Casting Industry Scenario

Hi All,
Need your help to map casting industry scenario. As per PP concern how to map this?
Regds,
Rajesh

Hi,
Come with the Business Scenario of your client.. Then you wil get the SAP mapping.
-Thaila Shree

Similar Messages

SAP implemenation in Casting Industry

Hi,
We are doing implementation for Casting Industry.
There are many stages in the process.
1) Core Manufactruing
2) Moulding
3) Motlen Metal
4) Casting-Pouring
5) Shot Blasting stage 1
6) Fettling
7) Re-shotblasting
8) Painting
9) Packing
Can any one guide me for following.
1) We should go for 9 Material codes.
or
2) Two matrial codes one before Pouring and second after pouring of metal
or
3) Any one has experience in Casting plant implementation.
There are approx 30 products each are manufactured everyday & with above 9 stages we are landing to 270 Production order a day. It will be very hactic activity for Releaseing, confirming , etc to the client.
Any one has good experience or expertise, please advice.
Regards,
Manish

Manish,
1) We should go for 9 Material codes.
Probably not, but only your client can tell you. Does he need to store inventory at any/all of the intermediate stages of production? Does he have reporting requirements about the valuation of the material(s) at various stages of production? What is the amount of time it takes to process something from RM stock to FG stock? How much commonality is there between the various components of the 30 FGs? Will any of the levels (from RM to FGs) be manufactured as MTO or MTS? Are there any quality inspection/sampling requirements at intermediate stages? What kind of material traceability will be required? You must get these and other important answers during your investigation phase of the project, before you can even begin to make a recommendation to your client.
2) Two material codes one before Pouring and second after pouring of metal
Maybe. Or, maybe even only one material number (just the FGs) from the beginning to end. Your client will decide when you give him the options.
There are approx 30 products each are manufactured everyday & with above 9 stages we are landing to 270 Production order a day. It will be very hectic activity for Releasing, confirming , etc to the client.
I guess this calculation is based on the '9-intermediate-materials-per-FGs' scenario. This may or may not be acceptable, only your client can answer. I have worked in environments where 1,000 production orders per day was acceptable, and also in environments where 30 orders a day was unacceptable.
As a side note, just because you manufacture something every day does not mean you must have an order every day. You can enter a production order for a quantity that equals 10 days worth of manufacturing capacity, and the system is just as happy as it would be if the order only consumed 1 day's capacity or 1 hour's capacity. The shop floor people just keep working on the longer orders until they are done. The size of the production or process or planned order is dependent again upon the client and his business requirements.
Many of the above decisions will have to be made in concert with requirements from functional areas other than PP. Usually during an implementation, all the functional areas will work together to come up with the solution(s) that best fit the client's requirements.
I have never worked in casting. However, SAP does have a Best Practice for Fabricated Metals that may be helpful. Here is the Building block library
http://help.sap.com/bp_fm604/FM_US/html/Content_Library_FM_EN_US.htm
Best Regards,
DB49

Service Industry scenario

Hello Friends,
I am going to implement SD first time in airline industry, I think it is going to be like service industry scenario,
Will you please let me know how the service order is created, How the process flow goes on?
Which are the transactions involved in it?
Thank you
Sadanand.

Hi,
Process Flow
This scenario includes the following process steps:
Creating a service notification
Changing the service notification (optional step)
Check the task list
Creating a sales order
Change the sales order
Changing the service order
Time recording
Confirming time to the service order (optional step)
Confirming the materials used
Creating resource-related billing request
Creating the invoice for the billing memo request
Closing the service order u2013 technical complete
Key Points
Service Order
Definition
Short-term agreement between service provider and service recipient, in which one-time services are ordered by the service recipient and resource-related billing performed upon completion.
A service order contains the following data groups:
Header data
Location and account assignment data
Object data
Settlement data
Operation data
Component data
Use
The service order is used to document service and customer service work. In particular, you can use the service order to:
Plan services specifically with regard to usage of material, utilities and personnel
Monitor the execution of services
Enter and settle the costs which arise from the services
The data for the service order is entered in the history and is important for evaluations and future planning.
You can also create a one-time customer in the order and transfer the data, for example, to the sales order. For more information, see Transfer of One-Time Customer Data and One-Time Customers and Vendors.
Structure
A service order contains operations that describe the individual work steps. An operation can be divided into sub-operations for greater detail.
Spare materials and utilities, which are required for service work, can be planned in the operation.
Integration
Using the "worklist for notifications" for a maintenance or service order, you can group together similar notifications for processing. For more information, see Completion Confirmation.
Services at several similar objects installed at the customer can also be processed using a service order.
Regards,
Murthy

I want to prepare FONDRY INDUSTRY scenario for MM ponit of view.

