Reporting of Rework / Scrap
Hi,
My scenario related to Rework reporting in ECC 6.0.
In my case, When i confirm the Rework at an operation, a Re work order is created automatically through Trigger point.
we account all the expenses against the Rework order and finally we settle the Re work order to the main order.
The rework order does not have the material .
Now how to get the report for the below requirements without involving any ABAP developments.
1. Rework quantity valued at Standard cost ( Rework qty X Standard cost estimate ) at any point of time.
2. How do i capture costs on the Rework order ? is it through regular CO activities ?
3. The rework expenses incurred for the original Order / Material ( Before Rework order settlement to main order).
4. Are there any special reports available for Rework / Scrap ?
Request your help.
Njoy
Siva
Hi,
I have given my inputs.
1. Rework quantity valued at Standard cost ( Rework qty X Standard cost estimate ) at any point of time.
As you have mentioned there is no material involvedin the rework, so the quantity valuation is not possible.
Only acitivity cost related to the rework production order are captured by the child order and settled to the parent order.
2. How do i capture costs on the Rework order ? is it through regular CO activities ?
Generally we wil have a Separate order type for the rework order.
So we need to view the cost collected through this order types in separate order type.
You can ues the coois ORDER confirmation report with the activities confirmed for this order type - but you will not get the cost displayed here.
3. The rework expenses incurred for the original Order / Material ( Before Rework order settlement to main order).
4. Are there any special reports available for Rework / Scrap ?
There are no special reports.
we need to use the standard reports like mb51 with scrap movement type for scrap reports.
coois with rework order type.
as this are not standard practices or best practicies SAP has not delviered any such standard reports.
Reg
Satheesh
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Hi,
Could you please suggest is there any standard SAP report to show component scrap usage or compare the BOM usage with the actual usage on the production orders?
Thanks & Regards,
NatarajTHis is a reply for the comparison of Bom usage with the actual usage in production order...
I am understanding ur requirement as you need to see the required qty(BOm qty) vs actual qty( GI qty) in a production order..
Go to COOIS, select components from the list.. give plant and execute...
you can add the fields reuired qty..(total)..
karthick -
Dear Gurus,
can anybody help tell me how rework and scrap are handled in discrete manufacturing. I have read that they can be handled using non standard discrete jobs. I need some details on how to get them workingHi
When manufacturing produces a defective item, you can move it to Reject or Scrap steps. You shall use Reject when you can rework the item, and Scrap when the item cannot be fixed.
Regards,
Ricardo Cabral -
Hi guys, anybody knows a report that shows scrap value or residual value of a set of assets?
Thanks in advance,
Daniel Moreno.Hi,
if you use an explicit scrap value in the asset master record, then you can simply add this field scrap value to your output list. How to do this is described in the SDN WIKI article [Include own fields in FI-AA standard ALV |https://wiki.sdn.sap.com/wiki/display/ERPFI/IncludeownfieldsinFI-AAstandardALV]. The field to be added is ANLB-SCHRW.
If you use a scrap value percentage rate, a memo value or a cut-off value key, then this is not possible. Scrap value percentage and cut-off value have to be calculated at report execution. And the memo value is not asset specific.
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Markus -
Hi SAP GURUS,
1) Is there any standard Raw Material Inventory report that shows value by inventory type (scrap, alloys, principal supplies, spare parts and minor supplies, WIP, finished goods, graphite, and the reserves for those material types
2) A report that shows Scrap receipts by plant u2013 by material and also a report that shows the recycled scrap receipts by type. Would like it to show quantity in lbs and gross tons as well as the value and average cost per gross ton
Thanks
Anusha
Edited by: anusha vemulapati on Jan 19, 2009 3:25 PM
Edited by: anusha vemulapati on Jan 19, 2009 3:25 PMYou try with this report. And selection option is there, select which option you required
Tcode: S_P00_07000139.
It may help full.
Regards
Jrp. -
Dear All,
In My Production order there 5 operations. My Production Order quantity 50 NOs.
I have confirmed first 2 operations with confirmed yield 50. In the 3rd operation, Rework qty 10 Nos and confirmed yield is 40 Nos
Once i entered the Rework quantity in the Rework field in confirmation screen, system is not generating stock for the Rework quantity entered.(10 Nos).
I created the stock for the Rework through confirmation Goods Movements screen as a bi-product(531 movement type).
I created a Rework Order through CO07 and issued the bi-product what i generated (through confirmation) to this Rework Order.
I confirmed the Rework operations.
Now i am trying to enter the 10 quantity(which was Reworked) in the 3rd Operation. System is not allowing to confirm and it gives the error message " over delivery not allowed"
System is adding confirmed yield + Rework+Scrap as the total operation qty confirmed.
How to confirm the Rework qty as confirmed yield after completion of Rework in the Same operation.
Please guide me to solve the issue.
