Scrap calculation on MRP process

Dear all,
I have a requirement from a customer which is the following:
They are using the functionality "scrap component calculation" (PP). They would like to change the scrap percentage (the one from material master data) taking the information from a sales order when the MRP process is running.
Do you know if there is any user exit available at that time?
Thank you very much for your information.
Ines Simes

Hello Ines,
I once have debugged the MRP under 4.6C to find a user exit where I could modify the result tables (for each plant, by material and such), but I haven't found /any/.
Since there was a serious problem to correct, we had to modify the MRP. There's a top-Level-Loop that breaks down the BOM where's a good place to start with.
Best wishes,
Florin

Similar Messages

Sap pp - Scrap Calculation

Hello SAP-Guruu2019s
Can anyone tell me How Scrap Calculation is performed or maintained in PP.

HI,
Calculating Scrap
Use
You can calculate and plan the scrap quantity that will result from production. These scrap quantities are then included in the planning run and in the calculation of production costs.
Prerequisites
Which calculation the system uses depends on the settings in the material master record or in the BOM.
Features
The scrap quantity is settled against the net requirements quantity.
Three calculation procedures are supported by the system:
Assembly scrap
Component scrap
Operation scrap
Assembly Scrap
Use
You use this function to plan the scrap that results from the production of an assembly.
Prerequisites
You have maintained the assembly scrap in the material master (MRP 1 view) as a percentage in the Assembly scrap field for the assembly header material.
Features
The system automatically increases the quantity to be produced by the percentage of scrap.
However, the system always uses the estimate yield for the availability calculation for the assembly. Furthermore, the estimate yield of the assembly is always displayed in the MRP list or in the stock/requirements list.
Assembly scrap increases the order quantity of the assembly and subsequently increases the order quantity for corresponding components. The dependent requirements of the material components are therefore increased correspondingly.
Example
Estimate yield
200
Assembly scrap
10%
This results in a scrap quantity of
20 pieces
and a required quantity of
220 pieces
Component Scrap
Use
You use this function to plan the scrap of a component that may break during production of an assembly.
Prerequisites
You have entered values for calculating component scrap in the material master or the BOM:
in the BOM on the Item Detail Screen: General Data (data block for quantity data). This component scrap is only relevant for the individual BOM.
in the material master (view MRP 4) in the Component scrap field. This component scrap is relevant for all BOMs.
The component scrap quantity maintained for a material component in the BOM has the higher priority.
Features
Component scrap increases the dependent requirements quantity of the component.
If a scrap quantity was planned for a higher-level assembly, assembly scrap and component scrap are added to the component level.
Example
Estimate yield
200
Assembly scrap
10%
Component scrap
10%
This results in a scrap quantity of
42 pieces
and a required quantity of
242 pieces
Operation Scrap
Use
Before high-value components are built into an assembly, the system carries out a quality control check of the assembly, if necessary. Faulty materials that were taken into account in assembly scrap are not passed on to the next operation. They are removed.
Therefore, for a high-value component, you plan using operation scrap instead of general assembly scrap.
Prerequisites
You have maintained the operation scrap in the BOM, on the Items Detail Screen: General Data, under quantity data. You must also set the operations scrap net indicator at the same time.
Features
This scrap quantity refers to the quantity of one component that is to be processed in an operation meaning that the planning run is more exact and you can determine service and quantity consumption more precisely.
I
f the component is contained in an assembly, for which an assembly scrap quantity has been maintained, the system only takes the operation scrap into account.
The net indicator instructs the system to calculate the component operation scrap without taking assembly scrap into account (net usage scrap).
You should also set the net indicator, if operation scrap has not been maintained and assembly scrap has been entered. The assembly scrap should not, however, be taken into account.
Example
Quantity to be produced (required quantity)
1,000 pieces
Assembly scrap
10 %
Component 1
Operation scrap
No entry
Net indicator
Not set => assembly scrap is taken into account
=> Scrap quantity
100 pieces
Component 2
Operation scrap
1%
Net indicator
Set => assembly scrap is not taken into account
=> Scrap quantity
10 pieces
Before component 2 is built into the assembly, the incorrect assemblies are rejected and the system only takes the smaller operation scrap quantity into account. Therefore, component quantity of component 1 refers to 1,100 pieces to be produced; and the component quantity of component 2 refers to 1,010 pieces to be produced.
HOpe this helps.
Regards,
Tejas
Edited by: Tejas Pujara on Sep 26, 2008 8:26 AM

Std. report for scrap calculation......

