149 ERP606 Process Overview en XX

7/29/2019 149 ERP606 Process Overview en XX

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Repetitive Manufacturing

SAP Best Practices



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Purpose, Benefits, and Key Process Steps

Purpose

Repetitive Manufacturing is commonly used when a production process meets the followingcriteria:o The same or similar products are produced over a lengthy period of time.

o The products produced are not manufactured in individually defined lots. Instead, a total quantity isproduced over a certain period at a certain rate per part-period.

o The products produced always follow the same sequence through the machines and work centers inproduction.

o Routings tend to be simple and do not vary much.

Benefits

Simplified handling of the production process with full cost control

Key Process Steps Creating Planned Independent Requirements

Material Requirements Planning at Plant Level

In-House Production

Confirming Assembly Activities




Required SAP Applications and Company Roles

Required SAP Applications

Enhancement package 6 for SAP ERP 6.0

Company Roles

Shop Floor Specialist

Production Planner Warehouse Clerk

Production Supervisor




Detailed Process Description

Repetitive ManufacturingMake to stock production REM

Repetitive Manufacturing is in this case a purely for make-to-stock production based on runschedule headers. This means that production is controlled without a direct reference to thesales order. Run schedule quantities determine the dates and quantities. Requirements arecreated in Demand Management.

Make to stock production REM-Material requirement Planning

The daily MRP run generates planned orders for the material that is to be produced. Thesystem automatically generates purchase requisitions for purchased parts within the 3-month opening period for the planned order.

Make to stock production REM-Planning table

Within the framework of repetitive manufacturing, planning and control is carried out on thebasis of time buckets. Starting from the existing requirements situation.

Make to stock production REM-Backflushing

Production completion confirmations are simplified and are made with reference to thematerial being produced. The completion confirmation includes the backflushing of components and the posting of production costs

Make to stock production REM-Cost Object Controlling

In repetitive manufacturing, cost will be determined per production version via a productcost collector (product cost per period).




Process Flow DiagramRepetitive Manufacturing

S t r a t e g i c

P l a n n e r

P r o d u c t i o n

P l a n n e r

W a r e h o u s e

C l e r k

E v e

n t

P r o d u c t i o n

S u p e r v i s o r

Operative MRP

Beginning of

Planning Cycle

CO-PA =Profitability Analysis, MRP = Material Requirements Planning, GI/GR = Goods Issue/Goods Receipt

Periodic Plan

Revision

Logistics Planning(144)

Planning Table

CreatePlanned

IndependentRequirements

Range of Coverage

Procurementof Stock

S h o p F l o o r

S p e c i a l i s t

MaterialStaging

RepetitiveManufacturing

Backflush

PostProcessing

List

P l a n t

C o n t r o l l e r

Period-EndClosing“General”

Plant FinancialAccounting

(181)

End Process

Pick List

ReprocessingListGI/GR Slip

InventoryConsumption @Standard Cost

InventoryReceipt @

Standard Cost




Legend

Symbol Description Usage Comments

To next / From last Diagram: Leadsto the next / previous page of theDiagram

Flow chart continues on the next /previous page

Hardcopy / Document: Identifies aprinted document, report, or form

Does not correspond to a taskstep in a document; instead, it isused to reflect a documentgenerated by a task step; thisshape does not have any outgoingflow lines

Financial Actuals: Indicates afinancial posting document


Budget Planning: Indicates abudget planning document


Manual Process: Covers a taskthat is manually done

Does not generally correspond toa task step in a document;instead, it is used to reflect a taskthat is manually performed, suchas unloading a truck in thewarehouse, which affects theprocess flow.

Existing Version / Data: This blockcovers data that feeds in from anexternal process

Does not generally correspond toa task step in a document;instead, this shape reflects datacoming from an external source;this step does not have anyincoming flow lines

System Pass / Fail Decision: Thisblock covers an automaticdecision made by the software

Does not generally correspond toa task step in the document;instead it is used to reflect anautomatic decision by the systemthat is made after a step has beenexecuted.

E x t e r n a l

t o S A P

BusinessActivity / Event

Unit Process

ProcessReference

Sub-Process

Reference

ProcessDecision

DiagramConnection

Hardcopy /Document

FinancialActuals

BudgetPlanning

ManualProcess

ExistingVersion /

Data

SystemPass/FailDecision

Symbol Description Usage Comments

Band: Identifies a user role, such as Accounts

Payable Clerk or Sales Representative. This band

can also identify an organization unit or group,

rather than a specific role.

The other process flow symbols in this table go

into these rows. You have as many rows as

required to cover all of the roles in the scenario.

Role band contains

tasks common to that

role.

External Events: Contains events that start or end

the scenario, or influence the course of events in

the scenario.

Flow line (solid): Line indicates the normal sequence

of steps and direction of flow in the scenario.

Flow line (dashed): Line indicates flow to

infrequently-used or conditional tasks in a

scenario. Line can also lead to documents involved

in the process flow.

Connects two tasks ina scenario process or a non-step event

Business Activity / Event: Identifies an action thateither leads into or out of the scenario, or anoutside Process that happens during the scenario

Does not correspondto a task step in thedocument

Unit Process: Identifies a task that is covered in astep-by-step manner in the scenario

Corresponds to a taskstep in the document

Process Reference: If the scenario referencesanother scenario in total, put the scenario number and name here.


Sub-Process Reference: If the scenario referencesanother scenario in part, put the scenario number,name, and the step numbers from that scenariohere


Process Decision: Identifies a decision / branchingpoint, signifying a choice to be made by the enduser. Lines represent different choices emergingfrom different parts of the diamond.

Does not usuallycorrespond to a taskstep in the document;Reflects a choice tobe made after stepexecution

< F u n c t i o n >


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149 ERP606 Process Overview en XX