Dear Sandeep,
Its really a huge requirement which you are looking for.Anyways I try to explain it in my own ways hope you get it.Please refer the below points.
1) Process Mapping-Take few FG material and try to do analysis of manufacturing process for them.just understand from core team member how they do planning and manufacturing process for FG.Ask them about RM,how they procure it,its UoM,either its procure in batches and all.After that what next process they do after the RM in stock.Please remember you have to create a material master for every part of FG where inventory analysis is done.With out matl code you cant find the stock of particular matl in system.
From PP point of view just think how they consume the RM and how they produce FG. This is will help you mapping the process from RM procurement to FG sales.For each new produce matl code you have to define separate order type.
2) Manufacturing- See as per my understanding,we use discrete manufacturing where the FG can be dis-assembled and again we can to able assemble mostly in automobile industry.The engine can be easily assembled and dis-assembled.In process industry we cant able to dis-assembled the FG e.g medicine or food products.In repetitive,the production go for long time e.g 6-8 months and much more.In your case you can go for discrete manufacturing.
3) Strategy-Please try to understand from core team how they do planning for FG. If they produce FG and kept in stock,they dont care for any customer requirement they you have to go MTS 10 or 11.If they produce against sale order then used MTO-20.Its depends on each material process wise.how they do planning for each process wise output material.You have to do a lot of self study to understand the strategy PIR consumption and all
4) MRP-Through MRP we can able to trigger the replenishment element e.g planned order on pur req.Its depend on on how you do processing for particular matl either inhouse or outsource.You can run MRP at material as well as at plant level also.Its a vast subject.
5 )
my query is client has 18 assembly work station i want to implement routing for that 18 assembly workstation
See first think is that you define routing for material i.e FG or SFG.e.g in 1 work stations you have 10 m/c then try to understand which output you get from which work center.remeber wherever client want to see stock of particular matl that is end of your process.you have to create a material master for that also,dont forget this in your whole life.If the material u get i.e FG or SFG after processing from all this 10 m/c,then you have to create only one work center with description of that line and then assign this workcenter in the routing of this FG or Sfg matl with one operation you peform on this 10 machine.For capacity you can add this 10 m/c in capacity overview of your one work center which is assign to your routing.
In your case I think you have to define 18 work centers for each line with one operation if the operation is not unique for the entire line(10 m/c).If you have multiple operations in one line then you have to create workcenters based on operation sequence.Try to understand my point its really very crucial.
I atleast hope now that you can get a basic idea of how to work out on your requirement.
Please let me know if you have any queries for the same!!!!
All the Best.
Regards.