Document on Repetitive Manufacturing

settings for MTS scenario

INDEX
1. Process Flow................................................................................................................3
2. Configuration settings for Repetitive Manufacturing..................................................4
3. Master data...................................................................................................................7
3.1 Material Master..........................................................................................................7
3.2 Production Version.....................................................................................................7
3.3 Product cost collector (PCC).....................................................................................9
4. Demand Management....................................................................................................11
5. MRP Run........................................................................................................................11
5.1 Display of stock requirement list MD04.............................................................12
5.1.1 Collective display of planned orders MD04..................................................13
6. Planning Table in REM..................................................................................................15
7. Configuration settings for Serial number profile...........................................................17
8. Serial number activation for Painted chassis.................................................................17
8.1 Confirmation of production by backflush MFBF.................................................21
8.2 Goods receipt in repetitive manufacturing MCP7...............................................23
8.3 Cancellation of the quantity confirmed by Document specific reversal.................23
8.4 Cancellation of the quantity confirmed by Document neutral reversal...................25
8. Clearing Error Goods Movements.................................................................................26
4.1.1 Message number 016........................................................................................29
4.1.2 Message number 021........................................................................................31
4.1.3 Message number 053........................................................................................32
4.1.4 Message number 897........................................................................................33
4.1.5 Message number 006........................................................................................33
4.1.6 Message number 024........................................................................................34
4.1.7 Message number 042........................................................................................35
4.1.8 Message number 092........................................................................................35
4.1.9 Message number 147........................................................................................36
4.1.10 Message number 018......................................................................................36

1. Process Flow

Master data
Product cost collector
Demand Management
MRP Run
Planning Table
Back flushing
Error goods movement posting
COGI
Settlement of
Product cost collector

2. Configuration settings for Repetitive Manufacturing

Repetitive manufacturing profile is has control parameters.

Whether you want to backflush activities.

Whether you want to work with reporting points in make-to-stock REM.
How you want to process errors which occur when backflushing.
Whether you want to post activities while doing backflushing
Whether planned orders are to be reduced while confirming

You create the repetitive manufacturing profile in Customizing for Repetitive Manufacturing and
assign it to a material in the MRP data of the material master record.
Path: Production Repetitive Manufacturing Control data Define repetitive manufacturing
profile.

3. Master data
3.1 Material Master
In Material Master in MRP View 4 we need to
Tick the Repetitive material check box
Fill the REM Profile Field with TEST

3.2 Production Version

After Creating BOM and Rate routing using Production line we need to create the Production
version in Material master
For using Planning table the work centre used needs to be of category type 0007

Then go to Material master MRP view 4 and click on the production version tab field.

Create the version and maintain validity period and check the Repetitive check box authorizing
this version to be used in Repetitive manufacturing.
Keep the cursor on the entry and click the

push button.

Click the check button

Status changes to green button
Click continue again continue.

3.3 Product cost collector (PCC)

Create Product cost collector in transaction KKF6N
Product cost collector has one to one relation with Production version
Enter Material and Plant

Click the create button

Select the version for which you want to create the PCC.
Click confirm button

Click the save button

Pop up comes

Click the Yes push button to create preliminary cost estimate.

System calculates all the preliminary cost and saves.

4. Demand Management
Planned independent requirements are created in MD61
Enter material and plant

Enter data for planning

Save the data

5. MRP Run
Run MRP for material by MD02

5.1 Display of stock requirement list MD04

Unlike normal planned orders in Repetitive manufacturing, system creates Run schedule
header planned orders which are non convertible to the production orders. We can do
production confirmation giving run schedule planned orders as reference in backflushing.
Note: If there is no indicator -2 in selection field of MRP 4 view for selection by
production version then system creates normal stock planned orders which are not
desired. Then we need to assign the version to the planned order by going into
change planned order to generate run schedule header type planned order.

5.1.1 Collective display of planned orders MD04

Planned orders can be viewed on MRP controller level also this can be done by clicking
on the collective display of planned orders in MD04
Enter MRP controller, Plant
MRP controller PPC- for Finished product
Enter

6. Planning Table in REM

Go to T.Code MF50
Enter Plant and Production line in which you want to change the planning

If you change the quantity here it is changes the planned order automatically.

