Production Model

Repetitive manufacturing is used when the production process is a continuous, and steady stream of demand. This demand must be met using minimal administrative effort, but with real-time insight and control of the process. In a repetitive manufacturing environment, products are manufactured based on predefined configurations that are specified in production models.

A production model contains all master data required for the production of an item in a specific work cell. An end item can have multiple models defined for manufacture, to differentiate between these models each has a unique key.

A production model is revision controlled, and must be activated by setting the status to Approved before production can start. You can make changes to a production model by copying an existing model. The copied model will have the status New, becoming the new revision upon activation and approval. Old production models are deactivated by setting the status to Expired.

Note: You can copy a production model to another item or another work cell.

A production model contains this data:

  • Production model code

    A production model can be used for planning and costing purposes. When multiple models for the production of a repetitive item are used, you must designate which models are used for this purpose. Note: Only active production models can be used for planning and production. The production model contains a calendar that is defaulted from the work cell that is used by the scheduling engine to manage production. A production model can be linked to a calendar.

  • Applicable item and the dedicated work cell

    Along with the item data, the warehouse where completed manufactured items are stored.

    • Select the item from the Item - Production (tiipd0101m000) session.
    • Select the work cell to be used for manufacturing from the Work Cells (tirpt0140m000) session. For each work cell, a production process is defined based on the work cell layout, you can manage this process in the Production Process (tirpt2110m000) session.
    • Select the type of production model. Note: For a multi-product production model various restrictions apply.
  • Current revision

    A revision number is mandatory for a production model, and is used to track the changes to the model. The revision number is generated automatically.

  • Production rate

    The time required for one cycle of production for one item, or production rate is stored in the production model.

  • Run quantity

    The order quantities used for material planning outside the scheduling horizon and order lead times used for material planning outside the scheduling horizon are maintained in the production model. The optimal, maximum and minimum run quantities that are used for planning and during the creation of the production run schedule are also maintained.
  • Man capacity

    Expressed in the number of shifts and man-hours allocation which are stored with the production model
  • Material list

    You can define the material list for a production model in the Materials (tirpt2120m000) session.

    The list contains the materials required for the production of the specific item. It is used for materials planning, the supplying of the work cell and material backflushing. The material list is date effective, and when updated a new revision of the production model is defined.

    A production model list of materials defines the required quantities of each material, and the expected scrap percentage, the units of measure, and supply warehouses responsible for the materials. It is possible to define multiple supply lines for the same material, so each line has a position number.

    Materials are supplied to the designated point of usage warehouse for the consolidated material demand for the active schedule lines in a specific period accounting, for the safety stock in the point of usage.

    Each material line is linked to a point of usage that requires specific material for production. The materials are supplied from a warehouse to the point-of-usage independent from the material demand. The replenishment is based on a Kanban card.

Multi-product production model

To use multi-product production models:

  • The Multi-Product Production check box in the Repetitive Manufacturing Parameters (tirpt0100m000) session must be selected.

You can define a production model with multiple end products that are produced in different quantities. A list of products is added to the single-item model containing the information about the different items the model is set up for, and their quantities.

In this type of production model the main tool used for production is the information carrier to identify the model for planning and costing. In the Work List (tirpt4602m000) session, the number of realized cycles of the tool is reported instead of the quantity of item completed as with a single-item model.

Note: 
  • The planning, scheduling and costing is done on the end product, not the tool.
  • Work station based reporting and transfer quantity data are not available in the multi-product repetitive environment.
  • You cannot reject produced items in the multi-product repetitive environment.
  • Process inspections are not possible in a multi-product repetitive environment.