Rework in Production Planning

Rework - In most of the manufacturing environment there would be some or other form of rework. This topic explains how to handle the rework by creating a new production order. Scenario: 1.When a rework is to be done a new production order is to be created. 2.This production order will not have any material. 3.This will have only one operation. Assumption 1. A header material HM1 is already setup in the system with all required master data like BOM,Routing,etc. before we go in detail the below T-codes are the one the person is to be familiar with Transaction codes: 1. BS02- status profile management 2. CA21- Rate routing 3. C032- Reference rate routing 4. Ca02- Routing change Configuration: 1.New order type 2.Order type dependent parameters 3.Default operation for the order type / Plant combination. I.Creation of status profile: a.Create one status profile Zrework with 2 status in the profile ex: Initial,Creat. b.The Status profile should be assigned to object types. II.Create a separate order type a.Create a separate order type b.Set up the order type dependent parameters c.Now assign the status profile in the header and in the operation in the created order type III.Create Rate routing

a.Create a simple rate routing IV.Create a Trigger Point. 1.Create a trigger point with co31. 2.In the Trigger point assign the status(create ) for the function - create a new order 3.Double click the assigned status this will pop an additional window to fill in the group,group counter and order type. 4.Fill in with the rate routing no and also the created order type V.Routing - Trigger point. a.Now the trigger point has to be assigned to the routing of the header material HM1. b.To assign this double click on the operation and in the Menu - find the trigger point and assign the trigger point a pop up window requests you if to copy from std trigger point - confirm yes. c.After the trigger point is assigned save it . VI.Test Rework Scenario. Step1.Create a production order for the header material HM1-release and save it. * Check in the status management if the status ZREWORK. Step2.Now confirm the production order with Co11. * When you confirm make the yield as zero and also delete if any goods movement was there Step3.Now save the confirmation,When you save the confirmation you will get a trigger point message - confirm the message it will take you to the next screen where the triggerpoint with the function to create the production order would be displayed. step4.Now execute the trigger point.This would generate a production order. Now the production order without material is created,

1)Goto Tcode Co07-production order w/o reference to a material 2)You can enter the same order type and plant as entered for the original order 3)Enter all the information in production order create header screen 4)Enter the operation and work center and enter the timings in the operation over view of the production order (it does not matter whether you have a separate work center for rework or not) 5)After entering all the above information , it will take you to the Maintain Settlement Rule overview screen- Here you enter the CAT as ORD, Settlement receiver as production order no.(original production order no.) and finally settlement % as 100%

6) You can add any components in the production order 7) Release the order and save 8) Carry out confirmation 9) go to Tcode Ko88 for settling this rework order- Whatever expenses incurred for thios rework order are captured to the original production order 10) Go to Co02 of the rework order , under menu GOTO ,select costs and analysis you will see the rework order costs settled against the original production order.

AFS-Rework Order.
There is no specific settings for creating re-work order for AFS. I have currently implemented in one my client.

First you need to create a rework order type. Follow below steps: 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. 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 opEnter 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 the operations. 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.

What are the cutover activities followed for PP module? I am listing some cut over activities to be followed (for PP - Discrete Manufacturing). Production Planning / Master data: For Production planning, only master data shall be migrated to SAP. In the 1st Stage, there is no master data. Following is the master data elements relevant for PP: - Bill of materials - Routing. - Work Centres. Transaction data: As of the cut off date, ideally there should not be any work in process. All the open production orders should be closed and semi finished goods should be dismantled and should be added to Raw materials. This strategy should be followed for all production orders where lead time to complete the production order is not large. Since, the production orders are for longer duration and it is not possible to dismantle the product and add it to inventory, following can be the strategy for migrating the data to SAP: - Create a material master for the work in process and set the standard price as the cost incurred for that product (ie. Work in process) - Create a bill of material (which will be used only for this production order) including this material and other materials still to be consumed. - Create Routing for rest of the production process.

- Bring the work in process material into inventory as of the cut off date. - Create the production orders in SAP for the Work in process and issue materials to production order. Complete the production process after the cut off date of the project. Tips by: K.S.Kulkarni What happens to planned after it has been converted into production order? When you convert Planned order to Production order. the planned order are offset by production order. Reference of planned order can be seen in the production order. How to attach a drawing for a material to BOM? Is it possible? Yes, you can attach a drawing. First create a document using Transaction Code "CV01N - Create Document". Attach your drawing in that document. The system will generate a document number. Assign this document in the BOM with item category D. Report in Long Term Planning - You use long term planning for your customers, what they need are very simple, just to calculate future requirements for 1 or 2 years. Are there any reports in SAP to list of material requirement from LTP? You need a list of material requirement from long term planning result for each item. Use MS70 then use MCEC. Scheduling planned order - How can you get planned orders scheduled so that you can do capacity leveling? MD11 and then Schedule works fine but ideally you would want the the planned order scheduled automatically on creation? You have tried setting up an action to schedule the orders but cannot get that to work either. When running MRP, try selecting "2" in the scheduling box this will bring planned orders into CM01 and CM21 Capacity planning CM01 - When you run capacity planning T-code: CM01, you found the plan orders are not included in the pegged requirement, you checked the profile, the check box for order and plan order are all actived. Guess that planned orders have been created without capacity requirement indicator in MRP ("2" - Lead Time scheduling), if this is the case, then when converted to process orders they will have impact on the Resource. If you want to see them as planned orders, re-run the MRP or change in every planned order, going to the Menu: Edit --> Scheduling Another couple of possibilities are to do with the routing/work centres used and whether it isactually calculates consumption of capacity of the category at the work centre being displayed in CM01 (it might consume a capacity pool or it might not consume the category). MPS in Backgound/Online - You want to run MPS for a plant either online or in the background, but you do not get any results. If you run MPS for a single material/plant, then everything is 100% OK. You need to run a planning file and a consistency check first, transaction OMDO and MDRE respectively you'll need to set up two jobs to do it but it is straight forward, once you've done this set up the background job for MPS to run and do it in NEUPL first time round and then change to NETCH after that. What is the output of MPS run?

From MPS run you plan the materials which are of 'A' type in the abc analysis (80% dollar value) that have to be planned before hand. MPS is also a type of MRP only in which components just below the materials on which MPS run is taken place, are planned. Table for production order status - What is the table for finding status (for Ex TECO ed prodn orders). We are not able to find from AFKO and AFRU tables the status of production orders or at least the link tables if known can be mentionned. You are unable to link the structure caufvd and IOHEADER WITH AFKO and AFRU. JEST is the table. Data dictonary table for SOP planning data - You are using Standard SOP (Info structure S076), in which table can you see the planning values that you maintained in MC93 transaction? You looked under table "S076" and did not see any values there. Use T.Code MC95 to display your entries under the version which maintained the the table S076. Production order operation's component allocation - How does SAP know that an operation has components as indicated by the component allocation indicator? Tcode CO08. Component allocation is done via routing maintenance or BOM maintenance for the assembly. This is master data maintenance. As soon as a PO is created, the master data is read into the PO. How to delete groups of products? How to delete a group of products that was created in screen MC84? Delete the members in the product group and then archive the product group in transaction SARA, object=MM_MATNR. (The product group is created as a material master record with material type PROD and this record is deleted in SARA.)