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Unit 3: Repetitive Manufacturing

Lesson 1: Drafting Repetitive Manufacturing


Lesson 2: Preparing Repetitive Manufacturing
Lesson 3: Planning Line Loading in Repetitive Manufacturing
Lesson 4: Using Material Staging and Confirmation
Lesson 5: Integrating Costing, Controlling, and Reporting

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Lesson 1: Drafting Repetitive Manufacturing


Lesson Objectives
After completing this lesson, you will be able to:

Outline the properties of repetitive manufacturing

Unit 3 Lesson 1

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Figure 43: Application Areas

Unit 3 Lesson 1

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Figure 44: Repetitive Manufacturing:


Characteristics

Unit 3 Lesson 1

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Figure 45: Repetitive Manufacturing: Basic


Functions

Unit 3 Lesson 1

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Figure 46: Cross-Application Functional Process

Unit 3 Lesson 1

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Figure 47: Master Data for Repetitive


Manufacturing

Unit 3 Lesson 1

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Figure 48: Demo Scenario: PC Production in


Dresden Plant

Unit 3 Lesson 1

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Unit 3 Exercise 9

Exercise 9: Check the Material Master of Repetitive


Manufacturing
.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the project team responsible for
implementing the functions of Repetitive Manufacturing.
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master data object: material master
Verify the Material Master

In the Logistics folder in the SAP ECC menu, navigate to the material master of
motherboard T-B10## (## represents your group number), plant 1200, and go to the
MRP 4 view. Use the change mode (transaction MM02).
1. Navigate to the Material Master of motherboard T-B10## and go to the MRP 4,
plant 1200 view.

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Unit 3 Exercise 9

Exercise 9: Check the Material Master of Repetitive


Manufacturing
.
2. Name the basic material master settings that are specific to repetitive
manufacturing.
____________________________________________________
____________________________________________________
____________________________________________________
3. Ensure that the Repetitive manufacturing profile 0001 is used for your material TB10## in plant 1200. Do not leave the transaction.
4. Display production version 0001 and perform a consistency check on the
combination of BOM and routing.
5. Which production line is entered in production version 0001?
____________________________________________________
____________________________________________________

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Unit 3 Exercise 9

Exercise 9: Check the Material Master of Repetitive


Manufacturing
.
6. Write down the task list group of the rate routing entered and save your changes to
the material master.
____________________________________________________
____________________________________________________

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Unit 3 Solution 9

Solution 9: Check the Material Master of Repetitive


Manufacturing
.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the project team responsible for
implementing the functions of Repetitive Manufacturing.
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master data object: material master
Verify the Material Master

In the Logistics folder in the SAP ECC menu, navigate to the material master of
motherboard T-B10## (## represents your group number), plant 1200, and go to the
MRP 4 view. Use the change mode (transaction MM02).
1. Navigate to the Material Master of motherboard T-B10## and go to the MRP 4,
plant 1200 view.

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Unit 3 Solution 9

Solution 9: Check the Material Master of Repetitive


Manufacturing
.
a) SAP ECC menu path: LogisticsProductionMaster dataMaterial
MasterMaterialChangeImmediately (MM02)
b) Enter your material number T-B10##, and choose Select Views.
c) Select MRP 4 view and select Organizational levels.
d) Enter plant 1200 and select

Continue.

2. Name the basic material master settings that are specific to repetitive
manufacturing.
____________________________________________________
____________________________________________________
____________________________________________________
a) Repetitive mfg indicator, Repetitive manufacturing profile, Production version

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Unit 3 Solution 9

Solution 9: Check the Material Master of Repetitive


Manufacturing
.
3. Ensure that the Repetitive manufacturing profile 0001 is used for your material TB10## in plant 1200. Do not leave the transaction.
a) Change the REM profile to 0001 on the MRP4 view.
4. Display production version 0001 and perform a consistency check on the
combination of BOM and routing.
a) On the MRP 4 view select

ProdVersions.

b) Double click on version 0001.


c) On the detail view for the production version, choose Check in the top righthand corner. The consistency check has the following results:
BOM and routing exist. There are no error messages.
Exit the screen by choosing

Cancel.

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Unit 3 Solution 9

Solution 9: Check the Material Master of Repetitive


Manufacturing
.
5. Which production line is entered in production version 0001?
____________________________________________________
____________________________________________________
a) From the detail screen of the production version, you can see that production
version 0001 contains production line T-L3##.
6. Write down the task list group of the rate routing entered and save your changes to
the material master.
____________________________________________________
____________________________________________________
a) The number varies. On the detail screen of the production version, the Task list
group is also displayed in the Rate-based planning line under Planning data.

