiteCalendar Type=Working.Get the

Calendar Code

2. Match the calendarcode obtained abovewith Calendar code ofIFLayout_DSM-M007_Calendar_Master, where calendartype= D and get theOff Week Day, whichfall within theeffective startdateand effective end

date. If zero recordsare returned populateas 1 else populate as0

1 for Workingand 0 for non-working

Associating the calendar created above to the Sites is done in SiteCalendar(SC) table.


14/131




FIXED_SCHEMA_FIELD

LOGIC REMARKS

SC.CALENDARNAME

Same logic used to create the

Calendar Name above

SC.SITEID SiteID used to create theCalendar name above

SC.CALENDARTYPE

WORKING

2. Capacity Calendar: - This is used to represent the working capacity eitherin units or in hours for different resource. This calendar is derived based onthe number of working days obtained through the above

--Considered in the Capacity modeling section

3. Safety Stock Calendar: - This represents the time varying safety stockrequirements for an item (either FG or Panel) at a site. There is a non-keyUI available for this and the related tables will be populated by UI team.The following figure is an example on how data will be populated in thedifferent tables of fixed schema.


15/131



4. Shipping Calendar: - When the number of working days in a week at a siteis defined through Site Working Days Calendar, then number of days theitem can be shipped is also guided through this. Currently solution team ischecking on whether there is any additional requirement to have additionalShipping Calendar. Need to confirm the need for this. DI Team will need topopulate custom table used by UI team to populate this information

Whether the Ship to code will be needed in Shipping Calendar is to be confirmed

5. NMI Ramp up Calendar: - For the products which are identified as NMI aspart of PLC, there will be a controlled production during ramp up stage. Tofacilitate this, a dummy resource is attached whose capacity is equivalentis quantity to be controlled. In modeling terms, a new resources is createdwhose capacity is controlled through this calendar and used assimultaneous resource (Fixed table OperationResourceAdditional table)


16/131



-- UI Populated (Considered in section of Capacity modeling)

6. BCD / Flex Limit Calendar: - To control the panels availability. Near termavailability of the panel is controlled through RTF information. Howeverthere is a flexibility to get more panels from the suppliers. There isdefinitive flexibility information against each panel and also at group of

panels. The flexibility at specific panel level is controlled through FlexLimit Calendar and at a group is controlled through BCD

a. Flex Limit Calendar:- RTF information for a given panel iscontrolled through inventory with future dates on Panel Seriesbuffer at Suppliers Panel Plant. But for each panel, there is alsosome additional flexibility for near term horizon. This is controlledthrough a producing operation into this buffer with a Flex Limitresource attached. Calendar attached to this resource wouldcontrol the same. This is marked as brown in the below picture.

-- Considered in section of Capacity modeling

b. BCD Calendar: - Apart from the flex limit, the additional panelsthat can be obtained are also capped at a group of panels. So, thisis controlled through a resource which is simultaneously attachedto multiple operations. The brown circled area in the below picturerepresents the same. UI Populated (Considered in section ofCapacity modeling)


17/131



6. FG use up calendar:- As part of engineering change control process,switching from one 8D to another 8D is controlled through AllowedQuantity Range and Cumulative Production. The difference betweenthese would give the quantity that can still be produced using an 8D. This iscontrolled through attaching a resource with available capacityrepresented through this calendar. A non-key UI is currently available to

show the quantity range that is possible. Cumulative production of that 8Dis obtained through interface.

Considered in section of Capacity modeling

7. Panel use up Calendar:- Same like FG use up calendar, but it is for panels

Considered in section of Capacity modeling

8. Supply Calendar for Local Parts: - In the supply chain planning, BOMinformation contains just the panel series. However users would like to anyother material constraint by dynamically adding another item to BOMstructure, and material constraints are placed on this buffer. Material

availability on this is controlled through Supply Calendar. There is a non-key UI available to control the same. This interface will be populated fromUI. The following figure is an example to show how data will be populatedin the fixed schema:


18/131



Need to finalize on which calendars are coming through interfaces Vs which are controlledthrough non-key UI. If the calendars are coming through interface, naming conventions aroundthe same are to be discussed. For each of the above calendar, with naming convention,appropriate mapping to the fixed schema table is to be added.

2.1.2. Modeling of Items (ItemMaster, Item Group Master, Item Group Detail,ItemSiteMaster)

ItemMaster (IM):- This represents the list of items available in the network. Differentitems part of the present network are LMN , 8D, Panel Series and Dummy item atthe supplier site. The areas circled around brown represent the different items.

In the SCM model, all items need to be associated with a site. So, to populate valid records thepresence of an item is checked in both ItemSiteMaster and also the corresponding item master.To bring clarity how different items are getting populated each section below specificallyaddresses loading different types of items.

Populating items of type LMN

This section addresses populating items of item type LMN.


19/131



For DP Sales Companies, the Blue file used is IFLayout_DP-IM003_LMNMaster

BLUE_FILE_FIELD IF_TBL_FIELD FIXED_SCHEMA_FIELD

LOGIC REMARKS

IFLayout_DP-

IM003_LMNMaster

IM.ITEM Join

condition

Get the list of all LMN Codes

where LMNMaster .LMNProduct Hierarchy 3= LCDand LMNMaster.Deletionflag X

IM.category LMN Hard Coded value

For non-DP sales companies, the ItemSiteMaster blue file will be used to fetch the LMN data

According to the new blue file layout, the LMN data for TV will come in from the blue fileIFLayout_DSM-M012_LMN_Master (TV).Hence, no need to refer to DP file for the same. Also

ItemSiteMaster will include the item-site combinations for DP sales companies


LOGIC REMARKS

DSM-M009_ItemSiteMaster.Item Code

IM.ITEM Joincondition

List of all items from ISMwhere ISM.itemtype = 50 andcorresponding SiteType in(Sales Company, SalesCompany DC, Account Group,FDS) .Match the Item CodewithIFLayout_LMN_Master(TV).LM

NCode whereIFLayout_LMN_Master(TV).Effective Start Date>=PlanMaster.EffectiveStartDate

