Assembly Scrap Calculation

Hi all
We are using assembly scrap scenario. To produce 3900 finished goods we have to start by producing 6000 and becaus of scrap end up with 3900. The scrap is 6000 - 3900 = 2100. We can achive this by putting a assembly scrap factor. The calculation would be 2100/3900 = 53.84615385 % will be the scrap factor. Now we will have to round this to 53.85 in SAP. Is there a way that the assembly scrap factor could be calculated in a way where 3900/6000 = 60% . This way I get a nice round number instead of 53.85
Any thoughts on this
thanks a lot

Hi John,
Donot calculate your %rejection on the basis of single reading...it should be calculated on the basis of you historical readings database...it is not necessary that everytime scrap will be 2100 pcs to produce 3900 pcs it may vary accordingly you % will also vary...so you should take mean of thease and decide the scrap % system will automaticaly plan that many additional pcs in planning run...
i.e. If your assembly scap is 55%and you want to produce 4000 pcs then 0.55*4000=2200 additional pcs are req. means actually you need to produce 6200 pcs.likewise everytime system will calculate scrap you just have to enter your req. qty.
where as %scrap fig can be kept on higher side as well lower side depending upon your tolerance limit and safety (buffer) stock if you maintain.
Regards
Hemant gadhari

Similar Messages

Difference between assembly scrap and component scrap

Dear All,
What is the use and difference between assembly and component scrap ?
Regards

Dear,
Please go through this page, you will understand clearly
http://wiki.sdn.sap.com/wiki/display/ERPLO/Scrap+Calculation
if satisfied, plz close all your other open threads too. Thx

BOM is with Assembly scrap

Hello
When we create BOM , CS01 and Expolde in CS11
then i want the scenario like Components 10% scrap and assembly is 25% scrap
these Copmponents scrap field is in MRP 4 view and assembly Scrap field is MRPview
what is the use of these field and when we will use these field s
plz explain me with one exapmle.
iam very greatful to those persons who give me answer.

Suggest you take help by pressing F1 on the Components scrap in MRP4 view of material master and follow the example given in the help, there is also a hyperlink to the documentation for this indicator. I am copying the same for you ref:
Indicator: Net scrap 
Definition 
This indicator determines whether scrap for the component is calculated on the basis of the net required quantity (the required quantity without assembly scrap from the material master record). 
Procedure 
- You must set this indicator if you want assembly scrap to be ignored.
- You must set this indicator if you enter operation scrap .
 - You can set this indicator if you only enter component scrap, to
 calculate scrap on the basis of the net required quantity for the
 assembly.
Examples 
Bill of material:
- Assembly MAT-1:
- Required quantity 100 pieces
- Assembly scrap 2%
- Component MAT-2:
- Component quantity 100 pieces
Depending on the applicable scrap and the net indicator, the following 6
 quantities are required for component MAT-2 for a required quantity of
 100 pieces of MAT-1:
1 2 3 4 5 6
 Comp 5% - 5% 5% - -
 Op. 6% 6% - - - -
 Net ind X X X - - X
Qty 11130 10600 10500 10710 10200 10000
Key
Comp Component scrap
 Op. Operation scrap
 Net ind Net indicator
 Qty Quantity calculated for component MAT-2 in pieces
Hope this will provide you a complete insight on how the scrap indicators in material master and Bill of Material work in relation to planning of the materials

Sap pp - Scrap Calculation

Hello SAP-Guruu2019s
Can anyone tell me How Scrap Calculation is performed or maintained in PP.

