REM: production tracking, rework, and in-process inspection

Gurus,
I have three issues with REM, and I have my own views on them:
1. Rework: In case of discrete manufacturing with the help of trigger functions we can generate an operation (in the same order) or a rework order to cary out reprocessing. But in case of REM we cannot achieve this because there would be no order for inserting new operation and since it is REM we should not generate a new order. The only way is to manually backflush the activities and components (without any reporting point).
2. Tracking: In case of discrete we have a set of system generated production orders through we can track the GRs, confirmations and issues. But in case of REM we can track those parameters only against cost collector. Only way to know the pending activities is to carry out backflushing against planned orders (which are subjected to reduction) and check pending GR/GI/Operations with the help of the remaining planned orders. Are there any standard reports on that?
3. In-process Inspection: Can be achieved through inspection type 13 and lot needs to be generated through t-code MFPR.
Kindly let me know if my understandings are correct. Please let me know if there are other way arounds in Standard SAP.
Thanks in advance!
Snigdho

HI
As In discrete there is no Rework order in REM.For Tracking you need to assign the Planned order to the Prdocution versions in Planning table thru MF50 and then Backflush against the planned order .Check report MCP6/ MCP8 for GR against planned orders.
Inprocess inspection can be done thru 13 and lot generation is done thru MFPR.
hope it is useful.
Regards
Anupam Sharma

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REM Product cost collectors and Production version

Hi All,
Can some one pls let me know
What are the product cost collectors in REM and how to create the product cost collectors ?
What is the production version and the difference between production version and controlling version?
Thanks & Regards,
Bujji

Dear Bujji,
A product cost collector is a cost object in Product Cost by Period that collects the periodic actual costs incurred in the production of a material. It can be created in txn KKF6N.
[Product Cosr Collector|http://help.sap.com/saphelp_47x200/helpdata/EN/08/77ba810a1611d3a6b900104b55d538/frameset.htm]
[Product Cost Collectors: Collective Entry for Repetitive Manufacturing |http://help.sap.com/saphelp_47x200/helpdata/EN/08/77ba810a1611d3a6b900104b55d538/frameset.htm]
A production version determines the various production techniques that can be used to produce a material. It defines the following information:
Alternative BOM for a BOM explosion
Task list type, task list group, and group counter for assignment to task lists
Lot-size restrictions and period of validity
A material can have one or more production versions.
It can be defined in the Material Master (txn MM02) in one of the following views:
MRP 4
Work Scheduling
Costing 1
The costing version is a different issue. It is a costing parameter and is used to save several cost estimates for the same material, with the same costing variant and the same costing date (e.g. in oder to cost the material several times with minor changes without creating new costing variants).
BR,
Antje

In process Inspection and Rework Qty Issue

Hi,
There is Production Order for 100 qty. There are 5 in process operations like 0010 Cutting, 0020 Welding, 0030 Inspection, 0040 turning, and 0050 Inspection
(1)0010 operation is finished by production for 50 qty and confirmed through co11n by entering yield as 50 qty.
(2)0020 operation is finished by production for 50 qty and confirmed through co11n by entering yield as 50 qty.
(3)0030 operation: Quality inspected and entered results as 25 as yield and 25 as rework. For defects Q3 notification is
     triggered.( ie CO11N transaction is called in QM)
(4)Production opened rework order CO07 and confirmed the rework operation and booked material and labor cost on cost
     center instead of orginal order.
(5)0040: Operation production could confirm only 25 qty as earlier 0030 operation of inspection yield was only 25 qty.
(6)Inspection already in 0030 operation 25 qty was entered as rework. Now after rework how results recording will be done
     and qty will be posted in yield. Unless yield is entered under 0030 operation for 25 qty , production cannot confirm the 0040
     operation for pending 25qty.
(7)Business requirement is what ever the qty production manufactures it has to be entered in system. Based on quality
     inspection incentive will be paid to only qty which is passed by quality.
Settings Made:
(a)100 Free Inspection, No Qty Relation, Quantity Valuation and Confirmation in Production for only inspection work center
     without any cost capturing.
(b)Confirmation parameters settings with error for over and under delivery tolerance, error if inspection sequence not adhered,
     error message if no inspection results exists
Any suggestion or any other way of handling this requirement.
Thanks & Regards,
RSR

