Material consumption is wrong as compared to BOM

[Former Member]

Hi experts,

Here is the problem I am facing:

100 product A has been produced, in MB51 enter the material No. and order no., select movement type 131, it appears 100 material documents have been created. Material B is a component of product A as configured in BOM, in CS12 you can see component quantity 2 for each product A. Come to MB51 again, enter material B and select movement type 261 and the same order no. , the material documents created is not 100*2=200.

Please can any body suggest what is the reason here?

Thanks

Danny

[tomas_talpa · Accepted solution]

Hello Danny,

please check the transaction/report COGI "Processing goods movemnts w. errors" -- here you could see any GIs which system tried to post, but failed for any reason.

Also -- depending on the PP configuration, users are/could be allowed to modify the components quantity during operation confirmation. Check it with your PP colleague.

Kind Regards

TomT

[Former Member · Accepted solution]

Hi Tomas,

Thanks for your answering. Actually I was thinking if this is a normal function of SAP system since the component material received from warehouse may be broken or unqualified and in that case more materials are rquired, if this is not the case then how does the system deal with the unqualified materials which I believe is unavoidable.

Thanks Danny

[tomas_talpa · Accepted solution]

Hello Danny,

the question "then how does the system deal with the unqualified materials" can be interpreted as "how can I report this", right?

Check the transaction COOIS "Order Information System", where the "Component List" will give you a comparison of Quantity Required vs Quantity Withdrawn; also, you can use LIS transaction MCRE (fed by infostructure S026, you might need to activate it).

Kind Regards

TomT

[Former Member · Accepted solution]

Hi Tomas,

Thanks for your kind reply.

I checked in COGI there indeed were error records for some of the components, one material had total 228 PC with error and that means the 228 PC were not consumed, and in MB51 it matches.

In the above situation, the component were consumed less than the amount required.

But my problem is that there are components which have been consumed more than the required amount as per BOM, and in COGI there are not error records for these components.

Best Regards

Danny

[Petepall · Accepted solution]

Please check in the material master MRP view if there is no component scrap defined.

If there is a percentage assigned for components scrap then your consumption for this part will be higher by the percentage that is defined.

[Former Member · Accepted solution]

Hi Peter,

There is no component scrap defined for the component material, please see the attached screenshot "MM03".

Regards,

Danny

[Former Member · Accepted solution]

Hi Tomas,

The MB51 report are generated by a cost collector (in the "order" field of selection screen), not by production order. therefore I have no idea as to what production orders are involved.

Thanks

Danny

[ajitkumar · Accepted solution]

DO you have any component scrap or operations scrap defined in bom?

why dont you check the documented goods movement in the order?

[Former Member · Accepted solution]

Hi Ajit,

Where can I check the component scrap or operations scrap defined in BOM? I checked in the material master there is no componnet scrap for the material, where else should I check?

Thanks

Danny

[kailas_ugale]

Hi,

Come to MB51 again, enter material B and select movement type 261 and the same order no. , the material documents created is not 100*2=200.

If its not 200 then how many system has created 100 ? or 1?

Regards

Kailas

[Former Member]

Hi Kailas,

Actually this is just an example, the real situation is as follow:

Explode BOM for material A (finished product) in CS12, you can see many components with their quantity, e.g. component B with componnet quantity 2, that means producing one material A requires two material B.

Go to MB51, enter material A, plant C, movement type 131, order no. (this order is a cost collector not production order) and posting date 01.01.2013 - 04.04.2013. then generate the report, total quantity of material A is 2360. 

Go to MB51 again, enter material B, plant C, movement type 261, order no. and posting date 01.01.2013 - 04.04.2013, total quantity of material B is 5035, while it would supposed to be 2360*2=4720 as per BOM.

So where from are the additional 5035-4720=315 ?

Regards,

Danny