Hi!
I want to generate a Scrap report for production order.
The requirement is system should display operaton-wise scrap and its cost. It should consider all material cost & activities cost (labour& machin)required for that operation & generate a overall scrap price.
Is there any standard report available in SAP?
OR any other way to get this report?
Please answer this, If u have any idea.
Thanks,
Pankaj.

I think you need to revalidate the Requirement Since.
1.Scrap is generated during a Goods is produced / Processed.
2.So in this case we have a wastage of material..only this material cost has to be calculated or accounted.
3.The operation cost and activity cost etc should be accounted for the Finished goods ,which is already done by Cost collectors -Say Production order.
May be you have a specific requirement.But the Approach towards the process (SCRAP calculation) has to be revisited.
since for a SCrap material called -x and qty called 2kg.the operation time or the acitivity time cant be calculated easily as this has scrap can be generated because of 1 hr of m.c operation or 10 hr of m.c operation..
Lot of factors like
>M/c Efficiency
>Rawmaterial Quality
>operator efficiency
lot of factors would be there
So better to revisit the requirement

MRP Process flow

Gurus
Is there anyone who has MRP process flow diagram . Pl send me the diagram or links to my email ID
Thanks in advance.

The system checks in the planning file whether a planning file entry exists for the material in the MRP area that is to be planned.
The system calculates net requirements for the material in the MRP area. During this calculation, the system checks whether the requirements that exist for the MRP area can be covered by the available stock in the MRP area and the planned receipts for the MRP area. If there is a shortage of stock, the system creates a procurement proposal for the MRP area.
The system calculates procurement quantities. If you have defined a lot-sizing procedure in the MRP area segment of the material master, the system calculates using this lot-sizing procedure.
The system carries out scheduling using the parameters defined in the MRP data of the material master.
The system determines the type of procurement proposal for the MRP area on the basis of the procurement type that is defined in the material master (see also Determining the Procurement Proposal). You can also have Delivery Schedules created for the MRP area of a material.
If you have defined a different special procurement type in the MRP area segment, the system creates the corresponding procurement proposal, for example, stock transport requisitions for the special procurement Stock transfer from plant to plant.
With the special procurement keys, which are entered into the MRP area segment, the material requirements planning for the MRP area only takes into account the settings for special procurement types that do not refer to the BOM explosion.
The settings for stock transfer are taken into consideration, for example, in contrast to the special procurement key Phantom assembly, which refers to the BOM explosion.
For every procurement proposal for an assembly, the system explodes the BOM and determines the dependent requirements.

