Lunch & Learn Recap: SAP Manufacturing Showdown: Process vs. Discrete

Presented by: Jason Craig and Karla Uys

If you’ve ever wondered why making a bottle of soda is nothing like building a car, welcome to the world of Process vs. Discrete Manufacturing. While both fall under the manufacturing umbrella in SAP, they operate very differently and knowing which one fits your production style can make a world of difference.

Let’s dive into how these two manufacturing types stack up, where they shine, and how SAP supports each like a champ.

🏭 Discrete Manufacturing: Think Pieces, Parts & Precision

What it is: This is your go-to method when you’re building stuff you can count, literally.

• Examples: Cars, laptops, toys, pumps, engines

• Style: One unit at a time, clear-cut processes

• Storage: Not a lot of “in-between” products, parts go from A to B to finished item

• Production: Based on individual orders (build 100 computers, not 100 liters)

In a nutshell? It’s like building LEGO sets, every part has a place, and every set ends up the same (mostly).

🧪 Process Manufacturing: Welcome to the World of Batches, Blends & Beakers

What it is: This type is all about recipes and formulas. You're not assembling parts, you're transforming materials.

• Examples: Paint, beer, shampoo, fertilizer, medication

• Style: Liquid, flowy, sometimes smelly, but very precise

• Storage: Bulk materials and intermediate storage are the norm

• Production: Batch or continuous process; recipes rule everything

  
  

In a nutshell? It’s like baking a cake in a lab, exact measurements, strict rules, and a clean-up required between every batch.

⚙️ Functional Face-Off: How They Work in SAP

Aspect	Process Manufacturing	Discrete Manufacturing
Production Style	Batch or continuous	Piece by piece
Order Type	Process Order	Production Order
Instruction Set	Recipe + Formula (like cooking)	BOM + Routing (like building IKEA)
Traceability	Batch-based (track every batch)	Serial-based (track each unit)
Output	Variable (due to yield differences)	Fixed, countable units

🧰 Behind the Scenes: What’s Happening Technically?

🔧 Execution & Tools

• Process: Uses PI Sheets and Execution Steps for instructions like “heat to 85°C” or “weigh 45.5 mL of acetic acid.”

• Discrete: Same tools, but used for things like “verify label” or “confirm packaging.”

🧪 Operations in Action

• Process: Mixing, sterilizing, sampling, heating

• Discrete: Assembling, scanning, counting, labeling

📏 Standard Values

• Process: All about the environment, temperature, pressure, time

• Discrete: Focused on time and labor, machine hours, shift duration

🍫 Real-Life Examples

Use Case	Discrete Example	Process Example
Label Check	Scan barcode on a tablet box	Not usually needed
Ingredient Weighing	N/A	Weigh 32.2g of citric acid before mixing
Output	5,000 assembled devices	2,500 liters of energy drink (variable yield)
Clean-Up	Optional between runs	Mandatory to avoid contamination

🎯 Flexibility vs Control: Who Wins?

• Discrete Manufacturing is super flexible. You can reuse routings and adjust instructions easily. Great for product variety.

• Process Manufacturing is stricter. Recipes must follow tight rules, especially in pharma or food. Not as flexible, but ultra-consistent.

🏁 Final Thoughts: Which One Fits You Best?

If you're building countable things like phones, pumps, or scooters, Discrete Manufacturing is your jam. If you're blending, mixing, or producing anything that flows or foams, Process Manufacturing is your best bet.

Both are powerful in SAP, the trick is knowing which one matches your production style and industry needs.

👋 Ready to Build Smarter in SAP?

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