Overview

The Plan-to-Produce process domain describes the collection of processes a company has implemented between developing a production schedule (from the production plan) and recording the completion of the production activities.

The span of processes involved depends on the Supply Chain Configuration and process architecture, but is typically concentrated on the Make processes. The scope of Plan-to-Produce typically includes:

  • Create a production schedule
  • Issue materials
  • Produce
  • Pack
  • Transfer to storage
  • Backflush
  • Invoice (for outsourced production processes and subcontracting)

Forecast-to-Plan provides inputs to Plan-to-Produce.

Alternative names for Plan-to-Produce include: Make-to-Plan, Plan-to-Make, Plan-to-Produce, Plan-to-Product, Produce-to-Plan.

Source: Plan-to-Produce

E2E Business Scenarios

Cluster: Production

E2E Business ScenarioOverview
Pl2P Make-to-stock (Discrete manufacturing)

The scenario describes the production process following the make-to-stock model, where products can be and usually made before a sales order confirmation.

Sales orders are typically supplied from existing stock, and production orders are used to replenish those stocks.

The scenario starts with the creation of plan-based production orders for large quantities of standardized products and ends with a production of all quantities of the product required by the plan.

The scenario is applied for discrete manufacturing and can't be applied for continuous manufacturing. Each production stage can be individually started, postponed, the lot can be changed at any moment of production. Discrete manufacturing requires a multistage production process with numerous interdependent steps to make a specific product. As the product structure is complex, it requires a complex bill of materials, routing, and operations with defined materials. The production is done in several stages with a lot of intermediate products which are used in other intermediate or finished products.

Very likely, the make-to-order/assemble-to-order and make-to-stock scenarios can be combined. Intermediate products are made in stock, while finished products are made on customer's orders.

The scheduling focuses on maximizing the output by maximized machine use and optimization of production lot sizes.

Pl2P Make-to-order (Discrete manufacturing)

The scenario describes the production process following the make-to-order model, where a good or service can be made after confirmation of a sales order.

The scenario starts with customer confirmation of the order and ends with a production of all required quantities of the product.

The final product is usually highly configured and includes a combination of standard and custom-designed items to meet special requirements of the customer.

Standard raw materials and components are stocked independently, but customer components are purchased individually.

The scheduling ensures that all sales orders can be fulfilled in the required quantity and dates.

Pl2P Assemble-to-order

The assemble-to-order scenario covers the process flow for managing manufacturing operations associated with assembly of a finished product from standardized components already available in stock.

The scenario is initiated when a sales order is placed, starts with converting the sales order into individual assembly orders. The assembly is then carried out according to the customer's requirements.

In contrast to the make-to-order scenario, the stock availability in the assemble-to-order scenario is checked at the sales order level. As a rule, assembly operations are simple, that is why they do not require complex planning and scheduling.

Pl2P Simple production

The simple production scenario defines the process flow of registration of products / works that are already produced, with simultaneous consumption of materials, components, services, and works used for this production.

There are simple production scenario variants:

  • Register production of products of supporting or repairing production.
  • Register non-production and supporting works that are usually consumed by manufacturing stages.

The scenario specifics:

  • Short production cycle, simple manufacturing process.
  • Impossible or unreasonable to plan the products/works manufactured by the simple production in advance.
  • Products of the simple production scenario are non-standard products or products made by individual special requirements.
  • The production process is not standardized, determined individually, it depends on the employee.
  • Impossible or unreasonable to plan the consumption of materials and equipment.
  • Materials in the simple production scenario are often recycled materials and components.
  • Material consumption is not standardized.
  • An individual variant for cost calculation can be applied: by product, by product and assignment, by the document, without specifying direct resources consumed.

Cluster: Corrective production

E2E Business ScenarioOverview
Pl2P Recycling

The recycling scenario is the process flow that covers recycling of materials, which can't be sold or used in their current form, into other materials ready for sale or use.

There are two widely used recycling strategies:

1. Cleaning/refining of the material in its contaminated or crude state into its clean state, ready for use. The variant also includes extraction of components ready for use from a complex product (used). The strategy specifics are the following:

  • The recyclable material quantity is known.
  • The recycling process necessary to extract the components is known.
  • There is a certain expectation of useful materials to receive from recycling.
  • The exact quantity of useful materials is estimated after the recycling process.

2. Receiving a certain quantity of useful materials from recyclable materials to use them in production of a new product. The features of the second recycling strategy are:

  • The main goal is to obtain a predetermined quantity of useful material as a result of recycling.
  • During the recycling process, the quantity of recyclable materials must be dynamically changed.
  • The exact quantity of recyclable materials required cannot be estimated in advance.
  • The exact quantity of recyclable materials consumed is known after the recycling process.

The recycling scenario in a manufacturing organization usually begins with quality management of recyclable materials. These materials can be:

  • Goods purchased from vendors.
  • Sub-products from their own manufacturing process.
  • Products returned by customers.

Recycling can also be carried out as a processing service, and after the recycling process the extracted materials are returned to the customer.

Pl2P Remanufacturing

The remanufacturing scenario covers the manufacturing process flow, in which used or unusable products are remanufactured to near-new condition. A remanufactured product typically retains its original design and key construction components, only worn and unusable components are replaced or maintained.

There are two key remanufacturing variants:

  • Previously manufactured product is recycled into components, components are repaired/replaced, the same product is remanufactured from recycled components.
  • Input and output products are different products in terms of functionality (an adjustment or upgrade order).

Remanufacturing scenario specifics:

  • It defines the required remanufacturing workflow.
  • BOM (materials and work centers) cannot be defined in advance. Production stages are usually created without material assignment. The remanufacturing scenario usually starts with identifying product quality defects and recycling the product into components. Then quality control procedures are initiated to evaluate further use of the extracted components coming directly from the production stage. Only after that it is possible to assign replacable new materials and components.
  • Usually the input and output product is the same product, only with different quality. Rarely, the input and output products are different, which is an example of an adjustment / upgrade order.
  • Manufacturing stages and components required for remanufacturing are usually added manually or filled with the reference to a standard BOM.

This scenario applies to both newly manufactured products recognized as defective and products returned by customers.

Remanufacturing can also be carried out as a processing service. The customer fills up the product for remanufacturing and receives the remanufactured product.

Cluster: External processing

E2E Business ScenarioOverview
Pl2P External subcontracting

The external subcontracting scenario involves the flow of processes required to transfer the entire production stage to an external subcontractor.

You can initiate the scenario from any production scenario.

Compared to S2P Subcontract manufacturing scenarios, the external subcontracting scenario does not require registration of transfer of raw materials and components to a subcontractor as well as return of a processed product/component.

This scenario is typically used when the production stage is performed by a subcontractor on the company's shop floor. More rarely, this scenario is used when the production stage is performed outside the company's shop floor, and transportation is managed by the company.

Purchase of an external subcontracting service follows the usual S2P Purchase standard services scenario.

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