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Project - Talema
USER MANUAL
Production Planning
USER MANUAL
Version 1.0
Document name
Production Planning
DOCUMENT INFORMATION
Version Filename Date
V 1.0
EUT -PP
Autho
r
Document location
Reviewed
by
Changes from
previous
version
19-032008
REFERENCE DOCUMENTS
Document
Version R Reference
DOCUMENT Submission
Prepared by
Received by
Anand Srinivasan
(Wipro InfoTech Ltd.)
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USER MANUAL
TABLE OF CONTENTS
___________________________________________________________1
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Material Master
SAP menu
Transaction code
SAP menu
Transaction code
SAP menu
Transaction code
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Enter Industry sector, choose Mechanical industry from the dropdown; choose
material type from the dropdown. In this case it is semi finished Product. Press
Enter. You will be prompted to choose the required material views. Production
Planning requires the following views viz. Classification; MRP1, MRP2, MRP3, MRP4,
Work Scheduling. Highlight these views and press tick button.
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Enter TSMU or choose TSMU (i.e. Talema mother unit Plant) from the dropdown for
Plant. Choose the Storage Location WPMU from the dropdown. This is where
material is stored. Press Tick.
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You will enter into MRP view no.1 screen.. Choose PD from the dropdown list in the
MRP Type field. PD is the simplest form of MRP type. It is the most flexible MRP
type. PD instructs the system to fine tune the planning... Choose appropriate MRP
controller from the dropdown menu. This is the person who does the planning run.
Choose the Lot Size EX from the dropdown. EX defines that production lot quantity
will vary for every production.
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Press the MRP2 tab. Here, Choose E from the dropdown. This states that this
material is produced in house. Suppose, if a material needs to be procured
externally sometimes, then choose X.
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Press MRP3 tab. Enter Strategy group as 10. This indicates that the strategy
adopted is Strategy No. 10, which is plain vanilla Make to Stock production. Enter
02 in the Availability check field. That is we will use checking group 02 for
availability check.
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Press MRP4 Tab. This view is the most important view of all. It stores essential
details of a material. For materials in Talema with alternate BOMs, for Selection
method field choose 3 from the dropdown menu. This instructs the system how an
Alternate BOM should be selected for a production order. 3 states that Alternate
BOM is selected via a Production version. A Production Version is another PP
master data, which identifies various BOM/ Routing combinations. For Individual/
Coll. Field, for materials which has options of components or assemblies, choose 1
from the dropdown. 1 states that the requirements generated are individually. For
other materials leave this field blank.
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In the same screen, press the Prod Versions button, there will be a pop-up
displaying the list of Production versions of that material. In this case it is S20461.
Click on the Continue button or press Enter.
[ Please note: Creating a Production version is dealt latter in this manual.]
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Press the Work Scheduling tab. Enter the appropriate person in the Production
Scheduler field. For 1008, 008 is the Production Scheduler. In the
Prod.Sched.Profile field, choose 000001 from the dropdown for all the materials.
This profile instructs the system how production is executed in shop floor. Example
as to when the production order should be released, etc.
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SAP menu
Transaction code
SAP menu
Transaction code
SAP menu
Transaction code
BOM is a master data which contains what proportions of input materials are
required to produce a std. quantity of output.
Choose the Material and Plant from the dropdown list.
Choose BOM Usage 1 from the dropdown. ( Usage 1 is Production)
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Enter the Alternate BOM No. Alternate BOMs are alternate combinations of input
materials. 1st Alternate will have 1. 2nd Alternate will have 2 and so on.
Press the Cap button at the top. It symbolizes Header data.
Here, enter, the Base quantity of the Header material as 1. Base quantity is used
as a base for requirements calculation.
Under Alt Text, you can give some text about this alternate say, some keywords for
you to identify later.
Press the Item button at the top.
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WORK CENTER
Work Center is a place, where the conversion of input materials to output takes
place. In ITL, we will using 2 types of work center category viz. (1) Machine 0001;
(2) Labour 0003
SAP menu
Transaction code
SAP menu
Transaction code
SAP menu
Transaction code
Data
Logistics->Production->Master Data
Centers ->Work Center -> Display
CR03
->
->
Work
Work
Choose the Plant where the work center will be located; Enter the Work Center
name.Choose the appropriate Work center cat. From the dropdown. In this case, it
is 0001.Press the tick button at the top
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For Usage field, choose 009 from the dropdown list. Here, we are instructing the
system to allow all kinds of task list types for this work center.