Thanks & Regards
BalaMicheal,
Either yield, rework or scrap are only the declaration that the particular operation has been completed.
It's nothing to do with he stock as it does not represent any stock.
So even if you post the rework material as by-product then too system won't establish the one to one relation.
Inplace of posting the qauntity as a by-product use concept of trigger point to create the rework order for rework quantity.
There is plenty of threads related to trigger points. Search for the same.
Moreover just for information purpose if you want to convert the error meassge for over dlievery to warning message you need to maintain the confirmation parameters in OPK4, under 'Checks' for overdelivery make setting as 'Over delivery tolerance is not checked'.
But this is not to solve your problem. Better go for trigger point.
Hope this helps you.
SmanS -
Rework with partail confirmation
Hi Friends,
i see almost all the threads related to Rework suggests triggering reowrk process( Adding ROS to Existing prod order or Creating a new rework order) with trigger points with PCNF Status.
Howvere if idn in actual business there could be N different reasons for the PCNF opartion status.
It is possible to set opartion status to PCNF with posting of full yild wty ( rework / scrap 0) .
If we set PCNF status to opartion with co11n confirmation where Reowrk is 0 and i find Rework order is cretaed with default qty of 1 automatically which is not ocrrect.
How to make sure Rework order is only created or ROs is only inserted *if Rework Qty is not Zero in Co11n.
any otherbeter way to handle this?
Can reason of varaince be used here to trigger the suer status and then use user status to trigger the trigger point?
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Santosh
AccentureExperts,
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Batch split during production order confirmation
Hi All,
This is the process which is followed at our customer end, they want to split the batches during confirmation,
1.Production order created
2.While going through each operation, some components are failing in the in-process inspection and they need to be quarantained for further process,(it may be rework, scrap, etc)
3.Now the question is we want to create individual batches, say for example out of 100qty which went operation number 10, 50 were found to be o.k. and the remaining 50 are having defects, we want to create two different batches for this scenario at the time of confirmation.
Is there anyway in SAP todo this , like userexit
Has anybody has gone through similar scenario's
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Venkat.Dear Vanket,
In the operation you can confirm Yield, Scrap and rework quantity.
In your case in each operation you need to create a batch for each qty what you enter.
As I told you before batch can be created either production order release or during GR.
In each operation you are not going to perform GR, hence batch creation is not possible.
You have 2 options as I see.
1. Create different intermediate materials and have production orders for each operation so that you can do the GR for each production order.
You can have the same batch for each stage material so that issuing material and production materials are different but batch is same.
If there is any defective quantity you need to decide you want to scrap it or you want to go for rework. If you want to go for rework then, using trigger point function you can create a auto rework order for the qty of rework entered during confirmation.
2. Second option is you can create a production order as you are doing now, but you need to create batch manually in MSC1n transaction for rework as well as yield qty.
You can confirm the yield qty and rework qty, but you cannot assign the batch as you are not performing GR. You can enter the batch number in the confirmation text field for information purpose. During the final operation when you do the GR, assign the batch to yield qty and post. About the rework qty you are not going to post qty to store, you need to create rework order and confirm the qty, during GR you can assign the batch and do GR.
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Please go through the above carefully and test the cycle and come back if you need any clarification. -
In-process inspection and confirmation
Hi, i have used 03 insp type in material master. for each operation, some characterstics were assigned. after prod order confirmation with co11n t-code, i have done results recording thru qa32 t-code. even without confirmation (co11n) also, system allows to record the results thru qa32. please advise how can we restrict this? is there any link or relation in between confirmation and results recording?
Dear Yadav
Let me explain to you in detail the business process and the relevance of 03 inspection .
1)Suppose you have a product A and routing of this product A be like this.
0010 Forming > 0020 u2013 Winding > 0030 Testing > 0040 Assembling > 0050 Final Finishing.
2) In a normal production process suppose you have a production order of 100 for product A
3) Now during the production process you need to confirm each operation through CO11N what was the yield, rework, scrap, activity time taken etc.
4) Once all the operation are confirmed the production order is GRu2019ed and this product A goes to quality stock for 04 inspections. 04 inspections is always considered as Final inspection.
5) 0030 operation being a inprocess inspection , 03 inspection type gives the Quality personal a control over the confirmation process.
6) Quality personnel can do not only result recording but also confirmation of the quantity thereby giving him the control over the production quantity.
7) Quality personal can also do the testing partially and record result multiple times and confirm partially
8 ) To bring the confirmation pop up in QA32 you will have to do
a) In Routing at header kindly maintain inspection point as 150
b) At Operation level maintain a QM work center ( testing ) with Control key QM04
b) double click on the control key and go to Quality Management : Inspection points
c) Maintain Inspection point completion : Quantity , Valuation and confirmation
10 ) For a better control over the 03 inspection these setting have to be defined in PP configuration for production order Type in Tcode OPK4 in config
SPRO > Production> Shop floor control> confirmation> define confirmation parameters
Maintain
1)Operation sequence u2013 error when order sequence is not adhered to
2) Overdeilvery u2013 Error when over delivery tolerance is exceeded
3) Results Rec. (QM)- Error message if no Insp results exist
Edited by: Gajesh Nagesh on Dec 17, 2009 9:12 AM -
Rejection qty stock at operation wise
Dear All
I have a problem for getting the Rejected quantity stock at each operation wise.