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Unit 3 Exercise 10

Exercise 10: Check the Bill of Material of Repetitive


Manufacturing
.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the project team responsible for
implementing the functions of Repetitive Manufacturing .
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master object: BOM (bill of material)
Verify the Bill of Material

1. Display your bill of material for T-B10## at plant 1200 with a BOM usage of 1.
2. How many assemblies are on the hierarchy level directly below the finished
product? Finally, leave the transaction.
____________________________________________________

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Exercise 10: Check the Bill of Material of Repetitive


Manufacturing
.
____________________________________________________

Unit 3 Exercise 10

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Unit 3 Solution 10

Solution 10: Check the Bill of Material of Repetitive


Manufacturing
.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the project team responsible for
implementing the functions of Repetitive Manufacturing .
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master object: BOM (bill of material)
Verify the Bill of Material

1. Display your bill of material for T-B10## at plant 1200 with a BOM usage of 1.
a) SAP ECC menu path: LogisticsProductionMaster dataBills of
materialsBill of materialMaterial BOMDisplay (CS03)
b) Enter material T-B10##, plant 1200, and BOM usage 1.

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Unit 3 Solution 10

Solution 10: Check the Bill of Material of Repetitive


Manufacturing
.
c) Choose ENTER to enter the component overview.
2. How many assemblies are on the hierarchy level directly below the finished
product? Finally, leave the transaction.
____________________________________________________
____________________________________________________
a) The Asm assembly indicator is set for one BOM item.

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Unit 3 Exercise 11

Exercise 11: Check the Routing of Repetitive Manufacturing


.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the project team responsible for
implementing the functions of Repetitive Manufacturing .
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master object: Routing
Verify the Routing

1. Display the rate routing for material T-B10##, plant 1200 in the Logistics master
data.
2. How many different routings are displayed in the overview?
____________________________________________________
____________________________________________________

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Unit 3 Exercise 11

Exercise 11: Check the Routing of Repetitive Manufacturing


.
3. Select the first routing with group counter 1 and choose the Operations button.
What is special about the routing?
____________________________________________________
____________________________________________________
4. Name the work center involved and the production rate for the routing.
____________________________________________________
____________________________________________________
5. Exit the operation overview and go back to the rate routing overview and view the
second routing.
6. Which work center belongs to group counter 2?
____________________________________________________
7. View routing header data by choosing the Header button to show the task list
group number.

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Unit 3 Exercise 11

Exercise 11: Check the Routing of Repetitive Manufacturing


.
____________________________________________________
____________________________________________________
8. Does production version 0001 enable repetitive manufacturing with the two
routings? Why (not)?
____________________________________________________
____________________________________________________

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Unit 3 Solution 11

Solution 11: Check the Routing of Repetitive Manufacturing


.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the project team responsible for
implementing the functions of Repetitive Manufacturing .
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master object: Routing
Verify the Routing

1. Display the rate routing for material T-B10##, plant 1200 in the Logistics master
data.
a) SAP ECC menu path: LogisticsProductionMaster
dataRoutingsRoutingsRate routingsDisplay (CA23)
b) Enter your material T-B10## and plant 1200 only.

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Unit 3 Solution 11

Solution 11: Check the Routing of Repetitive Manufacturing


.
c) Choose ENTER.
2. How many different routings are displayed in the overview?
____________________________________________________
____________________________________________________
a) Two routings exist (two group counters).
3. Select the first routing with group counter 1 and choose the Operations button.
What is special about the routing?
____________________________________________________
____________________________________________________
a) In the rate routing overview, select the line with group counter and choose
Operations. The special feature here is that there is only one operation.
4. Name the work center involved and the production rate for the routing.
____________________________________________________

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Unit 3 Solution 11

Solution 11: Check the Routing of Repetitive Manufacturing


.
____________________________________________________
a) The work center contains the (entire) T-L3## line and the production rate (30
pieces per hour).
5. Exit the operation overview and go back to the rate routing overview and view the
second routing.
a) In this transaction choose menu path Goto Routing Overview. Select only the
line with group counter 2 and choose the Operations button.
6. Which work center belongs to group counter 2?
____________________________________________________
a) The work center used in the second routing is T-L4## as well as reporting
points LINE4-1, LINE4-2, and LINE4-3.
7. View routing header data by choosing the Header button to show the task list
group number.