For Standard value key, choose SAP for Normal Production from the dropdown
menu. Then press tick at the top left of the screen.
For Set up, choose No checking from list
For Machine, choose should be entered from list
For Labour, choose should be entered from list
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You will be presented with the Capacity header screen. Here, you will enter wide
details about the capacity(s).
Enter the name of the capacity as BED LENGTH1100/CENTER HEIGHT. 250; Choose
Capacity planner grp. as 1;.
Choose Factory calendar ID as I8; Active version as 1; Base unit of meas. as HR
Capacity availability times: Enter Start as 08:30:00 till Finish as 00:00:00 the next
day.
Length of Breaks as 03:00:00; Capacity utilization as 100; No. of indiv. cap units as
3;
In Capacity field, enter HR
Indicate for all work centers in the following checkboxes : Relevant to finite
scheduling;
Can be used by several operations; Long-term planning.;
Press the tick button at the top left of the screen.
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Press the Scheduling tab. Here, we indicate that which capacity is used to schedule
this work center. Always use Capacity category 001 to schedule. Processing
formula is SAP002. (For Capacity Category 002 select SAP003.
Work dimension is TIME & Work unit is HR.
Press the tick button at the top left.
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ROUTING
Routing is a task list where work instructions regarding how material wise
production conversion takes place in the designated work center are stored.
SAP menu
Transaction code
SAP menu
Transaction code
SAP menu
Transaction code
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Enter the desired task list description by which one can recognize at the time
transactions eg. Production Orders. Here, enter 1008.
Enter Usage always as 1; Status is always 4
In this case, From Lot Size is 1 and To lot size is 99,999,999 and their unit is EA.
Press the tick button. Press the Operations button.
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You will see, Operation step nos. 0010 to 0080. Against each step, choose the
appropriate Work Center, where that operation takes place. In Control key column,
choose PP01 or PP06 for operations, Enter the individual Operation steps in the
Description column viz Winding1:75/1.02 by RW2/15, etc; Enter 1 as Base quantity(
Base quantity is the std. output quantity.); Enter the values for all the costing
activities for each operation viz. Dur M/C HR, Dur Lab HR.
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So far we have seen the master data. Now we shall see the transaction data.
Planned Independent Requirements (PIRs) are prime input for Production Planning.
Since Make to Stock strategy is adopted at component / assembly across whole of
ITL, PIRs are taken as requirements that are likely to be realized. In other words,
they epitomize the function of their 3 month plan to facilitate raw materials
procurement that has a lead time varying from 20 to 50 days and at the same time
give flexibility to change the production plan at any time, keeping in line with
changing sales situation.
SAP menu
Transaction code
SAP menu
Transaction code
SAP menu
Transaction code
Logistics->
Production->
Production
Planning->
Demand
Management
->Planned
Independent
Requirements-> Create
MD61
Logistics->
Production->
Production
Planning->
Demand
Management
->Planned
Independent
Requirements-> Change
MD62
Logistics->
Production->
Production
Planning->
Demand
Management
->Planned
Independent
Requirements-> Display
MD63
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Enter the desired Req. plan number, say, Anand01, and his Plant as TSMU
Under Planning Horizon, say, enter From as 19.03.2008 and To as 30.05.2008
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Press the Sched. Lines tab. Here, for materials you need a weekly requirement,
monthly requirement is split by choosing W Week format from the dropdown.
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Press the Table tab again. Now, the weekly split is visible.
MRP
MRP Run or Planning Run is an engine which converts the requirements elements
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(Issues) into planned supply elements (Receipts) and Balances the Demand/ Supply
gap. Issues & Receipts are called MRP Elements. Issues include PIRs, Dependent
Requirements, Order Reservations, Sales Orders, Issuing Stock Transfer Orders,
etc. Receipts include Planned (Production) Orders, Purchase Requisitions, Purchase
Orders, Open Production Orders, Receiving Stock Transfer Order, Schedule lines,
etc. Having said that, when we run MRP, Planned orders are generated to offset the
PIRs of Top level materials and Dependent Requirements of lower level products.
