The sequence in REM is

1.MM01-material creation and Assign the REM profile for all the Inhouse manufactured materials(FERT
&

HALB) and also tick mark for repetitive manufacturing in MRP4 view.

2.CS01 - BOM creation.

3.Work centre creation - CR01.

4.Rate routing creation - CA21.

5.Creating production version to link BOM & Rate routing in MRP4 view of the material master.

6.Creations of product cost collector using production version in KKF6N.

7.Cost rollup & Release using CK40N.

8.Demand values,in MD61,

9.MRP Run- MD02,Stock/Requirements List - MD04.Planning Table in MF50.

10.Planned orders generated.

11.Pull List MF60.

12.MFBF.Production booking

Hi,

Repetative manufacturing is period based planning and not based on orders. Normally same
products will be manufactured over longer period of time..products will not change frequently.
Confirmation is from backflushing and settlement is through from product cost collector for the
period. Confirmaton will be without ref to planned orders. Planned orders are sufficient to carry
out shop floor activity. In master data production versions and cost collector is must where this is
not mandatory in discreate.

You do these steps for rem production:

mm01 : Material Master

- MRP - 4 view you click rem

cs01 : Create Bom

cr01 : Create Work Center

ca21 : Create Rate Routing

mm02 : Prodn Version

md61 : Create PIR

mc74 : Transfer PIR to Demand

kkf6n : Create Product Cost Collector

mb1c : Create Stock

md02 : MRP run

mfbf : Rem Back Flush

The detailed sequence of T.Codes for REM including Std cost estimate.

Material master - MM01

BOM - CS01

Price Planning - KP26

Work Center - CR01

Rate Routing - CA21

Material Master Change, enter production version - MM02 (MRP 4 View)

Product Cost Collector - KKF6N

Costing - CK40N

Backflushing - MFBF

Dear Ravi,

1.Material creation/change - MM01.

2.BOM creation - CS01

3.Work center creation - CR01.

4.Rate routing - CA21.

5.Production version - C223 or else in MM02 ---> MRP4 view.

6.Product cost collector - KKF6N.

7.PIR - MD61.

8.MRP run - MD02.

9.Stock/requirements list - MD04.

10.Material staging - MF60.

11.Backflush - MFBF.

Apart from these T codes CK40N,MF50 also plays a major role

Also Check these 2 links,

Repetitive Manufacturing

REM Cycle..........

Regards
Mangalraj.S

See the answer in context

Helpful Answer by Rupesh Brahmankar

745 Views

Average User Rating

(0 ratings)

Re: repetitive manufacturing

Bakyaraj V May 14, 2009 11:06 AM (in response to ravi arora)

Pls check the link for the flow with the whole t.codes

http://www.sap-img.com/production/steps-to-do-repetative-manufacturing.htm

o Report Abuse
o Like (0)
Correct Answer Re: repetitive manufacturing

Mangalraj Senthamaraikannan May 14, 2009 11:13 AM (in response to ravi arora)

Dear Ravi,

1.Material creation/change - MM01.

2.BOM creation - CS01

3.Work center creation - CR01.

4.Rate routing - CA21.

5.Production version - C223 or else in MM02 ---> MRP4 view.

6.Product cost collector - KKF6N.

7.PIR - MD61.

8.MRP run - MD02.

9.Stock/requirements list - MD04.

10.Material staging - MF60.

11.Backflush - MFBF.

Apart from these T codes CK40N,MF50 also plays a major role

Also Check these 2 links,

Difference between repetitive manufactring
and discrete manufacturing
This question has been Answered.

SRINIVASAN MUTHU Jun 18, 2008 7:22 AM

Can any body tell me the difference between discrete manufacturing and repititive
manufacturing.

Regards,

Srini

Correct Answer by Vijai prasad shanmugam on Jun 18, 2008 7:28 AM

Hi Srinivas,
Discrete

This scenario describes the manufacture of a product based on production orders. Discrete
manufacturing is characterized by requirements that occur on an irregular basis and a workshop-
oriented process.

