Repititive manufacturing flow

If i want to implement sap for repetitive manufacturing type, can u please give typical process flow.

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 Rem profile.
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

Similar Messages

MTO-MTS- Repititive manufacturing

Hi Friends,
I am a FICO consultant and working on Product costing.So i need configuration steps of Make -to -Stock & Make - to - Order, Repititive manufacturing configuration steps with T-codes.
Kindly help me by giving some document related to that.
Points will be assigned.
Thanks
pratima
bachina gmail

Hi Pratima / SAPGURU,
Repetative manufacturing is period based planning and not based on orders. Normally same products will be manufactured over longer period of time..products will not change frequently. Confirmation is from backflushing and settlement is through from product cost collector for the period. Confirmaton will be without ref to planned orders. Planned orders are sufficient to carry out shop floor activity. In master data production versions and cost collector is must where this is not mandatory in discreate.
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
Hope clear to you.
Regards
R.Brahmankar.
Reward if use ul

Workflow trigger for Repititive manufacturing

Hi,
Can anyone suggest me how to trigger workflow for Repititive manufacturing(BUS2142) in production planning (transaction code : MFBF)..
Even trace doesnt display any events after executing the transaction...
Thank you
Srinivas

Hi Ravi,
Thank you for your quick reply....basically I didnt see any event for the
BO : BUS2142....Do we have to copy this and add events...
I would like to trigger the workflow when the document is posted through tcod : mfbf...
How do i go about it..
Thank you
Srinivas

Material Consumption error-In Repititive manufacturing

Dear all,
While doing MFBF,one of the raw material was not get consumed.
For that material,stock is available.
But still that particular raw material was not get consumed.
Kindly let me know
Regards
Rajasekaran

Dear Prashant,
While doing Post goods with corrections its showed all the three material was available.
But after goods movements it doesn't show ant error message,while checking the material documents in table only two materials was get consumed.
Regards
Rajasekaran

Repititive Manufacturing-Planned orders

Hello Experts
I have a REM planned order having a quantity of 100 nos. If I do GR of 110 for this planned order,it will give a warning message number: RM124: "Backflush qty> plnd ord qty. Over delivery for planned order carried out". I dont want over delivery. So I would like to make this message to error. Which is the tcode in spro.
Is there any other way to prevent overdelivery.

Dear ,
I do not think Over delivery or under delivery tolerence in GR can be given in Planned Order level .Basically this tolerence level are in Work Scheduling view which is not applicable in REM scinario.
To my knowledege , there is no such configuration set up to avoid execss GR in REM .We need to think some txan variant OR User exit in MFBF level
Re: User Exit For MFBF
User exit in planned Orders
Regards
JH

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

Why is the Planned quantity in MCP9 not appearing(Repetitive Manufacturing)

Sub:WHY IS THE PLANNED QUANTITY IN MCP9 NOT APPEARING(REPITITIVE MANUFACTURING
Why are the planned orders not displayed anymore. They are still in the system - in MD04 - but since we moved from release 3.1i to 4.0 the plan order qty disappeared from transaction MCP9!!!!.Now we are using Version 4.7
There must be a reason
Perhaps searching in SAP OSS system -if the transaction is not supported in rel 4.0 anymore and we should use something else instead
Or we need to apply an OSS note from SAP to repair the problem...
Or the info system update must be modified because of rel change... I don't know.
Please suggest your valuable guidance,Iam not able to enclose a screenshot of the problem,planned qty is 0 or it is not getting displayed.If you reply to this query i can send a detailed analysis to that mail id .

Dear Guruji Mr.Rajesha vittal,
Sir ,iam stuck with this problem,not able to proceed.
Can i send the activites i have completed till now ,I want your e mial id sir for me to send the attachments to you.
Also i dont know how to award points i need to award points to u for all the solutions i have recieved till now ,can you please explain to me
I am stuck with this MCP9 problem i have done it according to your suggestion,but still the planned quantities are not displayed. can you please help me out.Very urgent. I need u mail id
Thanks & Awaiting your reply
P.S.KIRAN
[email protected]
[email protected]

Epititive manufacturing-External operation

Can any body tell the sequence of steps that are to be done in external operation for repititive
manufacturing? is there any option to create a pur req like we do it in the creation of prod order?
If so, in activity backflush how to handle this external operation?

