Discrete vs Process vs Repetitive?

Can some one explain the difference between Discrete, Process, Repetitive process.
Can we implement all the three process in the same plant??

Hi George,
Find below the documentation from SAP:
REM
You can implement Repetitive Manufacturing if the following is true of your production process:
- You produce the same or similar products over a lengthy period of time.
- You do not manufacture in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate per part-period.
- Your products always follow the same sequence through the machines and work centers in production.
- Routings tend to be simple and do not vary much.
PP-PI (process)
It is primarily designed for the chemical, pharmaceutical, food and beverage industries as well as the batch-oriented electronics industry. PP-PI supports:
- The integrated planning of production, waste disposal, and transport activities within a plant
- The integration of plants within the company:
- Vertically by means of an information flow, ranging from central business applications down to process control
- Horizontally by the coordination of planning between production plants, recycling and waste disposal facilities, and production laboratories.
Discrete (my views)
Discrete production flow is normally adopted by firms who are manufacturing specialised products eg: custom built machines or where the volumes does not justify to opt for a repetitive kind of setup. Also from finance perspective, when you want to trace the costs at order level & not by period.
Now coming to your qns, whether all three can be implemented in the same plant, well can you let us know what processes are being followed, as to the best of my knowledge, no single plant has all 3 processes working in tandem.
Hope the above was helpful.
Regards,
Vivek

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Discrete production process after creating sales order with raw materials

Dear all,
I need your support on a specific solution related to discrete production process.
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Hi Seshi,
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Distinguishing features of Discrete and Process Manufacturing?

Hi
I need to know the difference between process and discrete manufacturing environment.
Also, what SAP PP offers to cater both environments?
Plz help.
Edited by: Chris SAP on Aug 5, 2010 5:01 PM

Hi Chrish,
A ) In Pharma the requirement of Key raw material's ingredient will differ based on the active ingredient of other component for key raw material to achieve desired result .
say A + B -
> C   where in A is the key raw material
         100 Kg -
>>> 100 Kg yield where in 100% of A & 50 % B gives 100 % C
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In the BOM we have MQC in that formula could be defined for making this balance
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Diff between process and repetitive ind.

Hi PP gurus,
Can anybody please explain whatz the difference between a process industry and a repetitive manufacturing industry?
my doubt is like if we are goin to implement SAP in some continuous running industry,how can we able differenciate whether its a process industry ya repetitive manufacturing industry.
kindly reply for my doubt.
thanks in advance
Rgds,
Madhu

Hi Madhu
In process industry , the production is booked as charges or batches ,these charge would have its own compositions , characteristics & operations required to produce them so these charges are produced using a process order. So production is recorded as how many process orders r produced.And the cost may differer form process order to order and cost's get settled based on order .
In repetative mfc the production is booked based on time rather that charge, i.e i produce 500 units in 8 hrs ( per shift) so every shift i book what ever i produce in that shift using t-code MFBF , no order gets created. So the cost is also setteled on the FG material directly using PCC. More over the production process is made simple by directly backflushing the components required in one transaction as the process is more repetitative type of thing.
There are many more diff, but hope this would allow u to make dicission on what process to adapt in ur case.
Regards
Prasad
Reward if useful.

In-process inspection in repetitive mfg- Inspection type - 13

Hi there,
Can any one please tell me what is the differrence between the inspection type -03 & 13.
As per my understanding the only diff is that 03 is used in discrete mfg & 13 in repetitive mfg...
what is the other differrence ........??
Regrads
Kaushik

Hello Kaushik,
actually you have already found out that 03 is for descrete and 13 for repetive manufacturing. What is the difference?
03 Descrete Manufacturing : Limited production numbers and can be assigned to a customer order. Example: A computer built with various extras (built to order).
Accordingly inspection plans and inspection points assigned can be configured rather freely.
13 Repetitive Manufacturing: Production lines produce the same product in an unlimited number over a longer period of time. Example: Screws M8 x 40 mm (Mass production). In this case inspection plans need a relation to either time, numbers etc.
I hope that this information answers your question.
Regards
Isabelle

What is discrete manufacturing and REM?

