BOM for textile (weaving process)

Hi,
Can any one tell me how to maintain BOM for textile (weaving process). I need BOM logic with stage wise.
For ex. I had order of following construction 60x60/154x58^3-120"
Now I need multilevel BOM logic for this construction.
list of operations as given below:
1. Warping
2. Sizing
3. Weaving
4. Packing
Thanks & Regards,
Dhamane

Dear Dhamane,
Whatever you have provided is the specification of your product which alone is not required to design the structure of a BOM.
Kindly provide the details of the materials used in production with the sequence in which the final product is formed.
Thanks & Regards,
Vijaya Bhaskar A

Similar Messages

GET BOM FOR MATERIAL

Hello everybody.
i want a program to get all bom for raw and processed materials.
input:
a range of material, example material from 100005 to 100008
output.
all bom of material 100005 to 100008.
in se37 i found function
CP_BD_GET_BOM_FOR_MATERIAL
but i don't know how to use it.and whether can get requirement output.
help me.
thanks.

tables : mara,stpox.
data : ibom1 like stpox occurs 0 with header line,
         ibom2 like stpox occurs 0 with header line,
         imatnr like mara occurs 0 with header line.
select-options : s_matnr for mara-matnr.
select matnr into corresponding fields of table imatnr from mara where matnr in s_matnr.
loop at imatnr.
CALL FUNCTION 'CS_BOM_EXPL_MAT_V2'
EXPORTING
FTREL                       = ' '
ALEKZ                       = ' '
ALTVO                       = ' '
AUFSW                       = ' '
AUMGB                       = ' '
AUMNG                       = 0
AUSKZ                       = ' '
AMIND                       = ' '
BAGRP                       = ' '
BEIKZ                       = ' '
BESSL                       = ' '
BGIXO                       = ' '
BREMS                       = ' '
   CAPID                       = 'PP01'
CHLST                       = ' '
COSPR                       = ' '
CUOBJ                       = 000000000000000
CUOVS                       = 0
CUOLS                       = ' '
   DATUV                       = SY-DATUM
DELNL                       = ' '
DRLDT                       = ' '
EHNDL                       = ' '
EMENG                       = 0
ERSKZ                       = ' '
ERSSL                       = ' '
FBSTP                       = ' '
KNFBA                       = ' '
KSBVO                       = ' '
MBWLS                       = ' '
MKTLS                       = 'X'
MDMPS                       = ' '
   MEHRS                       = 'X'
MKMAT                       = ' '
MMAPS                       = ' '
SALWW                       = ' '
SPLWW                       = ' '
MMORY                       = ' '
   MTNRV                       = IMATNR-MATNR
NLINK                       = ' '
POSTP                       = ' '
RNDKZ                       = ' '
RVREL                       = ' '
SANFR                       = ' '
SANIN                       = ' '
SANKA                       = ' '
SANKO                       = ' '
SANVS                       = ' '
SCHGT                       = ' '
STKKZ                       = ' '
STLAL                       = ' '
STLAN                       = ' '
STPST                       = 0
SVWVO                       = 'X'
   WERKS                       = '1000' " PLANT NO
NORVL                       = ' '
MDNOT                       = ' '
PANOT                       = ' '
QVERW                       = ' '
VERID                       = ' '
VRSVO                       = 'X'
IMPORTING
TOPMAT                      =
DSTST                       =
TABLES
    STB                         = IBOM1
MATCAT                      =
EXCEPTIONS
ALT_NOT_FOUND               = 1
CALL_INVALID                = 2
MATERIAL_NOT_FOUND          = 3
MISSING_AUTHORIZATION       = 4
NO_BOM_FOUND                = 5
NO_PLANT_DATA               = 6
NO_SUITABLE_BOM_FOUND       = 7
CONVERSION_ERROR            = 8
OTHERS                      = 9
IF SY-SUBRC <> 0.
MESSAGE ID SY-MSGID TYPE SY-MSGTY NUMBER SY-MSGNO
        WITH SY-MSGV1 SY-MSGV2 SY-MSGV3 SY-MSGV4.
ENDIF.
APPEND LINES OF IBOM1 TO IBOM2.
endloop.
LOOP AT IBOM2.
WRITE : / IBOM2-IDNRK.
ENDLOOP.
REGARDS
SHIBA DUTTA