Dear Srinivas,
As far I know in REM - sub-contracting can be done through reporting point's,
If you are going for normal backflush it does not help you,
For your reference , please check these links,
Re: Subcontracting in REM
Regards
Mangalraj.S

Customer directed parts issue

Hi,
In one of our running implementations we have the following requirement.
We have A material a which the plant procures from vendor G and H that material a is used in let's say 2 finished goods X and Y. The customer for finished good X informs us that in his product material A needs to be procured from vendor H whereas customer Y does not impose this rule onto us.
So how does the ERP system react to this?
Example:
We receive the following orders from our customer:
Customer for finished good X orders 200 pcs
Customer for finished good Y orders 100 pcs
These requirements are entered into SAP and we then run to MRP.
The result of MRP will be a requirement for component A of 300 pcs.
If we use a source list together with a quota arrangement (quota split 50% to vendor G and 50% to vendor H), purchasing will order the following quantities of material A at vendor H and G:
H : 150 pcs
G : 150 pcs
This means that when we produce finished good X we have not enough components that are received from the customer directed vendor which will cause problems.
Typically having 2 different part numbers for the same material would solve this issue. However the engineering department says that if a material is the same in fit-form or function it can only have 1 material number.
Is there a way in purchasing that we can split these requirements so that the orders for the customer directed material go to the correct vendor?
Regards,
Peter

Hi Peter,
You get different customer orders for lets say FERT -ABC1 which has component A1 this component is required to be utilized for specific customer order and needs to be procured from a perticular vendor
You create customer order which is taken in MRP , set the Indv./coll requirement field in MRP4 view of the material master of A1
In this case system will generate sales order specific purchase requiisition for different quantities
If you are using auto generation of PO using ME59 use user exit ME590001 to influence the source selection based on customer in the sales order updated in PR in account assignment tab
To manage and track inventory of same part from different vendors you can activate batch management at material level with manual assignment of batches, while back flush system will ask for batch in pull list based on the customer order for which the production order is created you can select the batch of A1, even in case of repititive manufacturing you have that option in pull list
Hope this will help you to take it ahead
Thanks
Diwakar

Reg KKF6N error

Dear all Gurus
Actually we are in Repititive manufacturing process ... And we are looking for Co-Product costing which is not captured in KKF6N .. We are getting the error as '' No source structure assigned for the cost element"
We have checked the notes what are available Still we r in big Mess .... We could not solve this..
If anybody got the eror and solved it , please we r in need of help ,,,
When we chcked in MFBF , we are getting an error .( Error RM078. )
Hoping for ur wonderful support
Regards
Karthik

Hi,
Basically coproduct scenario is meant for PP-PI or discrete manufacturing.
Definition of REM itself says it has less production control effort.
Co product is not possible in rem, I think because of Product cost is carried out For period in rem Not for an order.
Hope clear to you.
Reward if useful.
Regards,
R.Brahmankar

Required Month end process in MTS

Dear All,
Plz. explain me the details for Month end process in Make to Stock (Repititive Manufacturing)
OH Calculation
WIP Calculation
Variance Calculation
Settlement what is entries system will pass and how the system is picking the G/L account or Cost centers
and i have few more doubts life what is the use of
What is PCC
What is Production Version
What is Mixed price costing
What is Preliminary costing
What is Failure Cost how to post and how to analize.
Plz. dont send me any links i already go through it.
Regards
Radha
Edited by: Radha Yandrapu on Sep 15, 2010 10:28 AM
Edited by: Radha Yandrapu on Sep 16, 2010 3:27 AM
Plz. dont send me any links i already go through it.
Moderator: Apparently, not enough, if you are asking about basic concepts

