Unit 3: Repetitive Manufacturing Lesson 1: Drafting Repetitive Manufacturing Lesson 2: Preparing Repetitive Manufacturing Lesson 3: Planning Line Loading in Repetitive Manufacturing Lesson 4: Using Material Staging and Confirmation Lesson 5: Integrating Costing, Controlling, and Reporting
TSCM42_2
Lesson 1: Drafting Repetitive Manufacturing Lesson Objectives After completing this lesson, you will be able to:
●
Outline the properties of repetitive manufacturing
Unit 3 Lesson 1
TSCM42_2
Figure 43: Application Areas
Unit 3 Lesson 1
TSCM42_2
Figure 44: Repetitive Manufacturing: Characteristics
Unit 3 Lesson 1
TSCM42_2
Figure 45: Repetitive Manufacturing: Basic Functions
Unit 3 Lesson 1
TSCM42_2
Figure 46: Cross-Application Functional Process
Unit 3 Lesson 1
TSCM42_2
Figure 47: Master Data for Repetitive Manufacturing
Unit 3 Lesson 1
TSCM42_2
Figure 48: Demo Scenario: PC Production in Dresden Plant
Unit 3 Lesson 1
TSCM42_2
Unit 3 Exercise 9
Exercise 9: Check the Material Master of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing. Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master data object: material master Verify the Material Master
In the Logistics folder in the SAP ECC menu, navigate to the material master of motherboard T-B10## (## represents your group number), plant 1200, and go to the MRP 4 view. Use the change mode (transaction MM02). 1. Navigate to the Material Master of motherboard T-B10## and go to the MRP 4, plant 1200 view.
TSCM42_2
Unit 3 Exercise 9
Exercise 9: Check the Material Master of Repetitive Manufacturing . 2. Name the basic material master settings that are specific to repetitive manufacturing. ____________________________________________________ ____________________________________________________ ____________________________________________________ 3. Ensure that the Repetitive manufacturing profile 0001 is used for your material TB10## in plant 1200. Do not leave the transaction. 4. Display production version 0001 and perform a consistency check on the combination of BOM and routing. 5. Which production line is entered in production version 0001? ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Exercise 9
Exercise 9: Check the Material Master of Repetitive Manufacturing . 6. Write down the task list group of the rate routing entered and save your changes to the material master. ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 9
Solution 9: Check the Material Master of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing. Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master data object: material master Verify the Material Master
In the Logistics folder in the SAP ECC menu, navigate to the material master of motherboard T-B10## (## represents your group number), plant 1200, and go to the MRP 4 view. Use the change mode (transaction MM02). 1. Navigate to the Material Master of motherboard T-B10## and go to the MRP 4, plant 1200 view.
TSCM42_2
Unit 3 Solution 9
Solution 9: Check the Material Master of Repetitive Manufacturing . a) SAP ECC menu path: Logistics → Production → Master data → Material Master → Material → Change → Immediately (MM02) b) Enter your material number T-B10##, and choose Select Views. c) Select MRP 4 view and select Organizational levels. d) Enter plant 1200 and select
Continue.
2. Name the basic material master settings that are specific to repetitive manufacturing. ____________________________________________________ ____________________________________________________ ____________________________________________________ a) Repetitive mfg indicator, Repetitive manufacturing profile, Production version
TSCM42_2
Unit 3 Solution 9
Solution 9: Check the Material Master of Repetitive Manufacturing . 3. Ensure that the Repetitive manufacturing profile 0001 is used for your material TB10## in plant 1200. Do not leave the transaction. a) Change the REM profile to 0001 on the MRP4 view. 4. Display production version 0001 and perform a consistency check on the combination of BOM and routing. a) On the MRP 4 view select
ProdVersions.
b) Double click on version 0001. c) On the detail view for the production version, choose “Check” in the top righthand corner. The consistency check has the following results: BOM and routing exist. There are no error messages. Exit the screen by choosing
Cancel.
TSCM42_2
Unit 3 Solution 9
Solution 9: Check the Material Master of Repetitive Manufacturing . 5. Which production line is entered in production version 0001? ____________________________________________________ ____________________________________________________ a) From the detail screen of the production version, you can see that production version 0001 contains production line T-L3##. 6. Write down the task list group of the rate routing entered and save your changes to the material master. ____________________________________________________ ____________________________________________________ a) The number varies. On the detail screen of the production version, the Task list group is also displayed in the Rate-based planning line under Planning data.