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Unit 3 Solution 11

Solution 11: Check the Routing of Repetitive Manufacturing


.
____________________________________________________
____________________________________________________
a) View the task list group number. The task list group number is the same as
noted before when analyzing the production version.
8. Does production version 0001 enable repetitive manufacturing with the two
routings? Why (not)?
____________________________________________________
____________________________________________________
a) No. Production version 0001 only allows production according to the routing
with group counter 1. Leave the transaction using the Back button.

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Unit 3 Exercise 12

Exercise 12: Check the Product Cost Collector of Repetitive


Manufacturing
.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the SAP SCM project team responsible for
implementing the functions of Repetitive Manufacturing .
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master object: Product cost collector
Verify the Product Cost Collector

1. Display the product cost collectors, using the Repetitive Manufacturing menu, for
material T-B10## in plant 1200.
2. How many product cost collectors exist and how are they assigned? Finally, leave
the transaction.

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Unit 3 Exercise 12

Exercise 12: Check the Product Cost Collector of Repetitive


Manufacturing
.
____________________________________________________
____________________________________________________
____________________________________________________

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Unit 3 Solution 12

Solution 12: Check the Product Cost Collector of Repetitive


Manufacturing
.
Business Example
You work for a company that uses repetitive manufacturing to produce motherboards on
two production lines and you are a member of the SAP SCM project team responsible for
implementing the functions of Repetitive Manufacturing .
Therefore you first try to get a general overview of the basic master data for repetitive
manufacturing.
In particular, you focus on the following master object: Product cost collector
Verify the Product Cost Collector

1. Display the product cost collectors, using the Repetitive Manufacturing menu, for
material T-B10## in plant 1200.

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Unit 3 Solution 12

Solution 12: Check the Product Cost Collector of Repetitive


Manufacturing
.
a) SAP ECC menu path: LogisticsProductionRepetitive
manufacturingMaster dataProduct Cost CollectorProcess Product Cost
Collector (KKF6N)
b) Enter material number T-B10## and plant 1200 and choose ENTER.
c) In the upper left part of the screen, select material T-B10##. Expand the
selection.
2. How many product cost collectors exist and how are they assigned? Finally, leave
the transaction.
____________________________________________________
____________________________________________________
____________________________________________________

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Unit 3 Solution 12

Solution 12: Check the Product Cost Collector of Repetitive


Manufacturing
.
a) Two product cost collectors exist. They are assigned to the material by means
of the production version (one product cost collector for each production
version). Leave the transaction using theBack button.

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Summary
You should now be able to:

Outline the properties of repetitive manufacturing

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Lesson 2: Preparing Repetitive Manufacturing


Lesson Objectives
After completing this lesson, you will be able to:

Prepare repetitive manufacturing with regard to planning

Unit 3 Lesson 2

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Figure 49: Repetitive Manufacturing: Process


Flow

Unit 3 Lesson 2

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Figure 50: Planning in Repetitive Manufacturing

Unit 3 Lesson 2

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Figure 51: Basic Planning Strategies for


Repetitive Manufacturing

Unit 3 Lesson 2

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Unit 3 Exercise 13

Exercise 13: Verify Material Master Settings for Repetitive


Manufacturing
.
Business Example
You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried
out through planning and final assembly. To do this, the motherboards are planned at the
assembly level and produced according to the planning program.
First, check whether the master data for material T-B10## (motherboard) is correct.
Check the Material Master Setup

Before you can run MRP you must assure yourself that master data is in place for
repetitive manufacturing.
1. Is the material T-B10## (the motherboard) in plant 1200 permitted for repetitive
manufacturing?
____________________________________________________
____________________________________________________
2. Is there a repetitive manufacturing profile maintained on the same view?

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Unit 3 Exercise 13

Exercise 13: Verify Material Master Settings for Repetitive


Manufacturing
.
____________________________________________________
____________________________________________________
3. Finally, check the existing production versions: Is the REM allowed indicator set?
____________________________________________________

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Unit 3 Solution 13

Solution 13: Verify Material Master Settings for Repetitive


Manufacturing
.
Business Example
You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried
out through planning and final assembly. To do this, the motherboards are planned at the
assembly level and produced according to the planning program.
First, check whether the master data for material T-B10## (motherboard) is correct.
Check the Material Master Setup

Before you can run MRP you must assure yourself that master data is in place for
repetitive manufacturing.
1. Is the material T-B10## (the motherboard) in plant 1200 permitted for repetitive
manufacturing?
____________________________________________________
____________________________________________________

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Unit 3 Solution 13

Solution 13: Verify Material Master Settings for Repetitive


Manufacturing
.
a) Check whether the repetitive manufacturing indicator is set in the MRP 4 view.
It has been set.
2. Is there a repetitive manufacturing profile maintained on the same view?
____________________________________________________
____________________________________________________
a) Yes, either repetitive manufacturing profile 0002 or 0001 is maintained on the
MRP 4 view.
3. Finally, check the existing production versions: Is the REM allowed indicator set?
____________________________________________________
a) Yes. Select the ProdVersions icon on the MRP 4 view and display the
production versions one after the other to view the indicator. When complete,

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Unit 3 Solution 13

Solution 13: Verify Material Master Settings for Repetitive


Manufacturing
.
save (or leave the transaction via the Back button if you haven't changed
anything).