Hi,
Month end process for MTS using Product cost collectors:
In repetitive manufacturing we do the perios end closing for the material.(Product cost collector created for a material). all the costs are collected on the PCC instead of the individual production order.Pls follow the following month end process in rep manufacturing for individual processing.
Overhead calculation- Co42
WIP Calculation- KKAS
Variance Calc-KKS6
Settlement- KK87
The system will pick the GLs for wip and variance settlement based on the assignment we maintain in customising for Line IDs, Assignment and Update in the period end closing activities in SPRO.
PCC- it is a Product cost collector created using a production version, BOM, Routing for the material.
Production version- it is created using either Bom and routing or Plant material combination.
Mixed costing- it is a cost estimate created for a material using various procurement alternatives(based on equivalance nos).
Preliminary costing- it denotes the planned values for a cost object created like production order or product cost collector based on the quantity structure in PP module.
Hope this helps you.
Regards,
Vishnu.
VST IT Projects.

Batch derivation in subcontracting process

Hello experts
I ask for your help on the following point:
I subcontract packaging operation of a product managed by batch to an external vendor.
The bulk (component) I send to the vendor is also managed by batch.
I use batch derivation for transferring batch data from the bulk batch to the packed product batch.
I manage to do it with the manual batch derivation.
However I would like to create a derivation event to make automatic this process.
Is it possible to create new derivation event and associate it to "Good receipt for purchase order" event ? to the movement 101 or 543 ?
Thanks for your help
Best regards
Amaury

Batch derivation consists in transferring values of class characteristics of a sender batch to receiver batch.
This copy of results may be triggered automatically by the system during a manufacturing flow (event = good receipt on process/production order).
However I am looking forward to know if it is possible to do so at good receipt on subcontracting order ?
Thanks for your help

What is suppy chain management in SAP

hi
what is suppy chain management in SAP

Hi,
Supply Chain Management is the management of the entire value-added chain, from the supplier to manufacturer right through to the retailer and the final customer. This is the heart of value chain.
Processes that are covered by SCM are:
-Customer relationship management
-Customer service management
-Demand management
-Order fulfillment
-Procurement
-Manufacturing flow management
-Supplier relationship management
-Product development and commercialization
-Returns management
Best Regards,
Devesh K Singh

What is an ERP?????

Hi Experts....
can u tell me wat is an ERP exactly???????
Thank you

Hi,
Enterprise Resource Planning (ERP) systems integrate (or attempt to integrate) all data and processes of an organization into a unified system. A typical ERP system will use multiple components of computer software and hardware to achieve the integration. A key ingredient of most ERP systems is the use of a unified database to store data for the various system modules.
Ideally, ERP delivers a single database that contains all data for the software modules, which would include:
Manufacturing 
Engineering, Bills of Material, Scheduling, Capacity, Workflow Management, Quality Control, Cost Management, Manufacturing Process, Manufacturing Projects, Manufacturing Flow
Supply Chain Management 
Inventory, Order Entry, Purchasing, Product Configurator, Supply Chain Planning, Supplier Scheduling, Inspection of goods, Claim Processing, Commission Calculation
Financials 
General Ledger, Cash Management, Accounts Payable, Accounts Receivable, Fixed Assets
Projects
Costing, Billing, Time and Expense, Activity Management
Human Resources 
Human Resources, Payroll, Training, Time & Attendance, Benefits
Customer Relationship Management 
Sales and Marketing, Commissions, Service, Customer Contact and Call Center support
Data Warehouse 
and various Self-Service interfaces for Customers, Suppliers, and Employees
Assign points if useful
regards
jehade

REM process flow for food manufacturing.

Hallo,
I want to know what is the process flow in SAP REM for food manufacturing compony?
Thx
Nikam.D.A

Dear Dev,
Check these links for the REM flow along with the T Codes,
Repetitive Manufacturing
REM Cycle..........
Regards
Mangalraj.S

Repititive manufacturing flow

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