Industrial Machinery & Components > Manufacturing > Make-to-Order Manufacturing

Make-to-Order Manufacturing

Business Scenario

 


Business Scenario Maps

  • Customer-Specific Engineering
  • Discrete Industry: Make to Order
  • IM&C: Order Change Management with Variant Configuration
  • Manufacturing Execution
  • Key Performance Indicators

  • Installation Planning Costs
  • Number of Orders not delivered complete
  • Number of Orders without Complete and Accurate Documentation
  • Capacity Utilization
  • Customer Signature, Authorization to Order Receipt Time
  • Delivery Date Accuracy
  • Order Fulfillment Lead Times
  • Sales Cycle Time (Orders)
  • SAP Best Practices

  • IM & C: Make-to-Order (MTO) - with External Processing
  • IM & C: Make-to-Order with Component Availability Check (SCM)
  • IM & C: MTO - Sales Order Processing
  • SAP Solution Extensions

  • SAP Manufacturing Execution by Visiprise 5.1
  • Partner Opportunities

  • Partner Opportunities in Industrial Machinery & Components
  • See also

  • Customer Success Stories
  • Customer Success Stories by Sub-Industry
  • SAP NetWeaver Benefits
  • Scenario and Process Component List

  • Make-to-Order (MTO) process characteristics include configurable end products, minor engineering effort during production of end product, subassemblies and components procured to forecast and the manufacture of end products driven by customer order.

    Business Goals & Objectives


    Improving Customer Service

    Collaborate with business partners
    Reduce order lead-time

    Increasing Revenue

    Improve capacity utilization
    Improve customer retention and loyalty
    Improve RFQ/RFP processes
    Outsource excess capacity

    Lowering Working Capital

    Improve capacity utilization
    Increase inventory turns
    Lower cost procured goods and services
    Lower work-in-process inventory
    Reduce inventory carrying costs
    Shorten order-to-cash cycle
    Visibility to vendor/supplier inventory

    Reducing Operating Costs & Increasing Efficiency

    Lower logistics costs
    Reduce inventory levels

     



    Business Processes

    Sales Order ProcessingSAP Component or Feature Available

    You use this business process to create a sales order to respond to specific customer requirements by using variant configuration to select the right product characteristics to produce a product that is individually manufactured for a particular customer. Variant configuration helps you to configure complex industrial products. The variant configuration improves the data exchange between the different departments such as sales, engineering, manufacturing, and after market service. It also reduces the failure rate of sales order entries.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  • SAP Sales Management for IM&C
  •  
    Engineering (MTO)SAP Component or Feature Available

    You can use this business process to create an order bill of material (BOM) if you work in make-to-order (MTO) production and want to respond to specific customer requirements, or if you are manufacturing a product that you have never produced before in that form. After making the engineering changes you need to replicate the order BOM in the production planning system.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  •  
    Determination of Delivery DateSAP Component or Feature Available

    You can use this business process to determine a feasible delivery date for the order based no the current material and capacity situation. 

    This process is supported by the following SAP and/or partner offerings

  • SAP Extended Manufacturing Planning and Execution for IM&C
  •  
    Production PlanningSAP Component or Feature Available

    In make-to-order production, the in-house production or procurement of products is only started when the sales order has been received. This business process is suitable for products with short replenishment lead times for the finished product and all incoming assemblies and components. This business process is useful if the costs of procurement and production of assemblies and components is very high; additional storage costs can be avoided in case of incorrect forecasts.

    In case of long replenishment lead times for assemblies and components and low costs, forecasting for assemblies is useful in order to reduce the delivery time for the sales order. This business process is used in discrete industries.

    This process is supported by the following SAP and/or partner offerings

  • SAP Extended Manufacturing Planning and Execution for IM&C
  •  
    Production Planning, Optimization, Backlog ResolutionSAP Component or Feature Available
    You can use this process in make-to-order (MTO) and engineer-to-order (ETO) – project manufacturing to run a mixed finite-infinite planning scenario.

    The intention of the process is to have a finite stable sequence of orders in the current week, without disturbances caused by the planning or optimization run.

    In the short term (for example, first week after current week), the process results in a capacity optimized finite plan, since in the short term, it is usually not possible to add much additional capacity or to outsource the production.

    In the mid-term, companies in MTO and ETO manufacturing usually have many possibilities to shift capacities, add capacities by running overtime or additional shifts or by outsourcing part of the production. Therefore, an infinite plan is created in the mid-term. Planned and production orders are scheduled with planning-related minimum intervals and planning-related offsets (buffers) to ensure flexibility in mid-term scheduling and capacity planning.

    This process is supported by the following SAP and/or partner offerings

  • SAP Extended Manufacturing Planning and Execution for IM&C
  •  
    Production SchedulingSAP Component or Feature Available

    You can use this business process to perform production scheduling and capacity leveling. The production planner can evaluate alerts of assembly orders for sales orders sorted by delay to detect the most critical assembly order. By detecting the critical path for the complete order context, reducing minimum intervals between operations and orders, and performing multi-level rescheduling of the order context, the production planner can solve the delay or find a new feasible end date. After evaluating the capacity load situation, the production planner can reduce capacity bottlenecks by rescheduling, planning overtime or additional shifts, splitting orders, or switching from internal to external procurement for specific orders.