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Unit 3 Exercise 14

Exercise 14: Create a Production Program for Repetitive


Manufacturing
.
Business Example
You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried
out through planning and final assembly. To do this, the motherboards are planned at the
assembly level and produced according to the planning program.
Create a production program for material T-B10## (motherboard).
Maintain Planned Independent Requirements

1. Manufacturing is unsure of the accuracy of the sales department forecasts for the
upcoming months for your personal computers. However, operations wants to
hedge sales by putting a forecast in at the sub-assembly level. Enter 1200 PC for
next week for your material T-B10## at plant 1200 in version 00, and activate the
demand plan for MRP. Before saving the results split the weekly demand into daily
buckets.

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Unit 3 Solution 14

Solution 14: Create a Production Program for Repetitive


Manufacturing
.
Business Example
You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried
out through planning and final assembly. To do this, the motherboards are planned at the
assembly level and produced according to the planning program.
Create a production program for material T-B10## (motherboard).
Maintain Planned Independent Requirements

1. Manufacturing is unsure of the accuracy of the sales department forecasts for the
upcoming months for your personal computers. However, operations wants to
hedge sales by putting a forecast in at the sub-assembly level. Enter 1200 PC for
next week for your material T-B10## at plant 1200 in version 00, and activate the
demand plan for MRP. Before saving the results split the weekly demand into daily
buckets.

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Unit 3 Solution 14

Solution 14: Create a Production Program for Repetitive


Manufacturing
.
a) SAP ECC menu path:LogisticsProductionProduction PlanningDemand
ManagementPlanned Independent RequirementsCreate (MD61)
b) Enter material T-B10##, plant 1200 and version 00, and set the planning
period to W (weekly) buckets.
c) Choose ENTER.
d) When you reach the planning table, enter the 1200 PC requirements in the
second weekly bucket.
Caution:
Do not use the current week!

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Unit 3 Solution 14

Solution 14: Create a Production Program for Repetitive


Manufacturing
.
e) Choose the Sched. Lines tab. The quantity with period indicator W is to be
distributed over the individual working days. Therefore, set the Splt column
indicator to D (day format) and confirm your entry.
f) Confirm any warning messages that may be displayed by selecting ENTER.
g) When complete select

Save.

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Unit 3 Exercise 15

Exercise 15: MRP in Repetitive Manufacturing


.
Business Example
You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried
out through planning and final assembly. To do this, the motherboards are planned at the
assembly level and produced according to the planning program.
Carry out a multilevel MRP run for your material.
Perform Material Requirements Planning

1. Plan the T-B10## at plant 1200 using an multilevel single-item MRP run. Use the
default parameters that are set when you enter the transaction.
Hint:
Multilevel planning ensures that dependent requirements are also generated for
lower hierarchy levels in the BOM.

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Unit 3 Exercise 15

Exercise 15: MRP in Repetitive Manufacturing


.
2. Interpret the results of the planning run for the T-B10## at plant 1200, using the
stock/requirements list.
3. Review the details of your first planned order.
4. What is the order type of the planned order?
____________________________________________________
5. Can you convert this planned order to a production or process order? Why (not)?
Finally, leave the transaction.
____________________________________________________
____________________________________________________

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Unit 3 Solution 15

Solution 15: MRP in Repetitive Manufacturing


.
Business Example
You manufacture PCs in your plant 1200 in Dresden. The production of the PCs is carried
out through planning and final assembly. To do this, the motherboards are planned at the
assembly level and produced according to the planning program.
Carry out a multilevel MRP run for your material.
Perform Material Requirements Planning

1. Plan the T-B10## at plant 1200 using an multilevel single-item MRP run. Use the
default parameters that are set when you enter the transaction.
Hint:
Multilevel planning ensures that dependent requirements are also generated for
lower hierarchy levels in the BOM.

