工作生活与爱好

Is there anyone out there who knows if it is possible to make an automatic change of planned orders to production orders right away - or perhaps even to skip the planned orders and create pp - orders instead?
I have a customer who want to do this (skip the manual conversion).
Perhaps it is impossible?

To create production orders in MRP run without checking first the order proposals (planned orders) is not a recommended process at all. It is against the accepted norms in production/inventory management and its MRP-2 logic on which SAP software is also based on.

If you have complex production - you'd have a nightmare closing all the production orders with the errors not resolved at the prior to conversion stage. On the other hand, if it is too simple production with only a handful of operations and no strict requirement of production control (which seems to be your case, for me), then please do away with production orders, and use the repetitive manufacturing where planned orders are the final.

I am confident that a consultant who can see the need and benefit for the wisdom of planned order conversion as a separate manual process, should ALWAYS be able to convince customer.

As always, the question is, whether you want the right shoe to fit the foot, or cut the foot to fit the shoe.

Can anyone tell me what is backflushing for? When is it use?

Back flushing is nothing but automatic goods issue. System will automatically posts the goods issue when you confirm the operations.You have no need to make manual issue. It will reduce the effort.

Backflushing is automatic accounting (Goods issues - 261 mvt) of material consumed for production, at the time of confirmation. Eg. When a 4 wheeler automobile is rolled out from assy line, 4 wheels & Tyres are deemed to be consumed and issued to production order automatically by way of backflushing by the system.

Assy line picks the material from stores/ Assy line and use.

No Physical issue & Manual posting ( Goods Issue) by Stores.

Backflush is used for material which are a must and having fixed relationship.

This can be configured in MRP2 Screen,Work centre, Routing and production order.

Each has some special function.

If you configure this in routing or production order you have no need to activate this in MRP2 or Work center screen.

MRP2 Screen defines whether material components are backflushed are to be made at the work center.

When we do the back flush the backlogs are being created for the BOM components and we are getting the message "Backlogs from backflush were created or changed" - its just an informative message. Do you think this has got something to do with the negative postings ?

Backlogs are created due to different reasons.

This message tells that "there is no sufficient stocks for the bom component/not able to backflush all the material due to plant data locked etc" at the time of backflushing the BOM Material and hence the Post-processing list is created that you have to Re-process for stock updation of each material.

To avoid this you can confirm the following things.
1.Ensure that suffecicient stock is available in the backflushing locations of each materail.
2.To prevent the generation of "post-processing list" you can block the BOM from getting backflushed if sufficient stock is not available in specified location for the BOM COMPONENTS. To do this change the "REM profile" to "002"in MRP4 view for the BOM MATERIAL.(if the profile is not available you can crate it through SPRO).
3. To clear the existing Backlog use transcation MF47 and re-process(be ensure that required stocks is available for each bom component)

Can anyone please explain me the how the Costing takes place for the Production Orders.

Actually, I am new to this package , In Other Package (RAMCO ERP)
(The Process is like follows:
a. Production Work-Order Resource Cost Posts to Finance directly
b. Material Consumption postings happens from OSV(Order Settlement Variance) of MAC Module(Management Accounting).

Please somebody explain me as above in SAP.

The following are considered in costing,

1) cost of materials that you have issued for order

2) activity you have performed in terms of labour hours that you entered while confirming the order (the rates for the labour are defined in the activity planning tables of controlling module)..which is generally associated with a formula key and attached to a workcenter that is linked to a cost center also

3) overhead as applicable with respect to that cost center based on a predetermined cost center planning and its rate...

Anil

Costing updation in production order

How is costing updated for production order?
After goods issue, conformation & GR, we do TECO.
Before closing the order, costing details should be updated. Is it not?
Could you please guide me as to how this is done?
Also, what is the transaction code to be used?

Planned cost is caculated if you click 'cost calculation' in production order. GI go production order will update actual material cost. Confirmation of production order will update actual activity cost. You can settle cost once production order has status TECO or DLV. From PP side, the transction is CO02

In IMG we can define that when we calcu. the planned cost.

There are 3 ways.
- Determine planned costs when saving,
- Do not determine planned costs when saving,
- Determine planned costs when saving if released.

But the actual cost is posted when we draw the material, when we confirm the order......We can use co02 and click the calcu. cost to update the cost in the prd order.

Error in Cost Calculation

I am using 4.7. When I was saving my production order, there was this error message that told me that there was an error in cost calculation. Do you have any suggestions what I couldn't have done? What can I do to fix this?

Check the log file in the Production Order -> Goto -> Logs -> For costing

Then take it from here....

Check whether the material for which you have created a production order has a price define in material master like Moving average price or Std price.

I have a FG (A/C) which has a serial number. This A/c has a compressor in its BOM.

The client requirement is to link the compressor to A/c using serial number. So, I maintain serial number profile for the compressor also. But when I do mfbf (backflush) for the A/c, the system asks only for the serial no. profile only for the A/c & not for the compressor. How do I link the two?

You can assign componenets (with serial nos.) to assembly ( also with serial nos.) with COIB after goods receipt.( Menu path --Logistics -> Plant maintenance -> Management of technical objects -> Installed base -> Create (special) -> With reference to production data.)