Need BOM related solution for Textile Industry (Weaving proces)

HIi,
Made to Order Strategy:
Every times customer sends the specification of product. Specification format as given below:
Ex. 80x100/154x80*3-118u201D 4/1 Twill
Details of specifications:
     80: Count of EPI (Ends Per Inch)
     100: Count of PPI (Picks Per Inch)
     154: EPI
     80: PPI
     3: Insertation
     118u201D u2013 Width in Inch
     4/1 Twill : Design of Fabric
Operations Details:
1 Warping
2. Sizing
3. Weaving
4. Quality Inspection
5. Packing
As Is Business Process:
There are mainly four production lines viz. Warping, Sizing, Weaving and Quality Inspection. For all the production lines the individual machine work centers will be as listed below with brief description:
1.     Sectional Warping:
A kind of Warping specially used to prepare fabrics for shirting. In sectional warping dyed yarns are used to prepare warping beam. The end constraint of sectional warping is 720 ends at a time. The actual capacity of Sectional warping is 800 MTR/min. This activity is job work for DEESAN group.
2.     Direct warping:
Direct warping process is used to prepare warping beam. The end constraint of warping is 1088 ends per beam. Machine width of the beam in 2200 mm, speed of warping varying from 300 MTR to 1200 MTR per minute depending upon the construction required. It has backup procedure for next round. Uploading speed   for single yarn is 8 yarn / min / person.
3.      Sizing:
Sizing process is used to prepare specific number of EPI/ beam as per the requirement of construction. A calculated no of warp beam used to prepare a single sizing beam. Speed of sizing 45 to 55 MTR / minute depending on the requirement of fabric.
4.     Preparation of Drawing:
This process is used to preparation of new drawing for the loom machine. Drawing includes frame & reed. It will take 12 hr for 2 persons to prepare a single drawing i.e. 8000 ends per shift. This activity given as job work to some group of people.
5.     Weaving:
Two types of weaving machines used are CAM and DOBBY. Fabric to fabric PPI is varying, the capacity of loom machine depends upon the PPI so the capacity of loom machines varying with the type of fabric. CAM is used specially for plain fabrics.
6.     Quality Inspection:
The beams of fabrics coming from looming machine are inspected on Inspection machine. 100% fabrics are inspected on QA machine for further grading, which is then bifurcated in Export, Local and chindi type.
7.     Rolling:
Rolling machine is used for rolling of inspected fabric on card board rolls according to the quality of fabric. A roll contain of maximum 350 MTR of fabric. Which are then packed with LDPE followed by HDPE with appropriate coding on rolls.
Material Requirement:
For ex. 80x100/154x90*3-118u201D 4/1 Twill
Order Qty.: 20000 M
Currently they are using single level BOM.
Formulas for calculate raw material requirements as given below:
Warp wt / mtr = (EPIWidthCrimp) /(1693*Count of EPI)
          = (154 * 118 * 1.025)/(1693 * 80)
          = 0.137524
          = 0.138 Kg/Mtr
Weft wt / mtr = (PPIInsertationWidth * Crimp) /(1693*Count of PPI)
          = (9031181.025)/(1693100)
          = 0.192891
          = 0.193 Kg/Mtr
Total Qty req:
Warp = 0.138 * 20000 + add 5% loss
     = 2898 KG
Weft = 0.193 * 20000 + add 4% loss
     = 4014 KG
Packaging material requirement :
1. Paper tube = Total order qty / approximately for 300 m 1 paper tube required + 5% loss
          = 20000 / 300 *1.05
          = 70
2. HDPE sheet = No. of paper tube * 0.4 KG
      = 70 * 0.4
     = 28 KG
3. LDPE sheet = No. of paper tubes * 0.15 KG
          = 70 * 0.15
          = 10.5 KG
Chemical consumption in terms of yarn on KG basis. Its combination of 4-6 chemicals depends on construction to construction also material availability.
Note: We will consume chemicals against cost center.
Production planning at execution time:
Sizing and warping calculation:
1.     Sizing :
EPI per inch = 154
On loom will be = 154 * 1.025
           = 157.85
Total no of ends for 118u201D width = 157.85 * 118
                    = 18626
Add one more ends per 1000 ends = 18626 / 1000
                    = 19 ends
Total no of ends = 18626 + 19
          = 18645 for sizing
Warping :
Warping m/c capacity of output is 1088 Ends per set/beam.
Speed of machine 300-1200 MPM.
So for sizing we need 18645 ends. Now we want to calculate no warp set required for sizing & no. of ends per warp set.
Ends required per set = 18645 / 18 = 1036
     i.e. 18 * 1036 = 1 Sizing set
We need total yarn on KG basis
Issue related to BOM:
1.     How We can feet below 2 issues in BOM
a.     we want to calculate RM(Yarn) material requirement in Unit of u201CENDu201D
NOTE: Procurement of Raw material Unit- KG as well as it depends no. of ends required for warp set / beam. i.e. its multiple of yarn cone required for 1 warp set.
As per Bom of Raw Martial Unit- Ends (EA)
b.     Also we want to calculate no of warp set required for sizing and no of ends required for warping process.

