Repetitive Manufacturing

 Repetitive manufacturing is used in company which produces product in large number. The
production is quantity based and period based.
 Repetitive manufacturing is ( in the wider sense) is mainly used for production with high
product stability and high repetition rate as well as low production complexity. Typical
industries are for example mechanical, engineering, and the electronics industry.
 In repetitive manufacturing the same product is usually produced over a long period of time
on a single production line.
 It is not manufactured in individually defined lots instead a total quantity is produced over a
certain period at a certain rate per part period.
 Products pass through production in a relatively steady flow.

Repetitive Manufacturing Process Overview

Material Forecast Sales and distribution

Planned
Demand Program
Independent Sales Orders
Requirement

Planned
Material Requirement planning Stocks
Orders

Planned
Repetitive Manufacturing
Orders (PE)

Prodution

Confirmation with goods Receipt Inventory Management

Cost collector Settlement

Requirements are created in Demand Management. MRP run generates planned orders for the
material that is to be produced. The system automatically generates purchase requisitions for raw
materials. After receiving the required raw material, material staging is to be carried out. Then after
production execution start and component back flush activity confirmation and goods receipt takes
place.

Main Function in Repetitive Manufacturing:-

There are four main functions in repetitive manufacturing.

1. Master Data
Master data is the core data that is used as a base for any transaction. If you are producing,
transferring stock, selling, purchasing, doing physical inventory, whatever your activity may
be, it requires certain master data to be maintained .There are five types of master data
used in repetitive manufacturing.
 Material Master
The material master contains information on all the materials that a company
procures or produces, stores, and sells. It is the company's central source for
retrieving material-specific data. This information is stored in individual material
master records. There are certain prerequisite which is maintained in material
master. These are REM indicator, REM Profile and Production Version.
 Bill Of Material
A bill of materials (BOM) is a centralized source of information used to manufacture
a product. It is a list of the items needed to create a product as well as the
instructions on how to assemble that product. 
 Routing
Routing defines a list of activities/operations that are required to be performed, in
which sequence and machine they have to performed, and what is activity times
required in order to produce a product. In repetitive manufacturing rate routings are
used because normally during assembly back flush in transaction code MFBF, there
is no configuration setting or other control to choose the set of operation (Standard
sequence or alternative sequence of operation) which needs to posted for
production confirmation.

 Production Version
Production Version is nothing but the combination of BOM and Routing.
 Work Center
Work center is an organization unit where manufacturing activities are performed.
In other words, Work Centers are the master data which represent real machines,
Production Lines, Assembly Work Center, etc. Manufacturing activity or Operations
are carried out at Work Center.

2. Line Loading
Line loading will display which planned order is executed in in which line. For example there
are two lines like line 1 and line2 and also you have one planned order of quantity 100 kg.
To assign the quantity in line1 and line2 is called line loading.
3. Material Staging
Material staging is nothing but transferring the material from your main store to production
location. Before production we have to transfer the material to production location.
4. Back flush
Backflushing is nothing but automatic goods issue. System will automatically post the goods
issue when you confirm the operations.

REM Profile
Repetitive manufacturing profile to control how you want to carry out planning and
backflushing in repetitive manufacturing. Using the REM Profile control parameters, you
define the following, for example:
1. Whether you want to backflush activities.
2. Whether you want to work with reporting points in make-to-stock REM.
3. How you want to process errors which occur when back flushing.

Run Schedule Header

 Run schedule headers can be subdivided into run schedule headers with run
schedule quantities or run schedule headers with partial orders depending on how
the costs are to be settled.
 For a run schedule header with run schedule quantities, production is split into
production quantities by specifying quantity and period. The costs of the run
schedule header are collected at a Controlling object (cost collector).
 For a run schedule header with partial orders, the material is produced using
planned orders and production orders or process orders. The costs incurred in
production are assigned to the specific order.

Product Cost Collector

Product cost collectors are independent of the production type. This means that the actual
costs for a product cost collector can be collected. Product Cost collector is mainly used in
repetitive manufacturing. With the help of Product Cost Collector you can collect the
periodic actual cost involved in production of a material. In Repetitive Manufacturing, all
costs attributed to the production of a material are collected on a product cost collector and
settled periodically (period-based Controlling).

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