Hi RSR,
Your way of mapping is absolutely fine, few points to be clear...
03 inpection type and enable inspection characterisitics for operation 030
04 inspeciton type to be enabled and operation 050 shall be eliminated if possible, material stock posting will be done from 04 inspection lot for 25 nos.
let me know if you have questions..
regards,
Lenin. A

Production order should be confirmed before in-process inspection UD

We guys,
I have activated the In-process inspection for one Finished goods and inspection lot is getting created when Production order released. This production order can be confirmed without UD for In-process inspection lot.
Please let know How can I control that Production order should not be able confirm before UD of Inspection lot for in-process inspection.
When production order released it means an production has just starded. Then What is the meaning in getting the inspection lot created on release of production. I think it is supposed to be on completion of each opration.
Please give your inputs.
Thanks
Dhanu

Hello
inprocess inspection are used to assisst you to record results , defect , rework, during the production operation. It is defined to get created during the release of the order. It gives QM personnel a control over the quantity confirmation. You can do the result recording based on time and quantity.
Operation confirmation and UD are independent and it will not be possible to do confirmation once you do the UD.
The controls that can be brought in 03 inspection for a better usage
1) Result recording mandatory for all inspection points
2) QM operation can be confirmed only by QM personnel
3) At the time of GR of the order check whether UD for the lot is given. Make UD mandatory for GR of the order
4) Only after QM operation confirmation the next operation can be confirmed
5) make use of Rework to capture rework cost and First Pass Yield
Hope this gives some picture to you
Regards
gajesh

In-process inspection for rework operation

Hi all,
i have a production order to which the in-process inspection characteristics are assigned in routing. when a production order is released, an in-process inspection lot is created. Inspection is carried after the end of an operation. During which rework will be carried out if the product is rejected. Rework operations are trigged through trigger points assigned to the production order. A reference operations set indicating the rework operations is assigned to the trigger point. rework operation in the reference opeation set is also assigned with inspection characteristics. But during the results recording, the rework inspection characteristics are not displayed for results recording.....
pls explain the possible solution.
regards,
sravan kumar v

Hello
I think that the process can be mapped in one of these ways:
- according to what you describe this is closer to a good receipt inspection and not to in-process inspection, as the trigger for the inspection is the GR and not the release of the order. So, why dont you give a chance to a 04 inspection type, with inspection lot creation for every GR ? Check the indictor in MM02, QM view for "04" inspection, and uncheck the "Stock in quality", so you dont get caught by the stock in quality and resembles in process "Non-stock relevant" inspection
- alternatively you can define the use of inspection points ? So you are adding new results as new confirmations are made. Disadvantage: you can only give one usage decision to the inspection Lot, irrespective of the number of samples you have analyzed.
Regards

In process Inspection Lot Qty and Actual Lot quantity difference.

Hi Experts,
In case of In process Inspection
Scenario : 1. Production Order created, released but before saving the qty is changed.
2. Production Order created released and saved. Then qty is changed in Change Prod order txn.
These scenarios are causing a discrepancy in Inspection Lot Qty and Actual Lot quantity. Is there any method to avoid this ?
This can be made correct in Inspection lot by resetting the sample calculation. But once confirmation has started for Prodn Order (not necessarily QC operation) or RR has been done resetting is not possible.
Is this the std behavior ? Disallowing the resetting once RR done seems OK, but even if any of the operation in Prodn Order is confirmed it still give status error while resetting. Canceling all the confirmation all the way back also does not solve the problem.
Any suggestions ?
Regards
Joe

Hi
Although your suggestion is valid, it is not practical from user point of view.
Moving this thread to QM forum.
Rgds

About the first inspection before mass production ,and the end inspection after mass production

Hi ,experts :
       There is a scenario about my customer : before mass production they need to do first inspection avoid a lot of defect for the finish goods ; and he also need doing the end inspection to check whether the mold can be used for next batch or need to do some repair .
     I want to add two operations in the routing ,but it seems unreasonable .
     Can anyone give me some advice for it ? thanks advance .