Dear Saper,
i want to prepare FONDRY INDUSTRY scenario for MM ponit of view.
kindly help me .
thanks.
saran.

hi saaavanakumar
regarding foundry industry here process is different from other
here there my might be scenario where a company sends the material and pattern to sub contractor , for pattern notional cost comes in to picture,this is info i had
if my reply had helped u assign some points

Geography based industry scenario which can be implemented using user exit

Hi All,
I am searching for a geography based industry scenario which can be implemented using user exit strategy.
Please let me know me if anyone knows about any such scenario.
Thanks & Regards,
Pranjali.

Hi Amith,
IDOC configured throgh CHANGE pointers.So no need to worry about IDOCS and all.My work was trigger idocs by user exits.Wen ever i change venodr no.. idocs shoud be triger.
Now my question was Insted of going transaction( from there we can go to debuging mode) i want to check this Exit by RBDMIDOC programe(ofter excute this programe and give Message type as CREMAS,from there i want to go debugging mode).
Just now i checked,i put breakpoint in Include programe(INCLUDE ZXF05U01) and excute from XK01,it goes to debuging mode,so its fine.But i want triger from RBDMIDOC programe.Ofter excute RBDMIDOC programe,we can enter CREMAS.From there i want to go debuging mode.
Pls help me,
Thanks

Interesting scenario IN FOUNDRY/CASTING INDUSTRY

HI
my client charges ammortization cost of rs ea on finished product.
ammortization cost is based on the tooling & die cast divided by number of pieces produced and also on the die life
suppose the die cost is 10000 and finished goods produced will be 10000 ea so the ammortization cost will be 1 rs per piece
so while doing invoice we have to capture amoortization cost in invoice
suppose the cost of finished goods is rs 100 and order quantity is 100
proo =10000
zamd= 100(ammortization cost) this is only for statistical purpose to calculate excise dutyzexc= 110    1100*10%
zedu=    2
zhse=    1
total vale= 10113
zvat= 405
receivable from the cstomer=10518
my problem i have to monitor the ammortization cost. the ammortization cost should not be applicable after the die life is over i.e after 10000 ea finished products are produced.
for 10001 piece the ammortization cost should not be calculated
CAN THIS BE POSSIBLE THROUGH CONDITION UPDATE
regards

Dear Rithvika
Yes apart from ticking the Condition Update in V/06 for condition type ZAMD, you also have to maintain scale in VK11. Once you maintain the price in VK11, you block that line item and press F2.
There under Scale quantity maintain 10000 and in Amount tab, maintain 100. Save this and again come to condition tab and maintain the validity period to the tentative despatch date to be on the safer side. If you want, you can extend the validity period at a later date, if need be.
thanks
G. Lakshmipathi

Chocolate industry scenario

hi experts,
I need suggestion in line with industry best practice on the following scenario.
We have moulds for the finished products which need to be cleaned after use. We have decided to introduce some traceblity on the moulds staus . For instance how many of them are dirty, clean & currently used in production line .
how can we map it , how to represent the moulds in SAP.
kindly advice
regards
satish

hi all ,
as per discussion above , i think we need to create non-valuated material mould , use them in process order as input to order.
input will be clean mould , out put will be dirty that we can show as by product or co-procduct so that the after GR it goes to
unrestricted stock or storage location we maitain fro the mould. also the moulds can be batch managed so that once the GR is
made to a storage location we can put the status of batch as restricted (means dirty ) once it is cleaned we can change the
status to unrestricted use which will mean clean and ready to issue to process order.
let me know if i am in correct direction , also please suggest any other better and simple way .
regards,
satish

PP Module: Machine tool industry scenario

Hi Gurus,
My scenario is that the company is making machine tools -
A machine is assembled from about 60 sub-assemblies (60 sub-assemblies in BOM).
Which can be produced in-house or purchased. Each of these sub assemblies have
further child sub-assemblies. This BOM explosion may happen till about 4-6 levels.
In some cases, the suppose the customer already has certain machines which have
say servo motor sub assemblies from Seimens. He would prefer his new machines to
have same servo motors (so that maintenance is easy for him or say his trust lies
in servo motors of 'Seimens' make).
So, at the time of making the order for purchase of a new machine,
the customer may negotiate the scope of supply of parts/sub-assemblies as well.
As a result -
1. Some sub-assemblies (say about 25 of the 60 in the BOM) will be purchased by
the customer at his own end and provided to the machine tool company to be fitted
into his machine. (e.g. he will purchase directly from Seimens and send it to you
to be fitted into his machine.)
2. Some sub-assemblies may be produced by the the machine tool company in-house.
3. Some items may be purchased by the machine tool company from their vendors though
they can also be produced in-house. (e.g. you may decide to buy the sub-assemblies due
to shortage of time for production or there is request from the customer that please
use particular hydraulic components of 'Vickers' make).
In addtion, the customer may also ask for commercial quotation for the machine based on any
of the above permutation combinations (e.g. what will be the price of the machine if you procure all the components or what will be the price if he provides one or more materials).
We are in a position to freeze all this data at the time of punching the sales order.
We will then run MRP.
The MRP should provide the following -
1. Planned/production orders for materials to be produced in-house.
2. Planned orders/purchase requisition for materials to be purchased from Vendors.
3. Some PR (or return sales orders or some other document) to get material from the Customer
so that we are able to follow-up incase he delays sending the materials.
4. In case the sub-assembly is to be purchased the system should not give production orders for its child parts.
Kindly suggest how to map a solution of this scenario.
Shud I make Sales order BOM or variant configuration or what ?
Thanks and Regards,
Vishal Saha

Hi,
After the completion of Sale order, you wil come to know about the scope of work to be taken by the manufacturer i.e) the items to be manufactured in-house and to be extenally procured. So, in material master you wil define the type of Procurement.
Depending on this, after MRP run, in-house produced materials wil get a planned ordre and externally procured materials wil get a purchase requisition.
Customer Supplied Product can be made as a dummy code for which no costing is added to that sale order under the manufacturer's scope. You can define a new material type for this Customer supplied product and the items pending for this sale order under this material type can be filtered through a Z-report.
You can use Sales Order BOM for your Scenario as the BOM varies for each order.
Hope this gives you some hint to proceed further...
-Thaila Shree

Rubber Industry Scenario

hi all
plz help me for following scenario
we purchase material A (scarp rubber )
then we separate it in X Y and Z as per the nature of rubber
tehn this rubber is again separated as per quality
X1 X2 X3 and so on
now i have to do gr of A and payment
then separatin in X Y Z
then X1 X2 X3 ,Y1 Y2 Y3 .....
plz tell me how can i map the scenario
i als o want to keep tarak from A to X3.....
also we will make po for A and then the gr of A might be in diffrent lots ,
Split value is not useful as we need inventory for all material.
regards
raj

Hi,
You have to enable the classification system for your material.
You have to create some characteristics which stand for each quality parameter. Each char should have the possible values for that char lik X1,X2,X3 or Y1, Y2, Y3 etc.
By using this, you can classify the material whenever you want in your process.
Hope this helps.

SSI (Small Scale Industry) Scenario in CIN

Dear Experts,
We are using TAXINN - Condition based Tax Procedure for CIN (4.7 R/3 Enterprises). Can any one please share with me, how to handle the SSI scenario in TAXINN. I am looking for feasible solution other than modifying the condition records each time.
Thanks in Advance.
Babu.

Hi
As far as SSIs are concerned, there are two schemes. Under the first, an SSI can opt out of the CENVAT scheme. In this case, they apply basic excise duty at certain flat rates on all transactions. These rates vary according to their total annual sales.
Prerequisites :
define a separate SSI status for each of the various "slabs" .
Assigned the vendor the SSI status that you have just defined

Process industry scenario

Hi all,
           here in my scenarion, i got prodcution plant and R&D. in R&D production is going depends on sales indent.its prodcut is Bio fertilizer.one resource :fermenter.
           Machinary is fermenter.and one packing machine
           others are manual work.
           How can i define in sap .whether as seperate plant ..or one resource.
thanks
s.suresh kanna

Definition regarding the plants are not only based on resources but also in many logistic aspect, as inventories, transfer and deliveries.
If fermenter and packing machine are in the R&D section , and this is only related to prioduction,
I would create them in the same Plant but under a diferent Resposible or Planning Group. So you can follow the performance of this area separately.
Let us know if this can be helpful.
regards