TSCM42_2
Unit 3 Exercise 10
Exercise 10: Check the Bill of Material of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing . Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master object: BOM (bill of material) Verify the Bill of Material
1. Display your bill of material for T-B10## at plant 1200 with a BOM usage of 1. 2. How many assemblies are on the hierarchy level directly below the finished product? Finally, leave the transaction. ____________________________________________________
TSCM42_2
Exercise 10: Check the Bill of Material of Repetitive Manufacturing . ____________________________________________________
Unit 3 Exercise 10
TSCM42_2
Unit 3 Solution 10
Solution 10: Check the Bill of Material of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing . Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master object: BOM (bill of material) Verify the Bill of Material
1. Display your bill of material for T-B10## at plant 1200 with a BOM usage of 1. a) SAP ECC menu path: Logistics → Production → Master data → Bills of materials → Bill of material → Material BOM → Display (CS03) b) Enter material T-B10##, plant 1200, and BOM usage 1.
TSCM42_2
Unit 3 Solution 10
Solution 10: Check the Bill of Material of Repetitive Manufacturing . c) Choose ENTER to enter the component overview. 2. How many assemblies are on the hierarchy level directly below the finished product? Finally, leave the transaction. ____________________________________________________ ____________________________________________________ a) The Asm assembly indicator is set for one BOM item.
TSCM42_2
Unit 3 Exercise 11
Exercise 11: Check the Routing of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing . Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master object: Routing Verify the Routing
1. Display the rate routing for material T-B10##, plant 1200 in the Logistics master data. 2. How many different routings are displayed in the overview? ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Exercise 11
Exercise 11: Check the Routing of Repetitive Manufacturing . 3. Select the first routing with group counter 1 and choose the Operations button. What is special about the routing? ____________________________________________________ ____________________________________________________ 4. Name the work center involved and the production rate for the routing. ____________________________________________________ ____________________________________________________ 5. Exit the operation overview and go back to the rate routing overview and view the second routing. 6. Which work center belongs to group counter 2? ____________________________________________________ 7. View routing header data by choosing the Header button to show the task list group number.
TSCM42_2
Unit 3 Exercise 11
Exercise 11: Check the Routing of Repetitive Manufacturing . ____________________________________________________ ____________________________________________________ 8. Does production version 0001 enable repetitive manufacturing with the two routings? Why (not)? ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 11
Solution 11: Check the Routing of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the project team responsible for implementing the functions of Repetitive Manufacturing . Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master object: Routing Verify the Routing
1. Display the rate routing for material T-B10##, plant 1200 in the Logistics master data. a) SAP ECC menu path: Logistics → Production → Master data → Routings → Routings → Rate routings → Display (CA23) b) Enter your material T-B10## and plant 1200 only.
TSCM42_2
Unit 3 Solution 11
Solution 11: Check the Routing of Repetitive Manufacturing . c) Choose ENTER. 2. How many different routings are displayed in the overview? ____________________________________________________ ____________________________________________________ a) Two routings exist (two group counters). 3. Select the first routing with group counter 1 and choose the Operations button. What is special about the routing? ____________________________________________________ ____________________________________________________ a) In the rate routing overview, select the line with group counter and choose Operations. The special feature here is that there is only one operation. 4. Name the work center involved and the production rate for the routing. ____________________________________________________
TSCM42_2
Unit 3 Solution 11
Solution 11: Check the Routing of Repetitive Manufacturing . ____________________________________________________ a) The work center contains the (entire) T-L3## line and the production rate (30 pieces per hour). 5. Exit the operation overview and go back to the rate routing overview and view the second routing. a) In this transaction choose menu path Goto → Routing Overview. Select only the line with group counter 2 and choose the Operations button. 6. Which work center belongs to group counter 2? ____________________________________________________ a) The work center used in the second routing is T-L4## as well as reporting points LINE4-1, LINE4-2, and LINE4-3. 7. View routing header data by choosing the Header button to show the task list group number.
TSCM42_2
Unit 3 Solution 11
Solution 11: Check the Routing of Repetitive Manufacturing . ____________________________________________________ ____________________________________________________ a) View the task list group number. The task list group number is the same as noted before when analyzing the production version. 8. Does production version 0001 enable repetitive manufacturing with the two routings? Why (not)? ____________________________________________________ ____________________________________________________ a) No. Production version 0001 only allows production according to the routing with group counter 1. Leave the transaction using the Back button.
