Overview of Process Manufacturing

M3 Process Manufacturing overview

Process manufacturing is the production of goods that typically are produced in bulk quantities, as opposed to discrete units. Process manufacturing industries include chemical, food and beverage, and pharmaceutical.

Before implementing the PM functionality in M3, there are various elements of setup to be completed.

This figure illustrates the setup and transaction activity involved for PM.

An overview of each aspect of the PM flow is provided:

• Enable PM settings

  On 'Facility. Open' (CRS008), there are two settings:

  • The Process manufacturing check box activates functionality related to Process manufacturing in the facility.
    Note: If this setting is disabled in the facility, the system does not allow you to specify an output item in 'Output Items. Open' (PDS029) for formula and/or packaged item types of product structures.
  • The Version management field offers two alternatives to either allow or require product structures in the facility to use version management. Versions may be applied to product structures representing manufacturing processes when this facility setting is enabled.
• Item and Item Pack Setup
  • After adding an item record on 'Item. Open' (MMS001), navigate to 'Item Pack. Connect' (MMS023) and enter the bulk item details. This results in the creation of an item pack (better known as a packaged item).
  • On 'Item. Connect Warehouse' (MMS002), select the desired value (either '1-Process order' or '2-Pack order') of the MO consolidation method (MOCM) field to indicate how to optimize the planning of manufacturing orders for packaged items.
    Note: Any item that is not a packaged item must have a MO consolidation method of '0-Discrete'.
  • When the Process manufacturing check box is enabled in the facility, the system allows the selection of the Alternate structure (ALTS) setting on 'Item. Connect Facility' (MMS003).
    Note: The item must be assigned an Item type (ITTY) which has the 'Alternate structure' field control enabled for MMS003/F. The Item Type field controls are defined in 'Item Type. Select Fields' (MWS041).
• Product Structure Setup
  • When creating a product structure via 'Product Structure. Open' (PDS001), indicate a Product structure class (PSCL) based on the Product structure class type (PCLT) and Version (VRNF) setting:
    • If the Version setting is enabled, define the version details on 'Product. Version' (PDS028) .
    • Navigate to 'Product. Connect Materials/Operations' (PDS002) to define materials and operations.
    • The system checks the Product structure class type (PCLT) and if the value is '12-Manufacturing route':
      • You must add an existing work center via 'Product. Connect Materials/Operations' (PDS002).
    • The system checks the Product structure class type (PCLT) and if the value is '14-Packaging material':
      • You must add an item via 'Product. Connect Materials/Operations' (PDS002). You also can set up a packaging material as a component within another packaging material product structure on (PDS002).
    • The system checks the Product structure class type (PCLT) and if the value is '13-Bulk item product structure':
      • You must add a formula via 'Product. Connect Materials/Operations' (PDS002). You can add only one formula as long as the output item has been defined on 'Output Items. Open' (PDS029) for the formula. In addition, the formula's Quantity value on (PDS002) must be 1, in the basic U/M.
      • Any output item that has been defined for the formula is saved to the Product structure header (MPDHED) table. The associated output information for the product structure can be accessed on 'Alternate Structures. Open' (PDS023) at the time alternate structures are created.
      • In addition, you have the option of adding a route via 'Product. Connect Materials/Operations' (PDS002). The Quantity value on (PDS002) must be 1, in the basic U/M.
    • The system checks the Product structure class type (PCLT) and if the value is '11-Formula Bill of Material' or '15-Packaged item product structure', you may define output item details via 'Output Items. Open' (PDS029).
  • When the Alternate structure (ALTS) setting is enabled on 'Item. Connect Facility' (MMS003), this allows you to create alternate product structures for the item on 'Alternate Structures. Open' (PDS023).
• Manufacturing Order (MO) Planning
  • After the Material Resource Planning (MRP) process is run via 'Material Plan. Open' (MMS080), MO proposals (MOPs) are created and accessible on 'Planned MO. Open' (PMS170).
  • The system checks the Process code (PCCO) defined on the MOP to determine the next step:

    Process code is '3-Process order' on the MOP

    • You have the option of consolidating the MOP with other MOPs having a Process code of '5-Process child order' via 'Planned MO. Consolidate' (PMS172). Subsequently, use (PMS172) to release those consolidated orders to a MO.

      OR

      Simultaneously consolidate with compatible MOPs and release them via 'Planned MO. Consolidate' (PMS172).

    • Release the MOP to a MO on 'Planned MO. Open' (PMS170).
      Note: Direct release of the MOP via (PMS170) is also available when the Process code is '0-Discrete'.

    Process code is '4-Pack order' on the MOP

    • Consolidate the MOP with other MOPs having a Process code of '6-Pack child order' via 'Planned MO. Consolidate' (PMS172). Also use (PMS172) to release those consolidated orders to a MO.

      OR

      Simultaneously consolidate with compatible MOPs and release them via 'Planned MO. Consolidate' (PMS172).

  • The result of the planning process is the creation of an MO, or multiple MOs are created when child orders exist.
• MO Execution/Transactions
  • After the transformation of planned manufacturing orders into final products for disposition, a bulk item may be configured into types of packages (i.e. pack variants) in which they are delivered. This configuration process is performed via 'Output Balancing. Open' (PMS150).
  • After retrieving the MO from 'Manufacturing Order. Open' (PMS100), you may perform any or all of these MO transactions:
    • Issue materials on 'Manufact Order. Report Issue' (PMS060).
    • Report operations on 'MO Operation. Report' (PMS070).
    • Report receipt on 'Manufacturing Order. Report Receipt' (PMS050).
  • If child orders exist, perform bulk redistribution which is the apportioning of bulk quantities from parent MOs to child orders for costing purposes. Navigate to 'Bulk Redistribution. Open' (PMS155) after selecting the desired process order or pack order from 'Manufacturing Order. Open' (PMS100).
  • The final step in MO execution is the closing of the order.