Rework & Scrap Handling

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 working

Hi
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

Similar Messages

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

Reconcillation in scrap handling

Dear all,
How to do the reconcillation process in scrap handling ?
Can any body give the step by step Procedure ?
How to handle the SCRAP in FI please tell me the Possible ways !

Dear,
Please give your scenario in your company about SCRAP...we can give you the idea...SCRAP definition in SAP is different and normal what we call as SCRAP...be specific to your requirement os that we can give you some idea

Scrap Handling

Dear Sirs,
the company is selling empty oil drums, packing material like wooden pallets, card board boxes etc (in which the raw material has come) to some scrap dealer.
how can we capture this in SAP.
this is not supplier returnable packing
regards
ajay arora

Hi Ajay,
I. One way is 1. create a scrap material with sales views. 2. Then upload the scrap material stocks with 561 movement.
3. Then sell the material.(sales order, delivery, billing)
II. Other way is 1. create a scrap material with sales & purchasing views.
2. Create a dummy vendor.
3. Then create a PO on this dummy vendor for this scrap material for procuring this as a free goods item.
4. Then do a GR.
5. Then a sales order, delivery then billing.
Thanks,
Viswanath

How to handle scrap?

Hi,
I would like to establish the scrap handling process & i have the following queries. Kindly suggest from where i can get all these information or some body please suggest. Sorry if i have posted wrong query.
1) how scrap is handed in Production orders, BOMs etc.?
2) what material type should be used for scrap?
3) which movement types should be used?
4) about the accounting for scrap?
Regards,
Sathya.

Dear Sathyanarajana,
Visit the following links for information regarding Scrap Process:
http://www.sap-basis-abap.com/pp/scrap-management-in-finished-product.htm
Enter the Scrap
Regards,
Naveen.

How to handle subcontractor scrap

Hi All,
We have a requirement in subcontractor scrap handling , the process is like input materials are sent to subcontractor for processing , in some situation the input materials sent will have hidden defect/damage and at the time of subcontractor processing only the defect will be known and the whole assembly gets fully scrapped , so the vendor returns back the same.
My question is how to take back the scrap? by doing migo 101 and 543 and then scrapping in quality? or do 542 and take back the assembly and then scrap it in 551? if we do migo 101 and 543 , then the PO will be considered as closed and further if we need to send fresh input materials to vendor against the same PO reference this will be a trouble , since we have activated a user exit for not allowing excess qty against the PO line item for 541 movement type , this is same case if we do 542 and PO will get open once again and user exit will now allow the input materials to be sent in 541. The other option is doing 553 (scrap at vendor end) which will not suit our business need. Also if we do scrapping only the Assembly gets scrapped and not the components ? correct . Anyone who had this same requirement pls provide your valuable inputs/suggestions.
Thanks in advance
Benny

Hi There
1. Do 542 for the problematic components and send the fresh batch of material and it will solve,, it is not confused process, it is straight away you can get the clear vision,,
2. Scrpping at vendor- will may impact in Vendor Performance( if the Vendor evaluation is active) and the cost may involve in their cost,, (Check with your FICo team for more details on this)
If the user exist is not active, you can do the following also,,
Maintain in the PO-Sub con BOM, for the rejected qty as by product and receive the goods only for the finished qty, consumbtion will happen only for the recd qty and the rejected qty as By product, you can get the material back which is really scrapped,,
Hope it helps to get the idea of further step
Thanks
Senthil

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?
Regards,
Santosh
Accenture

Experts,
Any comments on this..

In-Process Rework

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
Bala

Micheal,
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 ooperations

Dear all,
I am facing a problem in rework operations.Can anybody suggest me how rework is handled and how it is to be configured in system?I have 3 options...creating an order without material,using reference operation set and inserting rework operations.Enlighten me which is used in what scenarios and how to configure?
thanks in advance...

