Production order for a multiple materials codes...

[Former Member]

Dear...

Could you please suggest me the SAP solution for the below production strategy.

This production process is of heat treatment. Actually I am doing heat treatment of Cast and Forge items. These items weights are in the range of 150 kgs to 40000kgs. For example I am having a 40 tons heat treatment furnace. So at a time I can load the materials upto 40 tons. I am having different materials of different sizes and chemical compositions. But heat treatment cycle(Routing) is same. So I can load different types of materials i.e. upto 40tons for the heat treatment for which same type of heat treatment is required. Sometimes this may be a single item .. if the weight of the items is 40 tons. If it is single item...then there is no problem. If I am loading different items...and if execution process is same for all the items, then how can I map this in the SAP. So that I can create a single order for different Items of different materials and quantity. I need to do the confirmation of these items with respect to the same item. Please suggest me...how can we map this scenario into the SAP.

Thanks in advance.

Regards,

Surya.

[Former Member]

hi suryanarayana,

as our member suggested you can make use of batch concept. maintain external batches, suppose you are processing 40 tons of different materials physically but in the system you place differnt orders for different materials with reference operation sets and give same batch number for all these orders so that tracebility will be there for these 40 tons as one lot.

regards

Robert

[Former Member]

Dear Robert,

I can not go for different order and batches. Because I can not go for the schedulling, capacity calculation...even data entry for the order will be more. One more thing ... all these materials are already having batch numbers for the inspection purpose. So I can not assign one batch number here....

Regards,

Surya.

[Former Member]

Hi surya,

As per the heat treatment process concern, total cycle time is constant, and load is also constant (if we havenot changed).

i hope u have defined workcenter formula and routing accordingly.

i think creating single production order for multiple material is not possible, instead of thsi, i would suggest one way,

> Since u have to maintain stock for Heatreated items, create sepearte Material code for each item to be heatreated.

> Create BOM ,Routing for New Material code.

> Acitvate Batch management for New Material Code has been created.

>Now create Production order for each material to be processed in one cycle, Assign the Batch Number manually.Batch number repersents your Heat treatment cycle number and same can de used for traceability.

>Confirm the each order seperately, Now the Heatrement process cost will be updated and stock will be posted to heatreated storage loaction.

But i am worrying about capacity planning and scheduling, For my knowlegde purpose i would like to know your existing scenoria, like workcenter formula and routing operation values has been assigned , if u wish plz share with us.

Please come back with your ideas..

regards

Pradeep

[Former Member]

Hi Surya,

One way is that you create a material " Weight" common to all your ingots.

Further you can differentiate by activating batches, like "Forgex123" and "Cast234" etc.

Hope this will serve your purpose.

Regards

Krishna

[Former Member]

Dear Krishna,

Please note that I can not segregate based on the same material code and weight. I can load upto Heat treatment furnace capacity for which same heat treatment cycle is required... So routing group, I can define based on the type of heat treatment cycle. My problem is...how can I create production order. I need a single order for multiple material headers. Please note that header material codes are differrent and output material codes are different. If I am placing 4 rolls for heat treatment...all the four rolls will have different material codes before and after heat treatment cycle. I hope I clarified ... if any further clarification is required, please let me know....

Regards,

Surya.

[former_member196398]

Surya,

Just a basic question, is heat treament considered part of the operation for a material? or is it process on its own and material number is changed after Heat Treatment? Menaning If I input material A then I get Material B after Heat Treatment, in this case only you can think of Prdn Order.

looks like input is not fixed, so we cannot have a BOM and Go for Co-product scenario. let me think..

Pls explain,

Regards,

Prasobh

Comments added.

[Former Member]

Dear Prasobh,

Actual process is heat treatment and induction hardening. After this process, machining is required. Here heat treatment and induction hardening process are for a group of items based on the capacity (weight). But the machining is for the individual item i.e. based on the dimensional requirement from the drawing. So I am planning for a separate material codes for before and after heat treatment. But all these group items which were selected for the same heat treatment cycle...need to have separate material codes because of dimensional & chemical compositional differences. I hope I clarified...if any further clarification is required, please let me know.

Regards,

Surya.

[Former Member]

Surya,

Create a production order for each material with Heat treatment as an operation in it.

Sumeet

[former_member196398]

Surya,

If your group of items is fixed meaning combination of materials and qty, then we can think of using co-products scenario. Pls explore using Co-products option, so that one order can give multiple outputs and the cost also can be splitted against the outputs.

Regards,

Prasobh

[Former Member]

Hi Surya,

Create Production Order for one finished product ( major output one ) and the rest of the finished products as CO-PRODUCTS.

EX: Creat Prod Order for : XFIN

Maintain these in the Production Order Component Overview:

Co- Products: YFIN ( quantity followed by '-'ve sign )

: ZFIN ( quantity followed by '-'ve sign )

COMPONENTS : XRAW ( consumption qty)

YRAW ( consumption qty)

ZRAW ( consumption qty)

Regards

Krishna

[Former Member]

Dears...

I can not group the materials and I can not define them as a co-product.....because combination is not fixed. There can be N combinations are possible.

I am trying the below scenario...please validate and let me know the implication from your side. Still I have not validated this from the CO view.

I will define the Reference operation sets based on the type of HT cycle and based on the furnace and capacity. That mean operations are fixed. I will create HT order without reference to any material (transaction CO07) and based on the reference operation set. Manually I will input the material codes as components and manually I will input the output material codes also as byproduct. So that I can issue and receive the materials with reference to the order. And I can schedule the order. Here the settlement need to be done based on the individual weight of the peice. This I need to check with CO.

Please validate this from your side and let me know your feed back please...

Regards,

Surya.

[former_member196398]

Surya,

Settlement cannot be done directly with respect to the individual outputs, but the order can be settled to an Internal order. The query here will be how to transfer the Heat Treatment cost back to the Product or Individual/Materials.

Regards,

Prasobh

[former_member698542]

Hi,

You can't create single production order for many maerial.

But you can create Reference Operation Sets for the items which will be kept in the furnace for same kind of heat treatment.

Thanks and regards

SAN

[Former Member]

Dear

My problem is not routing... my problem is order and order confirmation.

Regards,

Surya.