These Planned Orders can be converted to actual Production Orders later and are
executed then. Purchase Requisitions are generated for Raw materials, which are
converted to Purchase Orders to fulfill these requirements.
Total Planning: (Plant wise planning)
SAP menu
Transaction code
Logistics ->Production
Planning ->Online
MD01
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->
MRP
->Planning->Total
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Total Planning is used planning for all the materials in a plant in 1 transaction.
Enter Plant, as TSMU
Choose Processing Key as NETCH(Net Change in Total Horizon)
Create purchase req. as 2; Schedule lines as 2; Create MRP list as 1
Planning Mode: 3; Scheduling: 2.
Keep pressing the tick at the top left end multiple times and accept all the warning
messages.
Now, press this message box tick to complete the run.
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The above is the result of our planning run. It shows the number of materials
planned.
It also shows the no. of planned orders and purchase requisitions generated, etc.
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multi level
Transaction code
MD02
MRP LIST
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MRP list is a static report displaying the detailed results of the planning run
material wise. It displays the time of the MRP Run at the top.
SAP menu
Transaction code
MD05
Stock/ Requirements list unlike MRP list is a dynamic report giving you up to date
information about new requirements of that material like PIRs, Issue Stock Transfer
order, Sales orders etc. ( Please note that here Sales orders wont influence
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anything since we are making to stock) and new receipt elements like up to date
Stock level, newly converted Production order, etc)..
SAP menu
Transaction code
SAP R/3 Menu Logistics ->Production -> MRP ->Planning>Evaluation-> Stock/ Requirements list
MD04
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The above is Stock/ Requirements list of a semi-finished level material. Hence, one
finds Dependent requirements and the MRP element which it refers to i.e. all the
4000X level materials.
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Here, we take one of the planned orders which are generated against the
dependent reqts. Say, Planned order no. 0000000006 by double clicking the lens.
You will get this pop-up. Click the pencil image.
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You can also change the planned order dates and schedule/ reschedule it.
You may want to test the possibility of a new desired date. Enter a new basic finish
date, say 21.02.2008 in place of the old basic finish date. Press Schedule planned
order at the top. The system does Backward Scheduling from that date.
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System has generated new basic dates viz. 02.04.2008 to 02.04.2008. The above
screen displays the routing object of this material to do backward scheduling
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You can also do Capacity Leveling to level the uneven load on the BP, L1( our work
center in our example).
On the menu tree at the top of screen, click Goto and under that click Capacity
Leveling.
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You will get this pop-up input box. Here, click Detailed plnng radio button and Days
radio button.
Enter Period of evaluation as From 19.03.2008 and to 30.04.2008 .
Press the tick in the input box.
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This is Detailed Planning screen. It displays the available capacity for that month
day wise( equipment hrs.) and Total requirements( equipment hrs) every day.
Press the Pegged Requirement button at the top of the screen.
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Now we shall look at detail overload view by pressing the Overload button at the
top left corner of the screen.
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Here one can see that the max. load for this WC is 341.5%. Therefore a caution for
us.
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By clicking the + sign on the left side of the capacity, we get elaborate details of
the load. The WC Ruff is shown overloaded for a period of time
Now, press the Overview button at the bottom right of the screen.
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The capacity for all days of the month is displayed, along with overload.
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After correcting and editing the planned orders, we can find in that the capacity is
not exceeding beyond 100%. i.e. capacity is under check!
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We can see that the planned order 0000000048 now has an asterix sign in suffix.
This means that this planned order is firmed. That is this planned order will be
retained and not be replaced by any other planned order when the next MRP is run.
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You can see that this planned order is firmed as the checkbox Plnd order is ticked.
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The Capacity leveling we saw before can also be accessed directly in Stock/
Requirements list( MD04). In the menu tree at the top, click goto and under that,
click Capacity Situation.
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We have already created the planned production orders. Now we need to convert
these planned orders into actual production orders and execute. You can create
production orders through one of 3 ways.
(i) Directly from Stock/ Requirements list.
(ii) Entering the planned order no. eg. 0000000048 in the following transaction.
Logistics ->Production -> Production Control ->Order>Create ->From Planned Order
Transaction code
CO40
OR
(iii)
Creating a Production order without referring any planned orders.
