Automatic Rework Using Reason of Variance Key

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2010 SAP AG 1
Automatic Rework Order using
Reason of Variance Key
Applies to:
SAP Shop Floor Control (Production Orders) R/3 and ECC 6.0. For more information, visit the
Manufacturing homepage.
Summary
This is an article explaining the use of reason of variance in production order confirmation in Rework
Scenario. The entire necessary configuration, master data process and additional customer checks are
explained in detail.

Author: Santosh Sarda
Company: Accenture Services Private Limited
Created on: 25 August 2010
Author Bio
Santosh Sarda has 5.5 years of rich experience in production planning area including 3.5
years of techno functional experience in SAP PP. Currently I am working with Accenture as
SAP PP / QM Senior consultant.
Automatic Rework Order using Reason of Variance Key
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2010 SAP AG 2
Table of Contents
Introduction ......................................................................................................................................................... 3
Scenario .............................................................................................................................................................. 4
Problem statement .......................................................................................................................................... 4
Solution ........................................................................................................................................................... 4
Rework Process steps .................................................................................................................................... 5
Configuration Settings ..................................................................................................................................... 5
Step 1 .......................................................................................................................................................................... 5
Step 2 .......................................................................................................................................................................... 6
Step 3 .......................................................................................................................................................................... 7
Customer Exit ..................................................................................................................................................... 8
Step1 ........................................................................................................................................................................... 8
Step2 ........................................................................................................................................................................... 8
Step3 ........................................................................................................................................................................... 9
Step3 ........................................................................................................................................................................... 9
Step 4 .......................................................................................................................................................................... 9
Step 5 ........................................................................................................................................................................ 10
Master Data ...................................................................................................................................................... 11
Step 1 ........................................................................................................................................................................ 11
Step 2 ........................................................................................................................................................................ 12
Step 3 ........................................................................................................................................................................ 13
Results. ............................................................................................................................................................. 14
Step 1 ............................................................................................................................................................ 14
Step 2 ............................................................................................................................................................ 15
Step 3 ............................................................................................................................................................ 15
Assumption: ...................................................................................................................................................... 19
Related Content ................................................................................................................................................ 20
Disclaimer and Liability Notice .......................................................................................................................... 21

2010 SAP AG 3
Introduction
Rework is inevitable in any production process. Aim is to provide the perfect workable solution to handle the
rework scenario in case of discrete manufacturing using production orders.
This article explains use of Reason of variance key in production order confirmation to activate the user
status on rework in production order. This user status in turn activates trigger point for creating rework order.
This article also highlights how user exit can be used to add customer specific checks while order
confirmation.
2010 SAP AG 4
Scenario
In standard SAP, There are different approaches to handle the rework,
a) This can be done by creating a rework order with rework quantity posting in production order
confirmation.
b) Add reference operation sets for rework operations in the existing production order itself with
rework quantity posting in confirmation.
Both the above approaches can be implemented as below.
1. Handle rework automatically using trigger points in production order confirmation. This is useful if
rework can be planned in advance based on your past experiences at certain operations in your
production process. You can create a Rework order automatically or add Reference operation sets to
existing production order operations automatically on rework quantity posting in confirmation.
2. Create a rework order w/o material manually in CO07 or add rework operations manually in existing
production orders. This can be used to handle rework as and when it occurs. Rework costs can be
collected in the rework order and finally can be settled to parent production order from where rework
is generated.
I will describe the automatic rework order creation using trigger points in detail.
Problem statement
In SAP trigger point can be executed with production order status change. For example changing the
operation status to PCNF (Partially confirmed) during confirmation of order can trigger execution of a trigger
point.
In turn triggered point would facilitate creating a rework order or adding a new reference operation set to
existing production order.
However PCNF status of operation does not always means there is a rework at the said operation. We can
have PCNF status of the operation in the scenarios where we post yield as and when produced or we post
production activities as and when consumed.
In short using production order system status to accurately implement the Rework handling using trigger
point is not fool proof w/o further enhancement and customer exit checks.
Also it is also observed that Standard SAP triggers Trigger Point execution based on operation status in the
confirmation. When we are creating the rework order automatically, SAP does not ensure if rework quantity
is entered in confirmation. Trigger point is executed based on only operation status and If Rework quantity is
not entered still rework order is created with default quantity 1.
Solution
Implement rework scenario using Reason of variance key in confirmation.
Via this key you can specify why a confirmed value deviates from a planned value (for example due to scrap,
or due to an operating error).
Reason of variance facilitates triggering a user status and in turn user status would execute the trigger point
attached to the operation. It also helps to document the reason of the rework.
This can also be achieved by setting the user status manually in the production order however Reason of
variance would help in automating the process and handle the same at the time of posting rework quantities
in confirmation itself. This would save lot of manual effort in Rework order creation process.
User Exit CONFPP02 / CONFPP04 can be used to implement customer specific checks during confirmation.
Here if reason of variance is entered for Rework then rework quantity is made mandatory in confirmation and
vice a versa.
2010 SAP AG 5
Rework Process steps
1. Maintain required customizing and master data as described further.
2. Whenever rework is encountered, enter the Rework quantity and Reason of variance in CO11N
confirmation screen.
3. Save the confirmation. User exit is triggered and customer checks are carried out.
4. Trigger point is executed and a rework order is created with rework operations and settlement to
parent production order.
5. Once rework is complete, confirm the rework order for additional rework operations and excess
components used in rework. NO GR will happen for rework order. TECO the rework order.
6. Cost incurred in rework will be settled to parent production order.
7. Do the GR and follow normal production order processing life cycle for Parent production order.
Configuration Settings
Step 1
Create / Change User Status profile: Create a user status profile with status RWRK and assign Production
order header and operation as object types to this status profile.
Transaction BS02