7. Configuration settings for Serial number profile

Configuration settings for serial numbers can be accessed by
Plant maintenance and customer serviceMaster data in plant maintenance and customer
service Technical objects Serial number management serial number profile.

8. Serial number activation for Painted chassis

Once serial number is activated all the transactions with the material will be asking for
the serial number. So if any stock is there when we activate the serial number it has to be
made nil and then again generation of the stock has to be undertaken such that after
activation all the stocks are serial numbered.
Note: Once serial numbering is activated then we cannot reverse back as there would be
master data of serial number created.
A number you give to an item of material in addition to the material number, to
differentiate that item form other items of the material.
The combination of material and serial number is unique.
For serial number activation you need to maintain data in Material master
Go to MM02
Enter material number
Select MRP2 view and Work scheduling view.
Enter organization level data

In MRP 2 view remove the back flush entry

Go to work scheduling view

Select serial number Profile for Plant

Note: There shouldnt be any stock in the plant before you activate the serial
number as the quantity that is there in stock cannot be used later as serial number
will be needed for every transaction here after and the stock that is lying before
activation has no serial number on them.
Save the material master
When you do confirmation by MFBF back flush the system asks for the serial number
before posting Goods Receipt.

We have used an external serial number assignment so we need to put the serial number
that is to be confirmed taking the actual serial number chassis painted.
Suppose it is 150001 then enter the value in the serial number field

Select the check box and then click Continue icon.

If you confirm more than one qty then multiple entries will be asked for in the serial
number pop up.
You can enter the serial numbers which you have produced in these fields.

To view the stocks go to the MMBE

Give Material
Plant
Execute
Stocks will be displayed as below

For viewing serial number on these quantities

Right click on the quantity and select the Equipment/Serial number

System displays the serial number as below

The last column entry 01 indicates the stock in unrestricted stock to view all the stocks in
the system
Select the set filter icon on application tool bar
System displays the screen

Click Transfer at the bottom

Delete the entry in stock type (Primary posting) key

Then execute
Now system displays all the stock serial numbers with the stock indicators
02 is for stock lying in quality
07 for blocked stock

Shows that 150005,150006 are in quality stock

8.1 Confirmation of production by backflush MFBF

Select assembly backflush
Enter the planned order

Click on the post with correction tab on application menu bar

Save the goods movements
Save

8.2 Goods receipt in repetitive manufacturing MCP7

All the confirmation data relating to the finished product is obtained form the MCP7
transaction.
Enter the plant and execute for a period
You can narrow down selection by clicking on selection and click material then to view
daily production click on display periodically.

8.3 Cancellation of the quantity confirmed by Document

specific reversal

When we confirm the quantity the document is generated against the confirmation with
reference to this document we can cancel the production confirmation simultaneously
reversing the quantities.
Note that if we reverse the quantity by document neutral reversal all the quantity that is
posted by that document gets reversed.
Go to MFBF
Select Document specific reversal icon on application tool bar
Enter Plant and material code

Select the document that needs to be reversed and position the cursor on the Document
log number and then press document

Then the document gets cancelled and the production gets reversed cancelling the
confirmation.
Quantity before cancellation

After cancelling Document no 142808 having quantity as 3 is

The document specific reversal screen then shows a reversal indicator against the
document no as below

The serial numbers that were generated by this document will be reversed and will not be
shown in the stock report.

8.4 Cancellation of the quantity confirmed by Document neutral

reversal
By document neutral reversing we can only reverse the particular serial number chassis
instead of the confirmed quantity in the document.
Suppose you have confirmed 2 chassis with serial number 150005,150006 and you want
to reverse the chassis serial number 150006 then we have to go by document neutral
reversal.
Go to MFBF
Select back flush type assembly back flush

Click on the Document neutral reversal icon on application tool bar

Enter back flush quantity

Enter material code, Plant, and production version

Click the icon Post with correction

System shows the bill of material of the finished product

Save

on menu bar

System will ask for the serial number that is to be reversed. Enter the serial number and
select the check box and then Click continue

System displays the message

The stock in unrestricted stock gets reduced and the serial number also gets reversed if
you need to use the same serial number again you can do it by normal confirmation.
Stock data is

Note: If stock is in Quality inspection you can do document specific reversal but not
document neutral reversal. In such case first quantity needs to be moved to unrestricted
stock and then we need to do document neutral reversal.

