Discrete Manufacturing (Shop floor)

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 Discrete Manufacturing (Shop floor)

Production based on production orders when the patterns are irregular. 

Configuration Basics of Discrete Manufacturing

  1. OPJH: Define Order 
  2. Define order type-dependent parameters
    1. Planning:
      • How to select a production version ( pop up, or automatically )
      • How to select a routing ( manual, automatic ), copy a text and work centers from the Routing?
      • BOM: application and the explosion type
      • Batch determination procedure 
      • Quality inspection type
      • Substitute MRP scheduler
      • Should the system create reservation and PR
    2. Implementation: track changes
    3. Cost accounting: cost variant planned, actual, results in analysis key, distribution rule ( CC ) 
  3. OPKP: Production schedule profile ( Plant level )
    • What are automatic actions on creation and release? 
    • Material and capacity availability check
    • Batch creation and classification, batch split
  4. OPJG: Default values ( if no master data yet created ( routing ) 
  5. OPJJ: Availability check ( material availability check, capacity, and PRT checks)
    • During order creation and/or on the Order confirmation
  6. OPJ2: Stock and batch determination
  7. OPU3, OPJN: Scheduling
    • Basic date scheduling (for planned and production orders)
    • Lead time scheduling (only for production order)
    • Scheduling margin keys (Mat. MRP 1) for delays...
      • Forward sch.: Float before/after production ( add buffer days )
      • Open (time to convert to a prod.ord) and release period ( before start date )
  8. OPJS: Reduction strategy to cancel buffers
    • Type ( for all operations?) and Level (% )
      • Assignment: 1) routing, 2) plant-dependent setings
  9. Confirmation 
    1. Plant, order type parameters
    2. OPKC: time of confirmation
  10. OPK5: Reasons for variances ( Plant specific ) for partial confirmations
  11. Trigger point - Function when the user conditions met
    1. A usage, a Group for standard trigger points
  12. OPK8: Print control 

Production Planning for Discrete Manufacturing

Process 
  1. Pre
    1. Create materials, 
    2. CS01: Create a BOM (MRP rel.: operation and component % scrap; lead time offset ( for one day earlier before production start date ), special procurement type, prod. stor. loc. for backflush, costing ), 
    3. CR01: Create a work center ( capacities, scheduling, costing: only one cost center )
    4. CA01: Create routing, 
      • Components are consumed in the first operation if it is not specified;
      • One routing can be used for several materials.
      • Sequence: parallel, or alternative (minimum and max. lot sizes)
      • Assign PRT to operation
    5. C223: Create a production version, and assign BOM and Routing.
      • One BOM but multiple Routings
  2. CO01: Order creation
    • Order -> create material reservation 
      • Header
      • Operations
      • Components 
    • Scheduling: 
      • Work center: factory calendar, shifts, max. cap. util.
      • Routing: setup, processing, transition times, splitting 
      • From the end: Float before production, operation times, safety time ( after production ), GR processing time
        • MAD - GR processing time  ( ! basic finished date ) - In house prod.time - Float after prod. 
      • Finite scheduling: start/finish for operations
      • Splitting and Overlapping, Reduction
    • Availability checks
      • CO24: Missing parts
    • Capacity requirement planning
  3. Order release: automatic, individual, CO05N: collective
  4. CO04N: Shop paper printing
  5. Material withdrawal 
    • 261: Goods issuance against prod. order
    • CO27: Picking list
    • Backflush (on release, routing, material master+work center, comp.assignment)
  6. Confirmation 
    • CO11N: Enter Time Ticket 
    • CO1F: Progress confirmation 
    • CO15: Confirmation for order, and cancellation CO13
  7. Goods receipt to
    • Unrestricted
    • QM
    • Blocked 
  8. Post-processing ( correct errors )
    • COG1, COFC
  9. Order settlement 
  10. Completion 

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