Hi Pankaj,
Hope you might have completed the project for Textile industry. I need to know implementation in Textile and some specific process. If you can share some documentation for Textile industry would be very helpful for me. My id k.anamika06 at gmail
Thanks a lot
Anamika

Bom for production order and subcontracting

Dear guru ,
I have a finished material that can be use both produced in-house and procured externally with subcontracting.
Now i use one only bom with usage 1 (production ) for the two process.
I have a problem for one component.
For subcontracting i must consider this component as a phantom (with explosion of its components) , instead for the in-house production I must consider this component as a normal stock item.
Can I use only one bom or I must create an alternative bom for manage the two cases ?
Thanks for your help.

Dear CRIS,
In my understanding this may create discrepancies during the material transfer from own stock to the vendor and also during
month end checking process.
What's the problem of maintaining that component as a stock item?why it should be treated as a phantom only for sub-
contracting?
Even if you are maintaining 2 different alternative BOM's for the final product one with the component as a normal assembly and
the next one as a phantom,you will be facing issues during costing purpose and material inventory also.
Come back with your further questions.
Regards
Mangalraj.S

Tolerance limit for Components in Process Order

Dear Friends,
As we can provide underdelivery / overdelivery tolerance for GR of process order, likewise is it possible to provide tolerance for BOM components in process order?
The requirement is like that confirmation should be allowed with GI done within + / - 5 % of BOM qty in process order. Is it possible to cater this requirement with any exit / BAdi?
Kindly help with your valuable inputs.
Thanks in advance.
Regards,
Tejas

Dear,
Thanks for your prompt reply. Actually I have been already working on this exit only.But me & my technical fellow are stuck up for build logic for tolerance limit. It is working to restrict confirmation till GI has been done. But we are unable to give provision of tolerance limit for GI with this exit.
Can you pls share more details about writing logic for it?
Regards,
Tejas

How to map the Third Party materila for Job Wok process in our Plant

Dear All,
please guide me how to map the Third Party Subcontracting in Our Plant Means Customer materials to be Processed in our Plant and then we have to sent to customer after processing.
please Brief me with the Proces sflow
Reagrds
kishore Edagali

1) create a 2 material as non valuated (one incoming material "A1"& after processed material"B1")
2) create a BOM. for A1
& assign the B1 and maintain respective conversion
3) create a routing for A1 and assign the relevant work center
4) create a manual PO to receive the material from customer and store it in storage location
5) create a production order and release the order in co01
6)issue the material :B1 to the order 9 in MB1a, 261 movement)
7) and confirm the order (so that cost incurred for order is captured)
8) create a sale order and maintain service price in PR00 and send the material A1 to customer.

