A1D - Rework Production Order WIP in Process - BBP

A1D- Rework Production order WIP In process
My SAP ERP 2005 IMC Dash
A1D
Rework Production order WIP
In process
Business Process Procedure
SAP Channel Partner

KPIT Cummins Infosystems Ltd
Hinjawadi, Pune
________________________________________________________________________
IMC Dash Solution By KPIT 1 of 17
Process Flow Legend
________________________________________________________________________
Contents / Index
1. Purpose.......................................................................................................4
2. Prerequisite.................................................................................................5
Master Data.................................................................................................5
Required Primary Steps.................................................................................5
3. Process Steps...............................................................................................6
Process Flow Diagram....................................................................................6
Process Overview Table.................................................................................7
4. Scenario: Long Term Planning Capacity Evaluation...........................................8
A1D.10 Confirmation of Operation – Rework Occurred.......................................8
A1D.20 Check for Rework Production Order in Order Report.............................10
A1D.30 Release Rework Order......................................................................10
A1D.40 Extra Components for rework order is updated in Order........................11
A1D.50 Issue Goods to Rework Order............................................................11
A1D.60 Confirm Rework Order......................................................................12
A1D.70 Technically complete Order...............................................................13
A1D.80 Confirm remaining operations in Main Order........................................14
A1D.90 Goods Receipt.................................................................................15
A1D.100 Settlement of Main and Rework Order..............................................16
________________________________________________________________________
1. Purpose
While processing production operations for particular product, defect can be
identified which can be reworked to correct. As this rework is only for operation, this
activity can be treated as Operation Rework – Work In Progress.
While creating Master Data of a product, a Trigger Point is attached to every

operation where rework can occur. This trigger point is activated by particular status
in production order.
When an event of operation rework is occurred, user needs to set the rework status
active while confirming the operation. This will create rework production order
without reference to material automatically by system.
Any extra material needed for rework is consumed to rework order and cost will be
debited to Rework Order.
This production order will be finally settled on to Main Production Order. So after
confirmation of Main order and settlement of main order, Rework cost can be seen
separately.
The quantity which can not be reworked will be scrapped and charged to Cost center.
________________________________________________________________________
2. Prerequisite
Master Data
You have to Enter Master data to execute this scenario.
Following Master data to be maintain or ensure while going through all Business
Process Procedure of this scenario.
 Material Master
 BOM
 Routing
 Rework Work Center
 Standard Trigger Point
 Rework operation Set
Required Primary Steps

Production Order for Material is created, released and few operations
confirmed.
Standard Trigger Point created as Rework and attached to every operation in

Routing.
Components required to process operation is issued
________________________________________________________________________
3. Process Steps
Process Flow Diagram
________________________________________________________________________
Process Overview Table

Step Step Name External Business Role Transac Expected
Process Condition tion Results
Reference Code
1 Confirmation of Rework needs to Manufacturing CO11N Yield and rework
Operation – declare in Main is declared
Rework Production Order
Occurred
2 Check for Rework Order Production COOIS Rework Order
Rework number planner without material
Production is checked
Order in Order
Report
3 Release Production needs Production CO02 Rework Order is
Rework Order to be started Planner released
4 Create If any Production CO02 Reservation is
Unplanned components Planner created
Consumption required during
reservation for rework
Component
against rework
order
5 Issue Goods to Components Warehouse MB1A Goods Issued to
Rework Order consumption Clerk order against
reservation
6 Confirm Rework is carried Manufacturing CO11N Yield & scrap
Rework Order out declared
7 Technically Rework is Production CO02 Order status
complete Order completed Planner updated to TECO
8 Confirm Main order to Manufacturing CO11N Main Order is
remaining process confirmed
operations in
Main Order
9 Goods Receipts Main Order Production MB31 Material is taken
of main order completed & need planner in stock
to update stock
9 Settlement of Cost of rework to Cost Controller D1L Settlement is
main and be settled on Scenario Carried Out
Rework Order main order
________________________________________________________________________
4. Scenario: Long Term Planning Capacity Evaluation