I followed the same procedure of reverse calculation from MRP pricing calcu

hi,
sap gurus,
i followed the same procedure of mrp calculation but
MRP Pricing Procedure:
Go through the following:
I will brief your requirement in short
MRP = 1012.5/-
VAT = (1012.5/1.125) = 900/-
so price before discount will be = 900/-
discount given at the rate of 10% = 100/-
Initial Price = 1000/-.
1. Create condition types as below:
ZR00 for price
Condition class = B
Calculation type = C
Plus/minus = A
ZSET for settlement (to knock off the effect of ZR00)
Condition class = A
Calculation type = C
Plus/minus = X
ZWST for tax
Condition class = A
Calculation type = H
Condition category = D
Plus/minus = X
Z007 for discount
Condition class = A
Calculation type = H
Plus/minus = A
ZDUM for net price
Condition class = A
Calculation type = A
Plus/minus = A
YWST for tax (to knock of the previous effect - to be used for posting to G/L)
Condition class = A
Calculation type = A
Plus/minus = X
YOO7 for discount (to knock of the previous effect - to be used for posting to G/L)
Condition class = A
Calculation type = A
Plus/minus = X
2. The following will be the pricing procedure configuration:
Step......No........Cond Type........... From.........to..........Man.........Req........Sta................Acc Key
10........0..............ZR00..................--..........--..........-...........-........---.................ZDU
20........0..............ZWST..................10............19...........----.............X............X...................
30........0.............text.......................10...........29...........---...........----.........X
40........0.............Z007.....................30...........39...........-----.............X............X
50........0..............text.....................30............49...........---...........-----.........X
60........0............ZSET.....................10...........19...........----............X............--.................ZDU
70........0............ZDUM....................50...........59...........----............X............---...............ERL
80........0............Y007.....................40...........49...........----.............X...........---...............ERS
90.......0..............YWST..................20...........29...........-----............X...........---................ZWS
ZDU - dummy account key for posting extra not required items.
ERL - account key for price
ERS - account key for discount
ZWS - account key for tax.
3. Condition records in VK11
Condition type----
Condition record.......
ZR00........................................1012.5.....................INR will be positive (1012.50 +)
ZSET.......................................100%...............................will be negative (100 -)
ZWST.......................................10%................................will be negative (10% -)
Z007.........................................12.5%.............................will be positive (12.50 +)
ZDUM.......................................100%..............................will be positive (100% +)
Y007.........................................100%.............................will be negative (100% -)
YWST.......................................100%.............................will be negative (100% -)
Condition records for Z007 & ZWST will be decided as per the conversion required. You will first have to manually calculate the amount for the condition type.
4. I create a sales order for single quantity for an item & the pricing will be as under:
ZR00 = 1012.5 (dummy account) - positive
ZSET = 1012.5- (dummy account) - negative will knock off effect of ZR00
ZWST = 112.5- (negative & no posting)
Z007 = 100 (positive & no posting)
ZDUM = 1012.5 (positive & posting)
Y007 = 100-(negative & posting)
YWST = 112.5 (positive & posting)
but its not throwing any condition records for ZWST and YWST
can any body help me
plz
regrds,
balaji.t

HI,
Plz try Routin for Vat formula.
i am worked on MRP pricing but in our case formula is different.
eg.: If i want to calculate VAT for B=1000 Rs. it is like
A=1000 * ((100/100 + (12.5- VAT 5)))
= 889
VAT (Value) = B - A = 1000-889 = 111 which is passed to GL account.
For that we developed one Routine with the help of ABAP and assign to Pricing Procedure.
Regards,
PM

Error in starting MRP process in Standby database.