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Unit 3 Solution 15

Solution 15: MRP in Repetitive Manufacturing


.
a) SAP ECC menu path LogisticsProductionMRPPlanningMultilevel
Single-item planning (MD02)
b) Enter you material T-B10## and plant 1200.
c) Choose ENTER twice to start the run.
2. Interpret the results of the planning run for the T-B10## at plant 1200, using the
stock/requirements list.
a) SAP ECC menu path: LogisticsProductionMRPEvaluationsStock/
Requirements List (MD04)
b) Enter your material T-B10## and plant 1200, and choose ENTER.
3. Review the details of your first planned order.
a) Double click on the first planned order.

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Unit 3 Solution 15

Solution 15: MRP in Repetitive Manufacturing


.
4. What is the order type of the planned order?
____________________________________________________
a) Planned order type LA - Stock Order
5. Can you convert this planned order to a production or process order? Why (not)?
Finally, leave the transaction.
____________________________________________________
____________________________________________________
a) No - checking the details view of the planned order the conversion buttons are
missing. This is because of the REM flag in the material master MRP4 view.
Leave the details of the planned order and the transaction via the Cancel and
Back buttons, respectively.

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Summary
You should now be able to:

Prepare repetitive manufacturing with regard to planning

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Unit 3 Lesson 3

Lesson 3: Planning Line Loading in Repetitive Manufacturing


Lesson Objectives
After completing this lesson, you will be able to:

Plan line loading in repetitive manufacturing

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Figure 52: Overview: Planning Line Loading

Unit 3 Lesson 3

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Figure 53: Actions for Manual Line Loading


Planning (Example: ECC)

Unit 3 Lesson 3

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Unit 3 Exercise 16

Exercise 16: Perform Line Loading in Repetitive Manufacturing


.
Business Example
Two production lines are available for the assembly of the T-B10## motherboard. The
basic dates as to quantities and periods have already been determined in MRP and
production planning in the previous exercise. As the production planner, you now assign
the quantities to the relevant production line.
Assign the MRP Results to the Production Lines

As a result of the MRP run, planned orders have been created to cover the forecast
requirements for your mother board T-B10## at plant 1200. Earlier you reviewed your
master data and recognized that two production lines could manufacture the
motherboard. In order for execution to take place we must decide what quantities are
going to run on what lines taking capacity availability into account. Access the repetitive
planning table and assign quantities to production lines.
1. Access the planning table for repetitive manufacturing. for your production line TL3## and T-L4## in plant 1200. Make sure that you are scheduling using rate
based planning; that capacity planning data is visible, and that all other production

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Unit 3 Exercise 16

Exercise 16: Perform Line Loading in Repetitive Manufacturing


.
options are available for scheduling. Assign the planned orders to the production
lines, taking into account the available capacities.
Note:
Save your settings in order to speed up access during later reviews

2. Double-click a quantity in the planning table section that is ready for input to
display the detail data for the planned order. Which order type is assigned (F4
help)?
____________________________________________________
3. Change your user settings so the total requirements as well as supply is visible in
the lower table.
4. Put the table in assignment mode to schedule the unassigned quantities in the
planning table section that is ready for input. Assign the unassigned quantity to the
final assembly line.

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Unit 3 Exercise 16

Exercise 16: Perform Line Loading in Repetitive Manufacturing


.
5. Double-click the quantity you have just assigned. Which order type is now assigned
(F4 help)?
____________________________________________________
6. Look at the capacity data. Does the production line reach full capacity with the
planned order in the relevant time interval or is some capacity still available for
other orders in the same period?
____________________________________________________
____________________________________________________
7. Save your planning results.

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Unit 3 Solution 16

Solution 16: Perform Line Loading in Repetitive Manufacturing


.
Business Example
Two production lines are available for the assembly of the T-B10## motherboard. The
basic dates as to quantities and periods have already been determined in MRP and
production planning in the previous exercise. As the production planner, you now assign
the quantities to the relevant production line.
Assign the MRP Results to the Production Lines

As a result of the MRP run, planned orders have been created to cover the forecast
requirements for your mother board T-B10## at plant 1200. Earlier you reviewed your
master data and recognized that two production lines could manufacture the
motherboard. In order for execution to take place we must decide what quantities are
going to run on what lines taking capacity availability into account. Access the repetitive
planning table and assign quantities to production lines.
1. Access the planning table for repetitive manufacturing. for your production line TL3## and T-L4## in plant 1200. Make sure that you are scheduling using rate
based planning; that capacity planning data is visible, and that all other production

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Unit 3 Solution 16

Solution 16: Perform Line Loading in Repetitive Manufacturing


.
options are available for scheduling. Assign the planned orders to the production
lines, taking into account the available capacities.
Note:
Save your settings in order to speed up access during later reviews

a) SAP ECC menu path: LogisticsProductionRepetitive


ManufacturingPlanningPlanning TableChange Mode (MF50)
b) Enter the final assembly line T-L3## and select via Production line.
c) In the Scheduling tab, make sure Rate-based Planning is selected, and capacity
planning is selected.
d) In the Control tab, select Line Overview.
e) Select

Settings.

