Best Practice for Production Planning for Injection Molding

[manoj_reddy65]

Hi,

My company has decided to buy injection molding equipment to produce a part we currently procure externally. This is a brand new process for us.

We would like to know how other injection molders have set up standard SAP to put finished goods on hand.

Our thought right now would be to use repetitive mfg to put the top level on hand and consume the PET chip / colorant based on the BOM.

At some point we will reprocess some of scrap, so we are not sure how to handle that during the back flush. One thought we had was to consume the PET chip / colorant as we fill the hopper with a good issue to a cost center. This would also require the removal of the back flush flag from the raw materials, but this would we prevent fractional corrections and wouldn't cause any issue with using scrap.

Thanks for reading this and any suggestions you guys have.

Thanks,

Manoj

[manoj_reddy65]

Hi Mahe,

Thanks for your response.

Let share an example of a current issue we have with repetitive manufacturing.

We produce drinks and we use a concentrate to mix the drinks. For each batch of concentrate we mix, we expect to produce 10,000 bottles for example. Regardless of how accurate your BOM is, that number will change during every product run. One day it could be 9,500 bottles and the next day it could be 10,205 bottles. Because of these yield variations, we have to make inventory corrections for the concentrate inventory because we never consume 100%. I made a suggestion that we good issue the concentrate when it is mixed because regardless of the yield because we will not have any left. (I am not even sure if that is possible for repetitive mfg)

I see that type of situation with injection molding except we may also use scrap or regrind in a run which would throw of the expected yield. Do injection molders good issue each bag or truckload of resin so that they don't have to do an inventory correction after each run?

Also is the preferred SAP production process for injection molding production orders or process orders instead of repetitive mfg?

Thanks,

Manoj

[Mahendran8888]

Hi Manoj,

It is entirely needs to be observed if we are not sure with the quantity needs to be consumed. First we need to keep BOM with standard or thumb rule which is followed in your industry. Then each day we need to observe the consumption and scrap of the process.

If you do fine tuning with the bill of material you will get exact BOM, Process and consumption figure. Your questions seems like you are not sure about material consumption and more on scrap quantity. This is entirely the responsibility of the production process.

Next time while questioning please give an example data or share scenario you want to ge tanswers. If it is critical that is fine to the SCN. You read again the question, Isn't generic?

"What are your thoughts about consuming the raw materials? Specifically the scrap or regrind."

Please come with specific question. All the best. I am trying to help you.

Regards

Mahe

[manoj_reddy65]

Hi Anita,

Thanks for your response.

What are your thoughts about consuming the raw materials? Specifically the scrap or regrind.

Thanks,

Manoj

[anitaarifin04]

Hi Manoj Reddy,

I think you can try to use repetitive.

But for comparison please also check process industry and variant configuration

Best regards

Anita A.