HI,
Calculating Scrap
Use
You can calculate and plan the scrap quantity that will result from production. These scrap quantities are then included in the planning run and in the calculation of production costs.
Prerequisites
Which calculation the system uses depends on the settings in the material master record or in the BOM.
Features
The scrap quantity is settled against the net requirements quantity.
Three calculation procedures are supported by the system:
Assembly scrap
Component scrap
Operation scrap
Assembly Scrap
Use
You use this function to plan the scrap that results from the production of an assembly.
Prerequisites
You have maintained the assembly scrap in the material master (MRP 1 view) as a percentage in the Assembly scrap field for the assembly header material.
Features
The system automatically increases the quantity to be produced by the percentage of scrap.
However, the system always uses the estimate yield for the availability calculation for the assembly. Furthermore, the estimate yield of the assembly is always displayed in the MRP list or in the stock/requirements list.
Assembly scrap increases the order quantity of the assembly and subsequently increases the order quantity for corresponding components. The dependent requirements of the material components are therefore increased correspondingly.
Example
Estimate yield
200
Assembly scrap
10%
This results in a scrap quantity of
20 pieces
and a required quantity of
220 pieces
Component Scrap
Use
You use this function to plan the scrap of a component that may break during production of an assembly.
Prerequisites
You have entered values for calculating component scrap in the material master or the BOM:
in the BOM on the Item Detail Screen: General Data (data block for quantity data). This component scrap is only relevant for the individual BOM.
in the material master (view MRP 4) in the Component scrap field. This component scrap is relevant for all BOMs.
The component scrap quantity maintained for a material component in the BOM has the higher priority.
Features
Component scrap increases the dependent requirements quantity of the component.
If a scrap quantity was planned for a higher-level assembly, assembly scrap and component scrap are added to the component level.
Example
Estimate yield
200
Assembly scrap
10%
Component scrap
10%
This results in a scrap quantity of
42 pieces
and a required quantity of
242 pieces
Operation Scrap
Use
Before high-value components are built into an assembly, the system carries out a quality control check of the assembly, if necessary. Faulty materials that were taken into account in assembly scrap are not passed on to the next operation. They are removed.
Therefore, for a high-value component, you plan using operation scrap instead of general assembly scrap.
Prerequisites
You have maintained the operation scrap in the BOM, on the Items Detail Screen: General Data, under quantity data. You must also set the operations scrap net indicator at the same time.
Features
This scrap quantity refers to the quantity of one component that is to be processed in an operation meaning that the planning run is more exact and you can determine service and quantity consumption more precisely.
I
f the component is contained in an assembly, for which an assembly scrap quantity has been maintained, the system only takes the operation scrap into account.
The net indicator instructs the system to calculate the component operation scrap without taking assembly scrap into account (net usage scrap).
You should also set the net indicator, if operation scrap has not been maintained and assembly scrap has been entered. The assembly scrap should not, however, be taken into account.
Example
Quantity to be produced (required quantity)
1,000 pieces
Assembly scrap
10 %
Component 1
Operation scrap
No entry
Net indicator
Not set => assembly scrap is taken into account
=> Scrap quantity
100 pieces
Component 2
Operation scrap
1%
Net indicator
Set => assembly scrap is not taken into account
=> Scrap quantity
10 pieces
Before component 2 is built into the assembly, the incorrect assemblies are rejected and the system only takes the smaller operation scrap quantity into account. Therefore, component quantity of component 1 refers to 1,100 pieces to be produced; and the component quantity of component 2 refers to 1,010 pieces to be produced.
HOpe this helps.
Regards,
Tejas
Edited by: Tejas Pujara on Sep 26, 2008 8:26 AM

Std. report for scrap calculation......

Hi!
I want to generate a Scrap report for production order.
The requirement is system should display operaton-wise scrap and its cost. It should consider all material cost & activities cost (labour& machin)required for that operation & generate a overall scrap price.
Is there any standard report available in SAP?
OR any other way to get this report?
Please answer this, If u have any idea.
Thanks,
Pankaj.

I think you need to revalidate the Requirement Since.
1.Scrap is generated during a Goods is produced / Processed.
2.So in this case we have a wastage of material..only this material cost has to be calculated or accounted.
3.The operation cost and activity cost etc should be accounted for the Finished goods ,which is already done by Cost collectors -Say Production order.
May be you have a specific requirement.But the Approach towards the process (SCRAP calculation) has to be revisited.
since for a SCrap material called -x and qty called 2kg.the operation time or the acitivity time cant be calculated easily as this has scrap can be generated because of 1 hr of m.c operation or 10 hr of m.c operation..
Lot of factors like
>M/c Efficiency
>Rawmaterial Quality
>operator efficiency
lot of factors would be there
So better to revisit the requirement

Report for the list of materials with component & assembly scrap

Dear Experts ,
I have been told to generate a report for the materials which are subjected to component and assembly scrap . Please guide me for the same . Many thanks in advance.
Yours
Aman Khan

Dear Aman,
It you are maintaining both assembly scrap & component scrap both in MM you can read MARC table by creating simple query.
Read Field MARC-AUSSS & MARC-KAUSF.
If you are maintaining component scrap in BOM item read STPO-AUSCH.
[Query Creation|How do create query in SAP?]