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Unit 3 Solution 16

Solution 16: Perform Line Loading in Repetitive Manufacturing


.
f) Select

Planning Table.

g) In the window that appears select all production lines and select

Continue.

2. Double-click a quantity in the planning table section that is ready for input to
display the detail data for the planned order. Which order type is assigned (F4
help)?
____________________________________________________
a) The planned order has order type LA Stock order. Choose the Cancel button to
leave the screen.
3. Change your user settings so the total requirements as well as supply is visible in
the lower table.
a) Select

User Settings.

b) Check Total Requirements check box.

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Unit 3 Solution 16

Solution 16: Perform Line Loading in Repetitive Manufacturing


.
c) Select

Check Data.

d) Select

Adopt.

4. Put the table in assignment mode to schedule the unassigned quantities in the
planning table section that is ready for input. Assign the unassigned quantity to the
final assembly line.
a) Select the line labeled Not Yet Assigned.
b) Switch on the assignment mode using the push button with the truck icon.
c) A symbol appears at the start of the line, signifying that you are in assignment
mode for this line.
d) Assign the quantities in the Not yet assigned section. Enter the quantities in
one of the production line fields that belongs to the same period.

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Unit 3 Solution 16

Solution 16: Perform Line Loading in Repetitive Manufacturing


.
Note:
Be sure to choose ENTER in order for the system to recalculate the available
quantities and the capacity requirements.

e) Deactivate the assignment mode by choosing the according push button.


5. Double-click the quantity you have just assigned. Which order type is now assigned
(F4 help)?
____________________________________________________
a) The planned order has the order type PE (run schedule quantity).
6. Look at the capacity data. Does the production line reach full capacity with the
planned order in the relevant time interval or is some capacity still available for
other orders in the same period?
____________________________________________________

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Unit 3 Solution 16

Solution 16: Perform Line Loading in Repetitive Manufacturing


.
____________________________________________________
a) By dispatching a planned order on production line T-L3##, the line only
reaches a comparatively low capacity load (see the planning table: Capacity
data in the row for production line T-L3##). The capacity data is not available
on the same day as the production quantities since the quantities are
determined to the day according to availability, while the capacity load of the
production line is determined tothe hour and minute according to the
production date.
7. Save your planning results.
a) Select

Save.

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Summary
You should now be able to:

Plan line loading in repetitive manufacturing

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Lesson 4: Using Material Staging and Confirmation


Lesson Objectives
After completing this lesson, you will be able to:

Stage and confirm material in repetitive manufacturing

Unit 3 Lesson 4

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Figure 54: Material Staging Options

Unit 3 Lesson 4

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Figure 55: Backflush and Goods Receipt

Unit 3 Lesson 4

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Figure 56: Backflush: Reporting Point Backflush

Unit 3 Lesson 4

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Unit 3 Exercise 17

Exercise 17: Perform Material Staging for Repetitive


Manufacturing
.
Business Example
For assembly production of motherboard T-B10##, you want to check for missing
components in the production storage location PL03 and use stock transfer measures to
stage missing components for a certain production period.
Carry out Material Staging

Now that you have run MRP to cover your requirements and scheduled production to the
appropriate lines, you need to ensure that the material is available to support production.
In this section you will learn how material staging supports backflushing.
1. Execute the pull list for production line T-L3## in plant 1200, in order to stage the
necessary components for production. The staging should be performed for line
for all requirements that are received until Tuesday of the week after next. In this
example, material staging is performed at storage location level. Some steps in the
pull list can be carried out automatically, Create replenishment proposals and
Batch/stock determination. Make the changes in global settings.