Hi Avril Liu,
OPTION - A
I think, you can try the below option which may not be the best solution but looks logical to me -
a) Create to inspection types 8901 (Initial Mold Manual Inspection) and 8902 (Final Mold Manual Inspection) and assign them to inspection lot origin 89. Please note these inspection types are manually created and these are not linked to stock movement.
b) Use the inspection type 8901 to test the initial condition of the process. In case if the UD = R, then use enhancement to create a new 8901 inspection lot by linking the old number in "TEXT" field.
c) If the next inspection UD = R, then repeat the manual inspection lot 8901 inspection lot creation step. If the inspection lot 8901 UD = A, then this process is Good to start he process. So create a follow-up action and send emails to stakeholders.
d) If you are not interested in testing the in-process quality of the produced materials, then you need not need 04 inspection type to be added for GR inspection. If you do test (I think yes, based on your answer...) you can add this inspection type to your material. Then you will be able to Release/Block your produced materials too using UD= A/R respectively.
e) Once the production process is complete, you can create manual inspection 8902 to test the mold characteristic. If the UD = R, then again execute the enhancement to create a new inspection lot 8902, by adding the previous inspection lot number in TEXT field, and keep repeating this process. If the UD = A, then there is no further need for testing, and follow-up mail can be send to the stakeholders for the completion of the process.
OPTION - B
Else, you may need to use inspection type 14 linked to your equipment doing the production, to test the mold characteristics. This process will be linked to PM-QM module, and you need to map this process too.
1st inspection can be linked to 89 manual inspection to double check the process and the final inspection after entire production can be done through inspection type 14. Checking the produced material quality will again need inspection type 04 activation like normal process.
Thanks,
Arijit

In process inspection for partial confirmation of production order

Hi QM Guru,
how i will do in process inspection for partial confirmation of production oder
Senior is this I have maintain inspection type 03 in finish material u2026..suppose production order quantity 20 kg..there are 2 operationu202610 and 20.. I have maintained MIC on operation 20u2026after release the production order lot are generatingu2026but when they confirm operation 10 they do partial confirmation for 10 kgu2026.then again when do confirmation 20..they checku2026for quality resultu2026
Then I do the result record ok of 10 kgu2026then they confirm 20 operationu2026.
Now. again he do the confirmation of rest production order 10 kg..opration 10 ok..but in operation 20..system does not check for qualityu2026..
Again I want to do the quality inspection of 10kg on 20 operationu2026
How I will do. kindly suggest me
Regards
Aqueel

Hello
I think that the process can be mapped in one of these ways:
- according to what you describe this is closer to a good receipt inspection and not to in-process inspection, as the trigger for the inspection is the GR and not the release of the order. So, why dont you give a chance to a 04 inspection type, with inspection lot creation for every GR ? Check the indictor in MM02, QM view for "04" inspection, and uncheck the "Stock in quality", so you dont get caught by the stock in quality and resembles in process "Non-stock relevant" inspection
- alternatively you can define the use of inspection points ? So you are adding new results as new confirmations are made. Disadvantage: you can only give one usage decision to the inspection Lot, irrespective of the number of samples you have analyzed.
Regards

GATP Product allocation status report and backorder processing

Dear Experts,
We are using product allocation as the first and only step in GATP check.
The scenario is like this:
Sales order total quantity = 200
Planned allocation quantity=150
Thus
Confirmed sales order quantity=150
Questions:
1.Now how can see the confirmed/unconfirmed situation for all sales orders.
Is there any standard report.
I understand that this report need to show the planned allocation quantity,total sales order quantity and the confirmed sales order quantity may be bucket wise.Also this report can show the details of all sales orders in the bucket.
The GATP planning book only shows confirmed sales orders in the "sales order" keyfigure until you have introduced another order series key figure for sales order(not related to GATP) which has sales order/scheduling agreement category group assigned to it.
2.Can I do backorder processing of sales orders assuming that after the above report is run,I have changed the planned allocation quantity from 150 to 200 and I need that the sales order can be confirmed now by this program rather than by going into ECC and triggering the GATP check again.
Note that the stock availability situation may remain the same.
Request you to kindly suggest if this is possible in backorder processing.If yes,then what are the settings and the transactions to execute this.
Thanks,
Chandan