TSCM42_2
Unit 3 Exercise 12
Exercise 12: Check the Product Cost Collector of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the SAP SCM project team responsible for implementing the functions of Repetitive Manufacturing . Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master object: Product cost collector Verify the Product Cost Collector
1. Display the product cost collectors, using the Repetitive Manufacturing menu, for material T-B10## in plant 1200. 2. How many product cost collectors exist and how are they assigned? Finally, leave the transaction.
TSCM42_2
Unit 3 Exercise 12
Exercise 12: Check the Product Cost Collector of Repetitive Manufacturing . ____________________________________________________ ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 12
Solution 12: Check the Product Cost Collector of Repetitive Manufacturing . Business Example You work for a company that uses repetitive manufacturing to produce motherboards on two production lines and you are a member of the SAP SCM project team responsible for implementing the functions of Repetitive Manufacturing . Therefore you first try to get a general overview of the basic master data for repetitive manufacturing. In particular, you focus on the following master object: Product cost collector Verify the Product Cost Collector
1. Display the product cost collectors, using the Repetitive Manufacturing menu, for material T-B10## in plant 1200.
TSCM42_2
Unit 3 Solution 12
Solution 12: Check the Product Cost Collector of Repetitive Manufacturing . a) SAP ECC menu path: Logistics → Production → Repetitive manufacturing → Master data → Product Cost Collector → Process Product Cost Collector (KKF6N) b) Enter material number T-B10## and plant 1200 and choose ENTER. c) In the upper left part of the screen, select material T-B10##. Expand the selection. 2. How many product cost collectors exist and how are they assigned? Finally, leave the transaction. ____________________________________________________ ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 12
Solution 12: Check the Product Cost Collector of Repetitive Manufacturing . a) Two product cost collectors exist. They are assigned to the material by means of the production version (one product cost collector for each production version). Leave the transaction using the Back button.
TSCM42_2
Summary You should now be able to:
● Outline the properties of repetitive manufacturing
TSCM42_2
Lesson 2: Preparing Repetitive Manufacturing Lesson Objectives After completing this lesson, you will be able to:
●
Prepare repetitive manufacturing with regard to planning
Unit 3 Lesson 2
TSCM42_2
Figure 49: Repetitive Manufacturing: Process Flow
Unit 3 Lesson 2
TSCM42_2
Figure 50: Planning in Repetitive Manufacturing
Unit 3 Lesson 2
TSCM42_2
Figure 51: Basic Planning Strategies for Repetitive Manufacturing
Unit 3 Lesson 2
TSCM42_2
Unit 3 Exercise 13
Exercise 13: Verify Material Master Settings for Repetitive Manufacturing . Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program. First, check whether the master data for material T-B10## (motherboard) is correct. Check the Material Master Setup
Before you can run MRP you must assure yourself that master data is in place for repetitive manufacturing. 1. Is the material T-B10## (the motherboard) in plant 1200 permitted for repetitive manufacturing? ____________________________________________________ ____________________________________________________ 2. Is there a repetitive manufacturing profile maintained on the same view?
TSCM42_2
Unit 3 Exercise 13
Exercise 13: Verify Material Master Settings for Repetitive Manufacturing . ____________________________________________________ ____________________________________________________ 3. Finally, check the existing production versions: Is the REM allowed indicator set? ____________________________________________________
TSCM42_2
Unit 3 Solution 13
Solution 13: Verify Material Master Settings for Repetitive Manufacturing . Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program. First, check whether the master data for material T-B10## (motherboard) is correct. Check the Material Master Setup
Before you can run MRP you must assure yourself that master data is in place for repetitive manufacturing. 1. Is the material T-B10## (the motherboard) in plant 1200 permitted for repetitive manufacturing? ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 13
Solution 13: Verify Material Master Settings for Repetitive Manufacturing . a) Check whether the repetitive manufacturing indicator is set in the MRP 4 view. It has been set. 2. Is there a repetitive manufacturing profile maintained on the same view? ____________________________________________________ ____________________________________________________ a) Yes, either repetitive manufacturing profile 0002 or 0001 is maintained on the MRP 4 view. 3. Finally, check the existing production versions: Is the REM allowed indicator set? ____________________________________________________ a) Yes. Select the ProdVersions icon on the MRP 4 view and display the production versions one after the other to view the indicator. When complete,
TSCM42_2
Unit 3 Solution 13
Solution 13: Verify Material Master Settings for Repetitive Manufacturing . save (or leave the transaction via the Back button if you haven't changed anything).
