Repetitive Manufacturing

Repetitive Manufacturing

It is the interval and quantity based processing of production plans. It is mainly used where high repetition rates, high product stability, and low product complexity. 

Plan line loading, material staging, backflush assembly, components, and activities as

frequently. All costs associated with REM production of material continue to accumulate in the
PCC, and then can be settled. 

REM supports handling unit management, and serial numbers.

Configuration Basics of Repetitive Manufacturing

• OSPT: Repetitive Manufacturing Profile (MTO or MTS; A reporting point (RP) enables the system to record consumption or other details such as identifying the work in process (WIP) and better stock visibility in inventory management (IM); The automatic goods movement option applies to RP backflush only...)
• The movement type that the system uses to post GR and GI
• How the system reduces planned order and RSQs in the confirmation process?
• How the system makes the correction in the assembly’s components?
• How the system deals with production activities during confirmation, such as setup or machine hours?
• Parameters for planned orders in REM
• Material Staging (311: stock determination and batch search procedures )
• Global Settings for Confirmation and the Logistics Information System
• OLDPS: Operational methods sheets show the production details that a plant operator needs to produce the goods.

Production Planning for Repetitive Manufacturing

Prepare master data

• Material master: REM Indicator in the MRP 4 View of the Material Master and the REM Profile; BOM
• CR01: 
• Work Center (Production Line) is the entire production line (with all of its work centers) 
• It is modeled as one work center, more than one work center can be represented in a line hierarchy
• C223: Production version: REM ind., rate-based planning, BOM assignment, Production line assignment, Receipt storage location
• CA21: Rate routing: work center assignment, production rate ( REM allowed ind. )
• a rate routing describes the quantity of an item that must be produced within a given period of time
• The production rate is defined for each operation based on the production quantity, production time, and associated unit of measure.
• Cost object

Process flow

1. Material forecast, SD requirement
2. MRP generates planned orders
3. REM Production (planned orders PE)
1. Planning line loading and capacity checking
1. MF50: Check planning table
2. The system performs the line loading and checks the capacity requirements to see if it’s able to produce the required quantities. If not, it’s overloaded.
4. MDVP: Collective availability check; Availability check of the components
5. LDE1: Print operations method sheets that contain detailed instructions for producing the material.
6. MF51: Print production list contains quantities to produce and important dates ( a material or to a production line)
7. MF63, MF60: Material staging is a transfer posting from the main store to the production floor
8. Production execution
9. * WIP determination ( reporting with reporting point (RP) backflush (milestone confirmation) )
10. Final confirmation
• Posting GI for the components used by using the backflush option
• Reducing RSQs/planned orders and the associated capacity requirements on the production lines
• Posting production costs incurred (material costs, production activities, overhead costs) to a PCC
• Creating a data entry document (material and/or financial document)
• Updating statistics in the logistics information system (LIS)
1. MFBF Assembly confirmation
2. MF42N Collective confirmation
3. You record the production yield, record issuance, consumption of components, and postproduction activities
11. Reversals
• MF41 Document-Specific Cancellation of Confirmation
• MFBF Document-Neutral Reversal, Repetitive Manufacturing Actual Assembly Scrap, Repetitive Manufacturing Actual Component Scrap
• MF4R Reset Reporting Point Confirmation
12. Settlement