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

Similar Messages

Assembly, component + operation scrap

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.
Could you highlight/explain how these work?
(effects on MRP run + behaviour when booking against PrdOrd; e.g. when I book against PrdOrd what will be the movement types?)
thx
Csaba

Hi,
Assembly scrap:
              Assembly scrap takes into account all the faults that occur when the
              components are put into assembly.
              The system automatically increases the qty to be produced by the
               percentage of scrap.
               can be maintained in MRP 1 View as a percentage
              Reqd qty   100 pcs
              Assembly scrap 10 %
              After taking scrap reqd qty is 110 pcs
   Component scrap:
              Component scrap takes into account all the faults that occur before the
              components are built into assembly.
              Can be maintened in MRP 4 view if the scrap is going to be for all boms
              can also be maintened in BOM item detail screen if the scrap is for
              particular Bom .
              Reqd qty 100 pcs
              Assembly scrap 10%
              component scrap 10 %
              Reqd qty            121 pcs of components
Operation scrap :
             Befor high value components are built into assembly the system carries
             quality control check for the assembly.Faulty materials that were taken into account in assembly scrap aren ot passed on to the next operation and hence they are removed.
            Maintain the operation scrap in the BOM item details screen under general data /qty data.
           Qty to be produced 1000 pcs
            Assembly scrap     10 %
component scrap no entry
net indicator not set
scrap qty 100 pcs
           qty to be produced 1000 pcs
           Assembly scrap     10 %
           operation scrap 1 %
           net indicator set
            scrap qty              10pcs.
Regards,
nandha

Operation scrap in routing

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).
Pls guide

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.
The reduction of quantity is taken into account in scheduling and costing.
Hope you understood the point.
Thanks,
Srinivas

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
calculated the excee Material Required
so Pls Solve the problem
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.
Hope this helps.
regards
Prakash

Master Recipe - Operation Scrap

Hello,
We use master recipes. We are trying to maintain scrap% value for an operation/phase, and I don't this field on the screens.
Any thoughts? Is there a way to maintain scrap at operation level if we use Recipe?
I tried OP5D and I see that Scrap field is already listed as an Input field.

Hello
There is no operation scrap for master recipe and the phase scrap cannot be directly entered into the recipe like it is in the routings.
You can use material quantity calculation to calculate any loss during the phases.
Best regards
Caetano Almeida

Operation scrap and expected yield variance

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

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

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

Raw Material Incomong Defect Material and Operation Scrap flow

Dear all,
Can anybody explaian about the Raw Material Scrap flow in production Order , I know that the Scrap % is maintained in Mat. Master and BOM, i want to know that how to Post against the Production Order what is the Movement type can i use?, What is the Impact in costing?,Please explain me
Thanks in Advance

You can confirm the scrap in CO11n and CO15...but positng will be done from MB1C with 551 movement type to cost center or GL account of the material.
Planned scrap is always taken into account in standard cost estimate.
Regards
TAJUDDIN

Assembly, component and operation scrap

Dear All,
I haven't got experience in SAP, that's why I'd like to ask for your help in this issue.
Could you highlight/explain how these work?
(effects on MRP run + behaviour when booking against PrdOrd; e.g. when I book against PrdOrd what will be the movement types?)
thx
Csaba

Hi Csaba,
You will get more answers if you also post this on the SCM PP board, because this is more relevant to PP than MM.
But you didn't post it to the wrong forum, the movements are controlled within MM but the logic and processes are PP
You will probably still get help from the MM guys as well.
Steve B

Fixed Scrap Quantity In Production

Im using SAP ECC 6.0 now.
Is there any place I can set a fixed scrap quantity in BOM or PP related?
The situation is like this: While producing Semi-finishegoods A we alway need extra 10 Raw-mateiral B for scrap.
That means 100 A needs 110 B ; 10 A needs 20 B;
How can I configure it so that when I create the procution Order for 10 A, it will put 20 B in the components automatically;
I can only find scrap ratio in percentage.
thanks alot for looking into my problem.
Edited by: Liang Shi on Aug 25, 2010 7:08 AM

Hi
As you rightly mentioned , to my knowledge, as of now in standard SAP
All the SCRAPS are maintained in % only.
1) Component Scrap >>>>> Maintained in MRP4 in % & also in BOM General data tab
2) Assembly Scrap >>>>>> Maintained in MRP1 in %
3) Operation Scrap >>>>>>Maintained in BOM item detail General Tab in %
Regards
BRSR