TSCM42_2
Unit 3 Exercise 14
Exercise 14: Create a Production Program for Repetitive Manufacturing . Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program. Create a production program for material T-B10## (motherboard). Maintain Planned Independent Requirements
1. Manufacturing is unsure of the accuracy of the sales department forecasts for the upcoming months for your personal computers. However, operations wants to hedge sales by putting a forecast in at the sub-assembly level. Enter 1200 PC for next week for your material T-B10## at plant 1200 in version 00, and activate the demand plan for MRP. Before saving the results split the weekly demand into daily buckets.
TSCM42_2
Unit 3 Solution 14
Solution 14: Create a Production Program for Repetitive Manufacturing . Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program. Create a production program for material T-B10## (motherboard). Maintain Planned Independent Requirements
1. Manufacturing is unsure of the accuracy of the sales department forecasts for the upcoming months for your personal computers. However, operations wants to hedge sales by putting a forecast in at the sub-assembly level. Enter 1200 PC for next week for your material T-B10## at plant 1200 in version 00, and activate the demand plan for MRP. Before saving the results split the weekly demand into daily buckets.
TSCM42_2
Unit 3 Solution 14
Solution 14: Create a Production Program for Repetitive Manufacturing . a) SAP ECC menu path:Logistics → Production → Production Planning → Demand Management → Planned Independent Requirements → Create (MD61) b) Enter material T-B10##, plant 1200 and version 00, and set the planning period to W (weekly) buckets. c) Choose ENTER. d) When you reach the planning table, enter the 1200 PC requirements in the second weekly bucket. Caution: Do not use the current week!
TSCM42_2
Unit 3 Solution 14
Solution 14: Create a Production Program for Repetitive Manufacturing . e) Choose the Sched. Lines tab. The quantity with period indicator W is to be distributed over the individual working days. Therefore, set the Splt column indicator to D (day format) and confirm your entry. f) Confirm any warning messages that may be displayed by selecting ENTER. g) When complete select
Save.
TSCM42_2
Unit 3 Exercise 15
Exercise 15: MRP in Repetitive Manufacturing . Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program. Carry out a multilevel MRP run for your material. Perform Material Requirements Planning
1. Plan the T-B10## at plant 1200 using an multilevel single-item MRP run. Use the default parameters that are set when you enter the transaction. Hint: Multilevel planning ensures that dependent requirements are also generated for lower hierarchy levels in the BOM.
TSCM42_2
Unit 3 Exercise 15
Exercise 15: MRP in Repetitive Manufacturing . 2. Interpret the results of the planning run for the T-B10## at plant 1200, using the stock/requirements list. 3. Review the details of your first planned order. 4. What is the order type of the planned order? ____________________________________________________ 5. Can you convert this planned order to a production or process order? Why (not)? Finally, leave the transaction. ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 15
Solution 15: MRP in Repetitive Manufacturing . Business Example You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried out through planning and final assembly. To do this, the motherboards are planned at the assembly level and produced according to the planning program. Carry out a multilevel MRP run for your material. Perform Material Requirements Planning
1. Plan the T-B10## at plant 1200 using an multilevel single-item MRP run. Use the default parameters that are set when you enter the transaction. Hint: Multilevel planning ensures that dependent requirements are also generated for lower hierarchy levels in the BOM.
TSCM42_2
Unit 3 Solution 15
Solution 15: MRP in Repetitive Manufacturing . a) SAP ECC menu path Logistics → Production → MRP → Planning → Multilevel Single-item planning (MD02) b) Enter you material T-B10## and plant 1200. c) Choose ENTER twice to start the run. 2. Interpret the results of the planning run for the T-B10## at plant 1200, using the stock/requirements list. a) SAP ECC menu path: Logistics → Production → MRP → Evaluations → Stock/ Requirements List (MD04) b) Enter your material T-B10## and plant 1200, and choose ENTER. 3. Review the details of your first planned order. a) Double click on the first planned order.
TSCM42_2
Unit 3 Solution 15
Solution 15: MRP in Repetitive Manufacturing . 4. What is the order type of the planned order? ____________________________________________________ a) Planned order type LA - Stock Order 5. Can you convert this planned order to a production or process order? Why (not)? Finally, leave the transaction. ____________________________________________________ ____________________________________________________ a) No - checking the details view of the planned order the conversion buttons are missing. This is because of the REM flag in the material master MRP4 view. Leave the details of the planned order and the transaction via the Cancel and Back buttons, respectively.