The Discrete Manufacturing scenario can be used in different variants, production by lot size,
make-to-order production and assembly processing. The variants differ mainly in the type of
planning conducted before-hand and in the relation to the sales order.

Repetitive Manufacturing

This scenario describes production planning and control within a repetitive manufacturing
environment. In repetitive manufacturing, master plans are typically created on a period and
quantity basis (reduction in individual lot and order-specific processing). A quantity of one
product is manufactured over a certain period. The product is processed in a constant flow and
interim products are generally not stocked.

In repetitive manufacturing, you usually find that the effort required for production control is
significantly less than is required for single lot and order-based production control and the
recording of actual data is kept simpler.

Repetitive manufacturing can be used for various industries, such as the consumer packaged
goods industry, the electronic industry, packaging industry, for example.

You can use Repetitive Manufacturing purely for make-to-stock production, or in a sales order-
oriented environment, such as found in the automotive industry.
Note:

The above content taken from help.sap for your understanding

Rgds,

SVP

See the answer in context

3312 Views

Average User Rating

(0 ratings)

Correct Answer Re: Difference between repetitive manufactring and discrete manufacturing

Vijai prasad shanmugam Jun 18, 2008 7:28 AM (in response to SRINIVASAN
MUTHU)

Hi Srinivas,

Discrete

This scenario describes the manufacture of a product based on production orders.

Discrete manufacturing is characterized by requirements that occur on an irregular basis
and a workshop-oriented process.

The Discrete Manufacturing scenario can be used in different variants, production by lot
size, make-to-order production and assembly processing. The variants differ mainly in
the type of planning conducted before-hand and in the relation to the sales order.
Repetitive Manufacturing

This scenario describes production planning and control within a repetitive

manufacturing environment. In repetitive manufacturing, master plans are typically
created on a period and quantity basis (reduction in individual lot and order-specific
processing). A quantity of one product is manufactured over a certain period. The product
is processed in a constant flow and interim products are generally not stocked.

In repetitive manufacturing, you usually find that the effort required for production
control is significantly less than is required for single lot and order-based production
control and the recording of actual data is kept simpler.

Repetitive manufacturing can be used for various industries, such as the consumer
packaged goods industry, the electronic industry, packaging industry, for example.

You can use Repetitive Manufacturing purely for make-to-stock production, or in a sales
order-oriented environment, such as found in the automotive industry.

Note:

The above content taken from help.sap for your understanding

Rgds,

SVP

o Report Abuse
o Like (0)
o Re: Difference between repetitive manufactring and discrete manufacturing
 SRINIVASAN MUTHU Jun 18, 2008 11:28 AM (in response to Vijai prasad
shanmugam)

Thank you SVP

Report Abuse
Like (0)
Re: Difference between repetitive manufactring and discrete manufacturing

Tejas Kantilal Pujara Jun 18, 2008 7:31 AM (in response to SRINIVASAN MUTHU)

Hi Srini,

Discrete Manufacturing is generally order based Manufacturing process where products

are generally varying in nature more or less order by order / lot by lot you can say . This
is very commonly used Manufacturing scenario in SAP-PP in many Manufacturing
Industries. IN this Production Version is not necessary master data as in case of
Repetitive Manufacturing and Production Order is used in this type of manufacturing to
control production execution activities.

Repetitive Manufacturing on the other hand is Qty and Time Based Manufacturing which
is not mostly relavant to order and it is used in areas where product is not varying in
nature and it remains to be nearly same and repetitive in nature like this type of
manufacturing is mainly used in automotive industries.

Further in this type of there is no existence of production order instead production is done
through planned order only which is called RSQ ( Run Schedule Quantity) in case of
repetitive manufacturing.

HOpe this information helps clearing your doubt.

