Repetitive Manufacturing 1: Setup
1.1 Create Repetitive Manufacturing Workcenter
Repetitive Manufacturing is used to manage high-volume production lines where production
order processing is not needed for control and proves to require too much processing. To
configure, we first need to create a baking line workcenter that is configured for repetitive
manufacturing. To do this, follow the menu path:
Logistics Production Master Data Work Centers Work Center Create
which will produce the following screen:
Enter ##PT for Plant,
REPBAKE for Work Center
and 0007 for Work center cat.
Then click on the enter icon
this will produce the following screen:
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Repetitive Manufacturing 1: Setup
Enter ## Repetitive Manufacturing Bakeline
for the description, 200 for Person responsible,
0000 for Location and 007 for Usage
Check the Backflush indicator
Enter SAP1 for Standard value key
Then click on the enter icon
Enter the information shown above, then click on the enter icon (
additional data fields on this screen:
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). This will produce
Repetitive Manufacturing 1: Setup
Leave the default values, then
click on the default values tab
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Repetitive Manufacturing 1: Setup
Enter BAKE for Control key
Enter MIN for Setup and Machine time
units of measure
Then click on the Capacities tab
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Repetitive Manufacturing 1: Setup
Enter 001 for Capacity Category,
then click on the enter icon
Enter Capacity Category 001 then click on the enter icon (
following screen:
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). This will produce the
Repetitive Manufacturing 1: Setup
Enter Repetitive Bake Line for capacity description
Enter A for Capacity planner grp, US for Factory
calendar ID, H for Base unit of meas., 24:00:00 for
Finish time, 100 for Capacity utilization, 1 for No. of
indiv. Cap., H for Capacity unit
Check Relevant to finite scheduling , Can be used
by several operation and Long-term planning
Then click on the enter icon
Enter the data shown in the figure above, then click on the enter icon (
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):
Repetitive Manufacturing 1: Setup
Enter SAP001 for Setup formula,
SAP002 for Processing formula,
then click on the Scheduling tab
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Repetitive Manufacturing 1: Setup
Enter 001 for Capacity Category,
BAKE for Capacity, SAP001 for Setup
formula, SAP002 for Processing
formula, then click on the save icon
Enter the data shown above, then click on the save icon (
workcenter.
) to finish creating the new
1.2 Define Scheduling Parameters for Planned Orders
The next step in configuring repetitive manufacturing is to set the scheduling parameters for
planned orders. To do this, follow the menu path:
Tools Customizing IMG Edit Project
Click on
Production Material Requirements Planning Planning Scheduling and
Capacity Parameters Define scheduling parameters for planned orders (
)
which will produce the following screen:
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Repetitive Manufacturing 1: Setup
Click on New entries
Click on New Entries, which will produce the following screen:
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Repetitive Manufacturing 1: Setup
Enter ##PT for Plant, PE for
Order type, ##S for ProdScheduler
Under Rate-based scheduling, enter 30 for Rate.plng
horzn, 02 for SelID.rate plng
Check both Scheduling and Generate capacity reqs.
Select Scheduling level Via rate-based scheduling
Select Backwards for Scheduling type
Carefully enter the information shown above, then click on the save icon (
back icon (
) twice to return to the IMG.
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). Click on the
Repetitive Manufacturing 1: Setup
1.3 Define Scheduling Parameters for Production Orders
Next, we need to set the appropriate scheduling and capacity parameters for production orders.
To do this, follow the menu path:
Tools Customizing IMG Edit Project
Click on
Production Capacity Requirements Planning Operations Scheduling Define
Scheduling Parameters for Production Orders (
)
Select your plant (##PT),
then click on the details icon
Select your plant from the list, then click on the Details icon (
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):
Repetitive Manufacturing 1: Setup
Under Rate-based scheduling, enter
01 for SelD:rate plng, check
Scheduling and Generate capacity
reqs. , then click on the save icon
Set the Rate-based scheduling parameters as shown above, then click on the save icon (
Click on the back icon (
) twice to return to the IMG.
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).
