Variant Configuration

What is Variant Configuration? It is a tool which helps to simplify the complex manufacturing of final product with more varieties and Variation of the input material. e.g. Automobile manufacturing Furniture manufacturing Visit for more info

Variant Configuration..contd
Variant configuration helps To ensure right choice is delivered Easy for the sales person to select Communication is fast and clear Ensures production of right item

Super BOM:-

Variant Configuration-super BOM

containing all the components for producing all variants of the product. Advantage:No need to create a separate BOM One configurable material to cover variants.

Super Routing:-

Variant Configuration-super Routing

containing all the operations for producing all variants of the product. Advantage:No need to create a separate Routing One configurable material to cover variants.

Configurable Material - BOM
configurable material BOM contains all the components that are required to manufacture the material. The BOM contains components that are only used in specific variants (variant parts), as well as components that are used in all variants (non-variable parts)

Configurable Material - Routing
A routing (or task list) for a configurable material contains all the operations, operation sequences, and production resources/tools (PRTs) that are required to manufacture all variants of a configurable material

Variant Configuration-Class
To define the features of a configurable material, use characteristics. To enable to use characteristics to configure a material, assign the material to a class of class type 300. The customer can choose from among different options for each characteristic (values).

Classification & Characteristic
Various characteristics of the material can be Defined and these characteristics are attached To the class. Class is attached to the Material master. e.g Variant class – class type 300 Batch class -- class type 022

Item selection from super BOM
•Enter the variant part as a BOM item and assign object dependency to it. •Classify the variant part in a class and enter the class as a class item in the BOM. •Use the classification data of a material as a selection condition.

Object Dependency
Selection of item, Restricting the selection & changing the quantity of an item in the BOM are done through Object dependencies select condition, Precondition and Procedure respectively

Select Condition
Super BOM contains all the required and Variable items. From the variable items required items will be selected which are Matching the characteristic value.

Select Condition e.g.
Items in the super BOM are : 1. 70hp engine 2. 85hp engine 3. 95hp engine Characteristic: Power Char.Values: 70hp,85hp & 95hp select Condition : power = ’70’ Result:- item 70hp engine will be selected.

Pre Condition e.g.
Items in super BOM related to emission are :
1. DPCpump 2. DPAMpump 3. HYDpump
Characteristic1: Characteristic2: Char.2 Values : Engine_Power Emission_level euro1,euro2 & euro3


70hp can go with euro1 only; 85hp can go with all euro1,euro2 and euro3; 95hp can go with euro3 only.

Procedure e.g.
If there is a change in quantity depends on any Characteristic value, then Procedure is used. i.e Depends on number of wheel character, item ‘Fastner’ required quantity per engine may be 8 times the number of wheel. If no of wheel is 4 then fastner qty should be 32 Per product.

Creating Sales Order
When creating a sales order & enter the configurable material as an order item. see the configuration editor, where assign values to the characteristics of the material. when entering characteristic values, dependencies for the characteristics and values are processed.

Class item in super BOM
Another way to simplify the BOM creation Process is through class item in the BOM

Creation of class
Characteristics are created and attached with Class of class type 300(variant class). Class will be assigned to the material master With characteristic values Enter this class as a class item (K) in the BOM

Link between class,item & BOM
Link is established as class attached to the material master and the same class is entered As class item (K) in the BOM.

Item selection via class item
When the particular class is assigned to the Material master and the same class is Entered as a class item in the BOM, while Creating the sales order

Control on class and characteristics
Classes can be created through Engineering Change Management so that the better control can be Imparted to it. Changes to the characteristic & its effective from dates can be triggered through Engineering change Management.

Variant Configuration - Pricing
You can make the price of a variant dependent on the characteristic values assigned (Pricing). You can use variant conditions to define surcharges and discounts for a variant

Variant – Pricing steps
Create condition record create a procedure where you enter the reference from the characteristic Assign the procedures to either the characteristic values configure the material in the sales order The net price for the material is displayed

Pricing steps - process
If a value that triggers a variant condition is selected when configuring a material in a sales order, the price of the material displayed under Net value is automatically increased or reduced. In addition, the Conditions pushbutton is displayed. On pressing this pushbutton, One can see which conditions have influenced the price.

Making variant make to stock
For variants that are required frequently, you can create material variants, which can be produced without a sales order and kept in stock. When you receive a sales order, you can check whether the variant required is in stock, so that you can deliver immediately.

Variant matching in the SO
If material variants already exist for a configurable material, the configurable material can be replaced in the sales order by a material variant. Material variants that only partly match the configuration of the material in the sales order are ignored Note:-The configuration of the material must match the material variant Exactly

Simulating configuration
configuration simulation to check configuration model. In the configuration simulation, one can test whether it has created the objects correctly and whether dependencies work.

Simulating costing

Use the configuration simulation functionality to determine the costs for manufacturing a specific variant of the configurable material. Please note that this configuration is only a simulation – the costing data for a variant is not saved. use the function to simulate the costing for different characteristic values

Material Accounting
Relevant items are selected from the Super BOM through object dependency. The selected items form the BOM specific to SO. Items are copied to Plnd.order,prod.order And issued against the production order.

Example of VC
Finished Material : Bolerojeep Raw Material :- Many items

Characters (structure options)
Engine Power Emission Level Seating Capacity Body Material Thickness & colour Number of wheels

Character value & constraints
Engine Power – 70hp, 85hp, 95hp Emission Level – Euro1, Euro2, and Euro3 Matching 70hp can go with Euro1 only 80hp can go with all 95hp can go with Euro3 only

Character value
Seating Capacity – 6 ,7 and 8 Body Material Thickness & colour -0.5mmwhite;0.6mmwhite;0.7mmwhite 0.5mmred;0.6mmred;0.7mmred 0.5mmblack;0.6mmblack;0.7mmblack No.of Wheels – 4 or 5 This is to select the qty of fastner

Sales Order Creation

Assigning characteristic values

Selecting characteristic values

Selecting characteristic value for constrain

Selecting characteristic value for constrain-85hp

characteristic values for 85hp Engine Power

Complete characteristic values

View the Sales Order

MRP result Planned order with selected items

Planned order detail

View of Super BOM

View of Super BOM…contd

View of Super BOM…contd

Planning for standard variant
Planning of fast moving product as a standard item and Matching at the time of creating the sales order automatically.

Planning for standard variant example
95Hp,Euro3,6seater,0.6mmred colored Product is fast moving and it needs to be Planned and produced in advance. When the order is received, at the time Of configuring, it will pickup this Preconfigured item in the sales order.

Planning for standard variant example
Item code Beuro36seat0.6red for 85Hp,Euro3,6seater,0.6mmred colored product Item code beuro37seat0.6redfor 95Hp,Euro3,7seater,0.6mmred colored product


Configuring in the SO

Automatic replacement in SO

Item available in SO

MRP and Result

Planned order view

Component Accounting
From Planned orders components are Copied to production order and issued. All the items are accounted for consumption

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