Manufacturing: Material Master Org Structure
- Client
- Company code
- Plant
- Storage Location
Material types
- Raw materials
- operating supplies
- semi-finished products
- finished products
Control: Number assignment, procurement type, user departments, field selection, account determination,…
Material Master | Number Ranges
Internal number range + external number range
- Material type
- account group
- document type purchasing
- transaction inv. mangmt.
- document type accounting
Material Master views
- Basic data
- MRP
- stocks in plant/storage location
- financial accounting
- storage
- warehouse mgmt.
- purchasing
- costing
- work scheduling
- QM
- forecasting
- classification
BOM Structure (Product)
Header (Status, Description, Validity, Lot size area)
Items (Item category, Descriptions, Quantitites, Control data)
Production Processes: Routings
Operations Sequencing (Standard, Parallel, Split, Overlapp) Durchführung der Produktion
Materials Requirement Planning
- MRP prerequisites (batch or online, single or multiple materials, relevance,…)
- Net Requirements calc. (qualified demand, qualified supply, relevant planning horizon, lot-sizing)
- Dependent Requirements (BOM explosion->single level/multi level, net requirement calculation for (sub)components)
- Source of Supply assignment (External procurement, internal production, make or buy decision, special procurement options, quota arrangements)
- Scheduling (External procurement, lead time calculation)
Shopfloor planning
Wer macht was im werk?
production preperation
- Create Production Order
- Reserve components & Work center capacity
- print labels and documents
production execution
- Create Production Order
- Reserve components & Work center capacity
- print labels and documents
- stage components
- set up operations
- start 1st operation
- inspect quality
production confirmation
- Create Production Order
- Reserve components & Work center capacity
- print labels and documents
- stage components
- set up operations
- start 1st operation
- inspect quality
- Confirm 1st operation (yield and time)
- confirm last operation
Production Settlement
- Create Production Order
- Reserve components & Work center capacity
- print labels and documents
- stage components
- set up operations
- start 1st operation
- inspect quality
- Confirm 1st operation (yield and time)
- confirm last operation
- Post goods receipt (finished product) into inventory
- cost settlement of production order
Aufgaben eines Work Centers
- Default values Routings
- calculation of costing data
- Scheduling Data & Capacity Data
Capacity planning
Work center V Factory Calendar, Operations Plan & Maintenance Plan V Available Capacity
MRP V Planned Order V Capacity Requirements
Options to mitigate capacity constraints
- Increase capacity (add shifts, increase workforce)
- Reduce demand (prioritize demand, customer vs. internal)
- Capacity leveling (prework, evaluate to postpone)
- Alternate Source of Supply (alternate work center, other plant, contract manufacturer, make or buy)
Repetitive Manufacturing
- quantity and period-based planning and productions: specify quantitites per period
- planned orders (run schedule quantities
- Repetitive production: same/similar products produced over a longer period of time
kanban manufacturing
production is based on customer demand
make-to-stock
manufacturing strategy in which production planning and production scheduling are based on forecasted product demand
make-to-order
Produktion auf Bestellung -> Die Waren werden erst dann produziert, wenn ein realer Auftrag vom Kunden vorliegt
Configure to order
Manufacture products out of semifinished products based on customer orders
design-to-order
Engineer products based on individual customer demand
predictive MRP
- Scope (Define business scope and its top level demand)
- Calculate (Propagate the demand acroll the multi-level BOM individually
- Result (Derived demands and capacity loads on all (sub) component levels
- Evaluate (Which top level demands drive overlad? What are my limits?
- Simulate (How to make it fit?
- Apply (Enhance pMRP with automated update of simulation results for demand)
Demand driven MRP
- Buffer Positioning (Set up dynamic buffer profiles and determine threshold sizing)
- Buffer Sizing (Use Buffer Level Management worklists to review current planning situation based on the net flow position)
- Replenishment Planning (Generate replenishment orders at decoupling points based on actual demand)
- Replenishment Execution (Review the current performance situation based on the on-hand stock status)
- Insights to Action (Cockpit providing capabilities to 1. manager buffer levels augmented by system proposals and 2. centrally plan & carry out replenishment)
