Configuring Repetitive Manufacturing

Repetitive manufacturing profiles are created and maintained in the configuration activity, Define Repetitive Manufacturing Profiles.

When you open the configuration activity, you first find an overview of all the profiles that have already been created, as shown in the previous figure. You can make a new entry to create a new profile or create a new profile by copying and adjusting an existing one. You can also display or change the details of profiles.

In the detail view of an entry, in the Control data 1 tab, you find the following information and control settings:

• General:

  • Goods issue backflush at goods receipt posting:

    This check box controls whether the goods issues are to be posted at the same time as the goods receipt confirmations (backflush). If you only want to post the goods receipt in the goods receipt confirmation, you then have to manually post the goods issues later. You are recommended to set this check box in normal circumstances.

  • Reporting point confirmation:

    This check box controls whether you can carry out reporting point confirmations when creating confirmations in make-to-stock repetitive manufacturing. Using the reporting point confirmation:

    • You can withdraw the components close to the operation for which they are required which is very useful when working with longer lead times.
    • You can calculate the number of incomplete products (work in process).
    • You can post scrap quantities directly at the appropriate operation.

    You can carry out a reporting point confirmation 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 confirmation mandatory or optional.

    Note

    The reporting point confirmation is carried out in the same way as the milestone confirmation.

    The reporting point confirmation is not possible for make-to-order repetitive manufacturing.

  • Automatic goods receipt at last reporting point:

    This check box determines whether the system automatically posts the goods receipt for the assembly when backflushing the last reporting point.

    You use this function for procedure with mandatory reporting points because, in this case, you only post data for the reporting points. Here, you cannot post goods receipt manually.

    If you use the procedure with optional reporting points, you would not usually use this function (as in the optional reporting point procedure, you normally only execute a final backflush). You only execute a reporting point backflush in certain instances - if scrap has been produced, for example.

    If further operations exist in the routing after the last reporting point, the system does not post the goods issues and activities for these operations automatically. For these operations, you have to backflush components and activities separately selecting the option After the last reporting point.

  • Process Control:

    You use a process control key to determine which subprocesses are to be separated from the goods receipt posting or the reporting point confirmation. Possible processes are:

    • Posting the goods issue of the components
    • Activity posting

    You have the following options for specifying when these processes should be carried out:

    • Execute online.
    • Execute as an update task.
    • Execute in the background.

    You can define the process control key in the Configuration activity Define Confirmation Processes.

• Error Correction for Backflushing:
  • Create cumulated postprocessing records:

    This check box controls whether the system creates postprocessing records for components for which errors occurred when backflushing.

  • Also create individual postprocessing records:

    This check box controls whether the system is to create individual postprocessing records for components for which errors occurred in the backflush.

    Individual postprocessing records have the characteristic that two goods movements with the identical error are also saved in two different records.

    If you process the postprocessing records in repetitive manufacturing, you have to work with individual postprocessing records.

  • Execute correction in dialog mode:

    This check box controls your options for dealing with corrections in the BOM if errors occur when backflushing the components:

    • No correction in dialog mode:

      In this case, you make the corrections later based on the postprocessing records.

    • Mandatory correction in dialog mode:

      The system only allows the posting once you have corrected all errors. Therefore, no postprocessing records are created.

    • Optional correction in dialog mode:

      A dialog box appears in which you have the option of correcting any errors. If you select this option, you can make any necessary corrections later based on the postprocessing records.

• Cost Accounting:

  The Post activities check box controls whether the system also posts activities to the product cost collector when backflushing.

  You have the option of posting activities on the basis of the following cost estimates:

  • Standard cost estimate per material
  • Preliminary costing for the product cost collector
• Batch Where-Used List:

  If you set the Update Batch Where-Used List check box, the update of the batch where-used list is enhanced with a batch-specific update (multibatch function). This means that batches produced for the relevant repetitive manufacturing are linked with the used component batches you actually used. The enhanced update takes place during the entry of actual data for repetitive manufacturing.

