Discrete Vs repetitive Vs Process Industry in SAP PP
This document is regarding various Manufacturing Process in SAP PP .
Along with the technical differences within all process.
Based on different nature of products and complexity, there are 3 types
of manufacturing process followed in SAP PP:
Discrete Industry
Process Industry
Repetitive Industry
There are 2 methods of manufacturing in SAP PP:
Make to stock ( MTS )
Make to order ( MTO )
Discrete Industry Manufacturing Process
In discrete scenario, the manufacturing process is based on production orders.
Discrete manufacturing is characterized by requirements that occur on an irregular
basis and a
workshop-oriented process.
Basically the demand and supply varies time to time in this scenario.
Discrete manufacturing forms an industry type where in the products which are
manufactured can
be easily assembled and dis-assembled.
They can be reworked upon easily to a large extent.
You can say making pumps, engines, cars, airplanes, Cycles, Automobile industries,
Toys..
Facts in Discrete Process:
Production based on the production orders.
Planning and manufacturing depends on production orders.
Products change frequently.
Production is carried out on different production lines (scattered- discrete).
Product costing and settlement is done through production orders.
Planned orders are stock type later converted into production orders.
Production orders are required.
Materials will be issued always with reference to production orders.
Master Data includes work center , Production version , Routing and BOMs.
Industry Type: Mechanical engineering, Consumer goods, electronics, and many more
Process Industry Manufacturing Process
The component Production Planning for Process Industries (PP-PI) provides an
integrated planning tool
for batch-oriented process manufacturing.
It is primarily designed for the chemical, pharmaceutical, food and beverage
industries as well as the batch-oriented electronics industry.
Process manufacturing forms an industry type where in the products which are
manufactured cannot be easily dis-assembled.
Facts in Process Industry:
Batch oriented process manufacturing.
Process order based manufacturing. You copy the process described in a master
recipe and adjust it to the actual production run.
It is primarily designed for the chemical, pharmaceutical, food and beverage
industries as well as the batch-oriented electronics industry.
The integrated planning of production, waste disposal, and transport activities
within a plant.
Master Data includes Master Recipes and resources.
Process Management: In this area, you coordinate the communication between PP-PI
and process control during the execution of a process order.
Process Manufacturing can be used in Continuous production, discontinuous
production, Regulated production as well as Process-oriented filling
Industry Type: Chemical, Pharma, Poultry, Dairy and many more.
Repetitive manufacturing Process
Company manufactures product in large numbers and production is quantity
based and period based not order based.
You can use repetitive manufacturing as either
make-to-stock REM or make-to-order REM such as in the automotive industry.
Repetitive manufacturing form an industry type
where in the products manufactured can be discrete manufactured or process industry
type,
produced repetitively or continuously in production lines. This forms the
continuous production scenario.
Facts in Repetitive Manufacturing:
Production is based on the planned orders.
Planning and manufacturing is based on period wise.
Normally single products being manufactured for a longer period of time.
Normally production are carried out on a single production line (repetitively).
Product costing and settlement is done through product cost collector.
Planned orders are known as Run schedule quantities. Means quantity which is being
manufactured in a certain period.
Planned orders are sufficient to carry out production at shop floor area.
Master data includes production version, product cost collector and rate routing.
Materials will be issued anonymously to production lines means without reference to
planned orders.
Creation and revision of production quantities on a period and quantity basis
(reduction in individual lot and order-specific processing).
Reduction in the production control effort and simpler back flushing (with the
option of using the full scope of the PP functionality).
Repetitive manufacturing is mainly used for the production scenarios with high
product stabilit
y, high repetition rates, and low product complexity.
why Routing and BOM is required.
with out Routing and BOM create Production Orders.
SUGAR EXAMPLE:
(1) SUGAR- M-31, S-31, L-31
M-31 : SUGAR CANE, SOME CHEMICALS:
99 ALTERNATIVE BOMS
ROUTING: IT USED FOR ACTIVITY COST PURPOSE.
OPL8 ORder type we can make it Routing and BOM as optional.
Normal Industries we can use BOM and Routing
Variant BOM:
STPES ARE:
(1) MD61- PIR PLANNED INDEPENDENT REQUIREMENTS
(2) MD02- RUN THE MRP FOR FG PRODUCT
(3) MD04- STOCK REQUIREMENTS LIST
(4) PLANNED ORDER TO PRODUCTION ORDER
(5) PRODUCTION CO02, MATERIAL AVIALABILITY CHECK, SCHEDULING DATES BOM
(6) GOODS ISSUE AGAINST PRODUCTION ORDER
(7) PRODUCTION CONFIRMATION
(8) GOODS RECIPT
(9) TECHNICL CONFIRMATION
(10) VARIANCE CALUCLATION
(11) SETTLEMENT
ENTERPRISE: ORGANIZATION
RESOURCE: MANPOWER
PLANNING: EXECUTION
END USER: DAY TO DAY
SUPER USER: MANAGER, PRODUCTION IN CHARGE
SAP CONSULTANT:
