For a Production order - Operation wise Inspection Lot

Hi Experts,
Please help me out to resolve the following problems.
1. How can we create inspection lot for each operation for a production order?
If a production order has 10 operations, I will have to have 10 inspection lots for that order.
2. I have a final assembly called A with components B & C. Some other material called D has similar characteristics of B.
    But sometimes, for A, instead of B (if stock is not available), i want to use D also. Please note that, if B is not available, then
    only, I will use D. Otherwise always B only, so we cannot go with probability.
How can we map this scenario? and MRP run also should consider D if B is not there.
Thanks in advance.
Regards,
Vijay.

Dear
Answer Q1 : Go to SPRO > Production> Shop floor control> operations > confirmation> define confirmation parameters
Maintain
1)Operation sequence u2013 error when operation sequence is not adhered to
2) Over delivery u2013 Error when over delivery tolerance is exceeded
3) Results Rec. (QM)- Error message if no Insp results exist
So what these setting helps is that  :
1)All operation has to be confirmed operation wise means 0010 has to be confirmed for confirming 0020 operation. SO production guys can only confirm 0040 operations only after 0030 operations is confirmed by quality personal.
2)Over delivery is not allowed means of in 0030 operation if only 50 quantity is confirmed in 0040 operation only 50 can be confirmed. Production people cannot confirm more than 50 quantities
3) Also PP personal cannot confirm operation 0030 through C011N till the result recording of that operation is done through QA32.
4)Maintain Operation Control Key -PP01 with marked Inspection Character Marked -OPJ8  and maintain this Control Key for   those operation which are required for Inspection Lot .
Now For QM stand point , activate inspection type 03 and 04 in material master. For 03 type of inspection, you have to make routing in CA01. So when you release your production order, an inspection lot will be generated. This lot will not be stock relevant. This is just to check that you production is in accordance with quality norms. Only after clearing this lot from quality you can do your order confirmation, otherwise system will give hard error due to 3rd point of prev post.
For 04 type of inspections, prepare inspection plan in QP01. Now when order is confirmed, an inspection lot of 04 origin will be created in quality, and this is stock relevant and for final inspection of production order material.
If you need you can set for early inspection as well. That will give you another intermediate stage before final inspection. Inspection points are also an option if suites your requirement.
If you need more inspections, I suggest go for manual inspection lots of 04 origins, they are created in ref to order and are not stock relevant.
Q2 : Please explore this thread for options explained for Alternative Item selection .
Alternate Item in BOM
Regards
JH

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