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Step 2
Assign user status profile to order type definition:
Path: SPRO->Production->SFC->Master Data->Order->Define Order type
Transaction: OPJH:

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Step 3
Define Reason of Variance: Define key Reason of variance in configuration of operation confirmation. Also
assign the user status profile and status to this Reason of Variance key in the same transaction.
Path: SPRO->Production->SFC->Operation->Confirmation->Define Reason of Variance
Transaction: OPK5

2010 SAP AG 8
Customer Exit
Activate User Exit: CONFPP02
Transaction: CMOD
Step1
Create a new enhancement project: ZPPCO11.

Step2
Add Enhancement CONFPP02: Customer specific input checks1.

2010 SAP AG 9
Step3
Activate components under the Enhancement.

Step 4
Go to user exit include ZXCOFU12 and add customer specific checks with help of ABAPER.

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Text Elements in code:

Step 5
Activate the Include then enhancement and then Project.

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Master Data
Step 1
Create a standard trigger point in CO31

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Step 2
Add a trigger point to routing operation where rework is expected in CA02.

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Step 3
Save routing and confirm trigger point is added correctly.

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Results
Step 1
Create a production order in CO01 and release the same for material JJ1000.

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Step 2
Check trigger point is copied to production order from routing.

Step 3
Post confirmation operation wise in CO11n (single screen confirmation)
Operation 0010 is confirmed with yield of 25.
Expected rework is to be posted at operation 0020.
Case 1: Post a partial yield w/o Rework.
Result: No Error, No trigger point execution. Post partial yield.

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Case 2: At operation 0020, Rework quantity entered but no Reason of variance entered
Result: User Exit check is triggered to check the Reason of variance mandatory

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Case 3: Reason of variance Entered but Rework quantity Empty
Result: User Exit checks are triggered to check the mandatory rework quantity

2010 SAP AG 18
Case 4: Post Rework of quantity 5 at operation 0020 with reason of variance as RWRK.
Result: Trigger point is activated and rework order created.

Trigger point activated as shown below:

Confirmation is posted successfully and rework order created w/o material with rework quantity.
2010 SAP AG 19

Further rework is carried out based on this rework order. Activity and excess components are consumed
against the rework production order. Finally once rework is done it is settled and cost is booked to parent
production order.
Assumption:
1. For rework order Standard SAP order type PP03 is used, however it can be custom defines as per
business needs.
2. For parent production order Standard SAP order type PP01 is used, however it can be custom defines
as per business needs.
3. Creation of rework order without material is demonstrated below through trigger points. Same procedure
applies for adding addition Reference operation set for rework in the same production order, only
corresponding configuration of trigger point will change.
4. Required master data like material, routing, bom are already created for the production order header
material.
2010 SAP AG 20
Related Content
SFC: Production Orders
For more information, visit the Manufacturing homepage.
2010 SAP AG 21
Disclaimer and Liability Notice
This document may discuss sample coding or other information that does not include SAP official interfaces and therefore is not
supported by SAP. Changes made based on this information are not supported and can be overwritten during an upgrade.
SAP will not be held liable for any damages caused by using or misusing the information, code or methods suggested in this document,
and anyone using these methods does so at his/her own risk.
SAP offers no guarantees and assumes no responsibility or liability of any type with respect to the content of this technical article or
code sample, including any liability resulting from incompatibility between the content within this document and the materials and
services offered by SAP. You agree that you will not hold, or seek to hold, SAP responsible or liable with respect to the content of this
document.

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