CK11N - How to exclude assembly & Operat scrap factor from Cost estimate

Dear Experts,
We have assembly scrap maintained in the material master. We also maintained operation scrap in the routings.
Now the requirement is to create a costing of the material without scrap. We already working with Three costing variants one with legal valuation (inclusive of Scrap) other for profit center valuation now this one we need to do the comparision. I can do it by changing the material master and routing master data but this is not possible due to impact on MRP.
Thanks in advance
SK

Dear SK,
As explained by Ajay,either you have to remove the scrap related data in the material master/BOM before costing in
CK11N/CK40N and then include the same before MRP.
If my understanding is correct this is the standard SAP behaviour.
Check whether can you use a separate BOM for costing purpose or else check with this BADI - QUANTITY_STRUCT_CK
(Enables Quantity/Structure Changes in Costing) using the method --Item Data Manipulation Before Transfer into
Itemization and the other methods,whether can you exclude the same.
Check and revert back.
Regards
Mangalraj.S

CK11N - How to exclude assembly scrap factor from Cost estimate

Dear Experts,
We have assembly scrap maintained in the material master. We also have operation scrap in the routings.
During the Cost estimate runs, we just want the system to consider the Routing operation scrap. I know one solution is just to remove the assembly scrap from the material master. However, we can't do this since it can adversely impact our MRP runs.
Does anyone has any idea on this?
Thanks and regards,
Vishal Thakur

hi vishal,
if you want to exclud the material fromt the cost estimate here is the short cut .
go to the material master of the material which you dont want to be costed
go to the costing views and flag the dont cost check box in that views
Best Regards

Planning of subcontracting materials with scrap percentage

Hi All,
Need your help for below mention scenario,
For planning, where my planning is start with subcontracting materials.
To clarify more, strategy group is defined in subcontracting materials. Now when I entering Assembly scrap or Component scrap in material master or BOM, system is not considering this scrap percentage for planning.
when i defining scrap percentage with procurement type, E (Inhouse Production) or X ( Both) system is considering scrap percentage. But for external like F or X with special procurement 30 (Subcontracting) its not considering the scrap percentage.
Please suggest, how I can plan subcontracting materials with scrap percentage.
Regards,
Rajesh
Edited by: Rajesh Sawant on Feb 18, 2009 4:54 AM

Hi Jejesh,
Thanx for reply.
This scrap is required for subcontracting materials.
Setting in material master,
In MRP 1 and MRP 4 view- Define scrap as Assembly and Component scrap as per the requirement.
Procurement key - F or X
Special Procurement key - 30 (Subcontracting)
Strategy group- 40 (Planning with final assy) in MRP 4 view.
Bill of Material setting,
Component scrap and Operation Scrap in Bill of material.
Based on above master data, Plan Independent Requirement (PIR) cration for above materials and MRP Run.
Here after mrp run based on above setting, scrap percentage is not considered. Plz suggest the solution.
Regds,
Rajesh

Milestone Confirmations & Operational Loss

Hi I have a concern with the use of operational loss during milestone confirmations.
The system will increase confirmed qty's in each each preceding operation were
operational loss exists during a milestone confirmation. Normally this would make sense however some operations prior to the milestone may be confirmed in the normal manner.
As a result imbalances will occur when assessing the order - here's an example of the problem:
Op Control Key   "Cnf Qty"    Loss     Comments
10   PP01               10             0        Op confirmed first via CO11n
20   PP01               11             1%     Op confirmed via operation 30 milestone
30   Milestone         10             0        Op confirmed after operation 10 via CO11n
40   PP01                0              0        No yet confirmed
50   PP01                0              0        No yet confirmed
Does anyone know if you can change this logic so that the milestone will not inflate preceding operations by it's operational loss? I don't want to remove the operational loss as a solution.
Clearly the above scenario would play havoc with production stats. If op 10 confirmed 10 then how can 20 have 11 going through it (it should equal the qty confirmed at 30).

Hi Alex
check the routing for the operation 30 in operation details for the operation scrap.
if you maintain the operation scrap 10% then if you confirm 10 at operation 30 then the system will expect 11 from opertaion 20.
remove the operation scrap and then execute the milestone confirmation. now for operation 20 also only 10 will be confirmes.
Hope this helps
SK
Reward your points

Operation scrap

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