Hi All,
OS:Windows server 03
DB:11g
I am creating a Standby database, everything is fine until i fire the below command to start the MRP process to start the recovery of the database.
alter database recover managed standby database disconnect from session;MRP0 started with pid=27, OS id=6640
2013-02-07 17:59:48.515000 +05:30
started logmerger process
Managed Standby Recovery not using Real Time Apply
Errors in file d:\app\oracle\diag\rdbms\testdr\testdr\trace\testdr_dbw0_6000.trc:
ORA-01157: cannot identify/lock data file 1 - see DBWR trace file
ORA-01110: data file 1: 'D:\APP\ORACLE\ORADATA\TEST\TEST\SYSTEM01.DBF'
ORA-27086: unable to lock file - already in use
OSD-00002: additional error information
O/S-Error: (OS 32) The process cannot access the file because it is being used by another process.
Errors in file d:\app\oracle\diag\rdbms\testdr\testdr\trace\testdr_dbw0_6000.trc:
ORA-01157: cannot identify/lock data file 2 - see DBWR trace file
ORA-01110: data file 2: 'D:\APP\ORACLE\ORADATA\TEST\TEST\SYSAUX01.DBF'
ORA-27086: unable to lock file - already in use
OSD-00002: additional error information
O/S-Error: (OS 32) The process cannot access the file because it is being used by another process.
Errors in file d:\app\oracle\diag\rdbms\testdr\testdr\trace\testdr_dbw0_6000.trc:
ORA-01157: cannot identify/lock data file 3 - see DBWR trace file
ORA-01110: data file 3: 'D:\APP\ORACLE\ORADATA\TEST\TEST\UNDOTBS01.DBF'
ORA-27086: unable to lock file - already in use
OSD-00002: additional error information
O/S-Error: (OS 32) The process cannot access the file because it is being used by another process.
Errors in file d:\app\oracle\diag\rdbms\testdr\testdr\trace\testdr_dbw0_6000.trc:
ORA-01157: cannot identify/lock data file 4 - see DBWR trace file
ORA-01110: data file 4: 'D:\APP\ORACLE\ORADATA\TEST\TEST\USERS01.DBF'
ORA-27086: unable to lock file - already in use
OSD-00002: additional error information
O/S-Error: (OS 32) The process cannot access the file because it is being used by another process.
MRP0: Background Media Recovery terminated with error 1110
Errors in file d:\app\oracle\diag\rdbms\testdr\testdr\trace\testdr_pr00_7984.trc:
ORA-01110: data file 1: 'D:\APP\ORACLE\ORADATA\TEST\TEST\SYSTEM01.DBF'
ORA-01157: cannot identify/lock data file 1 - see DBWR trace file
ORA-01110: data file 1: 'D:\APP\ORACLE\ORADATA\TEST\TEST\SYSTEM01.DBF'
Recovery Slave PR00 previously exited with exception 1110
Errors in file d:\app\oracle\diag\rdbms\testdr\testdr\trace\testdr_mrp0_6640.trc:
ORA-01110: data file 1: 'D:\APP\ORACLE\ORADATA\TEST\TEST\SYSTEM01.DBF'
ORA-01157: cannot identify/lock data file 1 - see DBWR trace file
ORA-01110: data file 1: 'D:\APP\ORACLE\ORADATA\TEST\TEST\SYSTEM01.DBF'
Completed: alter database recover managed standby database disconnect from session
Can anyone tell me why is this comming?
Regards,
Sphinx

Hi ,
Yes, it is on the same server.
I have used the below mentioned parameters to rename the files
At Primary Pfile:
*.db_file_name_convert=('D:\app\oracle\oradata\test\test\','D:\app\oracle\testdr\oradata\datafiles\')
*.log_file_name_convert=('D:\app\oracle\oradata\test\test\','D:\app\oracle\testdr\oradata\redologs\')
At Standby:
*.db_file_name_convert=('D:\app\oracle\testdr\oradata\datafiles\','D:\app\oracle\oradata\test\test\')
*.log_file_name_convert=('D:\app\oracle\testdr\oradata\redologs\','D:\app\oracle\oradata\test\test\')
But the output of v$datafile at standby is showing the path of Primary datafiles
I manually tried recovering them but it is prompting me the same error.
Regards
Edited by: $phinx19 on Feb 7, 2013 6:23 AM

Could Not Plan MRP Process Planning.

Hi, all members of the forum. I Have a problem with MRP process from OPM Process Planning, Because it don´t make suggestion plan. I have already OPM Process Planning setup, I don´t have sales orders just forecast and associate it with the correct schedule, the schedule parameters are ok, Formulas have a effective dates, Recipe have a effectivity dates and validity rules. Besides already setup Warehouse, production and transfer rules, and items Plant-Warehouse relationship. When I run MRP, it doesn't show me any error message, in MRP
Material activity inquiry it only shows me the demand but not the supply and in the Action Messages inquiry shows me the action messages type: SHRT (Inventory Shortage) and in the message text indicate: Could Not Plan; Consequently I cannot manage any plan. Some of you could help me with this problem.
Thanks in advanced
RGVela

Hi
My suggestion is to check the lead times and to check the setup of Plant warehouse relationships. This normally is an issue with setups. This message come normally for any setup issue
Sorry, but at the moment I dont think I can anything more.....
Regards
Girish

Easy Cost Planning: Calculation Row (Business Process) in Cost Model Derivation Rule

Hi All,
The Requirement:
Using the Cost Model I am able to do up to Sub-Total Value. I tried with Calculation Row (Business Process) in the Cost Model Derivation Rule, but could not succeed.
I tried with Base Planning Object, but the formulas are different for other scenarios. Which require 5 to 6 Base Planning Objects are required to be created to get the total amount for a single line item, in the construction project there will be more than 10,000 line items and it is very difficult to maintain the data and also it is time consuming.
Can you suggest me, how to map the requirement?
Best Regards,
K. Rajendra Prasad Rao