DSM-M006_SiteMaster.Site Type

IM.category LMN Hard Coded value

Populating the items of type 8D


20/131




LOGIC REMARKS

DP-M001_Product_Master_TV

IM.ITEM Joincondition

List of all items from ISMwhereProductMaster(TV).ProductCode = ISM.ItemCode and

ProductMaster(TV).modeldropcode IS NULL andISM.itemtype = 10

DSM-M009_ItemSiteMaster

DSM-M006_SiteMaster


IM.category For all the records whichcome out with the above,category is 8D;

During the process, ifproductmaster.SKDflag=Y

then flag it as SKD instead of8D

Populating the items of type Panel Series


DP-M003_Panel_Seri

IM.ITEM Joincondit

List of all items from ISMwhere PSM.Panel Series Code


21/131



es_Master (PSM) ion = ISM.ItemCode and PanelSeries Code. Drop Flag ISNULL and ISM.itemtype = 40and ISM.SiteCode =SiteMaster.SiteCode andSiteMaster.SiteType in (Sony

Plant, Other Plant, Hub, andSupplier)


DSM-M006_SiteMaster


IM.category For all the records whichcome out with the above,category is Panel Series

Populating the items of type Dummy


LOGIC REMARKS

IM.ITEM DUMMY A fixed entry dummy

IM.category DUMMY A fixed entry dummy

ItemSiteMaster(ISM):- This represents the availability of an item at a site. To do planning,every item should be associated with a site.

Populating all ISM entries for LMN


22/131




LOGIC REMARKS


ISM.ITEM Join List of all items whereISM.Item Code =IFLayout_LMN_Master(TV).LM

NMaster.LMNCODE andISM.Site =SiteMaster.SiteCode andSiteMaster.Site Type in("Sales Company", "SalesCompany DC", "AccountGroup", "FDS"). Current LMNMaster is limited to EU DP asof now andIFLayout_LMN_Master(TV).Effective Start Date>=PlanMaster.EffectiveStartDate

DSM-M006_SiteMaster

DP-M003_LMNMaster

ISM.SITE join SiteCode of ItemSiteMasterthat results from above

ISM.ISRESPONSEBUFFER

1 Fixed value of 1. This isrequired for pegging

ISM.SELLABLE 1 For all items that get adirect demand, this flag hasto be set to 1

STAGE (customfield)

LMN_DC Hardcoded value

Populating all ISM entries for 8D at Sales Companies


LOGIC REMARKS

DSM-M009_ItemSiteM

ISM.ITEM Join List of all items whereISM.Item Code =


23/131



aster ProductMaster_TV.ProductCode and ISM.Site =SiteMaster.SiteCode andSiteMaster.Site Type in("Sales Company", "SalesCompany DC", "Account

Group", "FDS")

DSM-M006_SiteMaster

DP-

M001_ProductMaster TV




ISM.SELLABLE 1 How to distinguish itemswhich get demand on 8Dand which do not get. Totake care of all possible

cases, this is set to 1 in allcases.

STAGE (customfield)

8D_DC Hardcoded value

Populating all ISM entries for 8D at Sony Plant / ODM

BLUE_FIL IF_TBL_FIELD FIXED_SCHEMA_FIELD LOGIC REMARKS

DSM-M009_ItemSiteM

aster

ISM.ITEM Join List of all items whereISM.Item Code =

ProductMaster_TV.ProductCode and ISM.Site =SiteMaster.SiteCode andSiteMaster.Site Type in(Sony Plant or OtherPlant")

DSM-M006_SiteMaster

DP-M001_ProductMaster TV


24/131


25/131


26/131



BLUE_FILE IF_TBL_FIELD FIXED_SCHEMA_FIELD LOGIC REMARKS


ISM.ITEM Join List of all items whereISM.Item Code =PanelSeriesMaster.PanelSeriesCode and ISM.Site =

SiteMaster.SiteCode andSiteMaster.Site Type in(SupplierSite,SupplierVirtualSite)

DSM-M006_SiteMaster

DP-M003-Panel_Series_Master




ISM.SELLABLE 0 This is set to zero.

Populating all ISM entries for dummy items at Suppliers plant

BLUE_FILE IF_TBL_FIELD FIXED_SCHEMA_FIELD LOGIC REMARKS

ISM.ITEM DUMMY A fixed value as it is created


27/131



in ItemMaster.

DSM-M006_SiteMaster

ISM.SITE Filter SM.SiteCode where siteTypein (Supplier,SupplierVirtual Plant). Forevery site found through this,

data an entry is created withall the fields listed here



ISM.SELLABLE 0 A fixed value and is set tozero

ITEMGROUPMASTER (IGM)

The fixed schema ITEMGROUPMASTER is used to define the inventory style and also any customgroups defined during the implementation. Currently there are only three groups defined underthis category.

Above diagram illustrates how different buffers are grouped. The one brown indicates theplaces PFC buffers and in greenish blue (left most) indicates the INFINITE buffers. Apart fromthis, when a dynamic constraint is added, it will fall under SUPPLY_CALENDAR group.

IF_TABLE_FIELD FIXED_SCHEMA_FIELD DATA_MAPPING_LOGIC REMARKS

IGM.ITEMGROUP Create a fixed entriesPFC, INFINITE, SCSUPPLY_CALENDAR

IGM.GROUPTYPE Create a fixed entryINV_STYLE

IGM.GROUPDESC INFINITE Upstream,no supply constraint

PFCINV controlledby planning

SUPPLY_CALENDAR

Optional field


28/131



Upstream, regularsupplies

IF_PRODUCT_MASTER_TVIN_ITEMGROUPDETAIL (IGD)

The fixed schema ITEMGROUPDETAIL contains the association between the groups defined inITEMGROUPMASTER, and items that belongs to the group. This section is to be further updatedwith a picture.

