GR for a Production order to be controlled on actual /planned cost

Question

Hi,
               When I do a GR for a production order I want to restrict the GR if my actual cost of materials consumed for the production order is less that 80 % of the planned cost of that production order. There is no provision for restricting the above.
When GR is done for a partial quantity of the production order, the system should consider and compare the GR quantity material cost against the same GR quantity Planned cost in the production order. If the GR quantity actual material value is less than 80% of the GR quantity material planned value, then the system should stop the GR to stores.
Eg:
Production Order for 10 Units of material “X”
BOM for “X” are Material “A”, “B” and “C”
Planned quantity to manufacture 10 units of material “X” is: “A” – 10 unit, “B” – 10 Unit, “C” – 10 Unit
                                The planned value for the material BOM is : “A” – 100
                              “B” – 75
                              “C” – 25
                                     Total Value to manufacture material “X” is Rs .200                                        
Case 1
If only 5 units are manufactured using the production order.
The GR to stores must be allowed only after the system check the total actual materials consumed in the production to produce 5 units exceeds 80% of the 5 units planned material cost.
Planned Material Value               Actual Material Value
A. 510 = 50                         A. 59 = 4     
B. 57.5 = 37.5                         B. 56 = 30
C. 52.5 = 12.5                         C. 52 = 10                    
Total planned material Value is Rs 100            Total actual material Value is Rs 85
The above case shows that the actual material consumed in the production order is more than 80% of the planned materials. So, the system should allow the GR to stores.
It should check only material cost only.
Case 1I
If 10 units are manufactured using the production order.
The GR to stores must be allowed only after the system check the total actual materials consumed in the production to produce 10 units exceeds 80% of the 10 units planned material cost.
Planned Material Value                    Actual Material Value
A. 1010 = 100                         A. 109 = 90     
B. 107.5 = 75                            B. 56 = 30
C. 102.5 = 25                                     C. 52 = 10                    
Total planned material Value is Rs 200          Total actual material Value is Rs.130
The above case shows that the actual material consumed value in the production order is less than 80% of the planned materials. So, the system should not allow the GR to stores.
It should check only material cost only.
CAN ANY ONE SUGGEST ME ON THE ISSUE
Regards
Madan Mohan

Answer 1

Madan,
Try using the userexit in enhancement MBCF0002.
(A) Now the Planned cost can be calculated from the RESB table passing the Order no. For all the line items in RESB calculate the planned cost = Price * Qty.
(B) For actual costs take it from AUFM for mvt type 261. The fields DMBTR will give you the value. Sum for all line items.
Now suppose the GR bing done now is 5. This you will get in the user exit. In the exit check from CAUFV whta was the GR already posted. Say this is 2. So the total GR is 5 + 2 = 7.
Planned cost for 7 = (A) / Order Qty * 7
Actual cost = (B)
Compare planned and actual and give yr message,
rgds
ram