TSCM42_2
Summary You should now be able to:
● Prepare repetitive manufacturing with regard to planning
TSCM42_2
Unit 3 Lesson 3
Lesson 3: Planning Line Loading in Repetitive Manufacturing Lesson Objectives After completing this lesson, you will be able to:
●
Plan line loading in repetitive manufacturing
TSCM42_2
Figure 52: Overview: Planning Line Loading
Unit 3 Lesson 3
TSCM42_2
Figure 53: Actions for Manual Line Loading Planning (Example: ECC)
Unit 3 Lesson 3
TSCM42_2
Unit 3 Exercise 16
Exercise 16: Perform Line Loading in Repetitive Manufacturing . Business Example Two production lines are available for the assembly of the T-B10## motherboard. The basic dates as to quantities and periods have already been determined in MRP and production planning in the previous exercise. As the production planner, you now assign the quantities to the relevant production line. Assign the MRP Results to the Production Lines
As a result of the MRP run, planned orders have been created to cover the forecast requirements for your mother board T-B10## at plant 1200. Earlier you reviewed your master data and recognized that two production lines could manufacture the motherboard. In order for execution to take place we must decide what quantities are going to run on what lines taking capacity availability into account. Access the repetitive planning table and assign quantities to production lines. 1. Access the planning table for repetitive manufacturing. for your production line TL3## and T-L4## in plant 1200. Make sure that you are scheduling using rate based planning; that capacity planning data is visible, and that all other production
TSCM42_2
Unit 3 Exercise 16
Exercise 16: Perform Line Loading in Repetitive Manufacturing . options are available for scheduling. Assign the planned orders to the production lines, taking into account the available capacities. Note: Save your settings in order to speed up access during later reviews
2. Double-click a quantity in the planning table section that is ready for input to display the detail data for the planned order. Which order type is assigned (F4 help)? ____________________________________________________ 3. Change your user settings so the total requirements as well as supply is visible in the lower table. 4. Put the table in assignment mode to schedule the “unassigned quantities” in the planning table section that is ready for input. Assign the unassigned quantity to the final assembly line.
TSCM42_2
Unit 3 Exercise 16
Exercise 16: Perform Line Loading in Repetitive Manufacturing . 5. Double-click the quantity you have just assigned. Which order type is now assigned (F4 help)? ____________________________________________________ 6. Look at the capacity data. Does the production line reach full capacity with the planned order in the relevant time interval or is some capacity still available for other orders in the same period? ____________________________________________________ ____________________________________________________ 7. Save your planning results.
TSCM42_2
Unit 3 Solution 16
Solution 16: Perform Line Loading in Repetitive Manufacturing . Business Example Two production lines are available for the assembly of the T-B10## motherboard. The basic dates as to quantities and periods have already been determined in MRP and production planning in the previous exercise. As the production planner, you now assign the quantities to the relevant production line. Assign the MRP Results to the Production Lines
As a result of the MRP run, planned orders have been created to cover the forecast requirements for your mother board T-B10## at plant 1200. Earlier you reviewed your master data and recognized that two production lines could manufacture the motherboard. In order for execution to take place we must decide what quantities are going to run on what lines taking capacity availability into account. Access the repetitive planning table and assign quantities to production lines. 1. Access the planning table for repetitive manufacturing. for your production line TL3## and T-L4## in plant 1200. Make sure that you are scheduling using rate based planning; that capacity planning data is visible, and that all other production
TSCM42_2
Unit 3 Solution 16
Solution 16: Perform Line Loading in Repetitive Manufacturing . options are available for scheduling. Assign the planned orders to the production lines, taking into account the available capacities. Note: Save your settings in order to speed up access during later reviews
a) SAP ECC menu path: Logistics → Production → Repetitive Manufacturing → Planning → Planning Table → Change Mode (MF50) b) Enter the final assembly line T-L3## and select via Production line. c) In the Scheduling tab, make sure Rate-based Planning is selected, and capacity planning is selected. d) In the Control tab, select Line Overview. e) Select
Settings.
TSCM42_2
Unit 3 Solution 16
Solution 16: Perform Line Loading in Repetitive Manufacturing . f) Select
Planning Table.
g) In the window that appears select all production lines and select
Continue.