Material 'A' has 10 operations in the routing.
At each operation some qty may get rejected.
How to account the stock of rejected quantity at each operation level?
If i enter in the Rework / Scrap field in the confirmation screen, i can't getting the stock anywhere because there is no seperate material code for that operation.
I tried by creating a Seperate material code for the Rejection qty and assign it to the BOM. But it is not viable that creating seperate material code at each operation level.
Please explain me what is the standard procedure to follow.
Thanks & Regards
Balayes
stock will not be upadate unless until u maintain the material as negative qty in the bom if u know rejection qty is knwon before planed order creation.
i think in your case rejection qty is known at the time of confirmation, for this u declare rejection qty as scrap in scrap filed at the time of each operation,after that clcik on goods movemnt button,there u can add manually material name and storage location and movement type is 531 ,on which material u want to post the stock.
Edited by: sukendar neelam on Jan 22, 2009 8:22 AM -
Raw Material V/S Finish Product
Hi Experts,
Bellow i am giving the my scenario, kindly check it
I am creating 100 FG
For that FG i issue 100kg Raw Material
After Production i got 100Nos. FG
But in KG i got only 80 Kg., Because 15 Kg. is Rejection And 5 Kg. is Process Loss.
I have problem with process loss , where and how can i track this process loss .
Thanks
UtkarshDear Utkarsh,
Because 15 Kg. is Rejection And 5 Kg. is Process Loss
1) Can you let us know, in confirmation screen how ur giving rejection & process loss
2) based on above experts can give some inputs
3) more if ur going with rework, scrap or by-product process
4) you can track in COOIS against Prd order
Regards
Madhu -
Hi gurus,
can any one say how to hide rework and scrap field in co11n confirmation.
Regards,
RamRam,
OPK0, is the config where we can modify the layout or fields required for CO11N. I think for you to hide both Rework & Scrap you there is no option in this config.
I would suggest you to create transaction variant for CO11N using SHD0 transaction and assign the same to CO11N transaction.
Regards,
Prasobh -
Dear Friends
I want to inspect a semifinished product both in the inprocess stage & after the processing completion. Now in MMO1 I have to activate both 03 & 04 inspection types. Which inspection type I have to mark as preferred inspection type because during inprocess checking I have to mark 03 as the preferred inspection type and once inprocess checking is over I shall have to again go to MMO2 and change 04 as the preferred inspection type. Every now and then shall I have to frequently change the preferred inspection types between 03 & 04.Please guide.
SelvaDear Selva
Let me explain to you in detail the business process and the relevance of 03 inspection 7 04 inspection
1)Suppose you have a product A and routing of this product A be like this
0010 Forming > 0020 u2013 Winding > 0030 Testing > 0040 Assembling > 0050 Final Finishing
2) In a normal production process suppose you have a production order of 100 for product A
3) Now during the production process you need to confirm each operation through CO11N what was the yield, rework, scrap, activity time taken etc.
4) Once all the operation are confirmed the production order is GRu2019ed and this product A goes to quality stock for 04 inspections. 04 inspections is always considered as Final inspection. 04 inspection is triggeref when GR of the production order is done
5) 0030 operation being a inprocess inspection in the above production process quality personnel doesnu2019t have any control over anything. That is wherer 03 inspection type helps a lot in having control over the confirmation process.
6) By activating 03 inspection as the Production order is released inspection lot is created. quality personnel can do not only result recording but also confirmation of the quantity thereby giving him the control over the production quantity.
7) Also quality personal can do the testing partially and record result multiple times and confirm partially
8) Please note the partial quantity pop up which you get while result recording is just an information purpose recording. By entering any values it is not at all related to any quantity confirmation
9 ) To bring the confirmation pop up in QA32 you will have to do
a) In Routing at Operation level maintain a QM work center ( testing ) with Control key QM04
b) double click on the control key and go to Quality Management : Inspection points
c) Maintain Inspection point completion : Quantity , Valuation and confirmation
10 ) For a better control over the 03 inspection these setting have to be defined in PP configuration for production order Type in Tcode OPK4 in config
SPRO > Production> Shop floor control> confirmation> define confirmation parameters
Maintain
1)Operation sequence u2013 error when order sequence is not adhered to
2) Overdeilvery 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 operation only after 0030 operation is confimed by quality personal.
2)Overdeilvery 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.
Hope this gives a good idea of 03 inspection
Please let me know if you have any further clarification required
Regards
gajesh
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