In discrete scenario, the manufacturing process is based on production orders. Discrete manufacturing is characterized by requirements that occur on an irregular basis and a workshop-oriented process. Basically the demand and supply varies time to time in this scenario.
PP - Production Planning - Process Industries -...
The component Production Planning for Process Industries (PP-PI) provides an integrated planning tool for batch-oriented process manufacturing.It is primarily designed for the chemical, pharmaceutical, food and beverage industries as well as the batch-oriented electronics industry.
Repetitive manufacturing form an industry type where in the products manufactured can be discrete manufactured or process industry type, produced repetitively or continuously in production lines. This forms the continuous production scenario.
Very helpful document indeed ! But I have a comment to make: why is Active Ingredient Management marked only to function with PP-PI ? I think it does not have to do with selected production process as such, but it has to do with batch management (batch specific Unit of Measure) and typically QM integration (you measure the batch specific Unit of Measure characteristics coupled with master inspection characteristics value by means of QM). I f.ex have used Active Ingredient Management - (with Production Unit) f.ex for Pulp Industy with even Repetitive Manufacturing process.
One comment to add: if you mean with process management the Process Instructions, this is possible to maintain also for discrete production orders - it is called Control Instructions or commonly named as XSteps and available since EhP 3.
Process manufacturing is common[3] in the food, beverage, chemical, pharmaceutical, nutraceutical, consumer packaged goods, cannabis, and biotechnology industries. In process manufacturing, the relevant factors are ingredients, not parts; formulas, not bills of materials; and bulk materials rather than individual units. Although there is invariably cross-over between the two branches of manufacturing, the major contents of the finished product and the majority of the resource intensity of the production process generally allow manufacturing systems to be classified as one or the other. For example, a bottle of juice is a discrete item, but juice is process manufactured. The plastic used in injection moulding is process manufactured, but the components it is shaped into are generally discrete, and subject to further assembly.
By separating the product formula from a packaging recipe, a production or process order can be issued to make and store the cans of soup and later, when the customer is ready to order soup, a work order can be issued to label the cans according to customer specifications before they are shipped to the store. Thus segregation of the formula and pack recipe makes the world of process manufacturing efficient and effective.
Just like the products that they produce, discrete manufacturing and process manufacturing use different Enterprise resource planning (ERP) systems which have different focal points and solve different problems. For the same reason that the proverbial square peg does not fit in the round hole, ERP software geared toward discrete manufacturing, or even hybrid manufacturing will not work smoothly in a process manufacturing setting. With process manufacturing, the end-product is unable to be broken down to its original ingredients, for example beer or pasta sauce. Thus, the ERP software must be able to account for these intricacies in its ability to convert and transform raw materials to finished goods. Critical aspects such as recipe formulation, forward and backward lot traceability, handling of mixed units of measure and conversion, raw material calculations, and scalable batch tickets with revision tracking and recording of manufacturing steps and production notes are specific to process manufacturers and key functionality of process manufacturing ERP systems. An example is the SAP module, Production Planning - Process Industries (PP-PI). [7]
In process inspection for process manufacturing refers to inspection at any point in producing a product, and is also referred to as in process product verification. [8] The objective of in process inspection is to ensure the requirements of the product are being met before they are finalized and continue to the next stage. Identifying a problem at an early stage in the production process allows for correction and preventative action to avoid wasted time and resources at the end of a production run.
Abstract:Scheduling is a major component for the efficient operation of the process industries. Especially in the current competitive globalized market, scheduling is of vital importance to most industries, since profit margins are miniscule. Prof. Sargent was one of the first to acknowledge this. His breakthrough contributions paved the way to other researchers to develop optimization-based methods that can address a plethora of process scheduling problems. Despite the plethora of works published by the scientific community, the practical implementation of optimization-based scheduling in industrial real-life applications is limited. In most industries, the optimization of production scheduling is seen as an extremely complex task and most schedulers prefer the use of a simulation-based software or manual decision, which result to suboptimal solutions. This work presents a comprehensive review of the theoretical concepts that emerged in the last 30 years. Moreover, an overview of the contributions that address real-life industrial case studies of process scheduling is illustrated. Finally, the major reasons that impede the application of optimization-based scheduling are critically analyzed and possible remedies are discussed.Keywords: process scheduling; optimization; process system engineering; mixed-integer programming
The process industries are those industries where the primary production processes are either continuous, or occur on a batch of materials that is indistinguishable. For example, a food processing company making sauce may make the sauce in a continuous, uninterrupted flow from receipt of ingredients through packaging. Or batches may be produced depending on the cook kettle sizes but immediately combined and re-routed. In either case, there is no concept of a unit of sauce while it is being processed. Examples of the process industries include food, beverages, chemicals, pharmaceuticals, petroleum, ceramics, base metals, coal, plastics, rubber, textiles, tobacco, wood and wood products, paper and paper products, etc.
For more on the role of industrial engineering in process industries, read " Making Cereal Not Cars," a primer on process industries. This article was published in the December 2008 issue of Industrial Engineer magazine and is available only to IISE members. If you are not a member, join IISE for access to this article as well as additional member-only benefits.
Applying industrial engineering tools in the process industries can vary greatly from applying these same tools in discrete parts manufacturing. The Process Industries Division is a forum for the exchange of ideas in theory and practice of industrial engineering techniques applied to process industries; facilitating greater interactions among industry and academic professionals by organizing.
SAP PP process is related to production planning of a company and it encompasses all activities like MRP (Material Requirement Planning), BOM (Bills Of Material), Routing, Capacity planning, etc. but mainly it contains two segments
PP creates schedules for production, for procurement and for purchasing. This ensures that raw materials are available for production as required. The module records the production process with, for example, planned and actual budgets.
Process Industry is used for the production of products that cannot be disassembled. Here, a machine called a workcenter in SAP is usually used for the production of a single product. The PP-PI solution is mainly used in industrial processes that use the concept of batch management to differentiate between the items produced. The pharmaceutical, food and chemical industries in particular use this solution. Process manufacturing counts its products in litres, metres or grams.
SAP PP activities include material requirements planning, bill of material, routings and capacity planning. Everything in SAP PP revolves around master data that is stored and manipulated in centralized master data tables. Master data types include materials master, work center, BOM and routing. The master data is used to create transactional data in SAP ECC, such as creating a production order in PP, a sales order in SD, or a purchase order in MM. For example, when a production order is created in SAP PP, it uses master data from SAP MM about the raw materials needed to produce the finished product, which will subsequently be used to create a sales order in SAP SD.
SAP PP can be configured to meet various industry requirements and includes a number of modules that support specific manufacturing industry types, including discrete manufacturing, repetitive manufacturing, and process manufacturing. In discrete manufacturing the numbers of goods produced change by lot, and costs are calculated by orders and lots. In repetitive manufacturing, products remain unchanged over long periods of time and production occurs in total quantities, not individual lots. In process manufacturing, products are manufactured in batch-sized lots using a process described in a master recipe that can be adjusted for individual batches. Process manufacturing is used primarily in the chemical, pharmaceutical, and food and beverage industries.
The purpose of manufacturing planning and scheduling is to make your manufacturing process flow with maximum efficiency by balancing your production needs with your available resources cost-effectively. It ensures that your orders are fulfilled efficiently, without interruptions, delays, or stress. Does that seem like a pipe dream?
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