Repetitive Terminology

You should be familiar with the industry terminology before working with repetitive manufacturing:

Term

Description

Production line

A production line is a sequence of operations that are arranged to produce a family of products. The production line is defined as a work center. The operations that make up the production line might or might not be work centers. You defined these in the routing instruction. The capacity of the production line is determined by the constraining operation within the production line.

Bill of Material

For items produced in a repetitive manufacturing environment, the operation sequence number on the bill of material is crucial to ensure that the components are delivered to the production line at the operations for which they are needed. Because the line is setup to run in a continuous fashion, components typically are setup to be consumed through backflushing, at a specific paypoint, or upon completion.

Routing Instruction

The relationship between the production line and the operations or work centers that the line contains are defined in the routing instructions for the parent item. Each operation is tied to its production line by the line or cell number in the Line/Cell field on the routing instruction. The consuming location is the inventory location from which the production line pulls components that are necessary to produce the parent at a particular operation. The consuming location must be identified in the routing instruction to ensure that inventory is always available to the line. When the system backflushes and relieves inventory from the consuming location, it triggers the kanban, a visual cue, to replenish inventory as materials are consumed.

Kanban

Kanban is a method of just-in-time production that uses standard containers or lot sizes. It is a pull system in which work centers or locations signal that they need to withdraw parts from feeding work centers, inventory locations, or suppliers. This signal alerts manufacturing to build, or suppliers to furnish, the required part in the standard lot size that is defined by the Kanban Master table (F3016).

Item to Line Relationship

Item-to-line defines the relationship between an item produced in a repetitive manufacturing environment and the production line or lines on which the item is produced. Each relationship defines the number of resource units that are required by the line to produce one end product.