BLUE_FILE_FIELD IF_TABLE_FIELD FIXED_SCHEMA_FIELD DATA_MAPPING_LOGIC

REMARKS

IGD.ITEMGROUP 1. PFC

2. INFINITE

3. SC

IM.ItemCode IGD.ITEM 1. For PFCList of allitemswherecategory in(LMN,8D,PanelSeries,SKD)

2. ForINFINITEList of

all itemswherecategory inDUMMY

3. For SCListof all itemswherecategory inDYNAMIC

ORGANIZATIONID SONY_TV

2.1.3. Modeling of Network (Site Master, Supplier Master, Customer Master,BODs)

Site Master (SIM):- Site usually represents physical location of an enterprise. For planning,there can be some virtual sites being modeled. The following diagram represent mapping ofthese information to FLO diagram used for planning


29/131



The areas marked in brown color represent the sites. Some virtual sites are chosen forplanning. For example, all supplier sites of Sharp are converted into virtual sites specific toeach plant to which panels are supplied. The information about what sites to be modeled inthe solution is directly taken from SiteMaster (M006) blue file

Following tables defines the mapping to get different sites information:


IFLayout_DSM-M006_Site_Master.SiteCode

SIM.SITEID 1 1

IFLayout_DSM-M006_Site_Master.Site Name

SIM.SITENAME 1 1

IFLayout_DSM-M006_Site_Master.Site Type

SIM.SITETYPE 11 Will contain values like SC,Sony Plant, Other Plant,Hub etc.,.

IFLayout_DSM-M006_Site_Master.Site Type

SIM.CATEGORY 11 Same as Site Type

The blue file for SiteMaster has changed.Although the above logic remains same, the IF tabledefinition will change

Checking with solution team on whether they need any strict site types

Manufacturing Network (BODs):

The following diagram represents the physical transportation network in Sony. From thedifferent possible routes, the ones modeled in the solution are listed below. All informationrelated to BODs is obtained through Blue file IFLayout_DSM-M011_BOD_Master. This contains allpossible BODs along with transport mode, priority and associated lead time using that route.For planning, all air routes are frozen. Only fixed plan can be given as input on air route. ONthe fixed schema, this blue file gets mapped to BOD Header and BOD Detail. How to takethe overwrites from UI on BOD information into the masters is to be detailed out.


30/131



A: Panel direct shipment from the supplier panel plant to Sony set plant.

B: Panel series transportation from the supplier panel plant to panel Hubs.

C: Panel series transportation from panel hubs to set plants.

D: Panel series or PCB transportation from a set plant to another set plant (notin scopeof DSM Solution.)

E: Finished Goods transportation from a set plant to dealer DC directly(Factory Direct Shipment).

F: Finished Goods transportation from a set plant to S/Co. DC

G: SKD transportation from a set plant to a SKD plant, which will be modeled asdelivery operation from a set plant.

H: Finished Goods transportation from a SKD plant to S/Co. DC, which is not inscope of SCP system. (Not in scopeof DSM Solution.)

I: Finished Goods transportation from a S/Co. DC to a dealer DC (notin scopeof SCP system.)

Before loading the BODs we need to load the transport mode table which defines the various

transportation modes that will be used in BOD definition.

Loading the TransportMode (TM) table in the fixed schema


FIXED_SCHEMA_FIELD

LOGIC REMARKS

IFLayout_DSM-M011_BOD_Master.TransportMode

TM.TRANSPORTMODE

Get the distinct transportmodes from the BODMastertable

1 Maritime2 Rail3 Road4 Air5 Mail6 Multimodal

8 Inland Water9 Mode unknown

TM.TRANSAGENTID

Dummy Hardcoded value

TM.SERVICENAME

Dummy Hardcoded value


31/131


32/131



Populating the BODDetail(BD) table in the fixed schema


IFLayout_DSM-M011_BOD_Master.Item Code

BD.BODNAME From BODMaster,get all the recordswhere the fromsite is eitherSupplier orSupplier Virtualand to site is eitherSony Plant orOther Plant.From the aboveresult set, for allitems, ensure itemtype is Panel

Series and itemsite combinationsare valid.

For these items,using theTransporationMode andEffective StartDate, createBODNAME asBOD_Item Code_Ship From Site

Code_ Ship To SiteCode_TransportMode_Effective Start Date(YYYYMMDD)

BOD_____

IFLayout_DSM-M011_BOD_Master.Ship FromSite Code

IFLayout_DSM-M011_BOD_Master.Ship To SiteCode


IFLayout_DSM-M011_BOD_Master.EffectiveStart Date


FROMID Ship From SiteCode as obtainedabove

IFLayout_DSM-M011_BOD_Mast

er.Ship To SiteCode

TOID Ship To Site Codeas obtained above


ITEM Item Code asobtained above


PRIORITY 1 1


33/131



er.Priority

IFLayout_DSM-M011_BOD_Master.Transportation

Weeks

TRANSITTIME 1 1

TIMEUOM WEEK Hardcoded value


TRANSPORTMODE 1 1


EFFSTARTDATE 1 1

IFLayout_DSM-M011_BOD_Master.Effective EndDate

EFFENDDATE 1 1

IFLayout_DSM-M011_BOD_Master.FrozenPeriod Weeks forDeparture

FROZENSHIPHORIZON 1 1 If theIFLayout_DSM-M011_BOD_Master.Transport Modetransporationmode = 4Airset value defined

in theNUMBEROFBUCKETS field ofBucketPatternTable and updatethe same here.

IFLayout_DSM-M011_BOD_Master.Shipping LotQuantity

LOTSIZEINCREMENT 1 1

IFLayout_DSM-

M011_BOD_Master.

CALENDARNAME Are we using the

Shipping Calendar?

Shipping Calendarwill be created byUI. Need to syncup with UI team

CALENDARUSAGE OUTBOUND Do we need do thisfor all the


34/131



calendars?

BOD for Supplier Panel Plant / Virtual Supplier Plant to Panel Hubs

The Supplier plants also supply to the Sony Hub which act as storehouse of Panel Series whichare then supplied to the Set Plants. The BOD for this has been marked in the figure below:

Populating BODHeader Table:

Populating the BODDetail (BD) table in the fixed schema


FIXED_SCHEMA_FIELD

LOGIC REMARKS


BH.BODNAME From BODMaster, get all therecords where the from siteis either Supplier orSupplier Virtual and to siteis Hub. From the aboveresult set, for all items,

ensure item type is PanelSeries and item sitecombinations are valid.

