Repetative manufacturing

Sir,
While carring out repetative manufacturing scenario what are the details to be mentioned in production version in mrp4 in planning data like detaile ,rate,rough cut planning once maitained it shows an warnig like the date doesnot math with alternate bom,detailed plannig ,rate planning,rough cut plannig. the company does have repetative manufacturing scenario, how to rectify the error ,kindly help
Thanks

Dear Sadanand,
1.Assign the REM profile in the MRP4 view of the material master and REM allowed indicator.
2.Assign the created rate routing and BOM inthe production version and also REM allowed indicator
inside the production version.
3.Rate routing can be created using CA21.
4.Assign the rate routing against detailed planning if you have assigned the routing selection id against
detailed planning in OPU5.Ensure your routing selection id is having the first priority to the rate routing.
5.Production versions can be created and modified using C223 or else using MM02 in MRP4 view.
Check and revert back.
Regards
Mangalraj.S

Similar Messages

Rework in Repetative Manufacturing

Good morning all,
Can anyone tell me or point me in the right direction, can we and how do we manage rework loops and rejects in the repetative manufacturing model?
Thanks in advance

Hello,
If you are working with 4.7 then Rework is possible in MFBF screen also.
If you declare some qty as rework , it will appear in FCOST screen.
While booking in mfbf you have to specify the version.
From FCOST you can book it as scrap OR good.
Here also you need to specify the version.
When you book rework , system will generate an entry in the background for RO
document.If you given back this rework to production area then again RI document will be ganarated in the system.
These documents can be seen in FCODOC.
We are extensively using REM in our plant.
Reward points if helpful
Regards,
Mona tiwari

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

Repetative manufacturing vs discrete manufacturing?

hi
what is the difference between repetative manufacturing and discrete manufacturing
regards
sanjay kumar nanda

Basic difference is in REM, a same product will be manufactured for a long period of time...
In discrete,the products will vary frequently....
REM:prodcut dont change frequently
components are staged at lines periodically
Backflushing
COst control is period based
Discrete:Product chane freq
COmponents are issued with ref to order
COnfirmation
COst control is order based,
hope this helps...
karthick

Capcity planning in Repetative Manufacturing

HI , Gurs can any body tell me how can I map this scenario in the Repetative Manufacturing
We have different product category which require different type of embossing on Tissue
Paper based on the product characteristics, so we have different Embosser Rolls which can be used on the multiple Production lines.
Kitchen towel
Name of Embosser      No of Embosser      Line      Priority to line     Product Group
KC Fan      1     LC30-LC31     LC-31     KC-Fista, Towel kc
CCD     1     LC30-LC31     LC-30     Lide
WC     1     LC30-LC31     LC-31     Morrison kT,coop KT
Bath Tissue
Name of Embosser      No of Embosser      Line      Priority of line     Product Group
Kc leman      1     Lc25, lc21     Lc-25     Nordic KC
Kc Quilts     1     Lc23     L23     Andres quilts kc
LPC leman      2     Lc21-lc25     L21     Lide, Norma golds carford
LPC quilts      1     Lc23     L23     Morrion quilts,coop quilts
Scheduling of line LC-25 and LC 21 using Embosser KC Laman and LPC Laman
1)     Embosser KC leman can be used in the Two Production line Line LC 25, LC21 but LC 25 is the preferred line for Nordic KC product so if capacity is not available on LC 25 then it can be scheduled on the LC -21 .
2)     Embosser LPC leman can be used on the two Production line LC-21, LC25 but LC -21 is the Preferred line for the Lide, Norma gold car ford Product .
3)     One Embosser LPC Leman and Two KC leman can be used in the combination on the both Production line in such A that one only one change over is possible in one Production line in one month and when ever change over is happening 24 hours gap between should be on the line.
4)     Maximum possible combination which can be used for scheduling of Planned order will be six, because three Embosser is being used in the two production line.
Scheduling of line LC-23 using Embosser KC Quilts and LPC   quilts.
5)     Embosser KC quilts can be used in the one Production Line LC 23 for scheduling the Plnned order .
6)     Embosser LPC quilts can also be used on the Production line LC-23 for scheduling Planned order .
7)     One Embosser LPC quilts and one Emboser KC quilts can be used in the combination on the Production line in such a that one only one change over is possible in one Production line in one month and when ever change over is happening 24 hours gap between should be on the line.
Scheduling of line LC-31 and LC -30 using Embosser KC Fan and CCD, WC.
8)     Embosser KC Fan can be used in the Two Production line Line LC 31, LC30 but LC 31 is the preferred line for KC Fiesta product so if capacity is not available on LC 31 then it can be scheduled on the LC -30 .
9)     Embosser CCD can be used on the two Production line LC-30, LC31 but LC -30 is the preferred line for the Lide. .
10)     Embosser WC can be used on the two Production line LC-30, LC31 but LC -31 is the Preferred line for the Lide
11)     One Embosser LPC Leman and Two KC leman can be used in the combination on the both Production line in such A that one only one change over is possible in one Production line in one month and when ever change over is happening 24 hours gap between should be on the line.
12)     Maximum possible combination which can be used for scheduling of Planned order will be nine, because three Embosser is being used in the three production line.

Dear,
Please note that REM with minimum requirement can be used.
You can define production version for each production line and preferred production line will have the the first PV.
You can perfom the capacity planning in MF50 depending on the production line load.
please come back if you need more help

Maping of material in repetative manufacturing

Dear Guru
Plz suggest how to map the material in repetative manufacturing
scenario:
input material : A, B AND C
Output material: x y and z
how to map in backflush(mfbf) . In one shot we want to enter the input and output material . We have to enter actual consumption of input and output material

Dear Ank,
In the confirmation screen MFBF you can confirm at a time only for a single material and for this product the corresponding
components can be posted which will be carried out for 131 & 261 movement for GR & GI respectively.
It's not possible to make GR for more than one product at time,but however using MF42N it's possible to carryout collective
backflush for a set of products based on the input given.
now check with this and revert back with your queries.
Regards
Mangalraj.S

Difference between repetative manufacturing and discreate manufacturing

Hi,
Guru's
What is the difference between repetative manufacturing and discreate manufacturing in product costing.

Dear Manish,
Repetitive Manufacturing
In repetitive manufacturing, master plans are typically created on a period and quantity basis (reduction in individual lot and
order-specific processing). A quantity of one product is manufactured over a certain period. The product is processed in a constant flow and interim products are generally not stocked. In repetitive manufacturing, you usually find that the effort required for production control is significantly less than is required for single lot and order-based production control and the recording of actual data is kept simpler. Repetitive manufacturing can be used for various industries, such as the
consumer packaged goods industry, the electronic industry, packaging industry, for example.
You can use Repetitive Manufacturing purely for make-to-stock production, or in a sales order-oriented environment, such as found in the automotive industry.
Discrete Manufacturing
Discrete manufacturing is characterized by requirements that occur on an irregular basis and a workshop-oriented process.
The Discrete Manufacturing scenario can be used in different variants, production by lot size, make-to-order production and assembly processing. The variants differ mainly in the type of planning conducted before-hand and in the relation to the sales order. Production by lot size is identified by the grouping of requirements into lots during requirements planning, and by planning with existing basic data. Production by lot size is independent of a particular sales order. Make-to-order production describes the production of a material with reference to a particular sales order. The manufactured quantities are managed, in terms of stock, directly for the individual sales order. They cannot be exchanged with the stock of other sales orders. Starting from the sales order, single-item planning can be allowed as far down the bill of material (BOM) structure as you like. Assemblies and
components can also be procured for the sales order that generates the requirements, and managed in stock for this sales order. If the product is a configurable product, the system chooses a variant for the customer based on the characteristics that he or she selects. A sales order BOM can then be generated for the sales order. This BOM is used to produce the product.
Assembly processing is a form of make-to-order production, in which the production order (assembly order) is created together with the sales order. In assembly processing the components for the product have, in general, already been produced. They only need to be assembled. The advantage of assembly processing is that an availability check is carried out for the components when you create the sales order. This increases the reliability with which dates can be confirmed
considerably. Changes to the sales order are automatically also made in the production order and vice-versa.
And also you can follow the below link to know more about REPITITIVE MANUFACTURING its a pdf document from help.sap.com
http://help.sap.com/printdocu/core/print46c/en/data/pdf/PPREM/PPREM.pdf
One More Example
Repetive is usually a continuos flow, good example is making 5000 tv dinners you know how long it takes to make qty1 very little defects or fall out and you always have everything on hand to start the run, you may also make the same run 2-3 times per month so a cost collector is ok all cost go to top level.
Discreet, You do have falls out reworks and move into production missing materials, long lead time its essential to know what and where it is at in production, cost may vary a little but each production order will be costed independantly for review.
Best Regards
Mir
Edited by: mirosmank on Dec 28, 2010 11:25 AM
Edited by: mirosmank on Dec 28, 2010 11:28 AM

