This Blog will bring out some basics of Discrete Vs Repetitive manufacturing as a Snap Shot. Discrete Manufacturing: 1.

When production is done Based on Orders. 2. Cost is collected at Order Level. 3. Collection of cost 4. Complex Routing/Bom( Like Variant Configuration) Repetitive Manufacturing: 1. When Production is done Periodically( Same product Produced for over period of time) 2. Simple Back flushing is Planned. The below are few other points that are differentiate them. Master Data 1. Material Master Work Scheduling View: Discrete: You need to have the Work Scheduling View activated for this. REM: Work Scheduling is not Required. REM Profile: Discrete: No Rem Profile is required. REM: REM Profile is Mandatory. 2. Production Version Discrete: It is Optional REM: It is Mandatory 3. Product Cost Collector: Discrete: It is Not Required REM: It is Mandatory , it is the one which collects all the cost. 4. Settlement Discrete: Settlement is done at the Production order level. REM: It is at material Level. 5. Work Order. Discrete: Production order are mandatory. REM: No Order, 6. Confirmation

Discrete: confirmation is done at Production order Operation level or at Order level. REM: Confirmation are done at production version /Planned order level. 7. Capacity Planning Discrete: Done with CM01,02 etc, REM: Need to be done with MF50 Planning table. 8. Shop Floor Paper. Discrete: Can Create shop floor Print. REM : No Standard Shop floor Paper, need to do Custom Development if Required. 9.Order Information System Discrete: Has Detailed order information REM: No detailed list.

Discrete Manufacturing Vs Repetitive Manufacturing Below picture clearly depicts the differences between Discrete Manufacturing and Repetitive Manufacturing -

Typical of order-based production is the frequent switching from one product to another. Each product is manufactured in individually defined lots. Costs are calculated per order. In repetitive manufacturing, the same product is produced on a certain production line over a longer period of time. In production, a total quantity is produced according to a certain production rate over a certain period of time. Costs are collected periodically at a product cost collector. In order-based production, you usually have a changing sequence of work centers where the products are processed. The order of work centers is determined in routings, which can often be very complex. Semi-finished products are frequently placed in interim storage prior to further processing. Repetitive manufacturing usually involves a relatively constant flow through production lines. The routings of the individual products are very similar.
With production orders, component materials are staged with specific reference to the individual production orders. Confirmations for the various steps and orders document the work progress and can be used for fine control. In repetitive manufacturing, components are often staged at the production lines without reference to a particular order. The confirmations (backflushes) are usually executed periodically with no reference to an order (for example, all the quantities produced in one shift).

What is Discrete Manufacturing, REM and Demand Management?

1. What is Discrete Manufacturing? 2. What is REM? 3. What is Demand Management? Here are difference between Discrete and REM and small explanation about discrete and repetative manf.: - A typical characteristic of discrete manufacturing is the frequent switching from one manufactured product to another. The products are typically manufactured in individually defined lots, the sequence of work centers through production varying for each one of these. Costs are calculated on the basis of orders and individual lots. - In Repetitive Manufacturing, products remain unchanged over a longer period and are not manufactured in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate. - Discrete manufacturing typically involves varying the sequence of work centers through which the products can pass during production. The order of work centers is determined in routings, which can often be very complex. There can be waiting times between the individual work centers. Also, semi-finished products are frequently placed in interim storage prior to further processing. - Repetitive Manufacturing, on the other hand, normally involves a relatively constant flow on production lines. Semi-finished products are usually processed further immediately without being put in interim storage. Routings tend to be relatively simple. - In discrete manufacturing, component materials are staged with specific reference to the individual production lots. Completion confirmations for the various steps and processes document the work progress and enable fine-tune controlling. - In Repetitive Manufacturing, components are often staged at the production line without reference to a particular order. Completion confirmations are less detailed, and the recording of actual data is simplified. - The function of Demand Management is to determine requirement quantities and delivery dates for finished products assemblies. Customer requirements are created in sales order management. To create a demand program, Demand Management uses planned independent requirements and customer requirements. To create the demand program, you must define the planning strategy for a product. Planning strategies represent the methods of production for planning and manufacturing or procuring a product.

Using these strategies, you can decide if production is triggered by sales orders (make-to-order production), or if it is not triggered by sales orders (make-to-stock production).You can have sales orders and stock orders in the demand program. If the production time is long in relation to the standard market delivery time, you can produce the product or certain assemblies before there are sales orders. In this case, sales quantities are planned, for example, with the aid of a sales forecast.

Knowledge on Discrete and Repetitive

by: Sankaran 1. WHAT IS THE MAIN DIFFERENCE BETWEEN DISCRETE, REPETITIVE AND PROCESS MANUFACTURING. GIVE SOME EXAMPLES. PP-Discrete: Required where there will be discrete orders passing through a work center, here the capacity planning plays major role. i.e. if you have a lath machine, many orders are going through this lathe m/c and schedule plays very important role w.r.t lath as well as the product as the product has to go through many work centre. Every time the product many not be same can be different, but same work center can be used for many products. PP-PI: We are mainly concerned with quality parameters and Process management i.e control recipe is configured in this module. But the difference is the o/p is almost same, you will not change the product, but every step is very important to achieve the product quality. And it is entered by operator and approved by shift supervisor through control recipe function. REM: Mainly to reduce the data input by person working in SAP and in this case we are bother by the period end costing and not the each order level costing as the process is repetitive and one order is sufficient for the wile life.

2. HOW YOU CAN DECIDE AN ORGANISATION IS DISCRETE OR REPETITIVE OR PROCESS INDUSTRY? It depends on the client decision. In general it can be classified on the basis of product flow in the manufacturing process. If the production process under go same type of operation and process in their manufacturing, client can go for REM. If the production flow in their manufacturing process under go different operations depends on the requirement, client may go for Discrete. Also the production contains more and long operations can adopt discrete. REM contains similar less complicated operations. Even FERT can produced with Discrete and HALB can be produced by using REM.

3. FOR EXAMPLE CAR MANUFACTURING, WHAT TYPE OF INDUSTRY IS THIS, IF IT IS REPETITIVE, WHY NOT DISCRETE OR PROCESS INDUSTRY.

We can map the car manufacturing in REM or Discrete. It is to be decided with the business process owners and consulting partner, how they want to map the system. Production persons will explain how and about the production process. Also, the opinion of Costing department is important. Accordingly, it can come to a conclusion whether to go for Discrete or REM. It is to be decided before implementation starts.