For these items, using theTransporation Mode andEffective Start Date,create BODNAME asBOD_Item Code_ ShipFrom Site Code_ Ship ToSite Code_TransportModeEffective Start Date(YYYYMMDD)

BOD_____IFLayout_DSM-

M011_BOD_Mast

er.Ship FromSite Code





35/131




FIXED_SCHEMA_FIELD

LOGIC REMARKS


BD.BODNAME From BODMaster, get all therecords where the from siteis either Supplier or

Supplier Virtual and to siteis Hub. From the aboveresult set, for all items,ensure item type is PanelSeries and item sitecombinations are valid.

For these items, using theTransporation Mode andEffective Start Date,create BODNAME asBOD_Item Code_ ShipFrom Site Code_ Ship To

Site Code_TransportMode_Effective Start Date(YYYYMMDD)

BOD_____




er.TransportMode



FROMID Ship From Site Code asobtained above


TOID Ship To Site Code as obtainedabove


ITEM Item Code as obtained above

IFLayout_DSM-M011_BOD_Master.Priority

PRIORITY 1 1

IFLayout_DSM-M011_BOD_Master.TransportationWeeks

TRANSITTIME 1 1



36/131




TRANSPORTMODE

1 1

IFLayout_DSM-

M011_BOD_Master.EffectiveStart Date

EFFSTARTDATE 1 1


EFFENDDATE 1 1

IFLayout_DSM-M011_BOD_Master.FrozenPeriod Weeks for

Departure

FROZENSHIPHORIZON

1 1 If IFLayout_DSM-M011_BOD_Master.TransportMode .Transport

mode =4transporationmode = air setthis to the valuedefined in theNUMBEROFBUCKETS field ofBucketPatternTable and updatethe same here.


er.Shipping LotQuantity

LOTSIZEINCREMENT

1 1

IFLayout_DSM-M011_BOD_Master.

CALENDARNAME

Are we usingShipping calendars-Shipping Calendarwill be created byUI. Need to syncup with UI team

CALENDARUSAGE

OUTBOUND Is this need to bepopulated for all?

Panel series transportation from panel Hub to Set Plant / ODM

Panel series stored at the hubs are transported to the Set Plants. The BOD for this is marked inthe figure below:


37/131




Populating the BODDetail (BD) table in the fixed schema


FIXED_SCHEMA_FIELD

LOGIC REMARKS


BD.BODNAME From BODMaster, get all therecords where the from siteis Hub and to site is SonyPlant or Other Plant.

BOD_____


38/131



M011_BOD_Master.Ship FromSite Code

From the above result set,for all items, ensure itemtype is Panel Series anditem site combinations arevalid.

For these items, using theTransporation Mode andEffective Start Date,create BODNAME asBOD_Item Code_ ShipFrom Site Code_ Ship ToSite Code_TransportMode_Effective Start Date(YYYYMMDD)

rtDate(YYYYMMDD)>


er.Ship To SiteCode




FROMID Ship From Site Code asobtained above


TOID Ship To Site Code as obtainedabove


ITEM Item Code as obtained above

IFLayout_DSM-M011_BOD_Master.Priority

PRIORITY 1 1

IFLayout_DSM-M011_BOD_Master.TransportationWeeks

TRANSITTIME 1 1



TRANSPORTMODE 1 1

IFLayout_DSM-M011_BOD_Master.Effective

EFFSTARTDATE 1 1


39/131



Start Date


EFFENDDATE 1 1

IFLayout_DSM-M011_BOD_Master.FrozenPeriod Weeks forDeparture

FROZENSHIPHORIZON

1 1 If IFLayout_DSM-M011_BOD_Master.Transport Mode=4For TransportMode = Air -setthis to the valuedefined in theNUMBEROFBUCKETS field ofBucketPatternTable and updatethe same here.

IFLayout_DSM-M011_BOD_Master.Shipping LotQuantity

LOTSIZEINCREMENT

1 1

IFLayout_DSM-M011_BOD_Master.

CALENDARNAME

Is this needed?-Shipping Calendarwill be created byUI. Need to syncup with UI team

CALENDARUSA

GE

OUTBOUND Is it for all?

Finished Goods transportation from a Set Plant / ODM to S/C DC or FDS

The finished goods produced in the set plant / ODM are transported to Sales Company DCs. Insome customer cases, it is directly transported to Dealer DCs directly. Dealer DCs can bevirtual sites for planning.For PA and CA regions the demand information is taken fromProduction Plan at the factory with factory ETD. Hence, for these regions the Transit Time inBOD Detail has to be set as 0. Also, for all FGs, the if the BOD effective start date is after theFirst Shippable datethen the BOD effective date will be equal to the given BOD effective startdate but if the BOD effective start date is earlier than the First Shippable Date then the BOD

effective start date will be overwritten by the First Shippable date. These are marked in brown


40/131



as below:



FIXED_SCHEMA_FIELD

LOGIC REMARKS

IFLayout_DSM-

M011_BOD_Master.Item Code

BH.BODNAME From BODMaster, get all the

records where the from siteis either Sony Plant orOther Plant and to site isSC DC or FDS. From theabove result set, for allitems, ensure item type is8D and item sitecombinations are valid. Forthe above 8D code gets theFirst Shippable Date fromProductMaster_TV bymatching the productcodes.

-If ProductMaster_TV. InitialShippable Date>IFLayout_DSM-M011_BOD_Master .EffectiveStartDate , effstartdate =ProductMaster_TV .InitialShippable Date

-ElseIf ProductMaster_TV.First Shippable DateIf ProductMaster_TV. InitialShippable Date>IFLayout_DSM-M011_BOD_Master .EffectiveStartDate , effstartdate =ProductMaster_TV .InitialShippable Date

>ElseIf ProductMaster_TV.First Shippable Date1

IFLayout_BOMMaster.Site code


47/131



IFLayout_BOMMaster.Sitecode

BOMC_ALT.SITEID

The logic to get a BOM at asite in BOMHeader

IFLayout_BOMMaster.PrimaryComponent Item

CodeComponentItem Code

BOMC_ALT.ITEM 1 1

IFLayout_BOMMaster. AlternateComponent ItemCodePrimaryComponent ItemCode

BOMC_ALT.ALTERNATEITEM

1 1

IFLayout_BOMMaster.Consumed

Quantity

BOMC_ALT.QTYPER

1 1

IFLayout_BOMMaster.Priority

BOMC_ALT.Priority

In current blue file, lower thenumber, higher the priority.Whereas for Fixed Schema,higher the number, higher thepriority

IFLayout_BOMMaster.EffectiveEnd Date

BOMC_ALT.EFFENDDATE

1 1

IFLayout_BOM

Master.EffectiveStart Date

BOMC_ALT.

