Rework in Production

SAP ECC 6.00

August 2007

English

V5F: Rework Production Order (Work-in-Process)

SAP AGDietmar-Hopp-Allee 1669190 WalldorfGermany

Business Process Procedure

SAP Best Practices V5F: Rework Production Order (Work-in-Process) - BPP

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Process Flow Legend





Contents

1 Purpose........................................................................................................................................ 6

2 Prerequisites................................................................................................................................ 6

3 Process........................................................................................................................................ 7

3.1 Process Flow Diagram..........................................................................................................7

3.2 Process Overview Table.......................................................................................................7

4 Scenario..................................................................................................................................... 10

4.1 Create Notification from Parent Production Order...............................................................10

4.2 Insert Rework Operation on Parent Production Order.........................................................11

4.3 Confirm Parent Production Order at Rework Operation for Non-defective Quantity............11

4.4 Determine If Complaint Quantity Must Be Reworked or Scrapped......................................12

4.5 Scrap Defective Quantity That Cannot Be Reworked..........................................................13

4.6 Create Rework Order for Assembly Quantity That Can Be Reworked................................14

4.7 Confirm Parent Order for Reworked Quantity That Can Proceed to Subsequent Operations15

4.8 Set Notification Status to Technically Complete..................................................................15



V5F: Rework Production Order (Work-in-Process)

1 PurposeNotifications are used to process defective materials on a production order. Since the defective material is at the operation level of the production order we refer to this as WIP – In Process Rework. These defects are identified as specific operations on the Parent Production Order; hence the notification is created with reference to the specified operation on the Parent Production Order. The first step is to determine what quantity of materials can be reworked or should be scrapped.

The Rework on the Parent Production Order functions as a gate. A work center called “REWORK” needs to be created for inserting this operation on the Parent Production Order. The new operation is incremented by 1 as compared to the operation of the Notification. The new operation that is 1 greater than the operation on the notification is inserted into the Parent Production Order.

Non defective quantities are confirmed and allowed to pass through the inserted operation for the subsequent processing. The defective quantity that can not be reworked will be scrapped and charged to a cost center. A rework order is created and confirmed for correcting the defective materials. The rework order is linked to the Parent Production Order.

These are the business process alternatives that you must consider when executing this scenario:

Step 4.4: If the quantity will be scrapped, go to step 4.5. Otherwise, go to step 4.6.

These choices are denoted by the icon.

2 PrerequisitesYou have entered the master data required to go through the procedures of this scenario. Ensure that the following scenario-specific master data exists before you test this scenario:

Material Plant Description

F26 BP01 PenF1000-M1 BP01 Configurable Pen

For additional detail on the master data, see the V30_Master_Data_EN_CA document (located on the DVD under \BBLibrary\Documentation).



3 Process

3.1 Process Flow Diagram



3.2 Process Overview TableStep Step Name External

Process Reference

Business Condition

Role Transaction Code

Expected Results

4.1 Create Notification from Parent Production Order

When defective materials are discovered on a production order a notification is created for tracking the rework or scrapping of the defective materials and are linked to the Parent Production Order.

Shopfloor IQS1 New Notification of type ZI is created

4.2 Insert Rework Operation on Parent Production Order

For the defective materials that can be reworked a new operation “Rework” will need to be inserted

Shopfloor IQS2 New Operation that is 1 greater than the Operation on the Notification is inserted into the



on the Parent Production Order.

Parent Production Order

4.3 Confirm Parent Production Order at Rework Operation for Non-defective Quantity

In order for the non-defective materials to flow through the inserted “Rework” operation of the Parent confirm the non-defection quantity.

Shopfloor IQS2 Non-defective quantity is confirmed at the inserted operation on the Parent Production Order

4.4 Determine If Complaint Quantity Must Be Reworked or Scrapped

The first step is to determine if the defective material can be reworked or it should be scrapped.

Shopfloor IQS2

4.5 Scrap Defective Quantity That Cannot Be Reworked

The material that is defective and can not be reworked will need to be scrapped and charged to

Shopfloor IQS2 Creation of a Rework Order, linked to the Notification



a cost center.

4.6 Create Rework Order for Assembly Quantity That Can Be Reworked

A Rework Order is created for the defective quantity and is linked to the Parent Production Order.

Shopfloor IQS2 Creation of a Rework Order, linked to the Notification

4.7 Confirm Parent Order for Reworked Quantity That Can Proceed to Subsequent Operations

Confirm the rework order.

Shopfloor IQS2 Additional confirmation of specified quantity at the inserted Rework Operation

4.8 Set Notification Status to Technically Complete

At the completions of the rework the notification is set to technically complete. This indicated that there is no further processing necessary on the

Shopfloor IQS2 No further processing of the Notification. It switches to display mode and Action boxes disappear



notification.



4 Scenario

4.1 Create Notification from Parent Production Order

UseNotifications of type ZI are used to process defective materials on production orders. Since the defective material is the header material on the production order, this type of Notification is referred to as a Notification for Parent Rework / Scrap. These defects are identified at specific operations on the Parent Production order and hence, the Notification is created with reference to the specified operation on the Parent Order.

