SAP REM full cycle scenario with basic step

Repetitive Manufacturing(REM)

Company manufactures product in large numbers and production is Quantity based and Period based

not order based.

Repetitive manufacturing is mainly used for the production scenarios with high product stability,

high repetition rates, and low product complexity.

In master data production versions and cost collector is must where this is not mandatory in

discrete manufacturing.

Application Areas:

Industry Type: Mechanical engineering, Consumer goods, electronics, and many more

Tact-based Flow manufacturing

Period based production

Mass production

Difference b/w Discrete and REM

REM Prerequisite

A. REM Profile

B. REM Indicator

C. Production Version

D. Product Cost Collector

SAP REM Full Cycle scenario

Basic Data:

Plant : TAJA

Company Code : 1000

Storage Loc : TA01

Material Created :

Sir No Material Material Type

1 AIRCOIL FERT

2 CORE ROH

3 SLEEVE ROH

Repetitive manufacturing profile to control how you want to carry out planning and back flushing in

Repetitive manufacturing

Basic control parameter of the REM Profile

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

Create the REM Profile:

Create REM Profile Assistant (TControl Data Rep manufacturing Production

SPRO -Codes: OPP3/OSP2)

With help of the REM profile assistant create the Make-to-Stock REM Profile TJ (REM Profile

for plant TAJA) here GI backflush at GR posting check mark and RP backflush is

mandatory/Optional(as per requirements)

Here Planned order reduction period is given 3, so In this period system reduces all

planned orders and run schedule quantities in the period reduction

Here below mention all movement type set for the REM profile TJ

Create the finished material Air coil with Repetitive mfg. indicator and REM profile TJ

maintained in material master see view MRP -4 , ( MM01)

Please create and maintained the BOM(CS01) and routing/Rate routing (CA01/CA21)

Rate routing for top material Air Coil and assigned control key to the operation see in below pic,

(T-codes: CA21), here control key using for UK01 and UK02 for operation. (Standard SAP control

key with milestone confirmation is PP01)

Create the Control key UK 02, with milestone confirmation with help of the T-codes OP67.

The milestone confirmation is a special form of confirmation, in which the confirmation of one

operation causes other operations or sub operations to be automatically confirmed at the same

time.

Create the Production version T777 for finished material (Air coil) with help of material master

change (MM02), and in Selection method put indicator 2 or 3.

Production version is combination of the BOM and Routing/Rate Routing. Overview of

the production version T777, more than one production version created as per

requirement and make sure current prod. Version not locked.

As per REM profile selection for the product cost accounting

There are two different type of cost accounting exit.

1. Standard cost estimate per material.

You can create this cost estimate once in a period with reference to a routing. You can

post activities on the basis of this cost estimate if you produce a material using only one

production version in one period.

Using T-code: CK11N do the standard cost estimate for current date and period, And release

this standard cost estimate through T-code: CK24.

2. Preliminary costing for the product cost collector.

You can create this cost estimate per production version. This makes sense if you

produce one material using different production versions and routing in one period.

Using T-code: KKF6N for create Preliminary cost estimation in REM.

Here we selected preliminary costing for the product cost collector in REM profile

Create the Planned Independent Req. (PIR) for the finished material Air coil with help of the T-

code: MD61

See the below pic of the stock requirement list after generating the demand without run MRP.

(T-codes : MD04 )

After run the MRP with help of the MD02 for finished material(Air Coil), MRP element is RS and

order type is PE

In REM, we can do backflush(REM Confirmation) through planned order or finished material

using MFBF, here we selected the planned order

Checking with Post with correction in tool bar of REM confirmation page before saving and get

the detail information of the all transaction variant with all detail.

After saving system posted GR and GI document(As per REM profile setting GR and GI done

at same time)

After the confirmation of the both planned order, Good receipt done automatically and

available stock is 20. MD04 Screen

With help of the Document overview on MFBF tab, we know the detail of the GR and GI

transaction, and with help of the Reverse tab we can reverse the process of movement and

material back to the stock.

I prepared this document for understanding the basic step of the SAP REM process, and i hope this

document helpful to clear the basic concept of the REM process.

Please check which control key assign in routing/rate routing, Milestone confirmation maintained for this control

key. Please make sure the RP backflush checked on MFBF screen (Because in REM profile we maintained the RP backflush Mandatory) and assign Operation number (Control key with milestone confirmation assigned) on the

Reporting point field on MFBF screen,

If you want to run this process without reporting point then simply make change in REM profile, select the RM

backflush optional.

Revert back if facing any other issue.

Check the below link:

http://scn.sap.com/thread/1198104