2. Double-click a quantity in the planning table section that is ready for input to display the detail data for the planned order. Which order type is assigned (F4 help)? ____________________________________________________ a) The planned order has order type LA Stock order. Choose the Cancel button to leave the screen. 3. Change your user settings so the total requirements as well as supply is visible in the lower table. a) Select
User Settings.
b) Check Total Requirements check box.
TSCM42_2
Unit 3 Solution 16
Solution 16: Perform Line Loading in Repetitive Manufacturing . c) Select
Check Data.
d) Select
Adopt.
4. Put the table in assignment mode to schedule the “unassigned quantities” in the planning table section that is ready for input. Assign the unassigned quantity to the final assembly line. a) Select the line labeled Not Yet Assigned. b) Switch on the assignment mode using the push button with the truck icon. c) A symbol appears at the start of the line, signifying that you are in assignment mode for this line. d) Assign the quantities in the “Not yet assigned” section. Enter the quantities in one of the production line fields that belongs to the same period.
TSCM42_2
Unit 3 Solution 16
Solution 16: Perform Line Loading in Repetitive Manufacturing . Note: Be sure to choose ENTER in order for the system to recalculate the available quantities and the capacity requirements.
e) Deactivate the assignment mode by choosing the according push button. 5. Double-click the quantity you have just assigned. Which order type is now assigned (F4 help)? ____________________________________________________ a) The planned order has the order type PE (run schedule quantity). 6. Look at the capacity data. Does the production line reach full capacity with the planned order in the relevant time interval or is some capacity still available for other orders in the same period? ____________________________________________________
TSCM42_2
Unit 3 Solution 16
Solution 16: Perform Line Loading in Repetitive Manufacturing . ____________________________________________________ a) By dispatching a planned order on production line T-L3##, the line only reaches a comparatively low capacity load (see the planning table: Capacity data in the row for production line T-L3##). The capacity data is not available on the same day as the production quantities since the quantities are determined to the day according to availability, while the capacity load of the production line is determined tothe hour and minute according to the production date. 7. Save your planning results. a) Select
Save.
TSCM42_2
Summary You should now be able to:
● Plan line loading in repetitive manufacturing
TSCM42_2
Lesson 4: Using Material Staging and Confirmation Lesson Objectives After completing this lesson, you will be able to:
●
Stage and confirm material in repetitive manufacturing
Unit 3 Lesson 4
TSCM42_2
Figure 54: Material Staging Options
Unit 3 Lesson 4
TSCM42_2
Figure 55: Backflush and Goods Receipt
Unit 3 Lesson 4
TSCM42_2
Figure 56: Backflush: Reporting Point Backflush
Unit 3 Lesson 4
TSCM42_2
Unit 3 Exercise 17
Exercise 17: Perform Material Staging for Repetitive Manufacturing . Business Example For assembly production of motherboard T-B10##, you want to check for missing components in the production storage location PL03 and use stock transfer measures to stage missing components for a certain production period. Carry out Material Staging
Now that you have run MRP to cover your requirements and scheduled production to the appropriate lines, you need to ensure that the material is available to support production. In this section you will learn how material staging supports backflushing. 1. Execute the pull list for production line T-L3## in plant 1200, in order to stage the necessary components for production. The staging should be performed for line for all requirements that are received until Tuesday of the week after next. In this example, material staging is performed at storage location level. Some steps in the pull list can be carried out automatically, Create replenishment proposals and Batch/stock determination. Make the changes in global settings.
TSCM42_2
Unit 3 Exercise 17
Exercise 17: Perform Material Staging for Repetitive Manufacturing . 2. Go to the pull list. Interpret the results of the automatic steps. For which materials are there shortfall quantities until Tuesday of the week after next due to the planned requirements? How large are these quantities? ____________________________________________________ ____________________________________________________ 3. At which storage location are there shortfall quantities? ____________________________________________________ ____________________________________________________ 4. At which storage location has the system found a replenishment quantity? ____________________________________________________ 5. Can the complete shortfall quantity be covered from here? ____________________________________________________
TSCM42_2
Unit 3 Exercise 17
Exercise 17: Perform Material Staging for Repetitive Manufacturing . 6. You accept the system proposal. To trigger material staging for the relevant components from warehouse 0001 to production storage location PL03. 7. Caution: Material staging (using direct stock transfer in this case) is not carried out until you save the pull list. If you need a printout of the list for the physical stock transfer, we recommend printing it before you save (Pull List – Print). Save your results.