Transaction Type 'WIP assembly scrap' in Onhand, Availability/Available to Reserve/Available to Transact

Transaction Type 'WIP assembly scrap' in Onhand, Availability/Available to Reserve/Available to Transact
Dear All,
Version: 12.1.3
Problem Description/Question: A Item shows different quantity in Inventory > Onhand, Availability/Available to Transact/Available to Transact
total quantity = 1000
available to reserve = 800
available to transact = 800
Find quantity = 200 exists with Transaction Type = WIP assembly scrap
***Question: For Transaction Type = WIP assembly scrap, whether it is availble for Reserve and Transact?
Any response could be appreciated.
Regards,
Joy

Hi,
Your finding is correct.
As "WIP assembly scrap" transaction for 200 qty. system will not allow to reserve the same stock qty again.
200 qty Stock is reserved.
Available to Reserve: The available quantity of an item you can reserve across an organization.
Available to Transact: The available quantity of an item you can transact across an organization
Thanks
NS

CK11N - How to exclude assembly scrap factor from Cost estimate

Dear Experts,
We have assembly scrap maintained in the material master. We also have operation scrap in the routings.
During the Cost estimate runs, we just want the system to consider the Routing operation scrap. I know one solution is just to remove the assembly scrap from the material master. However, we can't do this since it can adversely impact our MRP runs.
Does anyone has any idea on this?
Thanks and regards,
Vishal Thakur

hi vishal,
if you want to exclud the material fromt the cost estimate here is the short cut .
go to the material master of the material which you dont want to be costed
go to the costing views and flag the dont cost check box in that views
Best Regards

Dynamic Assembly Scrap

Hi,
Our client is having an agreement with customer that goods can be delivered more than order quantity on certain percentage (based on lot size)
order is 1 to 100 then 10% extra can be delivered
If order is 101 - 500 then 5% extra can be delivered
and 501 to 1000 then 3% extra can be delivered.
But in standard we cannot able to define assembly scrap based on lot size to get extra requirement.. I have gone through many links but it seems there is no solution from standard need to how this can be achieved through user exit. if anyone has done this before then let me know how it can be achieved.
Regards / US

Hi US,
I don't think is possible to manage assembly scrap based on lot size.
Also, noted that the assembly scrap can not be enter at BOM level.
I think the solution to your problem is to create three different BOMs:
- BOM1 from 001 to 100 and enter a component scrap of 10% for all the items
- BOM2 from 101 to 500 and enter a component scrap of 5% for all the items
- BOM3 from 501 to 1000 and enter a component scrap of 3% for all the items
Then you will need to create the production versions:
- ProdVersion 01 for BOM1   --> from 001 to 100
- ProdVersion 02 for BOM2   --> from 101 to 500
- ProdVersion 03 for BOM3   --> from 501 to 1000
This way the MRP will assign the corresponding BOM base on the size of the planned order.
Kind Regards,
Mariano

Assembly scrap in REM scenario

Hi Experts,
My scenario is relevant to REM, during back flush in transaction MFBF am posting the assembly scrap by selecting assembly scrap radio button and in the scrap posting screen with reason of variance, as per logic the quantity of the plan order should be reduced by scrap quantity, am able to see the goods issue document but the plan order quantity is not getting reduced.
Are there any specific setting needs to be done for posting of assembly scrap?
Please help to explain the complete process of assembly scrap in case of REM.
Regards
cs

Hi Anupam,
I have checked the process as per your advise and it is working fine, but here am having an issue as if am scraping through quality it is scrapped with movement type 553, which is booked as loss.
But actually we are retrieving the components from these 5 units and reusing them in another FG.
As we are working with REM we are using CO07 production order without material for rework purpose in that case the scrapped assembly is issued to production order and components are retrieved with 531.
Is there any possibility that the scrapped assembly can be shown as stock and issuance can be done?
Or how can we address this scenariou2026
Regards
Chandan