Hello All,
What is discrete manufacturing and REM?
Sincerely,
Ketan

Hi ketan,
-Discrete manufaturing is Lot based production system, Porduction order is cretaed for Every Lot and order based confirmation & Cost control is carried out.
-Repetative manufacturing is period based production system, production order concept will not work, so period based confirmation & cost control is carried out.
Below points helps to underdstand the difference between them.
- A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots.
- In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate.
- Discrete manufacturing typically involves varying the sequence of work centers through which the products can pass during production. The order of work centers is determined in routings, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing.
- Repetitive Manufacturing, on the other hand, normally involves a relatively constant flow on production lines. Semi-finished products are usually processed further immediately without being put in interim storage. Routings tend to be relatively simple.
I hope u have understood if yes please reward and close the thread.
Regards
Pardeep

Mass processing by T.code COOIS

Hi,
How can I execute some mass processing in the T.CODE COOIS and not only reporting.
I canu2019t use u201Csettingsu201D and u201Cmass processingu201D in my system. They are deactived. Do I need some customizing.
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Hi Glenn,
Please use COHV - Mass processing by which you can execute the required changes.
COOIS is purely used to collectively get the desired reports for the discrete production process( production orders, etc)
Hope this clears your question.
Thanks & Regards,
Abhijeet Guha

Oracle Process Manufacturing Release 11i

Hi there,
Is there a free version of Oracle Process Manufacturing 11i for download? If so what is the site?
Thanks.
Regards,
Leon

Hi All,
Here I talk a step to explain about Discrete, Flow, Process and project manufacturing process.
Discrete:
1. Assemblies are built in specific (discrete) quantities. These jobs or work orders use specific materials and resources.
Say ship building, job shop companies etc are few examples of discrete.
2. Assemblies that are made in groups or batches.
Discrete Manufacturing is a Batch production situation related to most industries like Engineering
It use routings to schedule job production activities and create operation specific material and resource requirements.
Flow:
Flow manufacturing developed to support 'Lean manufacturing'.
Lean manufacturing concepts include:
JIT, pull, value stream mapping, kanban, single piece flow etc.
This module will enable flow manufacturing concerns.
Ex: Car manufacturing
http://forio.com/simulation/oracle/main.htm?page=background&FD_p=1
http://www.psa-peugeot-citroen.com/en/psa_group/visite/index.html
Process:
It is purely for process manufacturing concern
Ex: Chemical industry, pharmateicals etc jus think of chemical laboratory.
Project:
Projects are used to track costs by specifying revenue and billing methods. Each project can have a set of top level tasks, and a hierarchy of subtasks.
As rightly said ETO is example for project manufacturing
To answer your questions
1- A Steel making Company is under Discrete Manufacturing or not?
Depending the concern manufacturing practice only we can say it as discrete or not.
From the above explanation you can able to understand it.
All discrete industry will adopt few lean manufacturing principles to add value in their process.
2- Can we have Discrete & Process in one organization? because some part of my Org like Discrete Manufacturing and other like Process Manufacturing ?
Yes we can have, say for a final product two or more items may come from both discrete and process types.
Hope it is clear and helpful.
Tks
M J

Executing independent Forte processes

Ed,
You can create a very lightweight client object that has no windows and
launch it via an OS ftexec call. Using -fnw in the ftexec will indicate
that there are no windows. You can also include custom environment
variables that the client can pickup through task.part.CmdLineArgs. The
client object's startup method would in turn launch the process on the server.
Hope this helps,
Hunter
Return-Path: [email protected]
Date: Thu, 27 Feb 1997 08:14:28 -0500
From: [email protected] (Ed Best)
Subject: Executing independent Forte processes
To: [email protected]
Content-Description: cc:Mail note part
Sender: [email protected]
Reply-To: [email protected] (Ed Best)
We're attempting to set up a scheduler(external of the Forte
environment) for executing discrete Forte processes in a batch mode.
My questions are:
1. Is there a method for creating a distribution that does not
have a client partition? Basically, we want to define a
process to run on a server without a user-interface and
execute the process through an FSCRIPT call or something
similar. I know that you can run a project using FSCRIPT,
but this is in development mode.
2. Has anyone successfully set up a method for executing Forte
deployed applications through an operating system
command-line interface, Escript, or Fscript scripts?
3. What about using a c call-in to execute discrete Forte
processes? We've used a setup which uses a c program,
passing data to a socket, having a forte agent listen on
that socket, and conditional logic handles running the
necessary code. This works fine, but the processes are not
discrete(any time you add a process to your list of
executors, they must be integrated with the system agent
conditional piece and become part of the same deployed
application).
Any input would be truly appreciated.
-Ed Best
Deutsche Financial Services
* Hunter Weatherly *
* Albion International *
* [email protected] *
* Pager: 888.287.9206 *
* Work: 800.492.1048 *
**********************************