EFFSTARTDATE

1 1

1.2 Operation creation at Sales Sites

An Operation models a process, activity, or action that transforms or moves intermediate orfinal goods (Items) through the Supply Chain. At the Sales sites the operation comprises theLMN to 8D mapping.

Populating the Routing Header table in fixed schema which is used to define the routing:

BLUE_FILE_FIELD IF_TABLE_FIELD FIXED_SCHEMA_FIELD DATA_MAPPING_LOGIC REMARKS

IFLayout_BOMMaster.Assembled Item Code

RH.Routing ID For each item, there BOMcreated at sales company site,a corresponding route is


48/131



IFLayout_BOMMaster.PlantCode

created, using Routing ID =RT_Assembled Item Code _Plant Code

IFLayout_BOMMaster.Plant

Code

RH.SiteID 1 1

Populating the RoutingOperationtable in the fixed schema

This table associates the Routing with an operation.Basically, this is used to define the varioussub operations for a routing operation. In the case of Sony, it is a single step Operation.

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD

DATA_MAPPING_LOGIC REMARKS

IFLayout_BOM

Master.Assembled Item CodeCode

RO.Routing ID Same logic as used in Routing

Header



RO.SiteID Same logic as used inRoutingHeader

RO.OPERATIONSEQ

1 Fixed value

RO.OPTYPE Manufacturing Fixed value

RO.OPERATION 1 Fixed value

1.3 Associating BOM and Operation to the Item being produced

The ItemBOMRouting table in the fixed schema defines the association of a bill of materialwith a routing and defines the output part of the given BOM and Routing combination. Thisis populated for each item where BOMID and RoutingID is created. The data population logicis given below:

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD



49/131



IBR.BOMId BOMID as it is created in BOMHeader

IBR.Item The final assembled item code

IBR.RoutingId Routing ID as it is created inRoutingHeader table

IBR.SiteID Site ID to which this BOM andRouting belongs to

For DP participating sales companies

For DP participating Sales Companies, the BOM information will come from the blue fileIFLayout_DP-IM004_LMNto8DMapping.

Loading into BOM Header


IFLayout_DP-IM004_LMNto8DMapping.LMN Code

BOMH.BOMID Get the list of all LMNCodes and SalesCompanyCode .Ensure theseare valid ItemSitecombinations.

For all these items,

create the BOM asBOM_LMN Code_Sales Company Code

IFLayout_DP-IM004_LMNto8DMapping.Sales Company Code

IFLayout_DP-IM004_LMNto8DMapping.Sales Company Code

BOMH.SITEID From the above resultset,

1 1 between SalesCompany CodeSite

BOMH.QTYPRODUCED Fixed value 1

Loading to Bom Components:

BLUE_FILE_FIELD IF_TABLE_FIELD FIXED_SCHEMA_FIELD DATA_MAPPING_LOGIC REMA

IFLayout_DP-IM004_LMNto8DMapping.LMNCode

BOMC.BOMID This corresponds toBOMID created inBOMHeader

BOMcreatBOM


50/131



IFLayout_DP-IM004_LMNto8DMapping.SalesCompany Code

table

IFLayout_DP-IM004_LMNto8DMapping. Sales

Company Code

BOMC.SITEID Same BOMID, Sitecombination as it is in

BOMHeader

IFLayout_DP-IM004_LMNto8DMapping.ProductCode

BOMC.ITEM Make 1 1 mappingfor Product Code

BOMC.QTYPER 1 1

IFLayout_DP-IM004_LMNto8DMapping.EffectiveStart Date

BOMC.EFFSTARTDATE

1 1

IFLayout_DP-

IM004_LMNto8DMapping.EffectiveEnd Date

BOMC.EFFENDDATE 1 1

Loading into Routing Header

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD


IFLayout_DP-IM004_LMNto8DMapping.LMN

Code

RH.Routing ID For each item, where BOMcreated at sales company site,a corresponding route is

created, using Routing ID =RT_ LMN Code_SalesCompany CodeIFLayout_DP-

IM004_LMNto8DMapping.SalesCompany Code

IFLayout_DP-IM004_LMNto8DMapping.SalesCompany Code

RH.SiteID 1 1

Loading into Routing Operation

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD


IFLayout_DP-IM004_LMNto8DMapping.LMN

RO.Routing ID Same logic as used in RoutingHeader


51/131



Code

IIFLayout_DP-IM004_LMNto8DMapping.SalesCompany Code

IIFLayout_DP-IM004_LMNto8DMapping.SalesCompany Code

RO.SiteID Same logic as used inRoutingHeader

RO.OPERATIONSEQ

1 Fixed value



Loading into Item BOM Routing table:

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD






2. Manufacturing process at the Set Plants / ODMs:

At the set plants, manufacturing will be modeled as only one step. There may be caseswhere an FG LCD TV is manufactured by different panel series, in which case, it will bemodeled as alternate primary routing in plant sites.

The following diagram defines the Manufacturing process at the Set Plants which ismarked with a brown circle:


52/131



2.1 BOM Data creation at Set Plant / ODM

The 8 Digit FG code shown in figure above in blue circle will be located at the Set plants(brown circle in the site location) with the Panel Series components (shown in pink circles).Allthe TVs in the plants are in 8 digit codes and all panels are panel series codes. There may bemore than one panel series used to create a single 8 Digit code in which case, differentoperations with appropriate priority are created.