Repetitive Manufacturing 1: Setup
1.4 Create Rate-based Routings
Repetitive manufacturing is a method of planning that bases production scheduling on run times
rather than order quantities. To implement it in SAP, we need to create a (production) rate-based
routing rather than a standard routing. To do this, follow the menu path:
Logistcs Production Master Data Routings Routings Rate Routings
Create
which will produce the following screen:
Enter ##F100 for Material and ##PT for Plant,
then click on the enter icon
Enter ##F100 for Material and ##PT for Plant, then click on the enter icon (
produce the following screen:
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). This will
Repetitive Manufacturing 1: Setup
Enter 1 for Usage and 4 for Status,
then click on the Operations icon
Enter the data shown above, then click on the Operations icon (
):
Enter REPBAKE for Work Ctr, BAKE for Control,
Repetitive Bakeline for Operation short text, and 10
for Base Quantity, then click on the enter icon
Click on the enter icon (
):
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Repetitive Manufacturing 1: Setup
Scroll over, then enter 30 for
Setup and 60 for Machine time,
then click on the CompAlloc icon
Scroll over and enter 30 for Setup and 60 for Machine time, then click on the CompAlloc icon
(
):
Select the ##S200 material, then
click on the New assignment icon
Click on the New assignment icon to get the following pop-up window:
Enter 10 for Operation, then
click on the enter icon
Enter 10 for the Operation, then click on the enter icon (
save the rate routing.
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). Click on the save icon (
) to
Repetitive Manufacturing 1: Setup
REPEAT THESE STEPS TO CREATE A RATE ROUTING
FOR THE NRG-B BARS, MATERIAL ##F110.
1.5 Define Storage Locations for Materials
Data records are required to indicate that a particular material can be stored in a particular
storage location. The Fitter Snacker client is configured to create these records whenever a
material is received in a storage location, but this can also be done explicitly before a material is
placed in a storage location. To define this material-storage location record explicitly, follow the
menu path:
Logistics Materials Management Material Master Other Enter Storage
Location
which will bring up the following screen:
Enter ##F100 for material and ##PT for plant
Make sure List all existing storage locations
is selected, then click on the enter icon
Enter the data shown above, then click on the enter icon (
following screen:
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), which will bring up the
Repetitive Manufacturing 1: Setup
Enter 300 for SLoc (storage
location), then click on the save icon
Enter storage location 300 for SLoc (storage location), then click on the save icon (
Repeat this process for the following materials and storage location:
Material
##S200
##S210
).
Storage Location
200
200
Note that we don’t need to define material ##F110 for storage location 300. This record already
exists because inventory is already stocked in storage location 300.
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Repetitive Manufacturing 1: Setup
1.6 Material Master Changes
A number of changes need to be made to the Material Master MRP views. To do this, follow the
menu path:
Logistics Materials Management Material Master Material Change
Immediately
Enter material ##F100, then
click on the enter icon
Enter material ##F100, then click on the enter icon (
View(s) screen:
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), which will bring up the Select
Repetitive Manufacturing 1: Setup
Select the MRP 1, MRP2
and MRP 4 views, then
click on the enter icon
Select the MRP 1, MRP2 and MRP 4 views, then click on the enter icon (
up the following screen:
). This will call
Enter ##PT, then
click on the enter icon
Enter ##PT for Plant, then click on the enter icon (
Material Master:
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) to call up the MRP 1 view in the
Repetitive Manufacturing 1: Setup
Change the lot size to FX
with Fixed lot size of 1000,
then click MRP 2 tab
Change the lot sizing procedure to FX (fixed) with lot size 1000, then click on the MRP 2 tab:
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Repetitive Manufacturing 1: Setup
Enter 300 for Prod. stor. location, 3
for Backflush (Workcenter decides),
then click on the MRP 4 tab
Enter 300 for Prod. stor. location, then click on the MRP 4 tab:
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Repetitive Manufacturing 1: Setup
Select Repetitive mfg and
enter REM profile 0001
Then click on ProdVersions
Check the Repetitive mfg option, enter 0001 for REM profile, then click on the ProdVersions
icon(
), which will bring up the following pop-up window:
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Repetitive Manufacturing 1: Setup
Enter 0001 for Version, Repetitive Manufacturing
Bakeline for Text, then click on the Details icon
Enter 0001 for Version, Repetitive Manufacturing Bakeline for Text, then click on the Details
icon, which will produce the following pop-up window:
Click on the enter icon
This pop-up window is offering to set default dates for the Production Version. Click on the
enter icon (
) to accept the defaults, and the following screen will appear:
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Repetitive Manufacturing 1: Setup
Select Rate Routing for all planning types,
then click on the first Group field to search
for the Rate Routing you created previously
Set Rate Routing for all planning types, then click on the first Group field to search for the Rate
Routing. This will bring up the following search screen:
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Repetitive Manufacturing 1: Setup
Select the Rate routings tab, enter ##PT
for Plant, then click on enter icon
Select the Rate routings tab, enter ##PT for Plant, then click on enter icon:
Double-click on your
rate routing to select it
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Repetitive Manufacturing 1: Setup
Repeat the search process for
the other two planning levels
Repeat the search process for the other two planning levels:
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Repetitive Manufacturing 1: Setup
Enter 1 for Alternative BOM and
BOM Usage, select REM allowed,
then search for a production line
(workcenter)
Enter 1 for Alternative BOM and BOM Usage, select REM allowed, then click on the
Production line field and click on the search icon (
). This will bring up the following search
pop-up window:
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Repetitive Manufacturing 1: Setup
Make sure 0007 is entered for
Work center cat.