Ed,
You can create a very lightweight client object that has no windows and
launch it via an OS ftexec call. Using -fnw in the ftexec will indicate
that there are no windows. You can also include custom environment
variables that the client can pickup through task.part.CmdLineArgs. The
client object's startup method would in turn launch the process on the server.
Hope this helps,
Hunter
Return-Path: [email protected]
Date: Thu, 27 Feb 1997 08:14:28 -0500
From: [email protected] (Ed Best)
Subject: Executing independent Forte processes
To: [email protected]
Content-Description: cc:Mail note part
Sender: [email protected]
Reply-To: [email protected] (Ed Best)
We're attempting to set up a scheduler(external of the Forte
environment) for executing discrete Forte processes in a batch mode.
My questions are:
1. Is there a method for creating a distribution that does not
have a client partition? Basically, we want to define a
process to run on a server without a user-interface and
execute the process through an FSCRIPT call or something
similar. I know that you can run a project using FSCRIPT,
but this is in development mode.
2. Has anyone successfully set up a method for executing Forte
deployed applications through an operating system
command-line interface, Escript, or Fscript scripts?
3. What about using a c call-in to execute discrete Forte
processes? We've used a setup which uses a c program,
passing data to a socket, having a forte agent listen on
that socket, and conditional logic handles running the
necessary code. This works fine, but the processes are not
discrete(any time you add a process to your list of
executors, they must be integrated with the system agent
conditional piece and become part of the same deployed
application).
Any input would be truly appreciated.
-Ed Best
Deutsche Financial Services
* Hunter Weatherly *
* Albion International *
* [email protected] *
* Pager: 888.287.9206 *
* Work: 800.492.1048 *
**********************************

SAP defined process maps on SCM

I need SAP business and process maps on following areas for discrete and process industry.
1. Order Management process ( Procurement)
2. Warehouse management
3. Transportaion management
4. Demand planning
5. Inventory planning.
Please inform me the location ( website , sap address etc. ).
Thnaks.
Sumit

Sumit
Typically there is no single process flow defined for any given business scenario within SAP, normally there are a number of alternatives based on industry best practice.
When you have carried out the business blueprint phase and captured these requirements within Sap solution manager you are then able to generate process flows that describe the business scenario.
These are not currently able to generate BPEL or UML models, to do this you would need to use something like ARIS for SAP Netweaver.
Unless the context of the business requirements are understood and without access to SAP Solution manager you might be limited as to the "process flow" view you seem to be after.
Therefore please have a look at the business scenario maps, I would also recommend downloading the solution composer, this should be capable of generating the business scenarios for you.
http://www50.sap.com/businessmaps/91039F49E53F11D3874B0000E820132C.htm
While this may not be exactly what you are after, you could also search the best practice packages components on http://help.sap.com

Repetitive Manufacturing and Run Schedule Header

Dears,
Could you Please Explain to me the Process of Repetitive Manufacturing after run MRP and get planned orders for RS
What happend after that , how to deal with planned orders and and how to create Run schedule Header
Please note that i'm aware about no need to create RSH just product cost collector
Regards
Rami

Dear Rami,
As explained by our forum members the concept of creating RS header is more valid and not required,configuring a REM profile in
OSP2 and assigning the same in the material master and REM allowed setting in MRP4 view and in the production version and
scheduling parameters in OPU5 for order type PE is sufficient.
If you want more explanation regarding the same means please revert.
Regards
S Mangalraj

Repetitive manufacturig

HI.
Can some one explain me the process of repetitive manufacturing.
I mean.
what are the settings that i have to do in a FERT material. like MRP type , Planning strategy and MRp 4 view.
what is the process of production.
where do I confirm the process.

HI
The following steps are necessary for REM
1. Master Data -
- Create Material master - MM01
-Create BOM - CS01
-Create rate Routing - CA21
Create Rem profile - SPRO ->Production planning -> Rem.Manuf->Control data or use existing one
Assign Bom seelction method = 2 & 3 (Prod version) in MRP view
Rem MFG indicator - mrp view in MM01.
Assign the REM profile to a material - MRP view in MM01.
create Valid Production version - MRP view in MM01 & Check Rem mfg ind
Assign the BOM and routings in Prod. Version
2.For Preliminary Cost Estimate:
Create version specific product cost collecter for Header material and preiminary cost estimate - KKF6N as per the settings in Rem profile. -
3
for standard cat Estimate.
Create std Cost estimation (CK11n)
std cost Estimation Mark & release (CK24)
U can do any one of the cost estimation as per the settings in REMprofile.
4. create PIR in MD61.
5 .Run the MRP for your header material - MD02/MD01 - results run scheduler (PE type Planned order) will be created. Here planned order cant be converted to Producton order.
5. Use planning table for scheduling and capacity planning - MF50. Here u can assign u production quantities to production line
6. Use Pull list for material staging (if material stotage exists in prod location) - MF60
7. Backflush (confirmation) the planned order - MFBF. Results planned order will Reduced and GR, GI, activity cost will be posted. U need not convert the planned order to production order, Confirmation for planned order only.
8. To see Back flushed documents MF12
9. Then Go to KKF6n to see the Manufacturing cost.
10. Over head calculation - (CO42)
11 Variance calculation (KKS6)
12- Settlement (KK87)
Regards
Anupam Sharma