    By comparing different simulation versions, the production planner can find the best solution for orders with delay or capacity bottlenecks. The decision is supported by the plan monitor, where key figures for the different simulation versions can be compared.

     

    This process is supported by the following SAP and/or partner offerings

  • SAP Extended Manufacturing Planning and Execution for IM&C
  •  
    Manufacturing ExecutionSAP Component or Feature Available

    Supports the process of capturing actual production information from the shop floor to support production control and costing processes.

    • Make-to-Order
    • Repetitive Manufacturing
    • Flow Manufacturing
    • Shop Floor Manufaturing
    • Lean Manufacturing
    more...

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  •  
    Shop Floor IntegrationSAP Component or Feature Available

    SAP xMII enables real-time transactional integration between plant floor and enterprise (SAP ERP) systems out-of-the box through:

    • Universal Connectivity to the data, functionality and processes of existing plant floor systems
    • Business Logic for creating automated events, KPIs and alerts
    • Workflow to synchronize plant and Enterprise business processes
    • Message mapping between MES, SFA, legacy apps. and the ERP system based on industry standards (like ISA-S95, ...)
    • Manufacturing Intelligence: Near real-time analytics engine that aggregates and delivers unified visualization of events, alerts, KPIs and decision support to production personnel.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  • SAP Manufacturing Integration and Intelligence (SAP MII)
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    Supervision and ControlSAP Component or Feature Available

    Manufacturing visibility manages events throughout the production process from release of a manufacturing order through transferring the data to the data warehouse, where it is analyzed. During production, process steps but also exceptions are reported, ensuring a transparent manufacturing process and the possibility to take counter-measures immediately. It is also possible to provide information on events to external parties such as customers, subcontractors or sold-to parties, using various channels to provide the information quickly and to ensure transparency of planned and actual events and to continuously improve the manufacturing processes.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  •  
    Supply Chain Monitoring and ControlSAP Component or Feature Available
    Supply Chain Performance Management (SCPM) enables you to define, select, and monitor key performance indicators (KPIs), giving you an integrated, comprehensive view of performance across the supply chain. SCPM with SAP SCM includes a large number of predefined KPIs based on the Supply Chain Operations Reference model (SCOR) covering all supply chain activities including source, plan, make, deliver, and return.

    This process is supported by the following SAP and/or partner offerings

  • SAP Extended Manufacturing Planning and Execution for IM&C
  •  
    Engineering Change and Configuration ManagementSAP Component or Feature Available
    Tracks engineering changes to the product, due to customer requests or based on technical design changes, during the entire life cycle of an order, beginning with the quotation phase until the start-up. Traces changes and documents them continuously. Includes order-related changes due to changed customer requests reflected by changes to the product configuration or in order bill of material or order routing. Handles changes to master data (such as changes to bills of material) as a result of engineering design changes. Identifies existing procurement elements (production orders, planned orders, or purchase orders) that are affected by an engineering change, and assists in updating those orders.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  •  
    Quality Assurance and ControlSAP Component or Feature Available
    Quality assurance and control involves inspections at all stages, continuous monitoring, and quick intervention to deal with unexpected events. Quality inspections can be triggered by various events such as order release or goods movements, but also by manual actions. To document product quality, certificates can be created.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
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    ShippingSAP Component or Feature Available
    Outbound processing comprises the preparation of goods to be delivered from a warehouse to a receiving location. Outbound processing within the scope of warehouse management typically comprises activities like the notification of goods to be supplied from a warehouse to a customer for which the outbound delivery serves as the reference document, picking, packing, physical goods issue in warehouse, loading, goods issue and goods issue posting to IM, advising advanced shipping notifications to business partners and, obtaining a proof-of-delivery from the receiving business partner.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
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    Assembly & Start - UpSAP Component or Feature Available

    Checks the correct combination of all machines and components during start-up, after the partial components have been checked. Creates activity confirmation in accordance with the contract. Enters technical findings, and deals with measurement documents. Confirms successful start-up with an acceptance protocol from the customer that forms part of the order documentation..

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  •  
    BillingSAP Component or Feature Available

    Initiates billing according to the procedures stated in the order. Allows for both resource-related and fixed price-related billing. Maps down payments appropriately, including those involving security deposits. Creates invoices for partial delivery; for example, preliminary acceptance by the customer following a successful start-up that triggers the payment of an installment as stipulated in the contract. Determines and updates shared overhead costs. Calculates the project's interest rates based on payment and cost information. Determines the costs of sales, and assigns them to the revenues incurred and to the stocks of goods in process or in provision using various methods, including results analysis based on the determined percentage of completion. Creates completion confirmations from all elements of the project within the framework of a central planning and controlling system. Guarantees complete entry of all in-house and external deliveries and services, and avoids double entries.

    This process is supported by the following SAP and/or partner offerings

  • SAP ERP
  • SAP Sales Management for IM&C
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    SAP Product Available Partner Product Available SAP Product Available with Future Releases Partner Product Available with Future Releases Future Focus
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