Reward if useful.
 Regards,

Tejas

o Report Abuse
o Like (0)
Re: Difference between repetitive manufactring and discrete manufacturing

pravin dhokey Jun 18, 2008 7:32 AM (in response to SRINIVASAN MUTHU)

hi

REM (repetative manufacturing ): the same product is manufactured over period of time
on production line for ex. automobile industry assembly line.in this no of planned order
settled on a product cost collector

Discrete Manufacturing: order based production product may change over period of time,
for ex pump manufacturing is called as discrete manufacturing where production order
created.order settle individually.

if any query please come back

Regards

Pravin

o Report Abuse
o Like (0)
Re: Difference between repetitive manufactring and discrete manufacturing

Feby Johnson Jun 18, 2008 7:44 AM (in response to SRINIVASAN MUTHU)
Discrete manufacturing (that is, manufacturing with production orders) typically
involvesfrequently changing products and therefore manufacturing in restricted
production lots. Another characteristic of discrete manufacturing is the varying the
sequence of work centers through which the products can pass during production.

Discrete Manufacturing :

- Order-based production using production order

- Production in order lot sizes

- Status maintenance (created, released...) per order

- Availability check for material, capacity, PRTs per order

- Material provision controlled per order using material reservations

- Order backflush, operation backflush

- Cost monitoring per order or per product

In Repetitive Manufacturing, the same product is usually produced over a longer period
of time on one production line. The product is not produced in lots. Instead, a total
quantity is produced in a certain period at a certain rate. Products pass through production
in a relatively steady flow. Semifinished products are usually processed further
immediately without being put in interim storage.

Repetitive Manufacturing :

- Quantity- and period-based planning (planning periods) and production

- Planned orders (run schedule quantities) authorize production; production orders not
needed (no conversion).

- Repetitive production: The same/similar products produces over a longer period of time
 The aims of using Repetitive Manufacturing are the following:

- Creating and processing production plans based on periods (rather than individual lots
and orders)

- Reducing the administration costs for production control and simplification of

completion confirmation via backflushing, while at the same time still being able to use
the full range of PPC functions.

- Reducing controlling costs.

o Report Abuse
o Like (0)
Re: Difference between repetitive manufactring and discrete manufacturing

Vasim Basha Jun 18, 2008 9:53 AM (in response to SRINIVASAN MUTHU)

Discrete Manufacturing

Order-based production (production in individual production orders)

- Product change frequently

- Varying sequence of work centers (complex routings )

- Semifinished products often put into interim storage

- Components staged with reference to order

- Status processing

- Completion confirmation (backflush)

for individual operations or orders

- Order-based cost controlling

Repetitive Manufacturing
 Period-based production (production with certain quantities per period)

- Product produced unchanged over a longer period of time

- Steady flow through production (simplified routings)

- Semi finished products often directly processed without interim storage

- Components are staged at lines periodically and anonymously

- Reduced control effort (no status procedure)

- Period-based back flush

- Period-based cost controlling

o Report Abuse
o Like (0)
1. What is Discrete Manufacturing?
2. What is REM?
3. What is Demand Management?
Here are difference between Discrete and REM and small explanation about
discrete and repetitive manufacturing:
- A typical characteristic of discrete manufacturing is the frequent switching
from one manufactured product to another. The products are typically
manufactured in individually defined lots, the sequence of work centers
through production varying for each one of these. Costs are calculated on the
basis of orders and individual lots.
- In Repetitive Manufacturing, products remain unchanged over a longer period
and are not manufactured in individually defined lots. Instead, a total quantity
is produced over a certain period at a certain rate.
- Discrete manufacturing typically involves varying the sequence of work
centers through which the products can pass during production. The order of
work centers is determined in routings, which can often be very complex. There
can be waiting times between the individual work centers. Also, semi-finished
products are frequently placed in interim storage prior to further processing.
- Repetitive Manufacturing, on the other hand, normally involves a relatively
constant flow on production lines. Semi-finished products are usually processed
further immediately without being put in interim storage. Routings tend to be
relatively simple.
 - In discrete manufacturing, component materials are staged with specific
reference to the individual production lots. Completion confirmations for the
various steps and processes document the work progress and enable fine-tune
controlling.
- In Repetitive Manufacturing, components are often staged at the production
line without reference to a particular order. Completion confirmations are less
detailed, and the recording of actual data is simplified.
- The function of Demand Management is to determine requirement quantities
and delivery dates for finished products assemblies. Customer requirements are
created in sales order management. To create a demand program, Demand
Management uses planned independent requirements and customer
requirements.
To create the demand program, you must define the planning strategy for a
product. Planning strategies represent the methods of production for planning
and manufacturing or procuring a product.
Using these strategies, you can decide if production is triggered by sales orders
(make-to-order production), or if it is not triggered by sales orders (make-to-
stock production). You can have sales orders and stock orders in the demand
program. If the production time is long in relation to the standard market
delivery time, you can produce the product or certain assemblies before there
are sales orders. In this case, sales quantities are planned, for example, with the
aid of a sales forecast.
1. What is Discrete Manufacturing?
2. What is REM?
3. What is Demand Management?

