- SAP Managed Tags
Setupmatrix
The steup matrix is a configuration element used to specify the time required to switch from producing one product to another or to prepare a machine from old setup to a new production setup run.
For example Product A, B, C can be produced in same lathe machine but with different moulds. Product A and C uses same Mould 1 (1hr setup time), but product B use different mould 2 (2hr setup time). So it means if the lathe machine has mould 1 installed we can produce product A and C in single go and if need to produce the product B we need to change the mould which requires 2 hr.
Let us consider we need to produce the products A, B, C.
Production Sequence 1: A -> B -> C
Setup time = A (1 Hr) + B (2 Hr) + C (1 Hr) = 4 Hr
Production Sequence 2: A -> C -> B
Setup time = A & C (1 Hr) + B (2 Hr) = 3 Hr
If we produce the product in 1st sequence we need to change the moulds for each production. So it will take 1 he extra setup time. But if we produce the Products in 2nd sequence then we take 1hr less setup time. So in the 2nd sequence the remaining 1 hr of the machine can be used for producing another product. So like this we can reduce the setup time and increase the production time. All these can be done only if we have production resourse crunch.
Main Part:
Setup matrix Creation methods
1. Automatic creation
2. Manuall creation.
In automatic method characters are mandatory whereas in manuall method setup group are mandatory. Also manuall method can support campaign planning
Automatic Setupmatrix creation 1: reference SAP manufactory
For generation the setup matrix automatically, we need to define the class characters for material based on business and to create it in SAP. Consider we have 3 materials and which are produced in different forms & pack in same workcenter 'Lathe' which has 9 different moulds.
| Material | Character - Bulk | Character 2 - Pack |
| Powerppds | Power | 1000ML |
| Ultrapowerppds | Ultrapower | 500ML |
| Supremeppds | Supreme | 750ML |
Setup time required for changing moulds in lathe on product change.
| Production line A - Bulk type | Production line A - Pack type | |||||||
| Power | Ultra power | Supreme | 1 ltr | 500 ml | 750 ml | |||
| Power | 0 | 2 | 3 | 1 ltr | 0 | 1 | 2 | |
| Ultra Power | 2 | 0 | 2 | 500 ml | 1 | 0 | 1 | |
| Supreme | 4 | 3 | 0 | 750 ml | 2 | 1 | 0 | |
| 1 | 2 | 3 | 1 | 0.5 | 0.7 |
So here there will be 90 combinations of setup transistion times.
Process flow
S1. Creation of characteristics and class - CT04, Cl02 - (and moving it to APO system using CIF See)
2. Maintain setup matrices for characteristic value /N/SAPAPO/CDPS_CHARMAT.
3. Maintain rules for the generation of setup groups using /N/SAPAPO/CDPS_GRPRULE. 4. Maintain rules for setup matrix generation with /N/SAPAPOI/CDPS_MATRULE.
5. Generate the setup matrix based on the specified rule using /N/SAPAPO/CDPS_MATGEN.
6. After generation, display the setup groups and setup matrices with /N/SAPAPO/CDPS_SETUP.
7. Creation of PP master data - MM01, CS01, CR01, CA01, C223.
8. Creation of PP order - /n/SAPAPO/RRP3
9. Running heuristics - /n/SAPAPO/CDPS0
Menu Path: SAP Easy Access screen > Logistics > Advanced Planning > Master Data > Setup Group/Setup Matrix > Generate Setup Matrices.
Characteristics - CT04
Maintain setup matrix - /SAPAPO/CDPS_CHARMAT
Transform the setuptime table to below in excel and copy it here.
Maintain rules for generationg setup group - /n/SAPAPO/CDPS_GRPRULE
Give the characters inside and seperator as - hypen. We can use up to 6 characters
Maintain rules for generating setup matrices - /N/SAPAPO/CDPS_MATRULE
Generate setup matrix - /N/SAPAPO/CDPS_MATGEN
We can cross verify the values which we created. Now setup matrix is created.
Created Material Master in mm01 with class characters and dummy BOM in cs01 with no components.
Check that all characteristics moved to APO system in /N/SAPAPO/MAT1. CIF is mandatory.
Create Resource - CR01
Inside capacity header click APO resource and change the resource type to 2 - single reosurce. Setup matrix can be created only in single resource type.
In APO /N/SAPAPO/RES01 maintain the setup matrix which we created.
/SAPAPO/CURTO_SIMU - Display Production Data Structures
Let us create order in /n/SAPAPO/RRP3. Inside it click edit button. 
See the changes in production scheduling board - /n/SAPAPO/CDPS0
You can see the setup matrix time has been picked here. Even I mentioned 1 hr in routing it took the time from setup matrix.
