Different Scraps and their effects in SAP PP

There are three types of scraps used in SAP PP.

1. Assembly Scrap
2. Component Scrap
3. Operation Scrap.

1. Assembly Scrap

During Production there will be some loss always due to various reasons and due to this we will get less output than the planned one…for example if planned to produce a qty of 100 KG we may get around 99.5 KG as the final output or yield..Now to get the actual output as the planned one we need to increase the planned qty by some percentage so that we will get the output as per the expectation.. For this we use Assembly Scrap…

Assembly scrap increases the order quantity of the header material and subsequently increases the order quantity for corresponding components. The dependent requirements of the material components are therefore increased correspondingly.

Setting:

You have to maintain the assembly scrap in the material master (MRP1 view) as a percentage in the Assembly scrap field for the assembly header material.

Flow:

Following is the BOM structure of header material with two components….

Maintain 5% as the assembly scrap in the MRP1 view in material master for the header material…

Create Process order for header material with order qty as 1 

system increases the order qty by 5% as shown below….

Now go to components overview… you can observe components qty’s are also increased by 5%

Now save the order.

2. Component Scrap 

Some times a particular component always consumed more during a production process than the planned one.  component scrap only applies to one component. Component scrap increases the dependent requirements quantity of the component.

Settings:

▣ You can enter 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.

Flow:

Following is the BOM structure of header material with two components….

Maintain 5% as component scrap in in the BOM item details for the component 200-210 as shown below…..

create process order for header material with order qty 1

Now go to component overview in the process order and you can observe that only qty of component 200-210 is increased by 5%

You can maintain the component scrap in material master MRP4 view of the component 200-210 as shown below….

3. Operation Scrap

During Production process after a particular operation you may get some loss. Now you need to adjust the qty, standard  values and other values of the subsequent operations. For this Operation scrap is used in production.

Settings: 

You can enter operation scrap (in %) in the routing and in the BOM.

The operation scrap entered in the routing refers to the activity quantity consumed, while the operation scrap entered in the BOM refers to the material quantity used. In this case, the net indicator must be turned on.

Flow:

Following is the routing structure of header material with three operations….

Maintain 10% as operation scrap in the operation details of the operation 1 as shown below….

Now create Production order for header material with order qty 100 KG

Now go to Operation overview…

Scroll to right…..you will be able to see operation qty of second operation and third operations are reduced by 10%…

Maintain the operation scrap as 5% in the BOM component 2160 and also activate indicator Net ID in the item details as shown below…

Now create production order for 100 KG for header material

Go to components overview and observe that component qty of 2160 is increased by 5%

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Recurring Inspection process in SAP QM

Overview:

Recurring inspection means inspection of the material at regular intervals like every month, every year etc. The system can automatically create inspection lots at predefined intervals for selected batch materials. You can plan such inspections by having the system monitor the date for a recurring inspection. Recurring inspections are triggered by a report that you can execute manually or that the system can execute automatically (provided it has been planned as a background job). When recurring inspections are triggered automatically, the background job executes the report, which in turn selects the batches and creates the inspection lots according to your processing parameters.

Process Flow:

1. Activate Inspection type 09 in Quality Management View in Material Master
2. Inspection interval is Maintained in the Quality Management View in Material Master & Total shelf life in Plant Data / Stor.1
3. Next Inspection date is updated in the Batch Master record when the GR (against a Purchase Order/ against a Production order) is done
4. Execution of the Deadline monitoring Program – QA07
5. Automatic Inspection lot creation and Stock moved to QI
6. Results Recording and Usage decision of the inspection lot
7. Movement of the stock to Unrestricted Use.

Detailed Flow: 

1. Activate Inspection type 09 in Quality Management View in Material Master: This setting is mandatory to generate recurring inspection lots. In this example a Raw material (44502) and Plant 1000 is used.

MM01/MM02

2. Inspection interval is Maintained in the Quality Management View in Material Master & Total shelf life in Plant Data / Stor.1:

Inspection interval is Maintained in the Quality Management View in Material Master & Total shelf life in Plant Data / Stor.1 : this is to give the information about the frequency of inspection and expiry (SLED) about the material. In this example inspection interval is defined as 365 days as material is inspected after every year and expiry is 3 years (36 months)

MM01/MM02

3. Next Inspection date is updated in the Batch Master record when the GR (against a Purchase Order/ against a Production order) is done:

Create a Purchase order and make Goods Receipt against the Purchase Order through MIGO when the material is received

system creates a batch and system will update the next inspection date and SLED in the batch master record (MSC3N) as per the manufacturing date given during GR as shown below.  in our example date of manufacture is given as 13.10.2014.

Now save the GR and check in the Batch record for updation of SLED  and Next inspection date in T-code MSC3N. Next Inspection date is updated as 11.10.2016 (after one year of goods receipt date) as material is received on 12.10.2015. 

Now when the material is received initially, quality inspection done and stock posted to Unrestricted Use.

4. Execution of the Deadline monitoring Program – QA07: This transaction is executed on daily basis as a background job in the real time at Plant level. System will check for the next inspection date in the batches and if that date matches with current date then system will move the stock of the batch again to Quality inspection with generation of inspection lot for carrying out inspection for analysts in QC department.

In our case when this dead line monitoring is executed on 11.10.2016 system move the stock back to Quality inspection with generation of inspection lot as the next inspection date of the batch 11.10.2016 is reached. Select the option To insp.stock at lot creation to move the stock from Un restricted use to Quality Inspection on the selection screen on QA07 screen 

Now execute.

Now check for the stock of the batch in mmbe.Stock moved to quality inspection.

Now check in QA32 for automatic generation of inspection lot

Inspection lot created with 9 series to carry out inspection.

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How to debug the programs triggered by RFC to be run in background

While debugging a program, you may have the situation below. A function module like MRP_KD_AUFTRAG_RFC in this example is triggered through RFC to be run in background, so it is impossible to debug into the function module by clicking F5 key (Single step) to check how the function module runs.

This is so-called transactional RFC and cannot debug through normal way. in this case, please go to the debugger menu below.

Select the filed below then continue by clicking F8 key to complete the transaction.

Then, go to transaction SM58 and run for your user and current date. The function module planned in background is stopped in that.

Please go to menu below, which makes you debug the function module.

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