8. Check the stock transfer posting in the message log for the pull list (in a separate transaction).
TSCM42_2
Unit 3 Solution 17
Solution 17: Perform Material Staging for Repetitive Manufacturing . Business Example For assembly production of motherboard T-B10##, you want to check for missing components in the production storage location PL03 and use stock transfer measures to stage missing components for a certain production period. Carry out Material Staging
Now that you have run MRP to cover your requirements and scheduled production to the appropriate lines, you need to ensure that the material is available to support production. In this section you will learn how material staging supports backflushing. 1. Execute the pull list for production line T-L3## in plant 1200, in order to stage the necessary components for production. The staging should be performed for line for all requirements that are received until Tuesday of the week after next. In this example, material staging is performed at storage location level. Some steps in the pull list can be carried out automatically, Create replenishment proposals and Batch/stock determination. Make the changes in global settings.
TSCM42_2
Unit 3 Solution 17
Solution 17: Perform Material Staging for Repetitive Manufacturing . a) SAP ECC menu path: Logistics → Production → Repetitive Manufacturing → Material Staging → Pull List - Trigger Replenishment (MF60) b) Set the staging type to storage location level (SLoc Level). c) Enter plant 1200 and selection period Tuesday of the week after next. d) Enter production line T-L3## in the Plnd Orders area of the screen. e) Select Global Settings. f) In the Dialog Control tab set Create replenishment proposals and Execute Batch/stock determination to Automatic. g) Select
Continue.
h) Select
Execute.
TSCM42_2
Unit 3 Solution 17
Solution 17: Perform Material Staging for Repetitive Manufacturing . 2. Go to the pull list. Interpret the results of the automatic steps. For which materials are there shortfall quantities until Tuesday of the week after next due to the planned requirements? How large are these quantities? ____________________________________________________ ____________________________________________________ a) Due to the planned requirements, there are shortfall quantities for material TT6## until Tuesday of the week after next. The system automatically created a replenishment proposal and determined stock for component T-T6## in storage location 0001. The pull list shows the size of the shortfall quantity. 3. At which storage location are there shortfall quantities? ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 17
Solution 17: Perform Material Staging for Repetitive Manufacturing . a) There are shortfall quantities at production storage location PL03, where the components for assembly production are to be staged. 4. At which storage location has the system found a replenishment quantity? ____________________________________________________ a) The replenishment quantity was found in central warehouse 0001. 5. Can the complete shortfall quantity be covered from here? ____________________________________________________ a) Yes, the staging quantity is equal to the shortfall quantity. 6. You accept the system proposal. To trigger material staging for the relevant components from warehouse 0001 to production storage location PL03. a) Select the row with the replenishment element and select Stage.
TSCM42_2
Unit 3 Solution 17
Solution 17: Perform Material Staging for Repetitive Manufacturing . 7. Caution: Material staging (using direct stock transfer in this case) is not carried out until you save the pull list. If you need a printout of the list for the physical stock transfer, we recommend printing it before you save (Pull List – Print). Save your results.
a) Select
Save.
8. Check the stock transfer posting in the message log for the pull list (in a separate transaction). a) SAP ECC menu path: Logistics → Production → Repetitive Manufacturing → Material Staging → Log (MF68) The stock transfer was successfully posted in the system.
TSCM42_2
Unit 3 Solution 17
Solution 17: Perform Material Staging for Repetitive Manufacturing . b) Access the log from the Material Staging menu, enter today's date as the “To” date, and choose Execute. Finally, leave the transaction using the Back button.
TSCM42_2
Unit 3 Exercise 18
Exercise 18: Confirm Production Quantities in Repetitive Manufacturing . Business Example Now that scheduling is complete and materials have been staged at the production line production is ready to execute. In this section you will learn how backflushing is managed in SAP ECC. Carry out Confirmation
1. First, open a second session of the planning table for repetitive manufacturing (which you access by selecting production line T-L3##, plant 1200). 2. In the first session, execute a REM confirmation for 90 pieces of the motherboard material T-B10## produced on line T-L3## in plant 1200. Then choose Post with correction . 3. Look at the next screen and explain which components of assembly T-B10## were backflushed on the line. Save.
