Operation Scrap Process

Dear Gurus,
We have MTO scenario. I have a production order with order quantity = 2. We have two operations, op1 and op2. First quantity is confirmed in op1 while the other quantity is declared as scrap. The required components to produce the FG are assigned to op2. Since these components are not any more required for scrapped quantity the system should remove the reservation, which is not being done by the system automatically. Also, the production order status remains as PDLV which has to be changed to DLV manually.
Is there any other better process of handling scrap. I have already gone through a lot of posts in SDN, but I am not close to my requirements.
Thanks
Geravine

Thanks for the replies, what I have finalised is the following process:
Scrap during production
1.     Create sales order with multiple quantity
2.     Run MRP
3.     Convert Planned order to production order
4.     confirm operations
5.     one quantity goes ahead, second quantity gets scrapped/produced in a wrong manner
6.     keep on confirming operations for 1 quantity as partially confirmed
7.     confirm operation in which the second quantity gets scrapped with Scrap quantity as 1
8.     In production order -> Goods Receipt tab, tick Unlimited Overdelivery check box, this will allow confirmation of quantity more than the production order quantity
9.     Increase the quantity of the components which have already been issued to scrap quantity/modified material to compensate for the new quantity to be produced. Or create manual reservations.
10.     Start from operation 10 for the new quantity and keep on confirming operations despite warnings.
11.     Through MB1C get scrap quantity in system against a material code representing the modified material. The movement to be used is 531 against the respective production order. The values declared in material master of modified material as moving average price will be used to reduce the cost in the production order. The modified material will have the same value.
12.     The modified material can further be converted to scrap or used as a different material which can be further processed and issued to another production order.
13.     At the time of GR a check can be incorporated through user exit (Enhancement - MBCF0002, Functional Module - EXIT_SAPMM07M_001, Include - ZXMBCU02) which will ensure that GR quantity is not more than the production order quantity and will throw an error if someone tries to do GR more than the prod order quantity.
Kindly let me know if process is correct or needs any modifications.
Thanks
Geravine

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Hi All,
I want to know,what is the effect of maintaining operation scrap in routing?It does not effect the component qty allocated to that operation(as it dus in case of maintaining operation scrap in BOM).
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Hi Gautam,
Operation Scrap In the Routing is the amount of scrap (in percent) for the operation.
The effect of operation Scrap in the Routing :
The scrap in the operation causes a decrease in quantity in the next operation because the quantity to be processed is reduced by the scrap quantity.
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Hope you understood the point.
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Hello All,
I am facing problem after scheduling splitted operation in process order. The scenario is as follows.
In process order there are 5 operations. 10, 20, 30, 40 and 50. Out of the above operations 30 is splitted and two different resources are assigned to it. Control key assigned to splitted operation (30) is also scheduling relevant. Now the flow of operations will be as below.
1. Operation 10
2. Operation 20
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Best Regards.
Edited by: Avinash Mohite on Mar 19, 2010 12:43 PM
Edited by: Avinash Mohite on Mar 19, 2010 3:14 PM

Hi,
I hope u r doing in this way:
In the capacity header screen enter individual capacity as 2. then click on Got( on top of same screen) and go to individual capacites. Enter the names of two individual capacities, for example 1 and 2. These are the names of two work centres where u r splitting ur operation.
Double Click on operation 0030 and go to tab 'splitting' . Tick on ' required splitting' and enter maximum no. of splits as 2.Then go to capacity requirements assignment tab. enter the individual capacity as 1 and 2 and enter the splitted quanitites.Save and reschedule .
Check and revert.
Regards.

How to analyse actual cost for each operation in Process/Production Order?

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I know the object when I good issue material is ORDER, not OPERATION.
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Hi Emily,
as I see from one other message that you're using material ledger. Then your expectation is apparently to also see the actual costs of materials in your production order by operation.
This is not supported. Actual material costs are handed up in material ledger multi-level settlement from one material to the next, bypassing the production orders.
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After creating Master recipe in C201, under the operations tab you need to define the operations involved in recipe . along with the operation column there is phase indicator column is there which is to be selected whether this operation is phase or not...
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Dear All,
[I raised this issue on MM board and I was advised to come here. Maybe you can help me.]
I haven't got experience in SAP, that's why I'd like to ask for your help in this issue.
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(effects on MRP run + behaviour when booking against PrdOrd; e.g. when I book against PrdOrd what will be the movement types?)
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Hi,
Assembly scrap:
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              can also be maintened in BOM item detail screen if the scrap is for
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              Reqd qty            121 pcs of components
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component scrap no entry
net indicator not set
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Regards,
nandha