9. Clearing Error Goods Movements

Go to COGI

Enter Plant 5000

Execute
List of all the error goods movements are displayed these are aggregate records
To go to individual records click the individual records button on the application tool bar

System displays all the individual records of the errors.

Select the message column

Click on the sort button on application tool bar to sort the error messages.

Then messages are sorted in ascending order.

9.1 Message number 016

To process the error goods movement select the record

Click on the

to display the error description

For error 016 the message is

for this first look into the stock of the
material and then do batch determination to assign the batches.
Select the entry and then click on the change details screen on application tool bar
System displays the individual error records in change mode.
Select an entry and then click on the batch determination icon on application tool bar

If proper batch determination data is maintained system displays the batch but if not then
batches are not selected by system.

Select batch determination w/o class selection

System displays the batches available

Copy the batch by clicking the copy button on application tool bar
If batches are not displayed then we can assign them manually in the change details
screen by copying the batch from the F4 display screen obtained by placing cursor in
batch field.

Then after assigning the batch numbering to the error goods movement SAVE the entries
then goods are posted.

9.2 Message number 021

Message number 021 indicates stock is not available

It can be either to a specific storage location or due to the wrong entering of batch
number while posting.
So check the cause of the error.
Open the stock overview screen to check whether stock is available or not in this case
stock is nil in unrestricted use but an stock transfer purchase order is open for a qty of
25,000 against which goods receipt is pending so after confirmation of the receipt you
can clear the error goods movement.
Ask the stores department in charge to do GR for the pending stock transfer purchase
order.

As there is no stock, remove the batch entry in the change detail screen of the error goods
movement as the stock which comes to the plant will have its own entry of batch number
and this entry will again come under error message 016.

9.3 Message number 053

Message indicates that the posting period is closed so we cannot post the document with
the same date we need to change the posting date and then save.

Select the entry to be processed

Edit Replace Date

Default will be current date change it to the date for which system allows for posting
which is nearest to the created date of the document.

Save the entry.

9.4 Message number 897

Message indicates that some other user was using this material for some transaction and
posting is not possible at that instance so now we can post this entry.

9.5 Message number 006

Message indicates that material is maintained in some other storage location and is telling
the system to pick up from some other storage location this can be avoided by putting
correct issue storage location in the MRP 2 view.

To know in which location material is created go to material master display and select the
MRP view and display the allowed storage location after putting plant in organization
view of

The error occurred when the goods movement is being done for the following entry

The storage location that is defaulted for picking is SBC1 on which material master is not
even extended so this entry in MRP 2 view has to be changed to correct this error.

Change this entry in the field Production storage location SBC1 to GSG2.

And the error entries having wrong storage locations that are lying in COGI need to be
changed manually and posted.

9.6 Message number 024

The message indicates that the data is locked by the other user so we can process the data
right now.
Save the entries the entry will be posted.

9.7 Message number 042

Check the batch that is entered in the entry.

In this case there is no stock

If any batches are available then go to change details of the entry and change the batch
which is mentioned.
Save the entries.

9.8 Message number 092

Material is blocked for procurement indicates that decision has been made to stop
procurement and it is a warning message.
It is a warning message we can ignore it and we should check whether we really use this
material in our BOM or not.
Just select the entries with message 092 and then save.

9.9 Message number 147

If such message appears report to your accounting core team member for sorting out.

9.10 Message number 018

Form the entry itself we can make out that the storage location is not put in the entry.
Go to change details of the entry and put storage location and check the material master
for the entry in MRP 2 screen production storage location entry.
Here in this case it is missing

Enter the production storage location and then save the material master.