sap repetitive manufacturing with reporting point backflush

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Repetitive Manufacturing with Reporting Point Backflush

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Created by:- Devidas Karad

SAP PP Certified Consultant

E-mail:- devidas.karad@gmail.com

Repetitive Manufacturing

Purpose

This component can be used for production planning and control in a repetitive manufacturing

environment.

You can use repetitive manufacturing as either make-to-stock REM or make-to-order REM such

as in the automotive industry, for example.

The goals of repetitive manufacturing are the following:

_ 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 backflushing tools(with the option

of using the full scope of the PP functionality).

Reporting point backflush

It makes sense to use the reporting point backflush:

• If you work with longer lead times. You can use the reporting points to withdraw the components closer to

the time they are required for the operation.

• If you want to calculate work in process.

To do this, operations are defined as reporting points and the backflush is carried out at these reporting points.

Prerequisites

• To carry out a reporting point backflush for a material, you must have assigned an appropriate Repetitive

Manufacturing Profile to the material in the material master record.

• This type of backflushing corresponds to the milestone confirmation. Therefore, in the routing, you must

select a control key which has indicator 1 (= milestone confirmation) in the confirmation field.

• You must have entered the routing in the production version of the material. If you create a run schedule

quantity for the material to be produced using this routing, the operations with the control key for

milestone confirmation are then automatically copied to the run schedule header as reporting points. When

creating a run schedule header, the system first tries to copy the routing entered in the detailed planning

section. If no entry exists here, the system then uses the routing from the rate-based planning section.

Features

• A separate function exists in the main menu of Repetitive Manufacturing for the reporting point backflush.

• When backflushing at reporting points, the system backflushes all materials that are withdrawn and

consumed at the reporting point operation and at the previous operations. The system also determines

costs. If you backflush a production quantity, the system reduces the dependent requirements of the oldest

run schedule quantities.

• In the repetitive manufacturing profile, you can set that the goods receipt is automatically posted when

backflushing the last reporting point. The system does not reduce capacity quantities until backflushing the

last reporting point.

• You can also backflush actual times. The production activities are then posted on the basis of the time that

was actually taken for production.

• You have two options for backflushing scrap:

o Assembly scrap

o Component scrap

If you backflush assembly scrap, the system backflushes production activities and the goods issues for the

components. If you backflush component scrap, the system only backflushes the goods issues for the components.

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Configuration:-

Go to the following path or go to transaction code OSP2 to create REM Profile

In the profile you need to check RP backflush and need to select whether you want optional or mandatory

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Master Data:-

In the MRP 4 view of material master you need to check Repetitive mfg indicator and assign the repetitive mfg profile

in REM Profile, also you need to create production version

Production version: - You can create in material master or in C221

Create Production

version

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Routing:-

Also you can create Routing or Rate routing with the control key which supports milestone confirmation, In the

routing below both operations are milestone operations, One material assigned for each operation.

Product Cost Collector:-

Go to KKF6N to create Product Cost Collector with production version as the option to create it.

After calculation cost, system shows the BOM and routing with costs.

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Scenario:-

Create Requirement in MD61 for the Material.

After MRP run planned order type PE (Run Schedule Header) is created.

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In MF50 (Planning Table) you can see the planned order is assigned to Production Line REM001

You can stage materials in MF60

Quantity is assigned to

Production Line

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Material is staged to the production storage location.

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Backflush:-

In MFBF backflush you need to enter planned order number and click on RP Backflush and enter

System shows pop up asking to select the Reporting point.

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You can correct the quantities by choosing Post with correction.

Here you can change quantity, storage location if required.

Finally Save.

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System shows GI document at the bottom of screen

Click on RP stocks above OR go to MF26 to see the RP stock (WIP)

Here you observe that on first operation it shows 2 quantities are confirmed.

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Similarly select the second Reporting point.

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After backflushing the last reporting point both GR and GI happens

In MF26 you can see there is no stock at reporting point.

sap repetitive manufacturing with reporting point backflush

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