Difference between PP(discrete ) and PP-PI and repetative manufacturing

Dear all
1) What is the difference between PP(discrete ) , PP-PI and repetative manufacturing ?
2) In terms of SAP implementating how to choose out of these ?
3)What is the difference in terms of SAP for all three?
regards ,
Vishwas.K
Edited by: vishwas.k on Oct 9, 2010 3:31 PM

Dear
There are lot good threads and wiki abailable for this generic topic .
These are diffrences between REM/Discreate/ and Process manufacturing.
REM:
Production is based on the planned orders.
Planning and manufacturing is based on period wise.
Normally single products being manufactured for a longer period of time.
Normally production are carried out on a single production line (repetitively).
Product costing and settlement is done through product cost collector.
Planned orders are known as Run schedule quantities. Means quantity which is being manufactured in a certain period.
Planned orders are sufficient to carry out production at shop floor area.
Master data includes production version, product cost collector and rate routing.
Materials will be issued anonymously to production lines means without reference to planned orders.
Discreate:
Production based on the production orders
Planning and manufacturing depends on production orders.
Products changed frequently.
Production is carried out on different production lines (scattered- discrete).
Product costing and settlement is done through production orders.
Planned orders are stock type later converted into production orders.
Production orders are required.
Production version and product cost collector are not mandatory.
Materials will be issued always with reference to production orders.
Master Data includes Routings and BOMs.
PROCESS:
1) Batch Oriented process manufacturing.
2) Process order based manufacturing.you copy the process described in a master recipe and adjust it to the actual production run.
3) It is primarily designed for the chemical, pharmaceutical, food and beverage industries as well as the batch-oriented electronics industry.
4)The integrated planning of production, waste disposal, and transport activities within a plant.
5) Master Data includes Master Recipes and resources.
6) Process Management:In this area, you coordinate the communication between PP-PI and process control during the execution of a process order.
Best will be refer SAP help material .Appereciate if you carry out forum searh on the same .
Regards
JH

Partial Conformation for Repetative Manufacturing

Hi,
Business senario is like this, in Repetative Manufaturing wants to Parial conforatmion of plnd orders, by month ending only came to know the actual consumptions .
Regards
E.Rambabu

Hi,
As per my knowledge , there is no provision of Partial Confirmation in case of REM which is in case of Discrete Mfg.However you can use Reporting Point Backflush ( RP Backflush) in REM
Using the reporting point backflush:
1You can withdraw the components close to the operation for which they are required which is very useful when working with longer lead times.
2You can calculate the number of incomplete products (work in process).
3You can post scrap quantities directly at the appropriate operation.
4You can carry out a reporting point backflush at every operation defined as a milestone in the routing. In the repetitive manufacturing profile, you can also decide whether you want to make the reporting point backflush mandatory or optional.
The reporting point backflush is carried out in the same way as the milestone confirmation in Discrete Manufacturing.
Hope this helps.
Regards,
Tejas

QM in repetative manufacturing

Dear Experts,
We have a repetative manufacuring scenario. Production confirmation is done using MFBF ( Backflushing). I want to activate the inprocess inspection for the same. Please give me the steps to activate the same like Inspection set up , MIC , where to attach the MIC and Inspection Plan etc.
Thanks,
Ram

Dear Ram,
Check this,
Quality Inspection in the Production Process
Use
You have the option of linking Repetitive Manufacturing to Quality Management. Then a quality inspection during the production process is also carried out in repetitive manufacturing. This means that certain quantities of repetitive production are used for the quality inspection.
Prerequisites
In the material master record for the finished product, you must set the indicator for quality inspection in the Quality Management view. Moreover, in the QM inspection data, you must also select and activate an inspection type with the origin 13 (repetitive manufacturing).
The SAP standard inspection type is 13.
You must select a repetitive manufacturing profile in master record of the finished product.
You must create a production version and a product cost collector.
In the routing for the finished product, you must maintain characteristics for the operation for which inspection results are to be created. (Starting from the operation overview, choose Goto ® Characteristics overview.)
You can also use the control key to flag operations in the routing as milestone operations. In this case, the repetitive manufacturing profile must also allow reporting point backflushing. You must also maintain characteristics for these operations.
Features
If all the prerequisites are fulfilled and you have created the production versions, create the inspection lots (see Creating Inspection Lots). Later, the inspection results are saved in this inspection lot.
You create the inspection result for the inspection lot in Quality Management. If the material has a repetitive manufacturing profile that allows reporting point backflushing then you can use the function, Reporting point in repetitive manufacturing to branch to the reporting point backflush when creating the inspection result for the inspection point. The inspection lot quantity created for the inspection point is copied to the reporting point backflush and is proposed here as the backflush quantity.
For more information on maintaining characteristics and on creating results for the reporting point, please refer to the SAP document entitled QM Quality Management.
check the following link for further inputs.
__[For QM in REM |http://help.sap.com/saphelp_erp2005/helpdata/en/5f/1faba54aee11d189740000e8322d00/frameset.htm]__
Regards
Mangal

Repetative Manufacturing Scenario

We have configured the repetitive manufacturing on our client, we are doing the backflush with referance to planned orders that created via MRP. Every thing is working ok, my question is that wht should b the size of Product Cost Collector, either it is the total planned order quantities in that month or wht? we are confused at this point and need help in this regard we also have multiple Production Versions so we will create multiple cost collector but wht should be the size of each cost collector?

