Xilinx Confidential

Oracle APS and GOP – Getting To Automated Sales Order SchedulingMark Hopkins, Xilinx, Inc.1/17/06

Xilinx Confidential

Topics

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

Xilinx Confidential

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

Xilinx Confidential

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Nov-05 Dec-05 Jan-06 Feb-06 Mar-06 Apr-06 May-06 Jun-06 Jul-06

% Ontime % Auto Released

Results: Auto Release And On Time Delivery

~13k Line Items per month.

Xilinx Confidential

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

Xilinx Confidential

What’s In Production:ASCP 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

Xilinx Confidential

Our Model(example from our ATP Plan)

Plan Type: Cost Based Optimized Plan - HP 64bit ExeEnforce Material Constrained PlanHolistic Manufacturing Plan with Project PlanningTime Buckets: 35 days, 10 Weeks

Inputs:Orgs: 56Items: 22kDemands: 19kBOM's: 17K

Outputs:Demands: 64kSupplies: 56kPegging: 78kRes Reqmts: 200k

Xilinx Confidential

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

Xilinx Confidential

Standard Oracle GOP ProcessCustomer

Oracle ERP

Oracle APS

1. New Order

2. Request for Scheduling

3. Schedule Ship Date

4. Commit Date

Xilinx Confidential

Xilinx Gates in GOP ProcessCustomer

Oracle ERP

Oracle APS

1. New Order

2. Request for Scheduling

3. Schedule Ship Date

4. Commit Date

•Is order on hold?•Is order unusually large?•Do we want to force a particular schedule date to happen (ATP Override?)

•Is calendar date blocked?

•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?

Xilinx Confidential

Demand Management Form

Xilinx Confidential

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.

Xilinx Confidential

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