For first order the setup time 2 hr as the switch is from material empty to Power 1000ML For 2nd order its 0 hr as the switch is happening between the power 1000ml to power 1000ml. Same can be seen is setpmatrix - /n/SAPAPO/CDPS_SETUP 
Let us schedule it and see the difference in planning board
Below the switch is between power 1000ml and ultrapower 500ml material. so the 1st setup time is 3hr and the second switch is between ultrapower and ultrapower. so the setup time is 0 hr.
Manual Setup matrix creation 2:
Manual Setup Matrix are mostly used for process industries. Consider below 3 materials are produced and are grouped under below setup groups. Transistion times are given below.
| Product | Setup groups | SETUPGRP1 | SETUPGRP2 | SETUPGRP3 |
| MATLATHE01 | SETUPGRP1 | 6 | 2 | 3 |
| MATLATHE02 | SETUPGRP2 | 2 | 0 | 3 |
| MATLATHE03 | SETUPGRP3 | 3 | 3 | 0 |
Process flow
1. Creation of setup groups - OP43
2. Moving setupgroups to APO logical system using CFM1 and CFM2
3. Display setup groups in APO using /n/SAPAPO/CDPSC6 - Maintain Setup Groups
4. Create the setup matrix using /n/SAPAPO/CDPSC7
5. After Creation, display the setup groups and setup matrices with /N/SAPAPO/CDPS_SETUP.
6. Creation of PP master data - MM01, CS01, CR01, CA01, C223.
7. Assign the setupgroups to recipes in C202
8. Assign the setupmatrix to Resource in /n/SAPAPO/RES01
6. Creation of PP order - /n/SAPAPO/RRP3
7. Running heuristics - /n/SAPAPO/CDPS0
Configuration:
Create Setup Group 1: OP43 or Path - SIMG - Production Planning for Process Industries - Master Data - Master Recipe - Data for Operations and Phases - Define Setup Groups and Setup Group Categories
After creating setupgroups in ECC we need to create integeration model in CFM1 to create these setupgroups in APO logical system. You can add plant in general selection also in addition to setup groups. Here you can uncheck the objects if you have issue.
Later click Generate it
Activate the integeration Model in CFM2 by clicking activate and start. Keep the CFM1, OP43, CT04 and CL02 tcodes closed to avoid data locks. At a time only one model can be activated.
After activation the setup groups will be populated to APO logical system and seen in tcode /SAPAPO/CDPSC6 - Maintain Setup Groups .
Master data:
Create Setup Matrix in - /n/SAPAPO/CDPSC7
Create setupmatrix and save it. later go back and double click it
The same can be displayed in /SAPAPO/CDPS_SETUP - Display Setup Matrix
Now create the master data like material master, BOM, Recipe, PDS. Here additional step is we need to assign the setupmatrix to recipe at operation level for each material. You can add only to setup operations in recipe.
For MATLATHE02
Move the PDS and check it whether it has all the phase and setupgroup.
Detailed scheduling Board Results
Having issue in PDS. Will update the pics later. As per above method the setup matrix to be utilized for process orders.
Assumptions in PPDS vs Reality
Previously in ECC Mrp Type XO was used to run advanced planning and the materials with XO will not be planned in MRP.
But now in HANA the MRP will plan the mateirals with MRP type XO. But MRP live parameters in MD01N will not be for ePPDS materials. Because of this ePPDS production order scheduling dates were modified by MRP and planned orders created for eppds BOM components. To overcome this remove scheduling in planned order parameters (OPU5) and use basic date scheduling in MD01N. All BOM materials above eppds material to be set active for ppds. Planning procedures to be maintained accordingly in SIMG - Advanced planning - Maintain Planning procedure. Scope Limitaion in material master to be set accordingly.
Note: /n/SAPAPO/CCR is used to solve scheduling discrepencies.
Scope Limitation in Advanced planning view of material master
Note: Blank - PPDS Entire scope
Some additional data regarding class in ECC vs APO.
Class Characters in APO are used for below.
Shelf Life Planning, Campaign Planning, Setup Matrix, Alternative Mode Resource Scheduling, Detailed Scheduling with characters, Characteristic dependent planning CDP, Variant configuration. Integeration Model should be set in CFM1 to move class characters from ECC to APO logical system
Class type in ppds vs ECC
| Class Type | ECC | APO |
| Variant Configuration | 300 | 400 |
| Batch Class | 023 | 230 |
| Material Class | 001 | 001 |
| Work center Assignment | 019 | 019 |
No Integration Model required for data flow
Required only Organization area in use
In workcenter CR02 - More - Extra - Classification - Class type 019 can be added for Alternate mode resource schdeuling.
Configs to add class charactes in ECC and PPDS
SIMG - Logistics general - Batch management - Batch valuation - Update standard characteristics , to create default ppds charactersitcs
SIMG - Advanced planning - basic settings - Settings for data transfer, To move batch master to ppds
Conclusion: I hope this may help someone. Please mention if there are mistakes.
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