You need to check the following for the material cost to appear in network costing:
1. Check whether costing variant is assigned to the network or not.
2. Check whether costing relevancy indicator is checked in material component assigned to the network.
3. If costing variant exists, check the valuation variant and strategy sequence for material valuation.
4. Go to the material master and see whether price is mentioned or not.
I would suggest you to use Network costing, Also note network costing are recorded in Co version '0' so if you have maintained your ECP for '0' version, there is a chance of both the costing getting added up.
Edited by: Ahmed Rifaee on Mar 28, 2010 10:10 PM

What are the disadvantages of implementing APO- Demand Planning without improvements or cleaning up the MRP. in other words is DP implementation dependant on MRP process. Gurus please advise

HI All. What are the disadvantages of implementing APO- Demand Planning without improvements or cleaning up the MRP. in other words is DP implementation dependant on MRP process. Gurus please advise

Hi Amol,
DP is the demand planning machine, here you estimate your forecast (future sales).
The MRP is a supply planning machine, here you use estimate the replenishment.
Both machines in a technical perspective are independent one each other. Now in a business perspective they are not: The problem that you will have if you don´t clean your MRP elements is not a problem in DP itself. I mean, you can have a very success implementation in DP, your forecast accuracy will be very good.. and you will get a very good forecast, but when the MRP run and estimate the replenishment, the effort that you made in DP will not be translated in good results and your planning situation will be still not good.
Kind Regards,
Mariano

How we can make MVT 551 (scrapping) a 2 step process

Dear all,
Is it possible to make the movement type 551 (scrapping) a 2 step process similar
to 313,315 or park and post in accounts.
The requirement is one department will make the document and
another department will post that document
What are the possibilities and the methods by which it can be achieved ?
regards
Magi

It is not possible to make 551 a 2 step process. However this can be done via a workaround.
Create a storage location called Scrap. The first department can do a 311 to the 'Scrap' Sloc and the second department can do 551 from this sloc.
Hope this helps
Lakshman

Physical standby failed to start MRP process

Hi,
I have a qa db which is in ASM. I have a qa standby which is a physical standby also in ASM. I added space to the primary. Unfortunately, the standby diskgroup did not have enough space and standby mrp process crashed. I edited the primary data files to release some space and tried to restart the standby but it does not seem to work.
What next?

Er, Can you provide more information?
Like maybe some details from the alert logs?
Or maybe even the error message you get when you try to restart the standby
The more information the easier it is to debug at a distance.
jason.
http://jarneil.wordpress.com

MRP Process Execution

Hi,
Please guide me about the following query please:
Does MRP Process consideres the Purchase Requisitions and Purchase Orders in which items (Material Codes) are marked as deleted?
If yes, then please guide me how can i exclude these PRs and POs from the scope of MRP execution for the Materials got used in the PRs and POs.
Thanks and Regards

Hi,
Thanks for your reply please.
But my question is that the Materials are not deleted but their reference in the PRs and POs are deleted i.e. the PR line or PO line in PRs and POs are deleted but still is it possible that MRP considers these Material lines of PRs and POs?
Please guide.
Thanks and Regards

SAP HANA as accelerator (secondary DB) for MRP process

Hellow all.
Can we use SAP HANA as accelerator (secondary DB) for MRP process? Or HANA for MRP usefull only as primary Database?
We can't opportunity to change our curent DB, but want to improve speed of MRP.