Assembly scraps for subcontracting

Dear gurus,
I would that MRP consider assembly scrap (%) present in material master data to calculate planed order quantity of components of materials procuremented by subcontracting.
Is it possible?
Thanks in advance.
Best regards.
Juan

Dears all,
this the answer of Sap:
Assembly scrap is only used when the assembly is In House.
That is, when the material is produced internally.
I regret this can´t be changed.
If you want to increase the components qty you have to use the
'component scrap' field iin the BOM item.
In fact you have to do for all the items of the BOM,
unfortunately CS20 is not useful for this update.
I regret I can´t provide any other workaround, the
desired field can´t be check in external procurement.
However thanks for your help.
Sys,
Juan

Set TECO automatically when assembly scrap is used

Hi Experts,
could any of You help me pls with a mass processing of TECO status, when using assembly scrap at material master?
In my scenario we use COHV / PPIO_ENTRY as a background job for mass process and set TECO each night - worked well till no assembly scrap was set and used.
When assembly scrap is maintained at material master, we have a total order qty, a planned scrap and the output qty in prd order.
When cnf is made for prd order, and reached the planned output qty I expected the same as before: automatic TECO set - but it is not. The system still expect the total order qty to be reached - but we only go for the output qty. So when cnf qty = to output the status should be set - if scrap is lower than the planned scrap figures the order is not technically closed by the PPIO_ENTRY backgroung job.
Anyone pls support me with an idea, how to handle this situation, and set TECO automatically when cnf qty equals to expected output, pls?
Answers will be appreciated

dear friend,
can you please look at checkbox "Generated Confirmations w/o Quantity Adjustments" in OPK4 for your plant/order type?
do you have it 'ON' ?
regards,

How to ignore Assembly Scrap of MRP during Production order Creation

Hi All,
We want to ignore the Assembly Scrap maintained in MRP View during production order creation.
We are maintaining assembly Scrap for planning so we do not want to remove that.
Please let us know if any User exit is there during Production Order Creation.
Thanks,
Amit

Dear Amit,
Assume in CO01,once after entering the total order quantity the system proposes the scrap quantity field separately,now
remove this quantity for scrap field and press enter and once again adjust the total quantity and check for what quantity the
system is proposing the BOM components.
check whether this works for your requirement.
Regards
Mangalraj.S

How to eliminate assembly scrap in costing

We have the problem, that the costing considers the assembly scrap which we don't want to be included.
Is there a way to eliminate the assembly scrap only within the costing via customizing, user-exit or modification?
We would be pleased, if someone could give us a hint for a solution.
Thank you
Ignaz

Hi,
To use a user exit in validations, you have to perform following steps;
- copy SAP standard program GGBS002 to ZGGBS002
- create a user exit in this program (such as U902, U903 etc)
- the user exit you defined in the above mentioned program will be visible in validations on screen tab 'Exits'
- configure your validation with 'User exit' as option
This can help u.But see this is not the right place to post.You need to post in a different forum.
PS:If this helps you please award Points.
Regards,
Raja Akella.

Assembly Scrap Rate and Quality Notification

Hallo Gurus,
i have a big question!!!
I have to include scrap rate in order to guarantee that the MRP generate suggestions that consider the high scrap of my production processes.
The best solution is including Assembly scrap rate in MRP1, but unfortunately this cause problem in QM01 when I have to create a QP ( Production Quality Notification ).
The problem is because we launchProduction Order of1 and SAP doesn't allow me to create QP of a non integer QTY
ES:
Prod.Ord=1
Assembly scarp rate=100%
When i have to do a QP i have a complaint qty of 0,5 due to a scrap of (100%=0,5)
But the sistem doesn't allow me to generate a QP for such a fractional qty.
Any solution to force the creation of a QP of a non integer qty of other ideas?
Please help me, i know you certainly can!!!
Thanks, Ludovico

Hello Amol,
Thank u for your interest.
Here is the problem.
Thank you for the help.
Step1--> Assembly Scrap Rate Implementation on MRP1 View
Step2--> Production Order Creation
Step3-->Quality Notification Problem

Assembly Scrap Calculation

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