SAP menu
SAP menu
Transaction code
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Now, let us consider the first 2 methods. From Stock/ Requirements list, by double
clicking the desired planned order, you will get this pop-up. Press ->Prod. ord
button to convert this planned order to production order.
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You will enter into this screen, which is our CO40 transaction.
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You will get the pop up saying that Capacity available at all work centers.
Press the tick in this screen.
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Now press the button Materials at the top of the screen. You will get the messageAll checked materials in order are available. Otherwise you will get the pop-up
Missing parts overview/ Missing parts list. These lists will give the parts which is
deficit quantity.
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You can also view if there is any material shortage. From the menu tree goto ->
Missing parts->Missing parts overview.
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You can view the std BOM quantities required to produce 48 Nos of T-trans1 by
pressing the Component overview button (BOM sign) at the top.
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The above screen shows the std. reqd. quantities of the input materials. You can
also assign respective storage locations of those materials if you want to.
Press the Operations button at the top( next to cap sign).
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This is Operations overview screen, which gives the schedule of this production
order.
Now, double click on one of the operation nos., say, operation no. 0050. to enter
into the operation detail screen.
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This is operation details screen. In this, press the StandardVals tab at the centre.
Here you can see the std. costing activities for that operation. If you have not
entered these std. value at the routing level, you can enter this here at any time
before this order is released.
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Now, press the Cost Order button (calculator sign) at the top.
Press back button twice at the top to come back to main screen.
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Here, what you see is the planned costs of this production order.
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Transaction code
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>Change
CO02
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Now we need to dispatch the work center to this order. So, we can use this
workcenters for the order.
Highlight all operations; press the menu tree at the top Operations-> Dispatch to
dispatch this order to the work center.
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Now, you can see the column SysStatus, all the operations are having DSPT status.
That is, they are being dispatched.
Now, click the back button at the top to return to the header screen.
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From the menu tree at the top, press Goto-> Graphic->Gantt chart
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11
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CAPACITY PLANNING
Capacity Load:
SAP menu
Transaction code
Planning
In this transaction, one can see the weekly capacity load of a work center.
Enter the Work center code, TJ01
Enter Plant, TSMU
Press the Standard overview button at the top.
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->
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The above screen shows, the capacity requirements( equipment hours); available
equipment hours; capacity load( % of total capacity); Remaining available
equipment hours.
You can pick the required week by ticking the checkbox on the left side of that row.
After, selecting, press the Cap. details/ period.
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In this screen, you will see the detailed display of individual load elements and the
source of these load(s) in the column PeggedRqmt. Sources are planned orders &
production orders.
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Now in the same transaction, after entering Work center & Plant, press the button
Variable overview.
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In this screen, you can distinguish the group into Wk. orders (Production orders); Pl.
orders( Planned orders) and sum of the two, etc.
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12 CAPACITY OVERLOAD:
SAP menu
Transaction code
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You can see in this screen that the system displays the weeks in which there is
capacity overload.
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13
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SAP menu
Transaction code
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Choose the Order Cat. as 1 (which means only Production Orders will be displayed)
You can also further filter your criteria with Order, 1000017
You press the execute (clock) button.
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In the top section, tick the checkbox at the left side of the row of the Work center
capacity 001, which is Equipment Hrs.
Now, under the Requirements section beneath, tick the checkboxes at the left side
for all the rows relevant for dispatching. You can see, each operation, operations of
order no. 1000017. We are dispatching the capacities viz. Equipment Hrs.(001).
Press the Dispatch manually button at the top.
[Note: Please recollect whilst creating the work center we had indicated that
although these 2 capacities are used for dispatching, only Equipment Hrs. is used
for Scheduling the work center in the time dimension.]
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You will get this pop-up. In this, tick checkbox at the left side of Equipment Hrs.
row.
Enter the new desired scheduled production dates/ time viz. Start 20.03.2008 at
12:45 hrs. and Finish 20.03.2008 by 24:00 hrs.
Press the Dispatch button at the bottom.
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The above is the Planning message box. It says that there are 3 Information
messages; 1 warning messages and no error or termination messages. Former 2
are acceptable but not the latter two.
Click on the right side of Warning messages.
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The order slabs are in red. Choose each operation and drag it along the desired
date in the X axis time graph by a green color vertical line.