Example: Say assembly sr. no. is 1
And components serial no. are- 1,5,10,20 and so on.

After assignment of components it can be viewed on right part of screen, You can have the assignment history--- ie for which assembly no. which components are assigned or vice versa. In production order i.e in descrete mfg. it can be directly done at the time of operation confirmation.

The following is the detail steps:
1. T code--COIB
2. Enter material code ( Assembly). You can select specific serial no. of assembly --- by putting sr. no. in serial no. field.
3. Click on list tree- you will find all assembly with serial numbers.
4. Click on explode-- it will show the BOM ( in bottom left corner of screen)
5. Select the assembly numbers for which you want to assign the componets
6. Clik on tranfer
7. Select the component
8. Also select the assembly no. on right side screen.
9. Select the serial no. which you want to assign to an assembly
10. Click on assign
11. You will find all the components will get assigned to assembly with serial numbers.
12. Now on right side screen there is "save" button. ( It will ask you create/ change as built in foreground or background?
13. Select as foreground
14. Save
15. You will find a message at the borttom --- saved.
16. Now you will find tick mark ( in front of assembly material) in right part of screen ( indication of assignment of components)

Can anyone explain to me how the goods issue and goods receipt are done through a PI sheet. What's the logic behind calling the functional module.

Vasudha

Process instructions contain information on:

1. The individual processing steps to be carried out
2. The process data needed for further processing in process management such as process parameter,process data calculation formula,inspection results request etc. During maintenance of PI sheet, the material quantity consumed in each phases and the actual quantity produced are entered (confirmed). Based on the confirmed quantity the system generates GR
for the process order for the finished product and a goods issue for the material withdrawal as soon as the process messages are sent.

Hope this may clear your doubt.

S.Arulselvan

Thanks Arulselvan, if the materials are warehouse managed, how does the goods receipt work, does it work as a normal transaction in the background...

Vasudha

In general scenerio of warehouse management, GR and GI takes in different stages. When you post the GR (both for purchased material and finshed goods) the material stored in entry storage type. Based on the transport order materials are picked and moved to the permanant storage type. This will be taken care by warehouse controller. After entering the material quantity in PI sheet and posting the process messages, transfer request will be generated and the warehouse controller then convert the transfer request into transfer order. Based on the transfer order material will be picked from the permanent storage type and moves to exit storage type and from there material moves to shop floor.I have no experience in this but this is the general procedure.

If this is not working, please reply.

I am transfering a product from one plant (say 1000) to another plant (say 2000). By using MB5T, I could find the stock in transit. Unfortunately, the lorry met with a fire accident and all my goods destroyed. Now I have a scenario where I need to remove the stock which is in transit.

How do you wish to remove the stock? Are you going to scrap it or issue it to a specific GL account for insurance purposes?

It is for both scrap and for insurance purposes.

You have two options. Option number one being the simplest of the two. You will need to know the stock transport PO number or numbers. If you do not know them you can perform a search using transaction MB5T enter in the receiving plant, check the stock transfer order and the cross-company-code box and execute. All in transit PO's will be displayed for that plant. You can drill into document flow by double clicking on the PO number.

Option 1.

You complete the transactions into the intended plant and then perform the scrap transaction.

MB01 or MIGO (goods receipt against a purchase order) depending on which you use to perform goods receipts and LT06 bin put away,( if the plant is warehouse managed).

Scrap the goods using transaction MB1A movement type 551 or MB1A misc issue to a specific GL account. Use movement type 201. LT06 to remove the goods from the put away bin if the receiving plant is warehouse managed. If the receiving plant is not warehouse managed then MB1A is all that you need to do to complete the scrapping of the goods.

Option 2.

You wish to reverse the goods movement back into the supplying plant and then perform the scrap transaction.

VL09 reverse good movement. (You will need the delivery number in order to do this)
LT0G (if using warehouse management) to reverse the goods back into a bin.
VL02N to cancel the delivery
ME22N to cancel the PO.
MB1A choose the bin location in which you placed the goods when you performed the reversal. (again if you have warehouse management). If non warehouse managed MB1A is all that needs to be completed to remove the goods from inventory.

Like to share with you my Subcontracting Steps:

1. Define all the materials in your plant (subcontracting and packaging etc).

2. In the material master MRP 4 view there is one field in which you can mention that this material is not relevant to MRP planning, use this field for subcontracting material so that it will not be planned in MRP runs ( generally use this field for re-order point planning).

3. In the BOM for the subcontracting material put the special procurement key as Subcontracting and do not keep relevance for costing.

4. If you're using packaging material of your company and want to capture the cost of these materials in the subcontracting production order then put relevance for cost.

5. Define alternate BOMs for each customer.

6. Generally the routing will be the same but materials will change, define different prodcution versions for each alternate BOM and assign to the routing.

7. Define the activite types for packing and mixing in the work center and assign them to the cost center, use these for your routing.

8. Whenever you recive a sub-contracting order, use the relevant production version depending on the customer.

In my place all the palnts belong to the same client in sap and they want to use the same material code in both plants, so I think my subcontracting scenario might be different from yours but it give you some ideas to go about it.

Bye.....