TSCM42_2
Unit 3 Exercise 18
Exercise 18: Confirm Production Quantities in Repetitive Manufacturing . 4. Go to the second session (planning table). Refresh the screen and look at the quantities on the line. 5. How have the planned quantities changed? ____________________________________________________ ____________________________________________________
TSCM42_2
Unit 3 Solution 18
Solution 18: Confirm Production Quantities in Repetitive Manufacturing . Business Example Now that scheduling is complete and materials have been staged at the production line production is ready to execute. In this section you will learn how backflushing is managed in SAP ECC. Carry out Confirmation
1. First, open a second session of the planning table for repetitive manufacturing (which you access by selecting production line T-L3##, plant 1200). a) Select System – Create Session to open a new session and use the following path: b) SAP ECC menu path: Logistics → Production → Repetitive Manufacturing → Planning → Planning Table → Change Mode (MF50) c) Enter plant 1200 and production line T-L3## and choose ENTER.
TSCM42_2
Unit 3 Solution 18
Solution 18: Confirm Production Quantities in Repetitive Manufacturing . Note: The settings have defaulted in from a previous exercise step.
d) Select Execute Planning Table, select all production lines and confirm to enter the table. 2. In the first session, execute a REM confirmation for 90 pieces of the motherboard material T-B10## produced on line T-L3## in plant 1200. Then choose Post with correction . a) SAP ECC menu path: Logistics → Production → Repetitive Manufacturing → Data Entry → Repetitive Manufacturing Confirmation (MFBF) b) Enter the following data on screen of the backflush transaction screen:
TSCM42_2
Unit 3 Solution 18
Solution 18: Confirm Production Quantities in Repetitive Manufacturing . The production version contains the production on line T-L3##. Choose ENTER and choose Post with correction. 3. Look at the next screen and explain which components of assembly T-B10## were backflushed on the line. Save. a) The current BOM was exploded during the confirmation. The system determined the materials to be backflushed in the BOM explosion. The all or nothing principle applies, which means that all four materials displayed are backflushed. 4. Go to the second session (planning table). Refresh the screen and look at the quantities on the line. a) Select the other open session of SAP ECC. b) Use menu path from here: Planning → Reaccess
TSCM42_2
Unit 3 Solution 18
Solution 18: Confirm Production Quantities in Repetitive Manufacturing . 5. How have the planned quantities changed? ____________________________________________________ ____________________________________________________ a) The first planned order quantity is (or quantities are) reduced according to the confirmation quantity. Explanation: For demonstration purposes, the backflush was made with a date (today) that is before the actual production dates. The confirmation quantity is therefore interpreted as “over-production” that reduces subsequently planned orders accordingly (first planned orders first).
TSCM42_2
Summary You should now be able to:
● Stage and confirm material in repetitive manufacturing
TSCM42_2
Unit 3 Lesson 5
Lesson 5: Integrating Costing, Controlling, and Reporting Lesson Objectives After completing this lesson, you will be able to:
●
Outline the integration of costing, controlling, and reporting to repetitive manufacturing
TSCM42_2
Figure 57: Cost Debit/Credit (Product-Related Cost Object Controlling)
Unit 3 Lesson 5
TSCM42_2
Figure 58: Integration with Controlling
Unit 3 Lesson 5
TSCM42_2
Figure 59: Repetitive Manufacturing: Information Systems
Unit 3 Lesson 5
TSCM42_2
Figure 60: Period-Based Repetitive Manufacturing: Additional Functions
Unit 3 Lesson 5
TSCM42_2
Summary You should now be able to:
● Outline the integration of costing, controlling, and reporting to repetitive manufacturing
TSCM42_2
Open Question
Name some basic functions of repetitive manufacturing.
Unit 3
TSCM42_2
Open Question
Name some basic functions of repetitive manufacturing.
Unit 3
. Planning line loading, Scheduling, Calculation and monitoring of capacity requirements, Costing, Avaiability checks, Printing dispatch lists, Printing operational method sheet, Material staging, Goods issue/backflushing, Goods receipt with final confirmation, Periodend closing.
TSCM42_2
Open Question
Why do you need a material cost estimate to calculate production activities in repetitive manufacturing?
Unit 3
TSCM42_2
Open Question
Why do you need a material cost estimate to calculate production activities in repetitive manufacturing?
Unit 3
. Due to the handling of production quantities with planned orders there is no real "order" object to collect and carry the production activities. This is covered by a material cost estimate and subsequent price update in the material master.