Procedure

1. Access the transaction choosing one of the following navigation options:

Option 1: SAP Graphical User Interface (SAP GUI)

SAP ECC menu Logistics ® Central Functions ®Notification ® Create ® Extended View

Transaction code IQS1

Business Role Manufacturing

Option 2: SAP NetWeaver Business Client (SAP NWBC) via Business role

Business role (Name) SAP_AIO_SHOPFLOORSPECIALIST-S (Manufacturing)

Business role Menu Shop Floor ® Discrete ® Create Notification

2. Enter Notification type ZI and choose Enter.

3. Make the following entries:

Field name Description User action and values Comment

Plant BP01

Production Order number

<enter a production order number>

Operation number

<enter an operation number>

Choose Yes to obtain data from production order

Complaint quantity

<enter a quantity>

Reference quantity

<enter a quantity>

Description <enter a description>

Long text associated

<enter long text>



with defect

4. Choose Save.

5. Enter the mandatory partner field values (Author and Coordinator USERIDs). Make a note of the notification number:

ResultA new notification (of type ZI) is created.

4.2 Insert Rework Operation on Parent Production Order

UseThe Rework Operation on the Parent Production Order functions as a gate. A work center called 'REWORK' must be created for inserting this operation on the Parent Order which has an operation number that is incremented by 1 as compared to the operation of the Notification.

Procedure



SAP ECC menu Logistics ® Central Functions ®Notification ® Change ® Extended View





Business role Menu Shop Floor ® Discrete ® Change Notification

2. Enter the Notification number (from the previous step) and choose Enter.

3. Choose the Insert Rework Operation action item from the Action pane on the right hand side.

4. On the Insert operation 00XX dialog box, choose Continue.

5. Choose Save.

ResultA new Operation (one greater than the Operation on the Notification) is inserted into the Parent Production Order.

4.3 Confirm Parent Production Order at Rework Operation for Non-defective Quantity



UseThis confirmation is to enable non-defective quantities to be passed through the inserted operation for subsequent processing.

Procedure



SAP ECC menu Office ® Notification ® Change






2. Enter the Notification number (from the earlier step) and choose Enter.

3. Chose the Confirm Parent Order action item.

4. In the Accept confirmation quantity dialog box, enter the quantity that is not defective in Yield to confirm.

5. Choose Continue .

6. Choose Save.

ResultThe non-defective quantity is confirmed at the inserted operation on the Parent Production Order.

4.4 Determine If Complaint Quantity Must Be Reworked or Scrapped

UseIn this activity, manufacturing determines if the complaint quantity must be reworked or scrapped. A single Notification can handle both Rework and Scrap of quantities from the Parent Production Order.

After you process this activity:

Option A: if you are scrapping the quantity, go to step 4.5.

Option B: If you are reworking the quantity, go to step 4.6.



Procedure



SAP ECC menu Office V Notification ® Change







3. Choose the Quantities/MRP Controller tab.

4. Split the complaint quantity into the quantity to be scrapped and the quantity to be reworked.

5. Choose Save.

ResultA determination has been made.

4.5 Scrap Defective Quantity That Cannot Be Reworked

UseIn this activity, manufacturing scraps the defective material that cannot be reworked.

Procedure










3. Choose the Scrap parent action item.



4. Enter the quantity to be scrapped.

5. In the dialog box, enter the cost centers to which to charge the value of the scrap.

The proportion of cost distribution must equal 100%.

6. Choose Save.

ResultA rework order is created, linked to the notification. Do not process any other steps in this document.

4.6 Create Rework Order for Assembly Quantity That Can Be Reworked

UseIn this activity, we will create a rework order for the quantity that can be reworked.

Procedure










3. Choose the Create PP Rework Order action item from the Action box in the right hand side pane.

The rework order is created for the quantity in the Rework Quantity field in the Quantity tab of the notification.

4. When the prompt appears for Reference Operation Set to bring into the Rework Order, enter the Group number of the Reference Operation Set.

5. Enter the relevant cost center for the order costs to be directed to. Enter the percentage for the allocation of the costs, typically 100%.



6. Choose Back.

7. Choose Save.

ResultA rework order is created with a link to the notification.

4.7 Confirm Parent Order for Reworked Quantity That Can Proceed to Subsequent Operations

UseThis step will enable reworked quantities to be processed by subsequent operations.

Procedure










3. Choose the Confirm Parent Order action item.

4. Enter the quantity that has been reworked.

5. Choose Save.

ResultThe system provides an additional confirmation of specified quantity at the inserted Rework Operation.

4.8 Set Notification Status to Technically Complete

UseIn this activity, you set the notification status to technically complete.

Procedure












3. From the menu, choose Notification Functions Complete.

4. Choose Save.

ResultThe notification status is technically complete.


Documents

Rework in Production