Loading to BOM Header table:


IFLayout_BOMMaster.AssembledItem Code

BOMH.BOMID Get the distinctAssembled Item,Primary Component

Item CodeComponentItem, Site Code whereitem type = 8D orSKD and associatedsite type is eitherSony Plant, Other

IFLayout_BOMMaster. PrimaryComponent ItemCodeComponentItem Code


53/131


54/131



IFLayout_BOMMaster.PrimaryComponent ItemCodeComponentItem Code

BOMC.ITEM Primary Component Item Codeas it is used in creation ofBOMID

`

IFLayout_BOMMaster.ConsumedQuantity

BOMC.QTYPER 1 1

IFLayout_BOMMaster.EffectiveStart Date

BOMC.EFFSTARTDATE

Effective start date as it isused in creation of BOM ID

IFLayout_BOMMaster.EffectiveEnd Date

BOMC.EFFENDDATE

1 1

2.2 Operation creation at Set Plants

At the set plants, the assembly operation is modeled as one-step. However, for caseswhere an FG LCD TV is produced from different panel series it will be modeled as alternateprimary routing in the plant sites.

Populating the Routing Header table in fixed schema which is used to define the Routing:

BLUE_FILE_FIEL

D

IF_TABLE_FIEL

D

FIXED_SCHEMA_F

IELD



RH.Routing ID Get the distinct AssembledItem, Primary ComponentItem, Site Code assembled


55/131



IFLayout_BOMMaster.PrimaryComponentItemCodeComponen

t Item Code

item Codes where item type =8D or SKD and associatedplantcode type is either SonyPlant, Other Plant Ensurethese are valid ItemSitecombinations.

For all these items, create theRoutingId as RT_ AssembledItem Code _ PrimaryComponent Item Code_SiteCode_ Effective StartDate(YYYYMMDD)


IFLayout_BOMMaster.Effective StartDate

IFLayout_BOMMaster.SitePlan

t Code

RH.SiteID SitePlantCode as obtainedabove

Populating the RoutingOperationtable in the fixed schema

This table associates the Routing with an operation.Basically, this is used to define the varioussub operations for a routing operation. In the case of Sony, it is a single step Operation.

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD


IFLayout_BOM

Master.Assembled Item Code

RO.Routing ID Same logic as it is used to

create the RoutingHeader

IFLayout_BOMMaster.PrimaryComponentItemCodeComponent Item Code

IFLayout_BOMMaster.Plant

Site Code

IFLayout_BOMMaster.Effective StartDate


56/131



IFLayout_BOMMaster.PlantSiteCode

RO.SiteID Same logic as it is used inRouting Header

RO.OPERATIONSEQ

1 Fixed value



RO.RELEASEFENCE

2 Fixed Value

RO.RELEASEFENCEUOM

WEEK Fixed Value

2.3Associating BOM and Operation to the Item being produced

The relation between BOM, Routing Id and the final assembled item is maintained in theItemBOMRouting table in the fixed.

Populating ItemBOMRouting:

The ItemBOMRouting table in the fixed schema defines the association of a bill of material witha routing and defines the output part of the given BOM and Routing combination. The datapopulation logic is given below:

BLUE_FILE_FIEL

D

IF_TABLE_FIEL

D

FIXED_SCHEMA_F

IELD






IBR.Priority In blue file, priority isavailable at component level.In the model, this needs totranslate to route level.

Once allpossibleroutes arearrived, theorder is to bereversed.


57/131



3. Manufacturing process at the Suppliers Panel Plants:

At the Suppliers Panel Plants, there will be one step of Operation in order to considerproduction capacity of the supplier across the panel series. If the supplier is jointventure of Sony, this capacity is treated as Best Can Do (BCD) of the Suppliers.In theother suppliers, the assembly resource constraint will be reasonable upper limit in each

week, which will be decided by the panel planner.Panel series assembly operation willhave a dummy item as a component, and there will not be any other materialconstraint.

3.1 BOM Data creation at Supplier Panel Plants

In the figure below, the finished product (marked with pink circles) at the Suppliers PanelPlants (marked with brown circle) is produced by consuming the component dummy itemwhich has been identified by blue circle

Loading to BOM Header table:

BOM header will contain the BOM definition created by the concatenation of final itemproduced and site code information

BLUE_FILE_FIELD IF_TABLE_FIELD

FIXED_SCHEMA_FIELD



BOMH.BOMID List of all item codes andsite codes whereISM.Item Code =


58/131



DSM-M009_ItemSiteMaster.Site Code

PanelSeriesMaster.PanelSeriesCode and ISM.Sitecode =SiteMaster.SiteCode andSiteMaster.Site Type in(SupplierSite,

SupplierVirtualSite). BOMId will be generated asBOM_ItemCode_SiteCode


BOMH.SITEID Site Code as obtainedabove

BOMH.QTYPRODUCED

Fixed value 1

Loading into BOM Components table:

Panel series assembly operation at the Supplier Sites will have a dummy item (marked withblue) as a component, and there will not be any other material constraint.

BLUE_FILE_FIELD IF_TABLE_FIELD FIXED_SCHEMA_FIELD



BOMC.BOMID Same logic as it is used in BOMHeader


IFLayout_BOMMaster.Site code

BOMC.SITEID Same as in BOM Header

IFLayout_BOMMaster.Component ItemCode

BOMC.ITEM DUMMY

IFLayout_BOM

Master.ConsumedQuantity

BOMC.QTYPER 1 1

3.2 Operation creation at Supplier Sites


59/131



Each suppliers panel plant has one step of operation so that we also consider productioncapacity of the supplier across the panel series.

Populating the Routing Header table in fixed schema which is used to define the Routing:

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD


DSM-M009_ItemSiteMaster.ItemCode

RH.Routing ID List of all item codes and sitecodes where ISM.Item Code =PanelSeriesMaster.PanelSeriesCode and ISM.Site code =SiteMaster.SiteCode andSiteMaster.Site Type in(SupplierSite,SupplierVirtualSite). RoutingId will be generated as RT_Item Code_Site Code

DSM-M009_ItemSiteMaster.SiteCode

RH.SiteID Site Code as obtained above

Populating the RoutingOperationtable in the fixed schema.

This table associates the Routing with an operation.Basically, this is used to define the varioussub operations for a routing operation. At Sony Supplier plants this has been modeled as a singlestep operation with dummy item as component.

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD



RO.Routing ID Same logic as inRoutingHeader


60/131





RO.SiteID Same logic as in RoutingHeader

RO.OPERATIONSEQ

1 Fixed value



3.3Associating BOM and Operation to the Item being produced

The relation between BOM, Routing Id and the final assembled item is maintained in theItemBOMRouting table.