Hi,
I can explain how an rework order is created with
reference op set.
First check in Tcode OPJF for the selection id a
Priority is defined for the Task list type S
with usage 1 and status 4 and then Proceed as
follows.
1. First create a Reference op set in tcode Ca11.
Enter the plant,Description , usage and status
for the ref op set
Enter lotsize and unit of measure.
Enter the op as 0010 / workcenter/op control
key/Description for the op
Enter the standard values and save.
2. Create a Standard trigger point in CO31.(Ex
Production)
Enter the Trigger Point usage /Group as FERT.
3.Tick the Trigger Point Functions.
4. Enable the indicator create order with Reference .
5.Enter the system status as PCNF.
6. Enter change as +.
7. Enable the indicator once.
8 . Now place the cursor on the create order with reference.
9. Goto Parameters.
10. In the Parameter enter in the group the created Reference op set group no.
11. Order type as PP01 and group counter as 1 and save the Trigger Point.
12. Now goto the Routing for your Material.
13. Choose the last op to assign the Trigger point.
14 .Select the OP -
> Goto ---> Trigger Point overview.
15. Enter the Trigger Point usage as FERT.
16.Now choose that line ,select the Details---> Trigger Point
17. The system will says standard trigger point exists from which you can
select the created Trigger Point (EXx Production)and save.
18. MD02/MD04.
19. Convert the Planned Order into Production Order and Release the order.
20 .Now confirm th ops.
21. For the last op enter the yield and rework qty
and set the status as PCNF.
22. If the status of last op is PCNF then in the
system a POP UP will appear as Activited by
Trigger Point /Create order with reference/order
number/sequence and op number which trigger point
works and enter.
22. Now a rework order will be created.
23. In c003 enter the number which is next to the actual prodn order no.Rework
order will be seen.
Regards,
nandha

ETO and MTS

<b>What is ETO(Engineer to Order) and MTS(Make to Stock)?</b>

Hi
Make-to-Stock (MTS)
The scenario Make-to-Stock (MTS) Production with Serial Numbers, QM and WM focuses on: Sales-order-independent production by MTS (make-to-stock) combined with a variety of logistic functions, such as bulk material, scrap processing, missing parts management with workflow integration, rework processing, Handling Unit Management with serial numbers, batch management, warehouse / lean WM management with FIFO material consumption and QM in procurement.
Process Flow
This scenario involves the following processes:
Costing run
Sales order processing with availability check
Material requirements planning (MRP)
Procurement of components with purchase orders and scheduling agreements
QM on procurement and quality inspection
Make-to-stock production / Production order processing for finished good and subassembly
          o Order creation and release
          o Printing of shop floor papers with barcodes (optional)
          o Picking according FIFO strategy with/without WM (Full WM/Lean WM) integration
          o Scrap processing
          o Rework order process (for subassembly)
          o Order Confirmations
          o Workflow for missing parts
          o Bulk-material processing
          o Serial number assignment for finished goods
          o Goods receipt with Handling Unit Management integration (HUM only in DIMP)
Batch management for finished goods and components
Delivery with serial numbers and handling units (HUM only in DIMP)
Overhead- / WIP- / variance calculation / order settlement
Key Points
Material requirements planning (MRP)
Procurement
Quality management in procurement
Production order processing
Handling Unit Management (HUM only in DIMP)
Serial number management
FIFO processing with warehouse management (full WM / Lean WM)
Batch management
Scrap processing
Rework order process
Workflow integration
Cost Object Controlling
http://help.sap.com/bestpractices/industry/indusmachinerycomp/v1470/IMC_DE/html/E79_MTSSerNo_EN_DE.htm
Re: Make to Stock / Make to Order
Engineer-to Order (ETO)
One of your companys main tasks is the production of high-quality and technically complex turbines, which you manufacture on behalf of power plant construction companies, and so on. You purchase some of the turbine components from suppliers, the rest you manufacture yourself. Each process, from component assembly, to plant acceptance and delivery to the customer, is extremely time-consuming. Delays may lead to severe contractual penalties, and therefore, should be avoided at all costs, or possible delays should be recognized as such long before they arise.
You manage the manufacture of turbines as project business. This allows you to plan and monitor dates, costs, and revenue on a project-basis. Because of your long years of experience in this area, you already have standard project structures, such as project plans, and networks, as well as standard production data, such as task lists, prices, duration, and so on. You can use these templates at the start of a new project, and tailor them to the individual needs of each project.
Process Flow
   1. On the basis of an inquiry, you create an operational project. Because you are experienced in designing and manufacturing turbines, you can make reference to an existing standard work breakdown structure (WBS) and standard networks in the system. First, you check the feasibility of the project dates. So that you can quote a sales price, you perform sales pricing on the basis of the project planning data.
      Inquiry and Quotation Processing
   2. On acceptance you create a sales order and release the project. You plan revenue using a billing plan in the sales order. You control the different billing dates using project milestones. In accordance with the contractual negotiations with the customer, a down payment is made on conclusion of the contract.
      Order Entry Processing
   3. You procure one of the turbine components externally from a supplier, and run through purchase order handling for that part. You manufacture one of the components yourself. The decision on which components are to be externally procured, and which are to be manufactured in-house has already been made.
      You place orders for long-lead items early to avoid delays to project progress. Your project controls the requirement for particular components in the manufacture of the turbine. As soon as all components are available, you assemble the turbine.
      Project Processing
   4. You deliver the finished product to your customer. Using confirmation, you create the customer acceptance and generate the final invoice.
      Turbine Assembly
   5. During project processing, you constantly control project earned value using confirmations and the cost/revenue situation, so that you can take any corrective action that may be required. You run several period-end closings, however only one is run as an example. On completion of the project you create the final invoice and close the project technically.
Period-End Closing with the Schedule Manager
http://help.sap.com/saphelp_46c/helpdata/en/95/aba1376695d703e10000009b38f8cf/content.htm

