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Rework Scenario PDF
Rework Scenario PDF
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 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.
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Automatic Rework Order using Reason of Variance Key
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
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Automatic Rework Order using Reason of Variance Key
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.
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Automatic Rework Order using Reason of Variance Key
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.
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Automatic Rework Order using Reason of Variance Key
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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Automatic Rework Order using Reason of Variance Key
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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Automatic Rework Order using Reason of Variance Key
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
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Automatic Rework Order using Reason of Variance Key
Customer Exit
Activate User Exit: CONFPP02
Transaction: CMOD
Step1
Create a new enhancement project: ZPPCO11.
Step2
Add Enhancement CONFPP02: Customer specific input checks1.
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Automatic Rework Order using Reason of Variance Key
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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Automatic Rework Order using Reason of Variance Key
Step 5
Activate the Include then enhancement and then Project.
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Automatic Rework Order using Reason of Variance Key
Master Data
Step 1
Create a standard trigger point in CO31
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Automatic Rework Order using Reason of Variance Key
Step 2
Add a trigger point to routing operation where rework is expected in CA02.
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Automatic Rework Order using Reason of Variance Key
Step 3
Save routing and confirm trigger point is added correctly.
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Automatic Rework Order using Reason of Variance Key
Results
Step 1
Create a production order in CO01 and release the same for material JJ1000.
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Automatic Rework Order using Reason of Variance Key
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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Automatic Rework Order using Reason of Variance Key
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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Automatic Rework Order using Reason of Variance Key
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Automatic Rework Order using Reason of Variance Key
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.
Confirmation is posted successfully and rework order created w/o material with rework quantity.
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Automatic Rework Order using Reason of Variance Key
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.
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Automatic Rework Order using Reason of Variance Key
Related Content
SFC: Production Orders
For more information, visit the Manufacturing homepage.
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Automatic Rework Order using Reason of Variance Key
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