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Variant Configuration for coils sheets industry

Former Member
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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

Accepted Solutions (1)

Accepted Solutions (1)

Former Member
0 Kudos

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

Former Member
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Dear Gaurav

Thank you for your response, we have for example a product DC01_GV1 as a variant with characteristics:

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.

Regards,

Ahmed Rouby

Former Member
0 Kudos

Hi Ahmed

Below mentioned steps may be useful to you:

  1. Create Class for GV with types ( 300/023) & assign characteristics : Type, Concentration, Thickness, Weight , Width  to the both types  & assign this class to material the DC01_GV1.
  2. Create Class for SK with types ( 300/023) & assign characteristics : Thickness, Weight , Width  to both types & assign this class to material the DC01_SK1
  3. Create Class for NA with types ( 300/023) & assign characteristics : Thickness, Weight ,Width & surface & assign this class to material the DC01_NA1.
  4. Now create BOM for DC01_GV1 and assign DC01_SK1 as component.
  5. Now create BOM for DC01_SK1 and assign DC01_NA1 as component.
  6. No check the results in CU50 as per attached screen shot ( Please ensure you have maintained configuration profile for all configurable materials)

You can maintain single class for all the three given materials & characteristics values can be controlled using VC rules (If you don't want to maintain three classes)

For your concern regarding SUPER BOM, it is maintained only when one or more out of many inputs is used for production/planning & predefined rules are available for selection of these components.

For the case of one to one relationship , there is no need to maintain SuperBOM.

Regards,

Gaurav

    

Former Member
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Hi Gaurav

Do you means that if I've a group of thickness under one material code (With Batch Characteristics) to manufactured a product with different thickness also under one material code, we do not need to create a super BOM and just control variants with variants characteristics.

Regards,

Ahmed

Former Member
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Hi Ahmed

Rephrasing your words, lets have a material A which can be used to manufacture material B.

There is one characteristic 'THICKNESS' NUM format which is assigned to class say "C" (Both 300 & 023) & this class C is assigned to both the materials A & B.

To produce A with different thickness values from material B with different values, there is no need to create a super BOM. Just create normal BOM & assign a dependency(transfer procedure) for thickness flow in BOM component B from header material A.

Hope this will help you. Please come again if you have more query or if I didn't understand your latest point.

Regards,

Gaurav

Former Member
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Hi Gaurav

If I used HALB materials, and after the production line finished the first product what is the valuation class will assigned on material master.

Regards,

Ahmed

Former Member
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HI Ahmed

Go to t code OMSK where you can maintain valuation class .In order to maintain valuation class for  HALB material type u need to assign account reference (0008  - Ref. for semi finished products) to the valuation class you created.

Regards,

Gaurav

Former Member
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Hi Gaurav,

Thanks for support,but I've get another requirements if product product DC01_GV1 has different characteristics like:

Type: GV2, Concentration: G120, Thickness: 1.2 mm

I wander that still solution as it.

Thanks you for helpful support


Regards,

Ahmed

Former Member
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Hi Ahmed

Yes, The solution will remain same for different combinations of char values.

Regards,

Gaurav

Answers (3)

Answers (3)

Former Member
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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

former_member213946
Participant
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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

Former Member
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Hi Sanket,

Thank you for your reply, how can build using procedures and constraints at different product lines.

Regards,

Ahmed

former_member213946
Participant
0 Kudos

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

Former Member
0 Kudos

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,

Former Member
0 Kudos

Dear Vishal,

Thank you for that information, but we take about APO SAP component that not applied for our solution.

how can we deal with it without APO.

Regards,

Ahmed Rouby

Former Member
0 Kudos

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,