Enter ##PT for Plant
Then click on the enter icon
Make sure 0007 (Production line) is entered for Work center cat. Enter ##PT for Plant, then
click on the enter icon (
). This search will find the repetitive manufacturing workcenter you
created:
Double-click on your workcenter to select it
Double-click on your workcenter to select it:
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Repetitive Manufacturing 1: Setup
Enter storage locations,
then click on Check icon
Enter the storage locations for goods issue and receipt, then click on the Check icon
(
). This will produce the following report:
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Repetitive Manufacturing 1: Setup
Task lists (rate routings) exist. Scroll
down to see the bottom of the report
The top part of this report shows that the check function found the rate routings for this material.
Scroll down and note that the BOM was also found:
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Repetitive Manufacturing 1: Setup
BOM was found.
Click on cancel
Click on the cancel icon, and notice the green traffic lights that show the check was successful:
Notice traffic lights.
Click on Continue
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Repetitive Manufacturing 1: Setup
Click on the Continue icon (
Overview pop-up window:
). This will return you to the Production Version
Click on Continue
Click on the Continue icon (
changes to the Material Master.
) again, then click on the save icon (
) to save the
REPEAT THESE STEPS TO MODIFY THE MATERIAL MASTER FOR THE NRG-B
BARS, MATERIAL ##F110, TO SUPPORT REPETITIVE MANUFACTURING
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Repetitive Manufacturing 1: Setup
1.6 Configure the Stock/Requirements List
Next, we will configure the Stock/Requirements List so that it is easy to call up the Repetitive
Planning Table. To get to the Stock/Requirements List, follow the menu path:
Logistics Production MRP Evaluations Stock/Requirements List
which will produce the following screen:
Enter ##F100 for Material and ##PT
for Plant, then click on the enter icon
Enter the information shown above, then click on the enter icon (
following screen:
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). This will produce the
Repetitive Manufacturing 1: Setup
We want to add a direct link to the Repetitive Planning Table transaction. To do that, we will
configure a favorite. Follow the pull-down menu path:
EnvironmentOwn FavoritesMaintain
which will produce the following screen:
Click on the New entries icon
Click on the New entries icon, which will produce the following screen:
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Repetitive Manufacturing 1: Setup
Enter 1 for Navigation no., MF50 for
Transaction code, select with initial screen,
enter Rep. Planning Table for Text in
menu, then enter/select ICON_PERIOD,
then click on save.
Click on the save icon (
), then click on the exit icon (
). This will produce the
following pop-up window:
Click on Yes
Click on the Yes icon, and a new icon will appear on the Stock/Requirements List:
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Repetitive Manufacturing 1: Setup
Click on the new icon to call up
the Repetitive Planning Table:
Click on the new icon (
) to call up the Repetitive Planning Table:
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Repetitive Manufacturing 1: Setup
Select Production line, then enter
REPBAKE,
Click on the Scheduling tab, then select
Rate-based plng
Then click on the pull-down menu path
SettingsSave
Make the settings shown above, then save these settings using the pull-down menu path
SettingsSave
Click on the Planning Table icon (
Planning Table.
) to start the Repetitive Manufacturing
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