Populating ItemBOMRoutingtable in fixed schema:

The ItemBOMRouting table in the fixed schema defines the association of a bill of material witha routing and defines the output part of the given BOM and Routing combination. The datapopulation logic is given below:



BOMC.BOMID BOMID as it is created in BOMHeader

BOM ID ascreated inBOMHeader




DSM-M009_ItemSiteMaster.Item

IBR.Routing ID Routing ID as it is created inRoutingHeader table


61/131



Code

DSM-M009_ItemSiteMaster.SiteCodeIFLayout_BOMMaster.Plantcode


2.1.5. Modeling Capacities (Bills of Resource and Resource Capacities)

The different locations in the supply chain where the capacities and constraints will bemodeled have been highlighted with a circle in the figure below:

At the Panel Set Plants/ODMs

At the Supplier Panel Plants

Creating Bills of Resource and associating capacity to the resource is done in followingsequence

Creating a Resource

Creating a Work Center

Associating the Resource with Work Center, Load Policy

Associating a Resource to a specific Operation

Attaching a Calendar to the Resource

2.1.2.1 Modeling Capacities and Constraints at the Set Plants/ODMs:


62/131



The different types of resources at the Set Plants/ODMs are

Line Resource

Tool Resource

SKD Resource

NMI Resource

FG Use Up Resource

Panel Use up Resource

Line Resource:

A Resource can be Machine, Tool or People. It can be takt time or quantity based. The Bill ofResources and Capacity modeling for Normal Resources will be done by UI team. DI needs to

provide the number of working days information to UI team. Custom table for this is yet to bespecified by UI team

The figure below is an example on how data is going to be populated in the fixed schematables:


63/131



Tool Resource:

As per Jefri,currently, there are no plans to model tool resource

SKD Resource:

Not confirmed whether it will be modeled. As per Jefri,If Sony decides to maintain resource;it would follow same naming convention as Line resource

NMI Resource:

NMI Resources are created whenever there is New Model Introduction in the System. NMIResource creation and associated capacity constraint modeling will be done by UI Team

The following figure is an example to show how data will be populated in the different tablesin the fixed schema:


64/131



FG Use up Resource

FG Use UP or EOL Resource will come into picture when an existing model goes EOL phase anda New Model is introduced. At Sony, EOL is controlled on quantity basis. It means, theremaining quantity that can be produced before production is stopped is determined throughtotal planned quantity and cumulative production quantity. Tota l planed quantity ismaintained through non-key UI and cumulative production quantity is obtained throughinterface.


65/131



The logic for creating the FG Use up Resource is explained below and will be loaded in theResource Mastertable in the fixed schema


FIXED_SCHEMA_FIELD


ISM.Item RM.RESOURCENAME

Get the list of all item andsite combinations where theitem type = 8D and sitetype in(Sony Plant or Other Plant)and create the resource asEOL_ Item Code _SiteCode

There is anopenquestion asto how toidentify theEOL items

Need to syncup with UIteam

ISM.SiteId

ISM.SiteId RM.SITEID Site code as obtained above

Populating OperationResourcesAdditional(ORA) table


FIXED_SCHEMA_FIELD


ORA.RESOURCENAME

Get theSiteid,Workcentername andResource Name,RunTimePerfrom OperationResource(OR)table whereOR.Siteid=SiteId obtainedabove and ResourceNameLIKE LNE%

Line Resourcethat is used toproduce theFG at the asite

ORA.SITEID Site id obtained above

ORA.WORKCENTERNAME

Workcentername obtainedabove

Associatedwork centerfor the Line


66/131



Resources

ORA.ROUTINGID Get the RoutingID fromItemBOMRouting whereItem=Item Code used in EOLResourceName and SiteId =

Siteid used in EOLResourceNAme andpriority=max(priority)

Routing towhich Lineresource isattached

ORA.OPERATIONSEQ

1 Hard coded to1 as there isonly oneoperation in agiven route

ORA.ADDRESOURCENAME

FG Use up Resource createdabove

FG_use upresource name

ORA.ADDRESOUR

CESITEID

Site Id used obtained for FG

Use up Resource

ORA.ADDWORKCENTERNAME

Site Id used obtained for FGUse up Resource

ORA.RUNTIMEPER Runetimeper obtained inabove query forORA.RESOURCENAME

Sameproperties asit exists forproducing thisFG + sitecombinationusing the LineResource

(which is at awork center)

Loading WorkcenterDetail for FG Use upResource:

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD


IFLayout_DSM-M009_Item_Site_Master.

Item Code

WCD.RESOURCENAME

Create Resource name usingthe same logic used to createFG Use Up Resource in

ResourceMaster

OpenQuestion onhow to

identify forwhich itemsthis is to becreated?



67/131


68/131



Site Code

IFLayout_DSM-

M009_Item_Site_Master.Site Code

WORKCENTERNAME

Site Code as above

IFLayout_DSM-M009_Item_Site_Master.Site Code

CALENDARNAME Same logic used to create theFG Use up ResourceCalendarName inCalendarMaster

CALENDARTYPE CAPACITY Hardcodedvalue



LOGIC REMARKS

CD.CALENDARNAME

Same logic usedto create FG Useup CalendarName in

Calendar Master

CD.PATTERNSEQ Current datefrom PlanMAstertable inYYYYMMDDformat

CD.EFFSTARTDATE Current datefrom PlanMastertable

CD.EFFENDDATE Effective Enddate fromPlanMaster table

CD.PRIORITY 1

CD.PATTERNNAME EVERY_N_DAYS Hardcoded value


69/131





LOGIC REMARKS

CD.CALENDARNAME

Same logic used to

create FG Use upCalendar Name inResource Master

CD.PATTERNSEQ

Same logic used inCalendarDetail

ATTRIBUTE AVAILABLE_CAPACITY

Hardcoded value

IFLayout_DSM-T017_Cumulative_Quantity_Actu

al.Site Code+IFLayout_DSM-T017_Cumulative_Quantity_Actual.Product code

UI table to befinalized

VALUE 1. Match theSite Codeand 8D code

above to theSite Codeand ItemCode ofIFLayout_DSM-T017_Cumulative_Quantity_ActualwhereRecordtype= R3to get the

