Purpose
This scenario describes production planning and control within a repetitive manufacturing environment. In repetitive manufacturing, master plans are typically created on a period and quantity basis (reduction in individual lot and order-specific processing). A quantity of one product is manufactured over a certain period. The product is processed in a constant flow and interim products are generally not stocked.
In repetitive manufacturing, you usually find that the effort required for production control is significantly less than is required for single lot and order-based production control and the recording of actual data is kept simpler.
Repetitive manufacturing can be used for various industries, such as the consumer packaged goods industry, the electronic industry, packaging industry, for example.
You can use Repetitive Manufacturing purely for make-to-stock production, or in a sales order-oriented environment, such as found in the automotive industry.
Process flow
Processing the Master Plan
You can plan the planned orders created in the MRP run for this material in a planning table. Here, you no longer refer to planned orders but to run schedule quantities. You can then change these run schedule quantities in the planning table taking the capacity situation into account, if necessary. Production is now controlled on the basis of these run schedule quantities.
Material Staging
The purpose of the interactive pull list is to inform you of components whose stock levels have to be replenished at the production storage location. From the missing quantities screen, you can directly trigger a stock transfer from the central warehouse to the production storage location.
Production Execution and Backflushing
The product is usually manufactured in a constant flow over the production line. You record actual data (backflush) at regular intervals for the production quantities manufactured. The system posts the component consumption and production activities with the goods receipt of the finished product. If you work with longer lead times, you can also backflush at reporting points on the production line. This means you can post component consumption closer to the actual time that the components were consumed.
Quality Check in Production
The quality management processes relevant to this scenario are explained in the scenario
QM in Production.