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Former Member

Variant Configuration for coils sheets industry

Dears,

In a variant configuration for coils sheets industry with MTO, there are six production lines:

1. Pickling

2. Cold Rolling

3. Annealing

4. Skin pass

5. Galvanized

6. Coloring

Every product line manufacturing product with different characteristics:

1. Thickness

2. Surface

3. Galvanization types and concentration

4. Color concentration

How to build BOMs and Routing if every production line delivers a product to the next production line and we can sell the output of every production line.

I'm confused to use variant configuration scenario or material variant scenario.

Regards,

Ahmed Rouby

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4 Answers

  • Best Answer
    author's profile photo Former Member
    Former Member
    Posted on Dec 25, 2013 at 10:20 AM

    Hi Ahmed

    As per your business requirements you should go for Variant configuration.

    Your first step should be to decide & validate the product ( material codes) based on manufacturing products.

    After deciding the product structure, choose the characteristics depending upon product and assign to class in both class type(300 & 023). It would be feasible to use multiple class depending upon the wide range of products you have depicted as you can have option to use different set of characteristics for them.

    Regarding the BOM & ROUTE in such scenario, it is advisable to use material type HALB as it can used in house as well as sold. Try creating different set of material codes to dis-able recursiveness in the material flow.

    Regards,

    Gaurav

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  • author's profile photo Former Member
    Former Member
    Posted on Dec 25, 2013 at 10:53 AM

    Hii Ahmed,

    This kind of scenario is common to Steel Industries and for that first production definition need to be fixed.

    for any family of product, you need to fix which product attribute to be taken into material code and which one to be define in classification.

    Basis for fixing the attributes in product will be as following

    1) APO planning constraint (No of Material Code handling)

    2) level of Information to be working from SAP standard reports like (More the attributes in characteristic less will be the possibility to track and work with standard reports like stock, etc).

    3) To what extent sales person required product to be identified at material code and punch the Sales order with remaining characteristic.

    4) Project master data work and post maintenance. Generally, more the product attribute taken in material code more will be the PP master data and less will be the Object dependency work, same will be with the nature with maintenance like new product introduction.

    5) A business process flow check based upon clear identified input/output materials codes in relation with working rules and process.

    6) Legal requirements of Excise.

    7) Many more depend upon each and every module like SD, MM, CO, Excise etc business requirements

    On fixing the level of attribute coming in product material code, it will come out whether the business is left with limited number of variant or still left with large number of complex configuration. Generally the lesser the attribute taken in material code more will be the probability for variant configurable scenario and vice versa. (This even depend upon APO planning constraint)

    Once the business come out with proposed material definition then business need to identified the Super BOM and Super Routing for each header material having all the possible components and operations and identify the rules based upon product/Header material/parent material characteristic which can trigger correct dependent components and operations in routing. Similarly Super BOM and Routing and rules to be identified for further down the level components as header material . This will result in coming out with blue print of product flow chart for the end to end business process.

    As per my experience in steel industry, business get mapped with variant configurable scenario when APO is part of package and can even go to variant configurable to discrete manufacturing scenario when APO is not part. However it solely depend upon the business requirement.

    Do let us know any question in your journey.

    Regards,

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    • Former Member Former Member

      Hii Ahmed,

      Then holistically i believe the business will find its mapping on either side for its product definition on one end as discrete material to another end as variant configurable. But i belive the varaint configuration map in your business scenario will simplify lot things.

      Going to pure discrete material and considering the attributes like thickness, surface, Galvanization types and Color as part of material code and calculating the combination of material codes. Each of these header material processed from mutually exclusive lot many combination of other material and also from mutually exclusive lot many combination of operation to be calculated and if all these total combination are coming huge than business map will be easier with Variant Configuration in compare to material variant or discrete becasue it will avoid the huge amount of master data work to be handled and manual processing for running the system.

      In order to reduce the unnecessary combination in variant configuration, grouping the attributes which are process independent can be thought. Grouping decrease number of material code and all related work in proportionate like thickness can be categories in ranges with abbreviation like T1, T2, T3... and to be taken in material code so that the cold rolling process only with categories of thickness reduction get mapped without recursive issue. Further grouping help in product diversion during the process.

      Similarly value adding process where attributes like color, galvanization need to confirmed and costing to be seen that cannot be left in characteristic but to be taken in material code for avoiding recursiveness.

      Further the attributes which will be confirmed only once and also related with product main category which is already in Material code can be excluded from material code part and can come in characteristic like galvanized or coloring process is confirmed once and there product main category is also separately part of material code therefore galvanized/coloring can be exclude from material code and can run in characteristic.

      Further business need to check and validate the above material code combination obtained and by properly figure out for its each header material having all the possible components and operations and identify the rules based upon product/Header material/parent material characteristic which can trigger correct dependent components and operations in routing.

      Now such exercise will lead to come up with combination of material codes which are process wise sufficient to give you business tracking map in variant configuration scenario with less Master data and lesser post manual work.

      I hope these will add some value in your quest.

      Regards,

  • Posted on Dec 26, 2013 at 02:09 PM

    Hi Ahmed,

    Variant configuration is the best option to go for,

    You have six production lines means you need to create six work centers in super routing.

    First create detailed product structure at each level . To build an BOM STRUCTURE follow below procedure.

    In your case every production line delivers a product to the next prod line here create super BOM
    FOR all 6 production lines comprising possible components for that Product. If pickling is an product then it will have cold rolling and annealing as component and as per business scenario write dependencies under which condition before pickling, coiling or annealing will be selected.

    1. Assuming fulfilling dependencies, coiling is selected for BOM explosion.
    2. Accordingly in coiling super BOM include annealing or skin pass or coloring as component to be selected based on dependency written likewise till raw material BOM can be build.

    From FG characteristics should be flown from one
    BOM component to other for that write procedures to copy thickness character value from one level to other. Prerequisite could be all characteristics should be in all six product lines class. LIKEWISE MANY BUSINESS SCENARIOS CAN BE BUILD USING PROCEDURES AND CONSTRIANTS AT DIFFERENT PRODUCTLINES.

    Above details answers you’re below query:

    Type: GV1, Concentration: G60, Thickness: 0.8 mm, Weight:
    5 TO, Width: 1250 mm.

    DC01_GV1 need a semi-finished as a variant
    DC01_SK1 with characteristics:

    Thickness: 0.8 mm, Weight: 5 TO, Width:
    1250 mm.

    DC01_SK1 need a semi-finished as a variant
    DC01_NA1 with characteristics:

    Thickness: 0.8 mm, Weight: 5 TO, Width:
    1250 mm, Surface: Super Bright.

    How I build BOMs structures as we have
    configurable materials with super BOM and its variants.

    Super routing can be built on each product line
    with possible all operations required to manufacture it and write dependencies in this operation to be selected at a time under given character value fulfillers.

    PLS REPLY HOPE SO YOUR QUERY SPECIFIC ANSWER IS GIVEN.😊

    REGARDS AND THANKS

    SANKET

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    • hi Ahmed

      your previous query is answered , now you want details to to build procedures and constraints for that create these dependencies and assign them to respective materials.

      for building procedures and constraints pls refer SAP standard LO-VC PDF available on search engines. here entire detials is available from usage you can refer and proceed with same.

      you can close these thread..

      thanks

      sanket

  • author's profile photo Former Member
    Former Member
    Posted on Jan 03, 2014 at 05:54 AM

    hi Ahmed

    pl send your sap process cycle in my email id -naveenmittal29@hotmail.com , i am working in steel industury since 2004.

    thanks

    Naveen mittal

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