Quantity.Aggregate theValue to getthe totalCumulativeProduction

2. Get totalallowedvalue from UItable

3. Populate the

differencebetween theabove twovalues i.e,(Totalallowedvalue-Cumulative


70/131



production)

Populating CalendarPatternDetail(CPD):


LOGIC REMARKS

CPD.CALENDARNAME

Same logic usedto create PanelUse up CalendarName inCalendar Master

CPD.PATTERNSEQ

Same logic usedin CalendarDetail

CPD.ATTRIBUTE nth Hardcoded value

CPD.VALUE No. of daysbetweenPlanMaster.Effective End Dateand PlanMaster.Current Date


Panel use up qty will be modeled as an artificial resource at the set plant. It is treated same as

FG Use up Resource. The capacity of such artificial resource is calculated based on the paneluse up quantity minus actual production quantity from the effective start date.Panel use upquantity and its effective start date are maintained through DSM UI while the weekly actualproduction quantity and panel effective start date would come from data interface.

The logic for creating the Panel Use up Resource is explained below and will be loaded in the


71/131



Resource Mastertable in the fixed schema

BLUE_FILE_FIELD

IF_TBL_FIELD FIXED_SCHEMA_FIELD

LOGIC REMARKS

IFLayout_BOM

Master.Assembled ItemCode

RM.RESOURCENAM

E

Get the Assembled Item Code,

Component Item Code andSite Code where AssembledItem Type=8D,ComponentItem type= Panel Series andSite Type in (Sony Plant,Other Plant) .Create theResource name as USE_PNL_Component Item Code_Assembled Item Code_Site Code

Need to sync

up with UIteam

IFLayout_BOMMaster. SiteCode

IFLayout_BOMMaster.ComponentItem Code


RM.SITEID Site code as obtained above

Populating OperationResourcesAdditional table


FIXED_SCHEMA_FIELD


ORA.RESOURCENAME

Get theSiteid,Workcentername and

Resource Name,RunTimePerfrom OperationResource(OR)table whereOR.Siteid=SiteId obtainedabove and ResourceName LIKELNE%

SITEID Site id obtained above

WORKCENTERNAME

Site ID obtained above

ROUTINGID Get the RoutingID fromItemBOMRouting where

Item=Item code used in PanelUse Up ResourceName andSiteId = Siteid used in Paneluse up ResourceNAme andpriority=max(priority)

OPERATIONSEQ 1

ADDRESOURCENA Panel Use up Resourcecreated above


72/131



ME

ADDRESOURCESITEID

Site Id used obtained forPanel Use up Resource

ADDWORKCENTE

RNAME

Site Id used obtained for


ORA.RUNTIMEPER Runetimeper obtained inabove query forORA.RESOURCENAME

Loading WorkcenterDetail for Panel Use upResource:

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD


IFLayout_BOM

Master.Assembled ItemCode

RM.RESOURCENA

ME

Use the same logic as used in

Resource Master to create thePanel Use Up Resource

Open

Question onhow toidentify forwhich itemsthis is to becreated?




WCD.WORKCENTERNAME

SiteId as obtained above


WCD.SITEID SiteId as obtained above

WCD.LOADPOLICY

FLOW_LIMIT_CALENDAR Hardcodedvalue

Creating the entry in Calendar MasterTable:

BLUE_FILE_FIELD

IF_TBL_FIELD FIXED_SCHEMA_FIELD

LOGIC REMARKS


73/131



IFLayout_BOMMaster.Assembled ItemCode

CM.CALENDARNAME

Get the Assembled Item Code,Component Item Code andSite Code where AssembledItem Type=8D,ComponentItem type= Panel Series andSite Type in (Sony Plant,

Other Plant) .Create thecalendar name asRC_USE_PNL_ ComponentItem Code_ Assembled ItemCode_Site Code

Need to syncup with UIteam

OpenQuestion is

there on howto identifythese items

IFLayout_BOM

Master. SiteCode


Populating Resource Calendarfor Panel Use up Resource:

BLUE_FILE_FIELD

IF_TABLE_FIELD

FIXED_SCHEMA_FIELD



RM.RESOURCENAME

Same logic used to createPanel Use Up resource inResource Master

OpenQuestion isthere on howto identifythese items


IFLayout_BOM

Master.ComponentItem Code


RM. SITEID Site Code used in creating theResource Name above


WORKCENTERNAME

Site Code obtained above

IFLayout_DSM-M009_Item_Site_Master.SiteCode+IFLayout_BOMMaster. SiteCode+IFLayout_BOMMaster.

CALENDARNAME Same logic used to createPanel Use Up CalendarNamein Calendar Master


74/131



ComponentItem Code

CALENDARTYPE CAPACITY Hardcodedvalue



LOGIC REMARKS

CD.CALENDARNAME

Same logic usedto create PanelUse up CalendarName inResource Master

CD.PATTERNSEQ Current datefrom PlanMAstertable inYYYYMMDDformat

CD.EFFSTARTDATE Current datefrom PlanMastertable

CD.EFFENDDATE Effective Enddate from

PlanMaster table

CD.PRIORITY 1

CD.PATTERNNAME EVERY_N_DAYS Hardcoded value



LOGIC REMARKS

CD.CALENDARNAME

Same logic used tocreate Panel Use upCalendar Name inResource Master

CD.PATTERNSEQ

Same logic used inCalendarDetail


75/131



ATTRIBUTE AVAILABLE_CAPACITY

Hardcoded value

VALUE 1. Match the SiteCode andPanelSeries

code aboveto the SiteCode and ItemCode ofIFLayout_DSM-T017_Cumulative_Quantity_Actual whererecord type=R3 to gettheQuantity.Aggregate the

Value to getthe totalCumulativeProduction

2. Get totalallowed valuefrom UI table

3. Populate thedifferencebetween theabove two

values i.e,(Total allowedvalue-Cumulativeproduction)

Populating CalendarPatternDetail(CPD):


LOGIC REMARKS

CPD.CALENDARNAME Same

DSM Integration Architecture V2.4

Documents

Transcript of DSM Integration Architecture V2.4