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rework and reuse of components

Hello,

I have following scenario , need your views and guidance for configuring the same.

We are using production orders. The process has got rejections. Rejected materials are moved to repair area.The components which can be reused, are taken back to production.If the rejection is because of machine defect, the same is scrapped , else the product is sent back to vendors.

Large amount of machine scrap is generated during operation, is collected and sold out.

Please let me know the consideration used for configuring the above scenario.

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4 Answers

  • Posted on Sep 08, 2007 at 08:31 AM

    Hi Ravindra,

    1. You can create a rework orders for the material to reworked through trigger point assigned to the operations. So that whenever you confirm the operation with the rework quantity to which the trigger point is assigned, a rework order is triggered. Later you can process the rework order and while confirming accordingly you can scrap or put in unrestricted use.

    2. If you know that after a particular operation the rework is needed, then create a rework operation in the routing itself, with control key as rework operation.

    3. You can even plan the scrap quantities in the Material master and BOM prior to the planning and the execution if you know the probable percentages to be scrapped for components and the assembly.

    4.If large quantity of scrap is generated, than you can plan for the by-product as well.

    You can follow any one of the above.

    Reward if cleared and close the thread.

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  • author's profile photo Former Member
    Former Member
    Posted on Sep 08, 2007 at 08:44 PM

    Dear.

    As I understood the scenario

    You produce product A using B an C.

    When you prodiuce 100 TO, let us say 20 got rejected.

    20 pieces are taken to repair shop. After analysis you found that 5 are because of

    machine fault and 15 because of vendormaterial fault and will be sent back to vendor for replacement. The rest 5 peises are dismantled and the component B and C are sent back to stores for reuse.

    If the case is so,

    then proceed as below

    Activate QM in material master with insp type - 04

    Create a production order for 100.

    Confirm the qty for 100 and fo the GR.

    System will create a inspection lot.

    let us say 80 pieces are good other 20 pieces are rejected, in the results recording create a notification in which you mention defect qty is 20.

    In notification processing analyse the qty which are to be sent back to vendor and which are to be scrapped.

    Cose the notification and do the UD, in UD stoclk posting post the stock of 80 to unrestricted stock, 5 to scrap and 10 to blocked stock.

    Create a rework order in CO07 - Without Material refereing to the original order and issue the main material from blocked stock and make a by product (B and C) and do byproduct GR to stock (B and C) and issue the main prodeuct from blocked stock.

    I hope if you go through the solution and find nay problem please write back

    Then issue the

    then in the UD stock posting

    enter the stock of 80 to unrestricted stock and other 20 to scrap

    as keerthi explained use trigger point, can go through the link for more information

    http://help.sap.com/saphelp_47x200/helpdata/en/a5/63198843a211d189410000e829fbbd/frameset.htm

    If you want to seperate the rejected

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  • author's profile photo Former Member
    Former Member
    Posted on Sep 08, 2007 at 08:45 PM

    Dear.

    As I understood the scenario

    You produce product A using B an C.

    When you prodiuce 100 TO, let us say 20 got rejected.

    20 pieces are taken to repair shop. After analysis you found that 5 are because of

    machine fault and 15 because of vendormaterial fault and will be sent back to vendor for replacement. The rest 5 peises are dismantled and the component B and C are sent back to stores for reuse.

    If the case is so,

    then proceed as below

    Activate QM in material master with insp type - 04

    Create a production order for 100.

    Confirm the qty for 100 and fo the GR.

    System will create a inspection lot.

    let us say 80 pieces are good other 20 pieces are rejected, in the results recording create a notification in which you mention defect qty is 20.

    In notification processing analyse the qty which are to be sent back to vendor and which are to be scrapped.

    Cose the notification and do the UD, in UD stoclk posting post the stock of 80 to unrestricted stock, 5 to scrap and 10 to blocked stock.

    Create a rework order in CO07 - Without Material refereing to the original order and issue the main material from blocked stock and make a by product (B and C) and do byproduct GR to stock (B and C) and issue the main prodeuct from blocked stock.

    I hope if you go through the solution and find nay problem please write back

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  • author's profile photo Former Member
    Former Member
    Posted on Sep 10, 2007 at 08:13 AM

    hi there ,

    for scenario u r talking about , u can use the trigger points that can be used to trigger a function . in u r scenario c can create a reference operation set and assign it to trigger points & assign the trigger point to the operation which generate she scrap , when during the confirmation of operation if u have generated the scrap(u define that rework orderis generated if reason for variance ) , the system will automatically cretae rework order. the reason for variance is used to define the reason for producing less quantity .this reason for variance is used to trigger the rework order .u can settle this rework order cost on to the machine when setteling the the rework order .

    or u can keep the scrap material in to scrap yard that u define . collect the material over there . then create a production order with out material (co07 ) assign the material to order to comp allocaton .

    bring the material to production area thr respective movement type , carry out the inspection if the material is to be reworked rework it by specifying the opertaion that is required here only or u can post the good useable material to stores , during the confirmation by clicking to material movement tab page &scrap back to scrap yard .

    please check

    if not satisfied revert back

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