Here are difference between Discrete and REM and small explanation about discrete
and repetitive manufacturing:

- A typical characteristic of discrete manufacturing is the frequent switching from one

manufactured product to another. The products are typically manufactured in
individually defined lots, the sequence of work centers through production varying for
each one of these. Costs are calculated on the basis of orders and individual lots.

- In Repetitive Manufacturing, products remain unchanged over a longer period and

are not manufactured in individually defined lots. Instead, a total quantity is produced
over a certain period at a certain rate.

- Discrete manufacturing typically involves varying the sequence of work centers

through which the products can pass during production. The order of work centers is
determined in routings, which can often be very complex. There can be waiting times
between the individual work centers. Also, semi-finished products are frequently
placed in interim storage prior to further processing.
- Repetitive Manufacturing, on the other hand, normally involves a relatively constant
flow on production lines. Semi-finished products are usually processed further
immediately without being put in interim storage. Routings tend to be relatively
simple.

- In discrete manufacturing, component materials are staged with specific reference to

the individual production lots. Completion confirmations for the various steps and
processes document the work progress and enable fine-tune controlling.

- In Repetitive Manufacturing, components are often staged at the production line

without reference to a particular order. Completion confirmations are less detailed,
and the recording of actual data is simplified.

- The function of Demand Management is to determine requirement quantities and

delivery dates for finished products assemblies. Customer requirements are created in
sales order management. To create a demand program, Demand Management uses
planned independent requirements and customer requirements.

To create the demand program, you must define the planning strategy for a product.
Planning strategies represent the methods of production for planning and
manufacturing or procuring a product.

Using these strategies, you can decide if production is triggered by sales orders
(make-to-order production), or if it is not triggered by sales orders (make-to-stock
production). You can have sales orders and stock orders in the demand program. If the
production time is long in relation to the standard market delivery time, you can
produce the product or certain assemblies before there are sales orders. In this case,
sales quantities are planned, for example, with the aid of a sales forecast.


1) MASTER DATA

--> Material master

--> fill value in MRP 3 Tab page and enable the REM by right mark

--> Create the production profile.

--> BOM and work center will be same

--> create rate routing *** assign production version to it

2) Create the PIR in MD61 or you can create direct PIR in MD11

3)Then go to MF50 ( Planning of line loading) planning table

4)Then go to MF60 (Pull list) here you do

--> material statging

--> good issue

5)Production Execution

6) WIP determination by MFBF ( Reporting point)

7) again goto MFBF Final conformation and stock recipte with component Backflusing
thanks

sunil

Report Abuse
Like (0)

Re: REM Cycle..........

Pradeep Kumar Sep 26, 2007 1:20 PM (in response to Deven Deven)

Hi deven,

Following are necessary things for REM,

1. Master Data - MM01

- create Rem profile - SPRO

- assign the REM profile to a material - MRP view in MM01.

- Rem MFG indicator - mrp view in MM01.

- create Valid Production version - MRP view in MM01

- Assign the BOM and routings in Prod. Version

2.Create version specific product cost collecter for Header material - KKF6N.

3.create DEMAND in MD61.

4 .Run the MRP for your header material - MD02 - results run scheduler (Planned order) will be
created. Here planned order cant be converted to Producton order.