How to simulate discrete fourier transform using CMOS on multisim11.0

Please tell me how to simulate discrete fourier transform(DFT) using CMOS implementation in Multisim 11.0..

vlsi,
If I am reading your question correctly, I think this is more of an issue of IC design rather than how to use Multisim (the circuit you describe is likely very complex and would involve many CMOS/transistor components). If you have an existing or partial circuit already ready to start with, the group could better assist with how to implement or use in Multisim for simulation. Although it is possible to model a comlex digital parts with CMOS equivalent logic and gates, most of the more complex digital parts in Multisim are modeled in XSPICE, which allows the behavior to be described by a truth table and timing descriptions and the pins are modeled in SPICE.
However if you want to use a predefined DFT algorithm inline within a circuit simulation, you can likely use with a custom LabVIEW VI, we have several Fourier Transfer algorithms in which you could process a signal coming from a circuit simulation in which the transform and simulation could be run together.
http://zone.ni.com/reference/en-XX/help/371361B-01/lvanlsconcepts/discrete_fourier_transform/
There is an example of how this can be done with an FFT (which is a type of DFT)
https://decibel.ni.com/content/docs/DOC-7438
Another idea is to use our co-simulation technology in Multisim v12 together with the LabVIEW Control Design tools. The LabVIEW Control Design package has several discrete signal processing algorithms built in and you could use them together for very precise mixed signal co-simulation between an electrical simulation and a discrete processing algorithm.
http://www.ni.com/white-paper/13663/en
Regards,
Pat N

Inprocess inspection in REM

i just want to know as in discrete mfg, when we are creating production order, system is automatically generating the lot for inprocess inspection for the quanity equal to the production order quantity (with inspection type 03).And for this i have to set the inpscetion type 03 in material master and in routing ca01,i need to maintain the inspcetion characteristic.
same way if i want to use inspection type13 in REM,when system will gerate the lot automatically?or i will have to create the lot manually?
what will the inpscetion lot quantity?
what master data i will have to create?

please read the help file
http://help.sap.com/saphelp_erp2005/helpdata/en/5f/1faba54aee11d189740000e8322d00/frameset.htm
Creating Inspection Lots
Use
To link the quality inspection in the production process to repetitive manufacturing, you first have to create the inspection lot.
Prerequisites
See the prerequisites under, quality inspection in the production process.
Procedure
In the SAP overview tree, choose Logistics ® Production ® Repetitive manufacturing® Backflush ® Inspection lots for prod. versions. The system displays the Inspection Lot Processing screen.
Enter a material and, if necessary, a plant and a production version and choose Execute. The system displays the screen entitled, Processing Inspection Lots for Production Versions. The green flag indicates the materials that are relevant to Quality Management.
Expand the material row and select the production versions which do not yet have an inspection lot number.
You can set the indicator manually or you can choose Selection of versions w/o inspection lot. The system then automatically selects the production versions which do not yet have an inspection lot.
Choose Create inspection lot.
Result
The system creates the inspection lots for the production versions.
The light which was red until now (= no active inspection lot exists for any of the production versions) or yellow (= an inspection lot exists for one or more of the production versions) switches to green (= an inspection lot exists for all versions) the next time you access the screen Processing Inspection Lots for Production Versions.
I hope u understood

Repetative Manufacturing questions

Good day to everyone :o)
I have a question regarding Orders in Repetative manufacturing: -
The scheduling is done with planned orders if I am correct and the planning table (MF50) is normally used.
Is there a special order we can use for the shop floor control? that would be like a Producion/ Process Order?
I need to print out a BOM and Routing but whilst still using Repetative Manufacturing (I am sure I have seen like a "Work Order or something"
If any one could help me with this it would be much appreciated.
Kind regards

Hi,
With Repetitive planned orders we cannot have standard shop floor papers printed like discrete orders. Generaly repetitive orders do not have strict order quanitity control as it is available in Production orders. Routings generally do not vary for any repetitive order.
You can however print the following:
Production list: MF51
<b>If you want the task list (routing) to be printed along with the BoM use std transaction: CA51. Choose Display comp assignment</b>
Hope above is useful, if so reward points.
Regards
Ram
Message was edited by:
Ramanujan Chitrakootam

Discrete vs Process vs Repetitive?

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