Sales for Scrap process

Hi SAP expert,
i would like to know about Sales for Scrap process, We will have to scrap all the material by doing tendering process or sales for scrap, if tendering process is not successful. we will have to do sales for scraping.
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MM function for scraping ?
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Dear Kurosaki
You can maintain the standard OR-LF-F2 process itself.
Only thing is that Picking is not relevant for scrap process and hence, in 0vlp, just copy Item Category TAN and remove the tick from "Relevant for picking".
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Last but not least, I have briefed about Indian scenario. If you are asking for other countries, sorry I am not sure about that.
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G. Lakshmipathi

Can we maintain the operation scrap in each operation where ?

hi pp gurus
I have one finsh product Core
first operation is core making
second one is core assembly
so in each operation there is scrap say for first 5%
and for 2nd operation say 2%
I hav given the operation scrap in Routing but when I taking MRP Run it is not
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hoping for reply
dev

Hi
This can be handled in 2 ways.
The options used by me in similar situation were
1 Yeild the BOM to that effect.
2.Define the scrap in Material Master.
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regards
Prakash

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We use master recipes. We are trying to maintain scrap% value for an operation/phase, and I don't this field on the screens.
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Hello
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Hello guys,
I have a question on the operation scrap and the expected yield variance.
I have a product which has four operations, and on one of the operations (2nd operation) the operation scrap of 10 % is maintained.
So, I have created a production order for 100 Pcu2019s.
For the confirmation, I confirm first operation with the total order qty (100Pcs). After the confirmation the expected yield of variance of 10 Pcu2019s is set on the order.
I just wanted to understand why the expected yield variance is set with planned operation scrap. According to my understanding, the expected yield variance is only set if a scrap value is mentioned in the confirmation.
I am having a problem because my 4th operation is a milestone operation ( I confirm 2Nd, 3rd and 4th operation at a time.
I donu2019t use the back flushing option coz I do my GR in MIGO.
So here is the situation.
I created and order for 100 Pcu2019s and I confirm the first operation for 100 Pcu2019s
Second milestone confirmation (2nd, 3rd, 4th ops) for 40 Pcu2019s u2013 GR is done after that.
Third milestone confirmation (2nd, 3rd, 4th ops) for 40 Pcu2019s u2013 GR is done after that.
Fourth milestone confirmation (2nd, 3rd, 4th ops) for 15 Pcu2019s but I can only receive 10 Pcu2019s because of the operation scrap and expected yield variance.
Thanks,
sashi vardhan

Dear Shashi,
Since you have maintained 10% as operation scrap system considers that 10% of your total qty in the opration is scrap material and hence system allows only confirmation of 90 components only.
This is std SAP behaviour.
Regards
Suri

WIP Scrap Process - Pls Help

Hi Guru's
I am trying to Impliment Scrap Process to my client which is a manufacturing organization. The process what the client is expecting
Scrap Sale - Out of Finished Product scrap sale i.e every FG will generate a Scrap.
Abnormal Scrap - This is done at the Final Inspection if the product is rejected
Normal Scrap - When doing the move transaction, the user is going to move it to Scrap
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Regards

Check the BOM that is having the component UL26300.
May be the locator specified on the BOM record is not valid anymore.
Try correcting the same using Discrete Job's Material Requirement Screen.
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Hrishi

Operation scrap

Hi
How does operation scrap work
Can you please explain how it works during planning and execution with an example pls

Hi,
Operation scrap is a planned scrap. It means that for every order during this opn, scrap qty will generate, that might be in %.
Opn scrap is assigned in BOM componenet details. So when system explode that BOM operation scrap will come to effect.
Ex:
Order qty 100.
Opn scrap 10%.
When you do goods issue by MB1A against that order system will issue 110 instead of 100 no's due to opn scrap of 10%.
Regards,
Dharma

Operation Scrap senario not working

Dear All,
I have maintained the 5% operation scrap in routing. I have created the production order for 100 Qty and confirmed order, but system is not proposing the 5 % scrap anywhere.
What is the issue?
Kindly advise.
Regards,
Anil

Dear All,
Thanks V Much for your prompt replies.
I've checked the Goods movement in CO11n but system is proposing 100 qty not 105 qty.
System does not increasing the required qty.
Regards,
Anil

Production operation external processing goods receipt for subcontract PO

Hi PP/MM experts,
I searched for existing forum entries but no luck or final answer.
I have a question about the goods receipt for a subcontracting PO that is account assigned to an operation of a production order (external processing for operation).
The following situation:
Production order type PP02 - external processing
There is only one operation in the production order with control key PP02 - external processing. I marked the control key PP02 in configuration for 'Automatic goods receipt'.
I created a PO for the PR is the operation
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Reason for PP order and not only subcontract order is that we want to manage capacities of external suppliers with PP capacity planning.
Is that a bug in our system or normal behaviour? We use SAP ERP 6.5 with IS AFS.
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Hi Rizzi and all others,
thanks for your replies.
I'm using a production order for the following reasons:
We want to use capacity planning for external suppliers. At least to have some overview of work they have to do in a month
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Operation Scrap Process

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