How to Map Fomulas for Float Glass Process

Hi All,
Can anybody suggest how to map formulas for float glass process.
As in float Glass process continuous production is going on single line, within that continuous ingredients are added in furnace and molten glass mass is coming out. this molten glass is now adjusted to particular thickness and then finally cut into specific sizes as per cusotmer requirment.
Final product is in various thickness, width and length.
Entire process is automated.
If anybody already implemented same scenario, please share knowledge.

Hi
The following is the mapping process and it is tricky process need to map carefully.
You can define this as a single formula.
Output: Packed - cut to size - Finished Good Item.
Input: All the Raw materials (Sand, Dolamite, Limestone, Soda Ash, Sodium Sulphate, Carbon, Iron Oxide)
Packaging materials + Labels + Boxes etc.
Define Routing:
Resource: Furnace, Any other importance resource like Equipment that controls thickness, cutter etc, Labor, Associated Overhead
Create recipe using the formula and routing.
Various factors that can affect the mapping:
1) Formula maintenance: You have to define formula for each output item.
2) Possibility of dynamic determination of output item: If it is possible to produce different combination of thickness/width (and hence different FG item) in the same batch, then this won't be the right mapping.
3) Process variations: Also formula mapping depends on how accurate is production process. If user wants to produce item X (say thickness 10mm) but due to quality issue produced item Y (say thickness 9mm) and such cases happens very often, this won't be right solution.
4) Inventory measurement: This will determine the break-points. If you cannot measure the quantity (or even estimate) then you cannot define it as an intermediate item.
I will explain how point 4 can lead to different way of formula mapping.
Say you have a furnace that needs to run continuously for better quality or throughput. Hence you will be continuously adding raw materials to furnace and produce different outputs. You can break the single formula into multiple formulas as -
Formula 1) Output: Molten mass of glass
Input: All the Raw materials (Sand, Dolamite, Limestone, Soda Ash, Sodium Sulphate, Carbon, Iron Oxide)
Formula 2) Output: Packed - cut to size - Finished Good Item.
Input: Molten mass of glass
To have formula in such fashion you should have a way to measure or estimate the weight of Molten mass of glass.
If you are estimating the weight, there should be historical data available to determine what should be realistic output quantity for given input quantity. How much will be process loss and loss due to unwanted by product such as slag etc.
Further you can break formula 2 as
Output: One large sheet of give thickness
Input: Molten mass of glass
Output: Packed - cut to size - Finished Good Item.
Input: The large sheet of give thickness.
This kind of different mapping is possible which normally depends on:
1) Complexity of process
2) How complex BOM structure user wants to have
3) Are there any benefits of maintaining such complex system - like accurate costing or accurate production monitoring or facilitating planning process.
4) Can user maintain the complex system? Are they ready to capture data at finer level. Is it possible to capture the data.
5) And most important thing is how to handle exceptions. If every thing goes smoothly as planned (less exceptions) then user can have and afford any level of complexity. But if there are many exceptions to the normal process you have to concentrate more on how to handle the exceptions.
6) Satisfy all users: Accounting, Planning, Production, Quality, Inventory handling. Formula/Recipe touches all these modules.
Regards
Raj
Sierra

Differ Bom For Production order and Subcontracting

Dear all
Is there any process to defined BOM for Subcontracting & production Order separately and how can we make the Bom For Both case ,If it is possible then how can we choose in the production order for in house production and also for subcontracting for purchase order.
Rgds
Pankaj Agarwal