Dear Bashir,
1.You cannot have 2 standard cost estimate in the same period.
2.For a material if you have more than one production version, and if you want to book the confirmations using both the
production version means,then one production version can have a standard cost estimate and the other one can be based on
the preliminary cost estimate.
3.In case if you want to confirm using only the standard cost estimate means,you have to cancel the existing cost estimate
using CKR1 and then only you can take a new cost estimate in the same period.
4.Say based on production version1,a cost estimate has been carried out and in the mid of the period ,let us assume you want
to post using the second production version.So in this case the first one has to be cancelled using CKR1,and then taking a new
cost estimate using CK40N.
Now come back with your further queries.
Regards
Mangalraj.S

Post -Processing in repetative manufacturing

Hi
Currently we are facing problem with reversal posting in repetitive manufacturing MFBF
1. We want to change the quantity posted in the components and activities how it will be done.
2. We are trying to post using MB1A with M.Type 261 and order defined in Product Cost Collector but We are getting message that Order can not be processed
Please help.
Thanks in advance
Rushi

Dear Joshi,
You can use T Code MF41 for document specific reversal.
In this case whatever that's prsent in the document gets reversed.
For Eg,If the document contains 261,131 and activities means,then for this document 262,132 and the
activities gets reversed.
and if a document contains only 131 movement for 10 quantity,then for this 132 will be happening..
If you want to carryout document neutral reversal,then you have to use MFBF only.
you cannot use MB1A,the product cost collector number for carrying out GI.
This order number will be used for variance calculation and settlement process.
Now come back with your further queries.
Regards
Mangalraj.S

Sales Order Based Costing-Repetative Manufacturing

HI,
Can anyboydy send me the documents on Sales Order Based Costing & Repetative Manufacturng (confiq or any relevant material) to my id [email protected]
Thanks in Advance
Sunil.

HI,
Can anyboydy send me the documents on Sales Order Based Costing & Repetative Manufacturng (confiq or any relevant material) to my id [email protected]
Thanks in Advance
Sunil.

Regarding :Repetative Manufacturing

Dear Friends,
I wanted to know about repetitive manufacturing scenario , can anyone explain about this scenario in detail.
Also if anyone is having any test scripts on this , can you please share with me.
Thanks in advance

Dear,
See the below steps:
You do these steps for rem production:
mm01 : Material Master
              - MRP - 4 view you click rem
cs01    : Create Bom
cr01    : Create Work Center
ca21    : Create Rate Routing
mm02 : Prodn Version
md61   : Create PIR
mc74   : Transfer PIR to Demand
kkf6n : Create Product Cost Collector
mb1c : Create Stock
md02 : MRP run
mfbf    : Rem Back Flush
The detailed sequence of T.Codes for REM including Std cost estimate.
Material master - MM01
BOM - CS01
Price Planning - KP26
Work Center - CR01
Rate Routing - CA21
Material Master Change, enter production version - MM02 (MRP 4 View)
Product Cost Collector - KKF6N
Costing - CK40N
Backflushing - MFBF
Also check the below link:
http://www.sap-img.com/production/what-is-discrete-manufacturing-rem-and-demand-management.htm
Hope it will help you.
Regards,
Alok Tiwari

PP/PI (PP-PI (Production Planning for Process)with Repetative Manufacturing

Hi All,
Can anybody explain what is PP-PI (Production Planning for Process Industries) - Repetative manfacturing. What is BW Developers role in this and wht types of Cubes, Extractros etc.
Please suggest me.
Thanks,
KN

Thanks for your replay.
No really I don't like to make the batch mandatory, during the good issue is not feasible inform the batch due to it is not managed in the Process Control System. Due to the behavior of PI_CONS if for batch managed materials the batch is not informed in the message or in the reservation an error is trigger. In the reservation snot feasible inform the batch because in that moment is unknown.
My question is if it is feasible some how have like FIFO batch determination when the process message is processed without creating a custom message.
Thanks in advance

Repetative manufacturing

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