Repetitive Manufacturing

PALO20

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ARTHUR ANDERSEN BUSINESS CONSULTING

Contents
Repetitive Manufacturing

Chapter 60 Introduction Chapter 61 System example Chapter 62 Master data

Chapter 64 Material provision Chapter 65 Backflushing Chapter 66 Repetitive manufacturing with production orders

Chapter 63 Planning

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Flexible Production Strategies (1)

Repetitive manufacturing Production by lot
Lot PLine Lot WkC 1 WkC 2 Lot WkC x

Kanban

Supply source External vendor

Make-to-order production Create sales order

External procurement Part A Assembly

Demand source
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Flexible Production Strategies (2)

Make-to-order production
l Make-to-order production and

assembly processing l Configured assembly orders l Assembly control system

l Production by lots l Production orders l Work centers l Rate-based planning l Run schedule quantities l Production lines l Self-regulating via Kanban signal l Control cycles and Kanbans l Supply areas

Control Control Lean production Lean production

Production orders

Repetitive manufacturing

Kanban

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Make-to-Order Production
PP PPC System R/3 Assembly order (planned order) l Configuration possible when creating sales orders Action control Assembly control system R/3 Assembly order l Action control l Availability check at component level and scheduling

l Costs assigned to the sales order

l Creation of procurement element in the planning run or automatically when creating the order (assembly order)

Assembly

Material delivery Sched.agmt Vendor

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Production Orders
Order header

l
Operations

Based on quantities Based on dates Releasing procedures/status

l l

maintenance
Components

l l

Material provision per order Order confirmation

Resources

Cost controlling per order

Costs

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Repetitive Manufacturing: Characteristics (1)

l Orderless production ?using run schedule quantities l Period-based planning ?based on production-rate
l Assigning run schedule quantities to production lines l Simplified capacity planning

l Planning days?supply (range of coverage)

l No release strategy / status maintenance
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