Industrial Machinery Manufacturing scenario

Dear Sir,
We are in the business of manufacturing the Industrial Machinery as per customer specific requirement . The multilevel BOM for the machine comprise of almost 1000 differnt components / assemblies . Some of the components are bought-out and some are manufactured in-house .
We run the MRP on the basis of engineering BOM and this result into several planned orders getting generated .
The issue with our appraoch is that there are lot many Production Order getting generated and many of such production order require very small duration operation for producing their output components (eg a keyway cut in an input assigned forging) .
We think that instead of having so many production orders , there should be a better practice so that numbers of production orders gets reduced .
We seek the expert opinions from SAP Gurus as in such type of industry scenario what is the best procedure to be followed so that organization working becomes the efficient one .
With Thanks and Regards
Sonia Agarwala

Hi Sonia,
What I understood from your query, I think you need to use Special procurement key '50 - Phantom assembly' for your requirement.
Following are the links which will explain what is Phantom assembly, how it works and how it should be implemented.
http://www.sap-img.com/production/what-exactly-is-a-phantom-item-or-assembly-means.htm
http://help.sap.com/saphelp_470/helpdata/en/ca/72d91b941b11d1801200c04fadcb73/content.htm
http://help.sap.com/saphelp_46c/helpdata/en/f4/7d2b5f44af11d182b40000e829fbfe/content.htm
http://help.sap.com/saphelp_46c/helpdata/en/ea/e9b47a4c7211d189520000e829fbbd/content.htm
Please go through it and if any futher assistance required, please revert.
Regards,
Hiren Ramani

Order related intercompany billing scenarios

Hi,
Need suggestion for order related intercompany billing from project. The scenarios is as follows.
There will be two diffenr company code under the controlling area of the project. Parent company will use resources from supplying company for executing the Order from customer. The project is service industry scenarios. The billing will be order related milestone billing. Milestone will be triggred from Project builder. There should be automatic revenue & cost posting to respective WBSE on doing billing to customer i.e. Revenue of supplying WBSE will become Cost to Parent WBSE.
I would like to request you to suggest on the above process for mapping into SD-PS
Thank you for your coopearation.
Regards,
Rakesh Pradhan

In Sale Order at Line item level, maintain the plant of supplying plant & not the one which have received order.
Ensure intercompany setting is in place.
Regards,
Rajesh Banka

CTM planning for process industry

Hi,
We are taking CTM planning run in a process industry scenario where we are having continuous processing. But when we do CTM planning CTM creates PP/DS planned order to meet the delivery date of orders and for some orders their are unscheduled gaps between operation due to non availability of next resource.
Is it possible to create orders in CTM without any unscheduled gaps between the operations as is the case in case of orders created using PP/DS?
Regards,
Sanjog Mishrikotkar

Hi kiran Ghule,
With the functions of the Quality Management (QM) module, you can implement it.
The QM application component supports tasks associated with quality planning, quality inspection and quality control. In addition, it controls the creation of quality certificates you can do this
Explore your self in this module if any problem then come back.
Regards
R.Brahmankar

SAP - APO is it a feasible solution for my scenario

I am in a decision making process of my industry scenario to map in SAP.
My scenario is as below
My sales regional heads input their requirement for 1 months in system as below
Input is
     region(in SAP it is route destination)
     Qty
     Material number
     Selling price
     Period
Once they enter the data system should collect all the data from each regional and run a statistical calculation taken fast history and generate a unconstrained sales plan/regional for 18 months.
It will be passed to a optimizer where in we will put the following constraints
     Capacity of production line with respect to that material grade
     Selling price (from input data)
     Minimum allocation qty per region/Grade
     Customer grading ABC, A is good C is worst
     Inventory available in all region and production plant for that grade
     Net back that material can fetch
     One of the important sub assembly/intermediate material availability for future months
     Grade change over loss in USD.
With the above constraint system should generate a region plan giving details of which material (grade wise) and qty
Second output is the production plan telling which grade how much to produce and when
Is it possible to do the above in normal SAP PP or we need to go for SAP SCM?

Dear SHIBU UP / Anjali,
Thanks a lot for your response...
Please if possible send some good documents on these topics which will help me to configure the solution.
Edited by: Rajesha Vittal on Jan 22, 2008 9:33 PM

Casting Industry Scenario

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