  Together with the normal update of the batch usage data that is simply order-related, the batch where-used list can reproduce the actual relationship between produced and used batches with the help of the enhanced update. Without this enhancement, the batch where-used list delivers order-related totals records.

In the Control data 2 tab, you find the following information and control settings:

• Planned Orders:

  This check box controls how the system is to reduce the planned order quantities when backflushing.

  You have the following options:

  • The system does not reduce the planned orders.
  • The system reduces all the planned orders assigned to the production version of the material specified.
  • The system reduces the planned orders assigned to the production version of the material specified as well as the planned orders of the material not assigned to any production version.
  • The system reduces the planned orders assigned to the production version of the material specified as well as the planned orders of the material not assigned to any production version as well as the planned orders assigned to other production versions of the material.
• Firming Logic:

  This check box determines which firming logic is used in the REM planning table:

  • Planned orders are not firmed.
  • Planned orders are firmed.
  • Only planned orders that lie within the planning time fence are firmed.
• Creating Planned Orders when Reversing:

  This check box controls how the planned orders that are reduced when backflushing are recreated when reversing the backflush.

  The following options are available:

  • The system does not create any planned orders.
  • The system creates planned orders for the reversed goods receipt quantity on the current day.
  • The system creates planned orders in an asynchronous MRP run (single- item, single-level) which is carried out automatically after the reversal. The quantities of the planned orders depends on the current requirements situation.
• Material Requirements:
  • Stock determination rule:

    The stock determination rule of the repetitive manufacturing profile together with the stock determination group assigned in a material component define the stock determination strategy. For example, the stock determination strategy can be used to automatically find material stocks when backflushing.

  • Batch search procedure:

    The batch search procedure determines the batch search strategy for the batch determination of material components handled in batches.

In the Movement types tab, the movement types for the various goods movements in repetitive manufacturing are defined.

You define control data for stock transfers in the pull list in the configuration activity, Define Control Data for Pull List.

When you open the configuration activity, you first find an overview of all the entries that are already created, as shown in the previous figure. You can make a new entry or copy and adjust an existing one. You can also display or change the details of already existing entries.

In the detail view of an entry, you define the following control settings:

• Plant:

  The control data is plant-specific.

• Movement type for stock transfers:

  Movement type used in the pull list for the transfer of make-to-order stock.

  In addition to the movement type for stock transfer, you can maintain a make-to-stock movement type.

• Movement type for transfer of make-to-order stock:

  Movement type used in the pull list for the transfer of make-to-order stock.

  If you do not maintain a movement type, the system uses the standard movement type for make-to-order stock.

• Stock Determination Rule:

  The stock determination rule together with the stock determination group assigned in a material define the stock determination strategy. The stock determination strategy can be used to automatically find material stocks for replenishment in the pull list.

• Search Procedure:

  The batch search procedure determines the batch search strategy for the batch determination of material components handled in batches.

If you post a goods receipt confirmation in repetitive manufacturing, you can separate the subprocesses for goods issue postings and activity postings.

You define the corresponding control parameters for separating the confirmation processes in the configuration activity, Define Confirmation Processes.

Use this function if you must post large volumes of data and you want to improve performance.

When you open the configuration activity, you first find an overview of all the process control keys that are already created, as shown in the previous figure. You can make a new entry to create new process control key or create a new process control key by copying and adjusting an existing one. You can also display or change the details of process control keys.

In the detail view of an entry, you define the following control settings:

• When the goods issues and the production activities are to be posted:
  • Immediately online
  • Immediately in the update task: The information is passed on to the update task. Therefore, the user can continue processing immediately online.
  • Later, as a background job
• Whether the goods issues for the components are to be cumulated:

  If you set this check box, the system posts the cumulated withdrawal quantities for the same components. If you do not set this check box, the quantities are not cumulated.

• Whether the production activities are to be cumulated:

  If you set this check box, the system posts the cumulated production activities for the same components. If you do not set this check box, the activities are not cumulated.

  Note

  The standard system contains the confirmation process key, SAP1. In this confirmation process key, the following is defined for both confirmation subprocesses:

  • Posting later as a background job
  • Cumulation