Thanks so much Michael for a prompt reply.
Couple of points.
1./sapapo/ac42-This report is helpful but this has 2 issues.
It has to be run at individual CVC level.Thus it is not a comprehensive report.
It does not provide sales order original quantity.It just provides the planned allocation quantity,confirmed sales order quantity and the remaining quantity.This is normally already available in interactive planning of GATP planning area.
What we need is a report which must say what is the original sales order quantity and how much has been confirmed and how much is the bucket planned allocation quantity.
2.Running ATP in product view or interactive backorder processing view may not help as they seem to be working with ATP group and not with check mode.Note that product allocation gets triggered when check mode comes into play.
Do you know if we can make it work with check mode.
3.The batch backorder processing is working when I am using the "update changes" option.I am still evaluating the results as I don't understand many settings here.It will be nice if you can elaborate on some of the settings used in this transaction please.
Thanks again.
Regards,
Chandan

In-process inspection in repetitive manufacturing

Hi,
My client handles assembling of electronic products. product passes through different set of operations where in it proceeds to the next operation only when the prior operation is approved in terms of quality.
We are trying to go with repetitve mfg but we are unable to understand in-process inspection operation wise. Pls advise is this feasible or we only need to go with discrete mfg with production orders.
Regards,
Sravan Kumar V
Edited by: SRAVAN KUMAR on Oct 6, 2008 6:45 AM

Dear,
1. Setting up inprocess inspection
for inprocess REM you have to maintained inspection type 13 in material master. and select task list. for that you have to maintained inspection point in your rate routing for ex for partial lot quantity based.
2. GR Inspection from production
then you go for result recording for inspection point and do the reporting point backflushed through result recording of every inspection point.
3. At what stage the QM lot is generated .
for that you have to create inspection lot in t code MFPR for your production version and for that inspection lot you have do above work.
Please refer this link also,
http://help.sap.com/saphelp_46c/helpdata/en/8a/a5aadd4adc11d189740000e8322d00/frameset.htm
Regards,
R.Brahmankar

In Process Inspection for Repetitive Manufacturing

Hi All,
I'm trying to perform in-process inspection for repetitive manufacturing. I have a semi finished material which has the inspection type 13 activated in the material master. Rate routing for it has also been created. Characteristics have been assigned to its operation and the routing is attached to a production version. When I o to MFPR to create a lot, I specify the material, plant and production version with QM active (tried the other 2 options as well) but when I execute, nothing shows up in the list. When I click on create inspection lot, it says, "either select versions or place cursor on versions now" but there's nothing in the list?
Regards,
Bilal

Hi,
Please check whether the repetitive manufacturing check box and REM profile is defined in the MRP4 of material master.
Please define that and try to run the transaction MFPR.
It should solve your problem
Regards,
Sumit Gupta

QM In-Process Inspection for Batch Managed Material

Hi,
I have a issue related to UD of In-Process inspection for batch managed material. The production process is discrete manufacting for a cold rolling mill. A production order can have mutiple coils as per the production amount. To track the individual coil , batch management has ben activated. We have both in-process as well as inspection after production here.
For inspection after production we are fine as we are doing partial confirmation after every coil and have separate inspection lot having different batch number.
But for in-process I can have only one inspection lot for the production order (created on release of the production order). I can do the result recording but while trying to do UD u2013 it is asking for a batch number as the material is batch managed. W/o entering the batch number system is not allowing me to do the UD.
Is there any solution/work around of this problem.
-Regards
ashim

