Make-to-Order Repetitive Manufacturing (Non-Valuated Stock) (SAP Library)

Make-to-Order Repetitive Manufacturing (Non-Valuated Stock)

Purpose

You can use Repetitive Manufacturing in a make-to-order production environment. For each sales order item, the system creates one or several planned orders which directly reference the sales order item. The material is manufactured on the basis of the planned orders. Production is therefore triggered via sales orders.

If you are a repetitive manufacturer and work in a make-to-order environment with non-valuated sales order stock (see also: Special case: Non-Valuated Make-to-Order Stock), the costs are collected and analyzed for the sales order item. Therefore, you require a cost and revenue sales order item. This means, you carry out Controlling for Sales Order. In this case, it is not possible to collect and analyze the costs at a product cost collector. The calculation of the stock value is carried out in a results analysis. By settlement which is carried out using the results analysis data determined in the results analysis, you can activate the stock in Financial Accounting.

You are recommended to work with valuated sales order stock in make-to-order repetitive manufacturing. In this case, use the product cost collector for make-to-order production as the cost object.

Prerequisites

You are a repetitive manufacturer.

Make sure that you work with non-valuated sales order stock by specifying a requirement type for the sales order item that refers to a requirement class in which is defined that you work with non-valuated sales order stock (see also: Controlling Requirements Type Determination; Checking the Requirements Type in the Sales Order).

Make sure that the sales order item is for cost and revenue by saving an appropriate account assignment type in the requirements class.

You make the settings for the requirement type determination, requirement type, requirement class and account assignment type in Customizing for Sales Order Controlling under Controlling Make-to-Order Production.

You create a material with a production version. Set the repetitive manufacturing indicator for the production version.

The production version requires a BOM and a work center. If you want to represent several work processes, in Line Design, for example, you also need a routing.

You determine a REM profile in the MRP view of the material master record for which the settings described in the following point have been made.

In Customizing for Period Product Controlling, under Simultaneous Costing ® Check Control Data for REM Profiles make the following settings:

Make sure that the reporting point backflush is not allowed.

If you work with make-to-order REM, you will usually backflush the goods issue at the same time as the goods receipt. Make the corresponding settings in the repetitive manufacturing profile.

If, in the REM profile, you define that you want to post activities then at make-to-order production in the REM profile, you have to define that the activities are to be posted on the basis of the standard cost estimate and you also have to create a standard cost estimate for a configurable material. Only by making this setting does the system automatically carry out an activity posting at the goods receipt for the sales order.

Process flow

Create a sales orders and save the material to be manufactured in the sales order item. If necessary, configure the material.

The system creates one or several planned orders for the material recorded in the sales order item. The planned order contains all the material components required for the production of the material. The planned order can be created:

In the MRP run.
Directly when saving the sales order.

To create the planned order when saving the sales order, you must have saved the assembly type "1" in the requirements class (Planned order: static procedure) or "4" (Planned order: dynamic procedure).

As the REM indicator is saved for the material to be manufactured in the material master record, the planned order has no conversion indicator. Therefore, the planned orders is not converted into either a production order or into a purchase requisition.

If, in the material master, you have selected an alternative selection indicator for selection by production line, the system assigns the planned orders (order type KD) directly to the production line in the planning table.

If you have not chosen a BOM selection method, you can assign the planned orders (order type KD) created in the planning run to the production line(s) in the planning table.

You use Sequencing to determine the sequence in which orders are processed on the production line.

You access the pull list to calculate the missing parts for the components at the production line, and to create the appropriate replenishment elements.

After you have manufactured the material, post the goods receipt. To do this go to the Repetitive Manufacturing menu and post a goods receipt for the sales order (see also: Goods Receipt for the Sales Order, Posting the Goods Receipt for the Sales Order). The system posts the actual costs to the sales order item, reduces the planned orders and updates the statistics.

Here, the sales order item is debited:

By the costs resulting from the goods issue posting.
By the activity costs, if necessary.

Instead of an automated activity posting, you can also carry out a direct activity posting manually.

Carry out a results analysis for the sales order item to determine the stock value. Using the results analysis, you can also determine other results analysis data such as provision and sales costs.
By settling the sales order item, you bill the stock value to financial accounting.

It is not possible to use reporting point backflushing in make-to-order repetitive manufacturing. Total requirements, on the other hand, can only be used in make-to-order repetitive manufacturing.