The production process
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The Production Process. Introduction. Production is both a SCM function and an accounting function Simply put, the process involves turning raw materials into finished goods YOUR BOOK DOES A VERY GOOD JOB WITH THIS TOPIC. Production Steps. Types of Production (1). Discrete manufacturing

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The production process

The Production Process


Introduction

Introduction

  • Production is both a SCM function and an accounting function

  • Simply put, the process involves turning raw materials into finished goods

  • YOUR BOOK DOES A VERY GOOD JOB WITH THIS TOPIC


Production steps

Production Steps


Types of production 1

Types of Production (1)

  • Discrete manufacturing

    • The result is an individual unit (or many of them) such as a bicycle

    • The finished good “could” be decomposed back into its raw materials

    • Production lines are set up and torn down to make batches of different materials

      • Hewlett Packard


Types of production 2

Types of Production (2)

  • Repetitive manufacturing

    • Similar to discrete manufacturing

    • The same finished good is produced over time on the same production line

    • The production line is not changed to make different products

    • Used when production lines are very expensive

      • Intel (Chips)

      • Seagate (Disks)


Types of production 3

Types of Production (3)

  • Process manufacturing

    • Products are made by means of a recipe

    • Categories

    • Continuous (flow)

      • Gasoline

    • Batch

      • Soda and beer

  • We will not work with these


Means of production

Means of Production

  • Triggers cause production runs to be executed

    • Make to stock

      • Make a batch resulting from MRP or other production trigger

    • Make to order

      • Make a unit(s) as a result of a customer order

      • Dell


Production master data

Production Master Data

  • Bill of materials (BOM) contains components that make up a product or assembly

  • Work centers are locations within a plant where production operations are performed

  • Product routings list the activities involved in producing the product defined by the BOM

  • Product groups are used in planning to aggregate planning activities


Bill of materials overview

Bill of Materials (Overview)

  • In general, the components needed to produce semi-finished goods or finished goods

  • In the case of process manufacturing, we call a BOM a formula or recipe

    • We will focus on discrete manufacturing


Bill of materials sap

Bill of Materials (SAP)

  • SAP implements BOM as a flat structure

  • Hierarchical BOMs can be created using “component” materials (assemblies)

  • The BOM structure should mimic the manufacturing process

  • See the BOMs in Figure 6-4 on page 184


Bill of materials organization

Bill of Materials (Organization)

  • A BOM applies to a “plant”

    • Different plants might make the same finished good using a different BOM

  • A material can have “alternate” BOMs

    • These might be used for different processes having different lot sizes

    • This is more common in process manufacturing

    • We will not work with alternate BOMS


Bill of materials organization1

Bill of Materials (Organization)

  • Header section

    • Applicable to the finished good

    • List the plant and BOM number

    • The purpose of the BOM (production, engineering, plant maintenance)

    • Base quantity

    • Minimum and maximum lot size


Bill of materials organization2

Bill of Materials (Organization)

  • BOM Header


Bom usage

BOM Usage

  • (+must, .can, -cannot)


Bill of materials organization3

Bill of Materials (Organization)

  • Items section

  • The raw materials that go into making the finished good

    • Item type

    • Item

    • Item quantity


Bill of materials organization4

Bill of Materials (Organization)


Bill of materials organization5

Bill of Materials (Organization)


Bill of material item categories

Bill of Material (Item Categories)

  • Inventory is maintained for stock items (L)

  • Inventory is not maintained for non-stock items (N)

  • Variable sized items (R) are available in different dimensions (quantities)

    • Lumber, for example


Bill of material item categories1

Bill of Material (Item Categories)

  • Document items (D) represent applicable documentation

    • Manuals, for example

  • Class Items (K) are used in variant (configurable) BOMs

    • Different paint colors perhaps


Bom complexity

BOM Complexity

  • A 747-400 contains

    • 6.5 million parts

      • Countless assemblies

    • The process requires that many parts are inspected before, during, and after installation


Bill of materials navigation

Bill of Materials (Navigation)

  • Logistics / Production / Master Data / Bills of Material / Bill of Material / Material BOM

    • CS01 – Create

    • CS02 – Change

    • CS03 – Display


Work center introduction

Work Center (Introduction)

  • “A resource used to produce a material”

    • It can be a machine, a group of machines, or an entire production line

    • It can be a person or group of people (labor)


Work center introduction1

Work Center (Introduction)

  • Work centers can be arranged hierarchically

  • Work centers have capacities

    • They can produce finite outputs given a set of constraints

      • People work 8 hours a day

      • Machines can perform at some speed


Work center global bike

Work Center (Global Bike)

  • We have work centers for

    • Bike Assembly

    • Inspection

    • Packaging


Work centers sap

Work Centers (SAP)

  • A workcenter belongs to a plant

  • Work centers have a category that describes the work center

    • Machine / Labor / Production line / Etc..