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Unit 3 Exercise 17

Exercise 17: Perform Material Staging for Repetitive


Manufacturing
.
2. Go to the pull list. Interpret the results of the automatic steps. For which materials
are there shortfall quantities until Tuesday of the week after next due to the
planned requirements? How large are these quantities?
____________________________________________________
____________________________________________________
3. At which storage location are there shortfall quantities?
____________________________________________________
____________________________________________________
4. At which storage location has the system found a replenishment quantity?
____________________________________________________
5. Can the complete shortfall quantity be covered from here?
____________________________________________________

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Unit 3 Exercise 17

Exercise 17: Perform Material Staging for Repetitive


Manufacturing
.
6. You accept the system proposal. To trigger material staging for the relevant
components from warehouse 0001 to production storage location PL03.
7.
Caution:
Material staging (using direct stock transfer in this case) is not carried out until
you save the pull list. If you need a printout of the list for the physical stock
transfer, we recommend printing it before you save (Pull List Print). Save your
results.

8. Check the stock transfer posting in the message log for the pull list (in a separate
transaction).

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Unit 3 Solution 17

Solution 17: Perform Material Staging for Repetitive


Manufacturing
.
Business Example
For assembly production of motherboard T-B10##, you want to check for missing
components in the production storage location PL03 and use stock transfer measures to
stage missing components for a certain production period.
Carry out Material Staging

Now that you have run MRP to cover your requirements and scheduled production to the
appropriate lines, you need to ensure that the material is available to support production.
In this section you will learn how material staging supports backflushing.
1. Execute the pull list for production line T-L3## in plant 1200, in order to stage the
necessary components for production. The staging should be performed for line
for all requirements that are received until Tuesday of the week after next. In this
example, material staging is performed at storage location level. Some steps in the
pull list can be carried out automatically, Create replenishment proposals and
Batch/stock determination. Make the changes in global settings.

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Unit 3 Solution 17

Solution 17: Perform Material Staging for Repetitive


Manufacturing
.
a) SAP ECC menu path: LogisticsProductionRepetitive
ManufacturingMaterial StagingPull List - Trigger Replenishment (MF60)
b) Set the staging type to storage location level (SLoc Level).
c) Enter plant 1200 and selection period Tuesday of the week after next.
d) Enter production line T-L3## in the Plnd Orders area of the screen.
e) Select Global Settings.
f) In the Dialog Control tab set Create replenishment proposals and Execute
Batch/stock determination to Automatic.
g) Select

Continue.

h) Select

Execute.

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Unit 3 Solution 17

Solution 17: Perform Material Staging for Repetitive


Manufacturing
.
2. Go to the pull list. Interpret the results of the automatic steps. For which materials
are there shortfall quantities until Tuesday of the week after next due to the
planned requirements? How large are these quantities?
____________________________________________________
____________________________________________________
a) Due to the planned requirements, there are shortfall quantities for material TT6## until Tuesday of the week after next. The system automatically created a
replenishment proposal and determined stock for component T-T6## in
storage location 0001. The pull list shows the size of the shortfall quantity.
3. At which storage location are there shortfall quantities?
____________________________________________________
____________________________________________________

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Unit 3 Solution 17

Solution 17: Perform Material Staging for Repetitive


Manufacturing
.
a) There are shortfall quantities at production storage location PL03, where the
components for assembly production are to be staged.
4. At which storage location has the system found a replenishment quantity?
____________________________________________________
a) The replenishment quantity was found in central warehouse 0001.
5. Can the complete shortfall quantity be covered from here?
____________________________________________________
a) Yes, the staging quantity is equal to the shortfall quantity.
6. You accept the system proposal. To trigger material staging for the relevant
components from warehouse 0001 to production storage location PL03.
a) Select the row with the replenishment element and select Stage.

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Unit 3 Solution 17

Solution 17: Perform Material Staging for Repetitive


Manufacturing
.
7.
Caution:
Material staging (using direct stock transfer in this case) is not carried out until
you save the pull list. If you need a printout of the list for the physical stock
transfer, we recommend printing it before you save (Pull List Print). Save your
results.

a) Select

Save.

8. Check the stock transfer posting in the message log for the pull list (in a separate
transaction).
a) SAP ECC menu path: LogisticsProductionRepetitive
ManufacturingMaterial StagingLog (MF68)
The stock transfer was successfully posted in the system.

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Unit 3 Solution 17

Solution 17: Perform Material Staging for Repetitive


Manufacturing
.
b) Access the log from the Material Staging menu, enter today's date as the To
date, and choose Execute.
Finally, leave the transaction using the Back button.

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Unit 3 Exercise 18

Exercise 18: Confirm Production Quantities in Repetitive


Manufacturing
.
Business Example
Now that scheduling is complete and materials have been staged at the production line
production is ready to execute. In this section you will learn how backflushing is managed
in SAP ECC.
Carry out Confirmation

1. First, open a second session of the planning table for repetitive manufacturing
(which you access by selecting production line T-L3##, plant 1200).
2. In the first session, execute a REM confirmation for 90 pieces of the motherboard
material T-B10## produced on line T-L3## in plant 1200. Then choose Post with
correction .
3. Look at the next screen and explain which components of assembly T-B10## were
backflushed on the line. Save.