A1D.10 Confirmation of Operation – Rework Occurred
Use
When operation is completed it has to enter in the system as confirm
for completion. Now in this activity out of total quantity some quantity
is yield and some quantity can be reworked is observed. For this user
will enter rework quantity and give reason of variance as rework so
that an auto generation of rework order is generated. In routing
master Trigger Point needs to be specified for each operation.
Prerequisite
Rework Reference Operation set is created.
Trigger Point is created
In Routing Master or in Production Order, trigger points are assigned
to all operations where rework can occur.
Main order is created and released.
Procedure
Easy Access Path Logistics > Production > Shop Floor Control >
Confirmation > Enter > For Operation > Time
Ticket
Transaction Code CO11N
Business Role Production Supervisor
On the Initial screen, make following entries
Field Description User action and Comment

name values
Order <Production Order
Number>
Operation <0010> Operation to
No confirm
Confirm Partial or Full <Final Confirmation> For Final
Type Confirmation type
clear open
reservation
Yield Good <Quantity>
quantity
produced
Scrap <Scrap Quantity> If any Scrap done
Rework Materials <Rework Enter Rework
which can be Quantity> Quantity
still rework to
produce
finished
________________________________________________________________________
material
Reason <RWCK> Rework status is
for updated in system
Variance
Activities- Set Up time <Hours or min > User can refer to
Setup for an Planned activity
operation time
Activities- Machine time <Hours or min > User can refer to
Machine for an Planned activity
operation time
Activities- Labor time <Hours or min > User can refer to
Labor for an Planned activity
operation time
Confirm <text> 40 char text
Text
Click on Goods Movement to check for Backflush

components.
Post
System shows information message regarding Trigger point function,
Enter
System process the Rework Order in background. Confirmation for

Main order’s operation is saved.
All rework orders will be with Order type KR initials.
Result
Rework Order is generated for rework quantity entered. Main order’s
operation is saved.
________________________________________________________________________
A1D.20 Check for Rework Production Order in Order Report

Use
Rework Order is created in background as soon as user confirms the
rework qty with rework as reason of variance. This Rework order is
checked in Production Information system with order type KR11 for
Company code 1100, KR12 for Company code 1200 etc.
Prerequisite
Rework Order is created in the system
Procedure
Information System > Order Information
System
Transaction Code COOIS
Business Role Production planner
On the initial screen, select following parameters,
Field name Value

List Order Headers
Layout < /REWORK ORD >
Order Type <Rework Order type>
No Release Orders Deselected
Execute .
In the Order report, Superior Order column shows your main Order
and Order column shows your Rework Order.
Result
Rework Order is checked.
A1D.30 Release Rework Order

Use
Unlike Standard Production Order, all rework orders need to be
released to Shop Floor by authorize person. This will ensure control on
rework as well as rework order tracking.
Prerequisite
Rework Order is created in system
Procedure
Order > Change
________________________________________________________________________
Transaction Code CO02
Business Role Production Planner
On the Initial Screen of Change Order, Enter Order number

Enter
On the Production Order header screen, Click on Release to

release rework order.
Result
Rework Order is released
A1D.40 Extra Components for rework order is updated in Order

Use
For processing rework in rework order, if any extra components
needed to consume then can be updated in Order so that warehouse
clerk can issue goods to operator. This component’s cost will be added
to production Order cost of rework order and finally at settlement this
will be settled to main Order.
Prerequisite
Rework Order is created.
Need for Extra components for rework
Procedure
Order > Change
On the Production Order Header screen, click on components to

enter extra components required for Rework.
Enter Component code with Quantity and item category as L. Enter
storage location of Goods Issue. Enter Operation number to which
these components will be consumed.
Save .
Result
A1D.50 Issue Goods to Rework Order

Use
Components required for Production are issued to order
Prerequisite
________________________________________________________________________
All components required for Production Order are in Inventory with
required quantity
Procedure
Easy Access Path Logistics > Materials Management > inventory
management > goods movement > goods issue
Transaction Code MB1A
Business Role Store Executive
Field name Value

Movement Type 261
Plant <production order plant>
Storage Location <Goods Issue S Loc.>
Click on To Order for Production Order reference.