Hi Ashim,
you raised a very good question? i am helpless here to execute same scenario,
but i disussed with my QM guy here, he said, once the material is batch managed then it has to ahve batch in UD.
so i discussed ur case, which is very much valid for heavy ind like cement and all,
so what i suggest, u create a dummy batch in the UD for in process (no inventory posting)
and at confimation give ur usual batch (if system propose the dummy batch which u give in the UD for inprocess, try to change there--- i hope it should allow)
i would really like to here answer from u for this.
try to do as suggested, and let me know the results.
REgards,
Pravin mukkawar

In-Process Inspection material having inspection type 04

Dear Sir/Mam
My question.In-Process Inspection material having inspection type 04.As we accept the inspection lot we put the stock into unrestricted.But when we have to reject we convert that stock into new material or if rework to be carried out,the criteria is stock should be quality,than production people cancel the confirmation and rework is carried out through trigger point.So my concern can we put the stock in block and in background whole production order is cancelled.
Thanks
kunal

Dear Kunal
This is the process i have defined for rework. let me know your feedback
1.Reject the material in QA32 to block stock
2.Reverse faulty material using Tcode MB1A u2013 262 movement type against the production order
3.if you need to scrap highly faulty materials use Tcode MB1A u2013 551 movement type against a cost centre
4.Create a rework order using Tcode Co01 order type (PP03)
5.Enter the Parent production order number in the goods receipt tab in Co01. (inbound delivery)
6.Issue goods against the rework order using MIGO
7.confirm the rework order through co11n
8.Move the material back from block to quality using Tcode MB1B u2013 349 movement type (activate 08 inspection)
9.Inspection lot created
10.Do the posting accordingly
Regards
Gajesh

Rework and scrap note generation

hi friends,
i want to generate scrap and rework notes to be generated while doing in process inspection with reference to which the shop floor peoplle will create a production order for rework or post the quantity to the scrap store.
here while doing quality inspection in inprocess operation ie. result recording , we will find defects but how to list them as scrap or rework quant as we are not putting anu usage decession UD for inprocess inspection?
please suggest how to generate notes for scrap/rework.
thanks and regards,
omkar

hi,
while result recording time, if you find scrap then call defects recording from the page itself , enter the defects and create a notification with type F3. In notification you mention the task , and action to be taken (assign high priority)and send it to the users directly .
once they can receive the message , they will create the rework order.
regards
rajesh

Production order-rework

Hi friends,
My strategy is Make to stock production. I have created my production order of quantity 100. Then i have deliverd the same quantity of 100 to store in t.code MB31 (against my order). Then i closed my order
My order status is:
CLSD CNF DLV PRC MACM GMPS SETC.
I have stocked my quantity in my store. Afrer 3 months, our people wants to sell the product through sale order. Now they find some damages in that final product. Now sales is returning the final product to production for rework.
How to reprocess the closed order again? How to go about with this scenario?
please guide me
Thanks
kumar

Hi Senthil,
Good afternoon and greetings,
Made to stock in production term is called as Repetitive Manufacturing and the cost object for the same would be Product Cost Collector. The Product Cost Collector doesnt have the concept of closing fully basically because the product cost collector would be a replica of the material itself.
In your case, a rework for production order is applied through by adding an additional work centre in the routing called REWORK. Re-opening a production in a different period may lead to confusion basically because the planned cost at the time of creating the order say before 3 months would have been £100 per PC. Now the standard cost estimate is £125 per PC and reopening the order will redetermine the planned cost again and when it is settled it will hit your profitability very badly because the variance would be £25 + rework cost. Thereby it is advisable to use the concept of standard REM.
Alternatively, if you want to use the Production Order only, then follow the sequence as below
1. Move the material from one code to another rework code
2. Create a new routing with REWORK work centre for the rework material code.
3. Create a production order for the rework material code
4. Transfer the material from rework code to main material code.
5. Settle the production order for the rework material code and thereby your P&L would be intact for the additional cost involved on the Rework.
Please reward points if found useful.
Thanking you
With kindest regards
Ramesh Padmanabhan

REM: production tracking, rework, and in-process inspection

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