WorkShop Process

[Former Member]

Hi ALL

In the current implementation ( the client is not using SAP as of now) , the requirement is to map the spares supplied by the Internal Workshop the production/Site services deptt...............................

The workshop recieves a paper based job order to make the spares for the production machines. On the job order the workshop writes the different operations done to make that spare, material used and Labour hrs. ( There is no costing done yet) but they plan to do it in future.

The Production deptt, recieves these spares and uses in case of need. Also these spares can be procoured from outside vendor ( In case of load on workshop).

Workshop doesn't charges the cost of the spares to the production deptt. as this is factory internal work.

Can anybody help me, how this can be mapped SAP, along with the complete flow in SAP, using the PP/PM module.

Regards

Manish Bansal

[P745394 · Accepted solution]

No In Plant Maintenance Order You Cannot use tap Production of this Fresh Spare Part as It will difficult to Cost analysis & Settlement.

You Need to Use Production Order for This Spare Part Production.

Only for Repair of Old Spares or Damage Spares You Can Use Refurbishment Order

If U r using Ideas Check 100-100 Semi finished Product same as urs Requirement

Srinivas

[Former Member]

Dear All

I am really thankful to ALL ,for your timely valuable inputs on the possible flow in SAP. From here, I need to take this learning forward to PP/MM guys.

Once again thnks to ALL.

Regards

Manish Bansal

[P745394]

Hai Bansal ,

This Scenario Can be tapped in this way.

1.First Note Down the Spare Part the Workshop Supplies to Production Dept.

2.Create Material Master for Each Spare Part with Material Type "Semi Finished" Product.

3.You Need to Create Production Order for this Spare Part(Semi Finished) Production by Work shop Guys & Assign Routings to it.

3.1 Cost of Material Used will Come from Routing as you mention ask PP Guy.

3.2 Cost of Labour Is assigned by Acitivity Type defined in Work Center ask CO Guy for this.

4.After this Make confirmation of this when spares get Produced & Do settlement.

5.Let the Maintenance guy or Any one draw it from Store.

Next Scenario,

To Get this spare part from outside vendor.

1.Let the required people raise PR for this & MM People can Procure it from Outside Vendor

or

2.Work Shop Can Create Production Order , In Routing assign Control key of External Operation & Release Purchase order for External Vendor. Check With PP Guy for Varient Configuration In so that by using Characteristic is it easy.

For Repair of Existing Spares

You Need to use Refurbishment Order

Regards

[Former Member]

Manish

As explained by Srinivas whether internal or external making & storing in a Storage location the cost of the spare made should be settled to the Material from the production order created .

The cost flow will be seemlessly happening in this case and again will be incurred by a Maintenance order /Production order who ever consumes that material from the store

Regards

Satish

[Former Member]

Hi Sundar

This is fine, but the 90% of the spares made at workshop are new spares only 10% are refurbished , which involve workshop labour and new material.

If the Production deptt sends a Maintenance Notification/Or paper based request to workshop to prepare new spares, my concern is ,how the cost will flow to the new spares?

Once the spares made, they should be goods issued to Maintenance Order to settle to the cost center.

What will be flow in SAP , pl correct me:

1. The Maintenance Request/ Notification is send to Workshop to prepare spares

2. The workshop assigns this notification to the Production order ( If possible in SAP)

3. The production cost (workshop labour and raw material) is settled to the new spare produced and kept in storage location in workshop.

4. The goods issue of the new spare is done to the PM order on the need based requirement, or the stock can be transferred to the storage location of the spares inside the production.

Regards

Manish

[MTerence]

Hi Manish

You say Spares are the internal components produced inside the plant.

Once the spares are produced, u have to maintain in the Material master... cost can be defind there...

IN PM

you create a maintenance order, consume the spares as internal, doing goods issue, completing the order

Once u have done goods issue.. the cost u have maintained in the material master will flow to the order...

If u have maintained MRP in the material master, do the spares can be produced and the limited stocks can be maintained at stores for your maintenance activities...

- Pithan

[sundar_desai2]

Dear Manish,

Either you create completely new or refurbish the material, you will have to transfer it in warehouse. And from ware house you can withdraw the material as per requirement in maintenance or production order. Once that material is assigned in maintenance or production order its cost will get captured in that order.

Now if you are doing only 10% refurbishment of old material, for this you can use refurbishment type maitenance order. But for rest 90% spares, if you are creating it in workshop you can create seperate maintenance order/production order type, which will capture the cost of raw material & manhours required to create new material.

For above process, flow will be same as for both maintenance & production scenarios.

Sundar

[sundar_desai2]

Dear Manish,

This scenario can mapped with the help of refurbishment order in Plant maintenance.

For this you will have to create the three material types i.e. C1-New Material, C2-Refurbished Material, C3-Damaged material having different different costs.

Once the spare is damaged i.e. C3 type will be converted to C2 by doing refurbishment.

Sundar

Edited by: Sundar Desai on Apr 13, 2009 7:27 AM