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  Setup Matrix

Definition

Matrix that contains, for each possible setup transition at a single resource , the setup times and the setup costs that are necessary to change the setup status of the resource to another setup status.

Use

You can use a setup matrix to model sequence-dependent setup times and setup costs for a single resource. Based on the setup matrix, the system can do the following:

  • For detailed scheduling, it can determine the correct setup

  • Determine optimal operation sequences (with regard to setup time or setup costs) during optimization

  • Determine the production process model for creating a setup order and clean-out order during campaign optimization

    Note Note

    The determination of sequence-dependent setup activities and setup optimization can only be applied to single resources that are used exclusively in the modes of the production process models as primary resources.

    End of the note.

A setup matrix is only valid for a specific location.

Integration

Two forms of setup matrixes are offered:

  • Conventional setup matrix

    This setup matrix consists of setup groups that you create in the connected ERP system and transfer to SAP APO.

  • Generated setup matrix

    This form of setup matrix is created automatically by the system according to the rules that you specify. In the process, the setup matrixes for characteristic values form the basis for a generated setup matrix, because the setup groups and the actual setup matrix are generated from these setup matrixes. The system then determines the relevant setup groups when exploding the order.

You must decide on one of the two forms prior to planning the products. If you decide on the generated setup matrixes on the basis of characteristics, you must not assign any setup groups to the operations in the connected R/3/ERP system because otherwise the setup groups generated by SAP APO will be overwritten when the order is transferred.

Structure

Setup Transition Types

A setup status is defined in the setup matrix either by a setup groupor by a setup key. The following types of setup transition are possible:

  • Standard setup transitions

    Here you characterize the preceding setup status as well as the subsequent setup status in the setup transition using a setup group.

  • Exception setup transitions

    Here you characterize at least one of the setup statuses using a setup key.

    You can only define an exception setup transition as an exception to a standard setup transition in the setup matrix. The setup groups for this standard setup transition must contain the setup key for the exception setup transition.

  • Setup transitions without change of setup key

    You use this setup transition type to replicate the transition between two setup statuses in which the setup key does not change. This is always the case if, for example, a further order for product A is to be manufactured following an original order for this product and no re-setup is necessary.

    You can only create a setup transition of this type in the setup matrix if you have already defined a standard setup transition for this setup group that contains the relevant setup key.

As in the case of the setup matrix, setup groups and setup keys are only valid for a certain location.

Completeness of Setup Matrix

The setup matrix must contain all setup transitions that can occur at the resource. However, you do not have to define each setup transition explicitly. Using an asterisk (*), which you enter in a setup transition instead of a setup group, you can define generic setup transitions in the setup matrix. However, the asterisk (*) only replaces the setup groups that you also use in the setup matrix explicitly to define setup transitions, and not all setup groups that you defined for the location.

Example Example

Using the setup groups A, B, C and the setup key a, you have defined the following setup transitions in the setup matrix: AB, AC, Aa.

Using a setup transition ** in the setup matrix, you include the following setup transitions: AA, BA, BB, BC, CA, CB, CC. These are the missing combinations for the setup groups used explicitly in the setup matrix. If you have also defined the setup groups D, E, and F in the location, the setup transitions with these setup groups are not included when using the generic setup transition **. You have only explicitly used the setup groups A, B, and C in the setup matrix.

By entering a setup transition *a, you are including the following setup transitions: Ba, Ca. These are the missing transitions for the setup groups used explicitly in the setup matrix according to setup key a.

End of the example.
Initial Setup Statuses

It may be the case that the setup status of the resource is not defined at the point in time when you schedule an operation at this resource. This occurs, for example, in the detailed scheduling planning board if you reschedule an operation so that the first operation is in the resource schedule. At the beginning of the schedule the setup status of the resource is not defined for the system because no operation has yet been processed on the resource. In such cases, you can enter setup transitions in the setup matrix between an initial setup status for the resource and the possible setup statuses. You define such transitions by not entering a setup group or a setup key for the preceding setup status.

Recommendation Recommendation

For performance reasons , it is recommended that you define setup matrices that are as small as possible, with few setup transitions. You should therefore:

  • Classify the setup transitions using setup groups and setup keys only to the degree of detail that is necessary

  • Use as few exception setup transitions as possible

End of the recommendation.
Transfer of Setup Keys, Setup Groups, and Setup Matrixes

You can transfer these objects from one SAP APO system to another SAP APO system using the following report:

Report

Transfer from

/SAPAPO/SETUP_GROUP_COPY

Setup groups and setup keys

/SAPAPO/SETUP_MATRIX_COPY

Setup Matrixes

A prerequisite for a successful transfer is that the locations for which these objects were created are available in the target system. This also applies to the plan numbers that you can specify in the setup matrixes for campaigns. These plan numbers must also exist in the target system. You define the target system by specifying the RFC destination of the system.

Example

  • Example of standard setup transition

    You have grouped together the products A, B, and C to form product group 1 and the products D, E, and F to form product group 2. In the case of a change in the product group from 1 to 2, re-setup takes 5 hours. Re-setup from product group 2 to product group 1 takes 6 hours.

    To define this re-setup in the setup matrix, you create a standard setup transition from setup group SG1 to setup group SG2 with 6 h setup time.

  • Example of exception setup transition

    There is an exception to the standard setup transition ‘re-setup from SG 1 to SG 2’, which takes 5 hours: re-setup from product A (from product group 1) to product D (from product group 2) takes 2 hours. You have created one setup key for each of the two products. You can specify this re-setup via an exception setup transition with the setup key of SKA to SKD with 2 h.

  • Example of setup transition without change in setup key

    The re-setup of the resource due to a product change within product group 1 takes 2 h (for example, re-setup from product A to product B). You define this situation in the setup matrix with the standard setup transition of SG1 to SG1 with a setup time of 2 h.

    If there is no change in the product, as in the case of a further order for product A after an original order for the same product, for example, no setup time is necessary. You define this situation in the setup matrix by creating a setup transition without a change in the setup key from SRG1 (predecessor) to SG1 (successor) with 0 h setup time.