1. Oracle APS and GOP – Getting To Automated Sales Order Scheduling
Mark Hopkins, Xilinx, Inc.
8/23/06
Xilinx Confidential

2. Topics Goals of Our GOP Implementation Where We Are Today
How We Did It
Lessons Learned
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3. 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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4. Results: Auto Release And On Time Delivery
~13k Line Items per month.
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5. 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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6. 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)
Almost 100% of incoming sales orders get schedule dates recommended from GOP
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7. 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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8. 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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9. Standard Oracle GOP Process
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10. 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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11. Demand Management Form
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12. 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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13. 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
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