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Unit 3 Exercise 18

Exercise 18: Confirm Production Quantities in Repetitive


Manufacturing
.
4. Go to the second session (planning table). Refresh the screen and look at the
quantities on the line.
5. How have the planned quantities changed?
____________________________________________________
____________________________________________________

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Unit 3 Solution 18

Solution 18: Confirm Production Quantities in Repetitive


Manufacturing
.
Business Example
Now that scheduling is complete and materials have been staged at the production line
production is ready to execute. In this section you will learn how backflushing is managed
in SAP ECC.
Carry out Confirmation

1. First, open a second session of the planning table for repetitive manufacturing
(which you access by selecting production line T-L3##, plant 1200).
a) Select System Create Session to open a new session and use the following
path:
b) SAP ECC menu path: LogisticsProductionRepetitive
ManufacturingPlanningPlanning TableChange Mode (MF50)
c) Enter plant 1200 and production line T-L3## and choose ENTER.

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Unit 3 Solution 18

Solution 18: Confirm Production Quantities in Repetitive


Manufacturing
.
Note:
The settings have defaulted in from a previous exercise step.

d) Select Execute Planning Table, select all production lines and confirm to enter
the table.
2. In the first session, execute a REM confirmation for 90 pieces of the motherboard
material T-B10## produced on line T-L3## in plant 1200. Then choose Post with
correction .
a) SAP ECC menu path: LogisticsProductionRepetitive
ManufacturingData EntryRepetitive Manufacturing Confirmation (MFBF)
b) Enter the following data on screen of the backflush transaction screen:

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Unit 3 Solution 18

Solution 18: Confirm Production Quantities in Repetitive


Manufacturing
.
The production version contains the production on line T-L3##.
Choose ENTER and choose Post with correction.
3. Look at the next screen and explain which components of assembly T-B10## were
backflushed on the line. Save.
a) The current BOM was exploded during the confirmation. The system
determined the materials to be backflushed in the BOM explosion. The all or
nothing principle applies, which means that all four materials displayed are
backflushed.
4. Go to the second session (planning table). Refresh the screen and look at the
quantities on the line.
a) Select the other open session of SAP ECC.
b) Use menu path from here: PlanningReaccess

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Unit 3 Solution 18

Solution 18: Confirm Production Quantities in Repetitive


Manufacturing
.
5. How have the planned quantities changed?
____________________________________________________
____________________________________________________
a) The first planned order quantity is (or quantities are) reduced according to the
confirmation quantity. Explanation: For demonstration purposes, the
backflushwas made with a date (today) that is before the actual production
dates. The confirmation quantity is therefore interpreted as over-production
that reduces subsequently planned orders accordingly (firstplanned orders
first).

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Summary
You should now be able to:

Stage and confirm material in repetitive manufacturing

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Unit 3 Lesson 5

Lesson 5: Integrating Costing, Controlling, and Reporting


Lesson Objectives
After completing this lesson, you will be able to:

Outline the integration of costing, controlling, and reporting to repetitive manufacturing

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Figure 57: Cost Debit/Credit (Product-Related


Cost Object Controlling)

Unit 3 Lesson 5

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Figure 58: Integration with Controlling

Unit 3 Lesson 5

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Figure 59: Repetitive Manufacturing: Information


Systems

Unit 3 Lesson 5

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Figure 60: Period-Based Repetitive


Manufacturing: Additional Functions

Unit 3 Lesson 5

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Summary
You should now be able to:

Outline the integration of costing, controlling, and reporting to repetitive


manufacturing

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Open Question

Name some basic functions of repetitive manufacturing.

Unit 3

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Open Question

Name some basic functions of repetitive manufacturing.

Unit 3

.
Planning line loading, Scheduling, Calculation and monitoring of capacity requirements,
Costing, Avaiability checks, Printing dispatch lists, Printing operational method sheet,
Material staging, Goods issue/backflushing, Goods receipt with final confirmation, Periodend closing.

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Open Question

Why do you need a material cost estimate to calculate production activities in repetitive
manufacturing?

Unit 3

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Open Question

Why do you need a material cost estimate to calculate production activities in repetitive
manufacturing?

Unit 3

.
Due to the handling of production quantities with planned orders there is no real "order"
object to collect and carry the production activities. This is covered by a material cost
estimate and subsequent price update in the material master.