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
Thanks in advance
Regards
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.
If you ask me if you need to strict process to represent your case you need to go for first case.
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
Bala

yes
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

Specific changes are left undetected when using proxy indirection

Hello!
Recently, the following issue have been identified:
ObjectReferenceMapping together with ProxyIndirectionPolicy and *UnitOfWorkValueHolder fails to identify specific changes - setting a reference to 'null' when the attribute's value was not instantiated previously.
Detailed description:
Consider we have 2 objects: A and B, and A has OneToOneMapping to B and uses ProxyIndirection.
In initial moment we have A1 that references B1 in DB.
Then we register A1 for modification. What we have in memory in UnitOfWork? Something like the following:
A1(Clone) with attribute for B reference uninstantiated;
A1(Backup) with <null> reference for B, as the attribute is expected to be retrieved when we access B from A1(Clone).
Then we set reference in A1(Clone) for B to <null>.
This change then will not be identified during commit phase, because of the result of getAttributeValueFromObject both for B reference in A1(Clone) and A1(Backup) is <null>. This part is clearly visible from the ObjectReferenceMapping.compareForChange method code:
if ( !owner.isNew() ) {
backUpAttribute = getAttributeValueFromObject(backUp);
if ( (backUpAttribute == null) && (cloneAttribute == null) ) {
return null;
Accessing the B field in A1(Clone) fixes the problem, because in this case backUpAttribute value is initialized through *UnitOfWorkValueHolder.
So it seems the part should be reworked to handle such cases, it seems reasonable that fields in backup clones that are using proxy indirection should be initialized even if not accessed to contain all required information to allow correct comparision in such cases.
Can somebody from TopLink team comment this?
Thanks,
Sergey

This does appear to be an issue. I will log this problem internally, you may want to follow it up with support.
A work around is to instantiate the proxy in your set methods.
i.e.
public void setAddress(Address newAddress) {
if (this.address != null) {
this.address.hashCode();
this.address = newAddress;
}

Stock adjustment in CIN part

Hi all,
We are working in CIn client.
Now we have done Physical inventory for a material.
We done MI01, MI04 and MI07 and adjusted IM part.
To cover excise part in which tcode we need to do excise adjustments in case of shortage and excess? The material are excisable and we have paid exicse duties during procurement.
I also need to know in case of issue to cost center and scrap handling in CIN part.
Request your help.
Thanks
A.Gururajan

Hi,
I hope there is no link between physical inventory & excise.
Normally we do physical inventory to make sure that Book Qty & physical Qty are the same.
As you said, when you procure you have already paid the excess duties. So incase of any excess or shortage in stock if needed you can pass a excise JV using J1IH.
I am not sure whether we need to do an excise adjustment as part of the physical inventory activity.
Thanks & Regards,

Rework & Scrap Handling

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