To my understanding, MRP on HANA is available only as primary db and not in side car scenario

Help scope out MRP process

We are kicking off an MRP project in a couple months and I need some help filling in a few gaps in my knowledge. I am fairly familiar with MM but hardly at all with PP. We are on ECC 6.0. Not running SRM/APO.
Some background: My company wishes to do forecast based MRP. We have about 2 years of MM transactional history and inventory of data. We have not implemented any PP but are prepared to put in whichever components are required in support of the MRP process. However, a non-SAP system will remain our production order system. We use SAP MM/WM for procure to pay and IM of raw materials. The desire is to marry SAP's generated forecast based on historical data with a future sales/demand forecast created in Excel. This sales forecast lists out the finished good. The forecast gets generated quarterly for the next 3 months.
A few questions I had:
1) Since we do not care to valuate or inventory the finished good, I assume that we need to represent the finished good as a phantom material with the BOM components being the raw materials?
2) What is the BADI that is used to import the Excel sales forecast? What transaction calls the BADI?
3) I assume that after SAP marries the historical and future forecast data, there is the ability to view the consolidated forecast and make adjustments...what transaction is used for this?
4) We have three plants and so far each plant has been carrying out its MRP planning (outside of SAP) on its own. However, there are many raw materials and finished goods that are common to the plants (ie same SAP material numbers) and, if not already, could be sourced from the same vendor for better pricing. On occasion, when there is a shortage in one plant we do a plant-to-plant transfer.
a) I assume there is the capability to run MRP using the summarized forecast of all three plants? I'd group the plants under an MRP area, correct?
b) Can some raw materials be planned at the plant level while other materials at the global level?
c) Or if MRP takes place at the plant level, is there any functionality for our global procurement team to see a more summarized global view of the material requirements? He'd need this, for example, to negotiate better pricing on centrally agreed contracts with the vendor.
Thanks!
Vlad

Vlad,
1) Since we do not care to valuate or inventory the finished good, I assume that we need to represent the finished good as a phantom material with the BOM components being the raw materials?
Don't know where you got that idea. I wouldn't do that, but I don't know all the particulars. If you intend to sell finished goods, you probably will want to put them in a plant as stock. If you intend to build finished goods, you probably shouldn't use a phantom.
3) I assume that after SAP marries the historical and future forecast data, there is the ability to view the consolidated forecast and make adjustments...what transaction is used for this?
Big assumption. There are several ways to approach forecasting within SAP ECC. These functionalities are not a 'transaction'. I suggest you look at standard online help to get a feel of what is and is not possible. Below is a bit of info about forecasting within SOP. SOP is one of the planning methods with the greatest feature sets. If SOP doesn't have enough functionality for you, then you probably need APO. There are also simpler methods of forecasting in SAP.
http://help.sap.com/saphelp_erp60_sp/helpdata/en/a5/63201843a211d189410000e829fbbd/frameset.htm
4) We have three plants and so far each plant has been carrying out its MRP planning (outside of SAP) on its own. However, there are many raw materials and finished goods that are common to the plants (i.e. same SAP material numbers) and, if not already, could be sourced from the same vendor for better pricing. On occasion, when there is a shortage in one plant we do a plant-to-plant transfer.
a) I assume there is the capability to run MRP using the summarized forecast of all three plants? I'd group the plants under an MRP area, correct?
another big assumption. MRP, unlike forecasting, is generally done at the plant level. There are ways to manage MRP so as to consolidate your demand into a single plant, but ultimately the purchased materials will have to be sent to the place where they are needed. If you have 5 places where your RM is needed, you will either cut 5 POs, or one PO and then ship the parts internally to the point of use.
b) Can some raw materials be planned at the plant level while other materials at the global level?
Generally MRP planning parameters are set at the plant level. There are, however, ways to manage your requirement.
c) Or if MRP takes place at the plant level, is there any functionality for our global procurement team to see a more summarized global view of the material requirements?
Yes
In closing, expert Mario Adler has given you some sound advice. What you are describing is a project. Some companies take months or years to implement a solution similar to the one you are describing. If you want to get the best bang for your buck, engage a consulting company who has done this before. You will end up richer in the end.
Best Regards,
DB49

Using Component scrap differently in MRP and in production/process orders

Hello Gurus,
We use Component scrap in our BOMs.
MRP calculates the requirements including the scrap and that is fine. Is there a way that when we create production/process orders the components' required quantity will not include the scrap automatically? We don't want the components to be issued with the additional scrap, but rather issue the scrap by request only if required.
Thanks

Not possible.
The SAP logic is tht procurement of RM and Production & consumption has to be in line. Functionally tht is ideal

Scrap calculation on MRP process

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