Hi,
After giving 'X' in the procurment type, maintain quota arrange usage as '4'.
Then use T.code meq1, for creating quotas.
Give the material no. & then give validdity date. Double click the validity date, this will take you to another screen.
Here give the procurment type as internal production, the %quota & the prod version in the 'Version field'& then in the second row choose external procurement & choose sub-contracting in the special procurement field, then enter the %quota & prod version in the 'version' field.
After this in T.code omi4 (for lot-size), check if the lot size you use has got a tick in the splitting quota. If not check this indicator & then run mrp. Based on the quota %, pl order & pur req will be created.
Regards,
Senthilkumar SD

Mass upload of BOM for Equipment & Functional Locations

Dear Gurus,
I have an existing system with Functional Locations & Superior Functional Locations, Equipments with Superior equipments. I need to update the BOM for all (most) of these. Can we do it through LSMW or any other Mass update transactions?? Please guide me with the process.
Thanks & Regards
Krishna

Hi Krishna,
You Can use LSMW object by Direct INPUT method In which Sap ECC 6.00 has Standard Programme for uplaoding of BOM.Details are as below
Object:0030---> Material BOM
Method:0002--->Change
Program Name:--->RCSBI010
Program Type:B--->Batch Input
Regards,
Rakesh

2 Subcontractors for the Subcontracting process, how to deal with it in SAP

Dear all
I encounter this scenario, please advise how to design it in SAP system for Subcontracting (SC) as it involves 1st subcontracting vendor SC-V01 and 2nd subcontracting vendor SC-V02. I am using the simple example of Colouring Bottom cover and then putting Bottom label done by the above 2 SC vendors respectively
1. Unlike normal subcontracting, my company places the 1st PO to the SC-V01 by supplying SC-V01
    the Raw Material of bottle.
2. SC-V01 will COLOUR the bottom cover. Once done, SC-V01 will delivery this bottom with coloured
    bottom cover to SC-V02.
3. Once the SC-V02 receives it, they will put the label on this bottom. Once done, it is delivered back to
    my company.
Please advise me how to come out with the soluions on it and the Tcode.
Notes: Due to certain reason, we are not able to make only 1 SC vendor solely responsible for the whole thing. The business nature involves high volumes of Subcontracting which involves 2 SC vendors.
Marks will be given handsomely for helpful answer.
Thanks.

Hi Prashant
Thanks for your reply.
The 1st BOM for SC-V01 is:
Bottle with Color Cover
   - Bottle with uncolor Cover ->Lower BOM Component
The 2nd BOM for SC-V02 is:
Bottle with Color Cover with Label
   - Bottle with Color Cover ->Lower BOM Component
Question 01:
Should the BOM be above structure or it should be the one you mentioned in your previous reply
1) Create BOM as below -
Labelled Bottle
\--> Coloured Bottle
\--> Bottle
2) The procurement for material will be as below -
Labelled bottle: F - 30
Coloured Bottle: F - 30
I just want to know, what is the setting that allow the virtual GR for the SC-V01 in our system (physical GR is done to the SC-V01 as the input for the process of putting Label to the already colored bottle cover) that will " After GRN, the material will be treated as provided to the S/C-V02. You need not transfer the material agai to the S/C-V02".
Question 02:
I wonder how can the above happen? Is it due to any additional setting we have done or it is merely the linkage I have between 2 BOM, where the Semifinished material of 1st BOM becomes the Raw Material of the 2nd BOM?
Quesiton 03:
How about the Subsequent Adjustment? Should it be done at the end of each subcon or can I just do it once at the end of the 2nd subcon?
Question 04:
I just found out from SAP HELP [Multilevel Subcontracting|http://help.sap.com/saphelp_45b/helpdata/EN/6e/6bc5e672ef11d2a7350000e82a3c24/content.htm], that we actually need to set up MRP Area for it? is it really so complex?
THanks
Edited by: Daimos on May 14, 2009 3:16 PM
Edited by: Daimos on May 14, 2009 3:20 PM
Edited by: Daimos on May 14, 2009 3:46 PM

BOM for Services

Hi,
I am having two questions .
1) Can we have a BOM of Services?
If yes then what is the method to create it.
2) Can we have a mix BOM of Services and Material codes ?
My client is having a requiremnt that he supply to his client products and some services . So can he have the same BOM for both.
What is the process to create it. Is is created by the normal way CS01 T code or some other method is there .
Thanks In Advance,
Lekhram