Enter Production Order to Issue Goods.
Continue .
System shows list of components which are to be issued against this
production order. User can select / deselect materials with quantities
for Issue.
Click on Adopt + Details . System shows details for each
component issued.
Save .
Result
Goods required for Production Order are issued.
A1D.60 Confirm Rework Order

Use
After physically completing Production Order Operation work, an
operator needs to enter in the system as Operation done. This activity
is carried out to enter Confirmation of Operation in the Production
Order.
Prerequisite
All components required for operation needs to be issued.
Procedure
Ticket
________________________________________________________________________

name values
Number>
No confirm
clear open
reservation
quantity
produced
Rework Materials <Rework Quantity> If any rework
which can be
still rework to
produce
finished
material
operation time
operation time
operation time
Text

components.
Post
Carry out Operation confirmation for all operations in production order.
Result
All operations in Rework Production Order are confirmed.
A1D.70 Technically complete Order

Use
________________________________________________________________________
After completing confirmation of all operations in rework order, user
needs to give status to order as it is Technically Complete so that all
cost incurred on to Rework Order can be settled to main Order.
Prerequisite
All Operations in Rework Orders are confirmed
________________________________________________________________________
Procedure
Order > Change
On the Change Order Header screen, on Menu Bar go to Functions >

Restrict Processing > Technically Complete
Save .
Result
System Updates TECO status to Rework Order
A1D.80 Confirm remaining operations in Main Order

Use
After completing Rework Production Order, an operator needs to
confirm all remaining operations in main order.
Prerequisite
All components required for operation needs to be issued.
Rework Order is completed if full confirmation is to be carried out.
Procedure
Ticket

name values
Number>
No confirm
clear open
reservation
quantity
produced
Rework Materials <Rework Quantity> If any rework
which can be
________________________________________________________________________
still rework to
produce
finished
material
operation time
operation time
operation time
Text

components.
Post
Carry out Operation confirmation for all operations in production order.
Result
All operations in Main Production Order are confirmed.
A1D.90 Goods Receipt

Use
After Confirmation of all operations, Header material produced. This
Material is posted into stock against Production Order.
Prerequisite
All operations in Production Order are confirmed
Procedure
Goods Movements > Goods Receipts
Transaction Code MB31
Business Role Production Engineer
On Goods receipts for Order initial screen make following entries
Field name Value

Movement Type 101
Order <Production Order Number>
Plant <production order plant>
Storage Location <Goods Receipts S Loc.>
________________________________________________________________________
Enter
System shows Production Order quantity for receipts

Post .
Result
Finished Material is updated in Stock.
A1D.100 Settlement of Main and Rework Order

Use
Rework Order & Main Order actual Overhead calculations are
calculated and all variance are settled to Production Order.
Please refer to D1L- Period End Closing Scenario for further details
________________________________________________________________________

A1D - Rework Production Order WIP in Process - BBP

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A1D - Rework Production Order WIP in Process - BBP

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Авторское право:

Доступные форматы

A1D- Rework Production order WIP In process

My SAP ERP 2005 IMC Dash

SAP Channel Partner

Process Flow Legend

While creating Master Data of a product, a Trigger Point is attached to every

Required Primary Steps

Standard Trigger Point created as Rework and attached to every operation in

Components required to process operation is issued

Process Overview Table

4. Scenario: Long Term Planning Capacity Evaluation

On the Initial screen, make following entries

Field Description User action and Comment

Click on Goods Movement to check for Backflush

System shows information message regarding Trigger point function,

System process the Rework Order in background. Confirmation for

All rework orders will be with Order type KR initials.

A1D.20 Check for Rework Production Order in Order Report

On the initial screen, select following parameters,

Field name Value

A1D.30 Release Rework Order

On the Initial Screen of Change Order, Enter Order number

On the Production Order header screen, Click on Release to

A1D.40 Extra Components for rework order is updated in Order

On the Production Order Header screen, click on components to

A1D.50 Issue Goods to Rework Order

On the Initial screen, make following entries

Field name Value

Click on To Order for Production Order reference.

A1D.60 Confirm Rework Order

Field Description User action and Comment

Click on Goods Movement to check for Backflush

Carry out Operation confirmation for all operations in production order.

A1D.70 Technically complete Order

On the Change Order Header screen, on Menu Bar go to Functions >

A1D.80 Confirm remaining operations in Main Order

Field Description User action and Comment

Click on Goods Movement to check for Backflush

Carry out Operation confirmation for all operations in production order.

A1D.90 Goods Receipt

On Goods receipts for Order initial screen make following entries

Field name Value

System shows Production Order quantity for receipts

A1D.100 Settlement of Main and Rework Order

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