  • A work center has a standard value key

    • These are activities that consume time

      • Setup

      • Processing

      • Teardown


Work centers sap1

Work Centers (SAP)

  • Control keys define how an operation is scheduled

  • Default values containing wage data can be associated with a work center

  • Note that work centers are associated with cost centers. This is how we allocate production costs

  • See Figure 6-7 page 189


Work center categories

Work Center Categories


Work center navigation

Work Center (Navigation)

  • Logistics / Production / Master Data / Work Centers

    • CR01 – Create

    • CR02 – Change

    • CR03 – Display


Work center basic data

Work Center (Basic Data)


Work center scheduling

Work Center (Scheduling)


Work center costing

Work Center (Costing)


Routings introduction

Routings (Introduction)

  • These are the detailed operations performed by (at) one or more work centers to produce a finished good

    • Think of the detailed operations required for an assembly line to run

  • Routing Sequences Have

    • Operations that get performed

    • Material(s) required

  • Routings apply to a material and plant


Routing header

Routing (Header)

  • Task (production / plant maintenance / …)


Routing sequences

Routing Sequences

  • Routing sequences

    • Using sequences, you can create standard and parallel sequences

    • Sequences are performed “in-order”

    • Alternate sequences might be performed in place of standard sequences


Routing operations

Routing (Operations)

  • The tasks we perform to manufacture

  • Data

    • The time it takes to perform the task

    • How many items are processed per interval of time

      • Setup, labor, machine

    • Steps in a routing operation are performed by a work center


Production routing for dxtr1000 operations

Production Routing for (DXTR1000) (Operations)


Production routing materials

Production Routing (Materials)

  • The materials needed to produce the good

  • This information comes from the BOM


Production routing for dxtr1000 materials

Production Routing for (DXTR1000) (Materials)


Routing navigation path

Routing (Navigation Path)

  • Logistics / Production / Master Data / Routings / Routings / Standard Routings

    • CA01 Create / CA02 Change / CA03 Display


Production capacity

Production Capacity

  • Production has a capacity that relies on

    • A factory calendar describing workdays and holidays

    • A capacity for people and machines

    • Some number of shifts that workers work

    • Look at page 195 in your text.


Production capacity factory calendar

Production Capacity (Factory Calendar)

  • Multiple calendars describe

    • Public holidays and the current

    • The calendar used by the factory

    • The assignment of a calendar to a plant


Production capacity factory calendar1

Production Capacity (Factory Calendar)

  • Holiday calendar


Maintaining capacities

Maintaining Capacities

  • Each work center in a plant has a capacity

    • A capacity name (SHIFT for example)

    • A capacity category (machine or person for example)


Maintaining capacities1

Maintaining Capacities

  • Capacity header describes available capacity


Maintaining capacities2

Maintaining Capacities

  • Global Bike runs 1 shift with 1 hours of breaks per shift


The production process overview

The Production Process (Overview)

  • Request production

  • Authorize production

  • Release production order

  • Goods issue to production order

  • Actual production

  • Production confirmation

  • Goods receipt into inventory


Request production

Request Production

  • Production is typically requested because of a trigger

    • A customer order (make-to-order)

  • An MRP

  • Manual creation

  • In the end, a production order gets generated


Authorize production

Authorize Production

  • This is the actual commitment to produce

    • Production (machine / people) time is allocated for specific dates

  • Authorization might be created from planned or unplanned orders


Authorize production sap

Authorize Production (SAP)

  • Production might be authorized because of

    • Planned production / a sales order / for a material (finished good)

  • We get preliminary estimates of cost

  • Logistics / Production / Shop Floor Control / Order / create

    • C001


Production order illustration

Production Order (Illustration)


Release production order

Release Production Order

  • This is where the authorized order is actually released to production

    • Production starts the manufacturing process at a given date and time

    • RTP might happen manually or automatically

    • Shop papers are generated


Goods issue

Goods Issue

  • Raw materials are removed from storage triggered by the production order release

  • Material staging takes place

  • Backflushing


Goods issue 2

Goods Issue (2)

  • Raw material inventory is updated

  • Inventory accounts are updated

  • Material costs are added to the production order

  • See the GL transactions on page 208


Actual production

Actual Production

  • We make the material and record production times


Production confirmation

Production Confirmation

  • Accounting finalizes the production run

  • Production costs are recorded

Here the produced goods are transferred from production to goods storage


Goods receipt

Goods Receipt

  • Here, the goods are released into inventory

    • Inventory

    • Held for a particular customer

    • Held for QA or other reason


Introduction to planning

Introduction to Planning


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