Hi Lekhram
Instead or looking in the lines of a BOM for service , if ur client requires both service & materials ,let him create a service order for service materials & a normal sales order for salable BOM materials.
Regards
Prasad
Reward if useful

How can we pick WBS BOM for a Subcontrat order

Hi,
We are using WBS BOM instead of Material BOM for our projects.We also use Subcontract order scenerio.
Where we wnat to pick WBS BOM.
Can any one sujjest how to pick WBS BOM.
Regards,
somiraghu

As per Standard SAP the stock should be unresrticted stock for Subcontracting process.It should not be a special stock.

BOM for the Rawmaterial

Dear all,
I need your help to build a BOM for the Rawmaterial, my scenario is:
I have a FERT material as "A'. Which has components B,C,D (B and C are Rawmaterials which is procurred externally and D is a semi-finished product).
I have to maintain BOM for the component 'B' and having components X,Y and Z. (Here the cost of X,Y and Z should not be rolled to the material 'B', so am not maintaining the costing relevancy indicators for the X,Yand Z materials).
Now i have to sent the component 'X' for external processing and bring it back as Component 'D'.
Please let me know how to process the above scenario.
Thanks & Regards
Dhanasekar

Hi,
As per your scenario you are manufacturing FERT A with compmonents as B,C & D. For component B you want to create bom with externally procured materials X, Y & Z.
X is sent for externally processing & bring back as semifinshed product D.
So you can map this scenario as,
1. Create BOM for HALB material D with component as X (with the material master setting as SPK- 30 subcontacting to get it done from outside)
2. Create BOM for FERT material A with the components B, C & D.
3. You don't need to maintain BOM for ROH materials B & C as they are the externally procured materials.
With this scenario when the BOM explosion is done for material A, then dependent requirements will be created for components B, C & D. Purchase requisition will be created for components B & C, and then they will be converted to purchase order. For component D planned orders are created & then purchase requisitions will be created for material X.
Hope this resolve your issue, reward points if helpful.
Regards,
Avinash.

Wip bom for main bom ?

HI ,
can any body explain me what is meant by Work in Process BOM for Main BOM....... in which scenario it is used in the business.
regsrds,
venkat.

Can you please explain your question in detail.
there is no Work in Process BOM ...
thanks
Chandan.

Selection of BOM for a purchase order based on Vendor

Hello Gurus,
We have one material which when ordered from two different vendors should have different components. To make this simple and easy for person creating Purchase Order how should it be implemented?
How should we create BOM that it automatically picks up the right components when a Vendor is chosen in the Purchase Order? We don't want to create two different materials and different BOMs under it. As it is for same product. Please give guidance on this.
Thanks
Regards
Sreepati Hari

Hi Hari,
Read the below SAP documentation for the mode of selection of BOM:
- Selection by order quantity, the system chooses the alternative BOM into whose lot size range the order quantity falls. The lot size range and area of validity of the BOM apply.
- Selection by explosion date, the system chooses the alternative BOM into whose area of validity the date falls according to the setting BOM via dates.
- Selection by production version, the system chooses the alternative BOM defined in the valid production version. The lot size range and area of validity of the production version apply.
- Selection only by production version, the system chooses the alternative BOM defined in the valid production version. The lot size range and area of validity of the production version apply.
If no production version is found, no production orders or process orders can be created.
So based on the above you can clearly understand that it is not possible to have BOM's tied to the Vendor. What you can do as a work around is, i.e. before creating the sub-contracting PO :
1. Change the lot size to ensure the BOM you want gets picked
2. Change the validity dates
3. Change the status of the BOM in header, i.e. make the BOM which you do not want as Inactive
4. As mentioned by you, have different materials & BOM for them.
Hope the above helps.
Regards,
Vivek

BOM for textile (weaving process)

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