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Logistics->Production->Capacity
Planning->Leveling>Order view->Planning Table- Order View (Tabular)
CM23
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You will get this pop-up. Choose the work center where you want to dispatch and
schedule this order in.
Press the Dispatch Manually button at the bottom left of the pop-up.
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Now we will resume our Order execution 1000017 from where we left.
Remember, we have dispatched & scheduled our order with Start. at 07:00 hrs, on
20.03.2008 & Finish by 11.41 hrs. on 20.03.2008.
Having dispatched this order to new scheduled dates manually, we will release this
production order. Please remember after releasing & saving the order, one cannot
change the order parameters anymore.
Press the Release (Green colour flag) button at the top left.
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You can see that our order now has the Released status.
Click the back (arrow) button to go to main header screen.
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Now, the most important step: Press the save button at the top.
16 GOODS ISSUE
SAP menu
Transaction code
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Logistics ->Production->Production
Movement->Gods Issue
MB1A
Control
->Goods
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Goods Issue Reversal is canceling the Goods Issue given for that order. Goods Issue
can be cancelled for any order any time until the order status becomes CNF, which
is Confirmed.
SAP menu
Transaction code
Logistics ->Production->Production
Movement->Gods Issue
MB1A
Control
->Goods
All details are same except that the Movement type in this case is 262. Enter.
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Enter the Material codes, reversal quantities( mirror image of the issue quantity),
unit of measure, even the same batch no. that was issued before. So, care must be
taken whilst doing this one.
Press tick button at top left of screen. In the next screen, press save button to post.
18
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Production Order Confirmation is a transaction which lets the system know that the
production order execution has been completed. The resulting actual yield
quantity, costing activity actuals like time taken, steam consumed, fuel consumed,
electric power used, etc.
SAP menu
Transaction code
Logistics
->Production->Production
Control
->Confirmation->Enter-> For Operation->Time Ticket
CO11N
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By confirming at the order level, all the operations are confirmed at once
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You can see that the order 8000017 is now having the status CNF, i.e. CONFIRMED
SAP menu
Transaction code
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Logistics
->Production->Production
->Confirmation->Cancel
CO13
Control
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SAP menu
Transaction code
Logistics ->Production->Production
Movement->Goods Receipt
MB31
Control
->Goods
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[Please note: This step is very important for the order status to get DLV, Delivered.
Otherwise status becomes PDLV, Partially Delivered. For CO users to calculate
variance & settle a production order, status has to be either DLV or TECO]
Press Adopt button at the top left.
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You will get this screen by double clicking at the bottom of the screen, which says
that this Goods Receipt is being posted in the document no. 5000000040.
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Now, we see in the order header screen in the Goods Receipt section. The
checkbox Delivery Completed, is being ticked.
Please note that, suppose in case of production orders having co-products with
indefinite receipt quantities, we may have to do multiple goods receipt
transactions, even if we forget to click del. Comp checkboxes in those transaction,
we can click it here. Till this checkbox is ticked, the order wont have DLV status.
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You can see that our order has the status DLV, Delivered.
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Now, we can see the costs analysis by clicking the menu tree Goto-> Costs->
Analysis
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The above screen gives the analysis of actual costs realized from this order.
Press the Layout (Cube) sign.
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You can select the required columns from being hidden into display by
manipulating the directions.
The desired columns have been added for our display.
21 STOCK OVERVIEW
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In the Stock overview, one can see the display of available stock at any point in
time.
SAP menu
Transaction code
Logistics
->Materials
Management->Inventory
Management->Environment->Stock-> Stock Overview
MMBE
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You can see from the above screen that the qty is in unrestricted use
SAP menu
Transaction code
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Logistics
->Production
->
Production
Control
->Information System-Production Order Information
System
COOIS
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This transaction can be used to convert multiple planned orders into production
orders. For example, you can convert all/ some of the planned orders of the any/
some/ all of materials controlled by the MRP Controller. 001 can convert all/ some
of the planned orders of the any/ some/ all of the materials at one go. However,
some care should be taken in choosing the orders to be converted.
Enter Plant, TSMU
Choose MRP Controller from the list , 001
You can filter the selection criteria with Material
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REWORK ORDERS:
Rework order will be differentiated from standard order by order type :PP03
Rework orders can be created manually or automatically using trigger point in an operation
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When going to component overview there is no component assigned in the BOM for
that rework order
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