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Rejected finished goods reprocessing

Jul 15 at 09:55 AM

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Hi Sap gurus,

I am new in PP and Need your advice how to map this scenario as per best practice of SAP.

We are a paper manufacturing company and have in house production of both semi-finished (jumbo roll) and finished goods. Finished goods are produced in batches from jumbo roll by trimming it into different sizes as per sales orders.

QM module is involved in our scenario and using inspection type 04. Whenever batch is rejected from quality department they do return delivery while making usage decision which uses movement type 122 and stock disappears from system.

But physically stock exists and is used again in Manufacturing process of Semi-finished Products.

How can we map this rejected material to use again in manufacturing of S.f in SAP? One way is to use this Finished good in bom of S.F but management wants to see the Loss of this rejected material in different account?

Thanks in Advance.

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8 Answers

Amit Sharma Jul 17 at 12:11 PM
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Hi,

Kindly go through below blog

https://blogs.sap.com/2013/07/06/rework-in-manufacturing/

Regards,

Amit

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Thanks.

I think with co07 we can not achieve in our case because we can not distinguish our product after reprocessing as it gets mix up with the raw material of Semi finish good (bulk material). That's why i am looking for suggestion.

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Hi,

As told by you can Process FG in SFG order by creating a new process order type for reprocessing.

Regarding Value posted to different account, you can create a new settlement profile by doing that whole settlement on G/L account and then this New G/L account by putting that in process order in settlement rule. Kindly take help of your Costing consultant.

Regards,

Amit

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Hi thanks for your feedback.

Our rejected quantity is not saleable. Its like a scrap which is reprocessed again. I am attaching a screenshot of the process for your better understanding.

How can we map this rejected material in sap?

I do appreciate your cooperation.

Regards,

capture.jpg (146.8 kB)
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Hi,

The batch C of FG which is rejected , You want that to put in Scrap and then reuse it/ sell ?

Or you want to use it again in SFG and do the process again ?

Please clarify process with business

Regards,

Amit

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We are using it again in SFG BOM. And process runs again.

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Jürgen L Moderator Jul 17 at 11:24 AM
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The movement type depends how you define "rejection" . also it is unclear if you use QM module

Usually the goods are there, they sit in the warehouse while you inspect the quality. And if the quality is not good then you either post it to blocked stock or in case you have batches with status management then you post it into restricted use status.

Restricted use makes it easier to move and rework the product as you do not need to transfer it into unrestricted use before consuming it in a rework process.

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Thanks for your support and the possible procedures i came to know for reprocessing are.

1. Using the same material again in the BOM of S.F product.

2. Material to material transfer.

What would be the implications in second case?

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the second case has no link to a rework order, it does not reflect any costs that you have when reworking the item. it is a second process. If you use production orders to manufacture the material then you should also use it to rework it. You probably use it on purpose to better plan the capacities and requirements, to get your costs etc etc. All this is not covered by a simple MM transaction. We locked this material to material transfer already many years ago as it allows to make an elephant out of a mouse.

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SAP New Jul 17 at 02:30 PM
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Hi thanks for your feedback.

Our rejected quantity is not saleable. Its like a scrap which is reprocessed again with BOM of semi finished. I am attaching a screenshot of the process for your better understanding.

How can we map this rejected material in sap?

I do appreciate your cooperation.

Regards,

capture.jpg (146.8 kB)
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raju 123 Jul 17 at 02:35 PM
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Hi, You can define Batch C as bi-product and which will be part of bom of other finished products.

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Batch 3 becomes BOM of Semi finished material not the Finished one.

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SAP New Jul 16 at 05:53 AM
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Dear experts,

Waiting for your opinions.

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better tags would be an option to speed up the process of an answer.

Do you know what a Rapid Mart is (the main tag that you used)

SAP BusinessObjects Rapid Marts packages are blueprints for building data marts with SAP BusinessObjects technology: • Data Services • Universe Designer • Web Intelligence. Rapid Marts packages deliver jump-start ETL (extract, transform & load) mappings, schema, and initial reporting content, accelerating the deployment of BI (business intelligence) for enterprise applications from SAP, PeopleSoft, Oracle, and Siebel.

It does not look like your question is related to that, rather to MAN Production Planning (PP) or PLM Quality Management. 122 is certainly a totally wrong movement type in an inhouse production scenario.

Please click the Actions icon and then EDIT to the right tag.

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What would be the accurate movement type and how can we treat rejected goods movement in such scenario?

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Thanks for your guidance. Actually i posted question here first time and also searched about it before posting. At first instance i used MAN Production Planning (PP) but did not get any reply so changed to this one.

Changing tags again. Thanks.

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Arijit Banerjee Jul 17 at 01:49 PM
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Form quality management prospective please use MvT 349 / 350 + Inspection type 08 to control the rejected inspection lots to be reposted back to quality and repeat the inspection testing, till you get the quality after re-processing is satisfactory. Please go through Brahma's document and that will explain you in details what needs to be checked and validated.

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Craig S Moderator Jul 19 at 04:32 PM
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Are you using batch status?

If rejected, the stock should have a rejection UD code that posts to "Unrestricted stock, restricted batch status". This is set up on the UD code in the selected set configuration.

Batches with a restricted batch status can be selected and consumed as inputs to the process orders. But restricted batches normally cannot be put against a sales order for sale to a customer. To make sure, you can always add a batch search strategy in SD that includes the standard SAP batch characteristics LOBM_ZUSTD.

This would all be standard SAP.

Craig

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shailesh mishra Jul 18 at 09:10 AM
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Hello

You can think to valuate each batch with concept of Split Valuation. Your FG will be marked with valuation category as X and each batch of FG to be produced will carry batch specific Accounting view. Say the rejected Batch C will have its batch price stored. Now, you may conceptualize to make a production version which will have a Alt BOM 2 having Batch C material and raw component 3 which will be called upon while creating a production order having settings done in order type dependent parameter and in material master mrp view 4. You can track the incurred value of Batch C will a separate order type.

Best regards

Shaiilesh Mishra

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