5. Use planning table for scheduling and capacity planning - MF50.

6. Use Pull list for material staging (if material stotage exists in prod location ) - MF60
7. Backflush (confirmation) the Planned order - MFBF. Results planned order will reduced and
GR,GI, activity cost will be posted

8. then Goto KKF6n to see the Manufaturing cost.

this is the simple REM flow.

regards

pradeep

Report Abuse
Like (0)

Re: REM Cycle..........

Mangalraj Senthamaraikannan Sep 26, 2007 1:21 PM (in response to Deven Deven)

Dear Deven,

The sequence in REM is

1.MM01-material creation.(MM01- FERT,HALB,ROH Types).

2.CS01 - BOM creation.(CS01- Create BOM's for your FERT & HALB).

3.Work centre creation.(CR01)

4.Rate routing.(CA21 - For In house manufactured HALB & FERT's).

5.Creating production version to link BOM & Rate routing.(Using MM02 - MRP4view or else
C223).

6.Creations of product cost collector using production version.(KKF6N,KKF6).

7.Cost rollup & Release using CK40N.

8.Demand values (MD61 - Planned Independent Requirements),

(In addition to this after giving PIR's in MD61 ,we can also use Planning table MF52).

9.MRP Run(MD02 - Single Item Multi Level),

10.Planned orders generated(Checked in MD04).

11.Pull List MF60(Using Planned orders to stage the material).

12.MFBF(Assembly Backflush - 261 & 131,Component Backflush - 261,Activity Backflush for

extra time spent for the operations).

13.Settellement - month end if any variance.

If useful reward points.

Regards

Mangal
Repetitive Manufacturing - Basic Cycle
In this post I will Explain a simple REM cycle for the PP Module.

Master data:
************
* Material Master:
* In this you need to have the REM indicator activated.
* A Rem Profile attached
* Production version with BOM, routing, production line( it is nothing but a work centre)
REM indicator activated.
* BOM
* Routing( Routing or rate routing both will work fine for the rem)
* Production version.

Configuration:
*************
1. REM Profile

Process Flow:
***********
1. First Create all the required material master as indicated above.

2. Once this is done now you have to create a product cost collector

* REM- works on the Product cost by period.

* So the Product cost collector is a CO order which helps to collect all the cost at a material /
production version combination to an internal order
* Which later settles the variance against a material
* You can create the Product cost collector with KKF6N
3. during the creation of the Product cost collector it will prompt you to do the Preliminary cost
collector- for rem you need to run this one also.

4. Once the above is done , now you have to run the Cost estimate Mark and release the same with
CK11N AND CK21(you can reach the help of FICO consultant to complete this process)

5. Once the above is done now the master data and prerequisites are complete and ready for the
PLANNING AND CONFIRMATION of the product/material.

6. Now you can maintain the demand in the md61 for the required quantity.
7. Once the demand is maintained and the MRP is run you will be able to work with the REM PLANNING
TABLE.

8. One of the best features in the REM is the Rem Planning table

9. This can be accessed with the T.CODE MF50.

10. Here when you try to access the MF50 you have multiple choices to make selections and also
restrictions.

11. Inside the planning table you can see 2 major things
a. In the upper section of the planning table you can see the available/ actual capacity
b. In the lower section of the planning table you can see the demand and few other attributes like stock,
ROC, Production version etc.

12. This MF50 helps you to make the Planning- the Creation / modification of the planned order are very
dynamic in this screen and is well integrated with all the functionalities.

13. Once all the planning is done with the MF50 then comes the EXECUTION ie) our confirmation.

14. In REM production confirmation is called as MATERIAL BACK FLUSH.

15. you can access the Material back flush with MFBF.

16. HERE in MFBF you can have some mandatory parameters like Quantity, material, production version,
date etc which has to be given as input , and the system will in turn perform the back flush.

17. the MFBF is single screen which allow you to perform the below function
* Material back flush
* Excess consumption
* scrap posting
* Only activity posting
and few more.

18 Once the back flush is done the stock gets posting

19. You also have cogi/mf47 FOR clearing the post goods movement errors for automatic posting.

Hope the above process flow will be useful for someone to get introduced to REM. Again this is a short
glimpse .
You can post your questions as comments , which will be answered by Me.