Los problemas de la paz. El Desarme

Lesson Overview

The overview presents the most important steps in repetitive manufacturing along with their characteristics. As well as planning, the processes also cover material staging and backflushing.

Lesson Objectives

After completing this lesson, you will be able to:

• Outline the most important characteristics of repetitive manufacturing

• Compare repetitive manufacturing with the alternative production methods

Business Example

In order to compare repetitive manufacturing with other production methods, you need to get an overview of the most important characteristics of repetitive manufacturing.

Figure 14: Repetitive Manufacturing (Period-Based Production)

In repetitive manufacturing, you create and process production plans on the basis of the periods and quantity (rather than individual lots and orders).

Planned orders of order type PE (run schedule quantities) specify the production quantities and dates. These planned orders are not converted to production orders.

A printed list of these planned orders authorizes production.

The aims of repetitive manufacturing are to:

• create and process production plans based on periods (rather than individual lots and order-related processing).

• reduce the administration costs for production control, and simplify completion confirmation via backflushing, while still being able to use the full range of PPC functions

• reduce controlling costs

Figure 15: System Landscape in Repetitive Manufacturing

You can use the following mySAP components to perform planning in repetitive manufacturing:

• SAP ECC (standard planning process)

• SAP SCM (using the advanced planning functions Advanced Planner and Optimizer – SAP APO)

• SAP BW (using the Business Information warehouse as a data basis for requirement forecasting and evaluations)

Up to Release 3.1, the APO functions are used as a separate system. As of Release 4.0, APO (along with other components) is fully integrated into the SCM system.

Demand planning, requirements planning, capacity requirements planning as well as line loading planning and the availability check can either be carried out in the ECC system or in the SCM system, whereas sales orders must always be created in ECC and – if required for planning purposes – transferred to the SCM system.

A plug-in provides the interfaces used to integrate ECC with BW or SCM (APO).

The interface between ECC and SCM (APO) is called the Core Interface (CIF).

Figure 16: Planning in Repetitive Manufacturing

The mySAP SCM solution offers two general solutions for integrating planning and production: Planning with the functions of the APO component (included with the SCM system), and planning with the functions of the ECC component.

Final preparation, production execution, and production control are always carried out using the functions of the ECC component. The master data and movement data (planned orders, purchase requisitions, purchase orders, stock, and so on) are exchanged between the two SAP ECC and SCM(APO) components through the Core Interface (CIF). Sales orders are generally entered in ECC and then transferred to APO.

Planned orders can be generated using material requirements planning in ECC using MRP, or in SCM (APO) using a) Supply Network Planning in APO Planning (SNP). This component allows you to perform cross-plant planning in a long-term planning horizon across the whole supply and procurement chain. Here, purchase requisitions of stock transfers (distribution), planned orders (in-house production) and purchase requisitions (external procurement) are created for the relevant production plant. And b) Production Planning and Detailed Scheduling as part of APO planning (PP/DS). This creates planned orders and purchase requisitions in a defined, short-term period (production horizon) in the production plant.

A distinguishing feature of repetitive manufacturing is that planned orders with order type “PE” (run schedule quantity) are used for production, which means that planned orders are not converted. Only their status changes when they are assigned to the production line.

Figure 17: Repetitive Manufacturing as MTS and MTO Production

Make-to-stock production:You can use repetitive/flow manufacturing for pure make-to-stock production. This means you produce products with no direct reference to sales orders. The planned independent requirements from demand management are used as the basis for planning. Depending on your planning strategy, the planned independent requirements from demand management may be consumed by sales orders. The same product is often produced repeatedly over a substantial period of time. It is not manufactured in individually defined lots.

Instead, a total quantity is produced over a certain period at a certain rate per part-period. Products pass through production in a relatively steady flow. Sales orders are filled from warehouse stock.

Make-to-order production (sales order-based production): You can use repetitive/flow manufacturing for make-to-order production. This means you produce products with direct reference to the sales orders. The products are stored in the sales order stock. Sales orders can be processed separately. A planned order is created with direct reference to the sales order. Production is therefore controlled via sales orders. The quantities produced cannot be swapped between the individual sales orders. The produced quantities are stored specifically for the individual sales order (sales order stock) and not in the make-to-stock inventory.

If you use variant configuration, you can plan and manufacture configurable materials using make-to-order repetitive manufacturing.

Sales orders are filled from sales order stock.

Prerequisite: You use the strategy group in the ECC material master record to control whether you want to use make-to-stock or make-to-order repetitive manufacturing.

Figure 18: Material Provision and Backflushing in Repetitive Manufacturing In repetitive manufacturing, products are generally produced repeatedly over a substantial period of time. The production quantities are not necessarily high.

Products generally pass through production in a steady flow and several products can be manufactured on one production line.

The necessary components are staged anonymously at the production line.

At the end of the shift or at the end of a day, you can backflush all the quantities produced in one go (daily quantities).

In one of the repetitive manufacturing exercises for example, a “mother board”

assembly is produced. To produce this assembly on the production line, we require the components “BIOS”, “processor”, and “RAM”.

Lesson Summary

You should now be able to:

• Outline the most important characteristics of repetitive manufacturing

• Compare repetitive manufacturing with the alternative production methods

Unit Summary

You should now be able to:

• Explain the most important characteristics of the production types in the repetitive manufacturing environment

• Outline the most important characteristics of repetitive manufacturing

• Compare repetitive manufacturing with the alternative production methods

Test Your Knowledge

1. Discrete manufacturing cannot be combined with repetitive manufacturing in the case of multi-level production (finished product, assemblies, components).

Determine whether this statement is true or false.

□ True

□ False

2. In repetitive manufacturing, a planned order is not converted to a production order.

Determine whether this statement is true or false.

□ True

□ False

Answers

1. Discrete manufacturing cannot be combined with repetitive manufacturing in the case of multi-level production (finished product, assemblies, components).

Answer: False

The production type can be selected according to material. This means, for example, that assembly production in repetitive manufacturing can be combined with final assembly in production order processing.

2. In repetitive manufacturing, a planned order is not converted to a production order.

Answer: True

Production orders are not used in repetitive manufacturing. There is no conversion.

Unit 3