SAP PM Proceso de Remanufacturados

SAP Best Practices for Mining

Release 4.72

June 2004

English

Scenario Documentation

SAP AGNeurottstr. 1669190 WalldorfGermany

Refurbishment Processing

© SAP AG June 2004 Page 1 of 24

SAP Best Practices for Mining Scenario : Refurbishment Processing

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ContentsRefurbishment Processing...................................................................................................................... 4

Displaying an Overview of Rotable Before Refurbishment..................................................................8

Creating a Refurbishment Order.......................................................................................................10

Issuing Defective Material to Work Order..........................................................................................13

Returning the Refurbished Material to the Store...............................................................................15

Settling the Costs on the Refurbishment Order.................................................................................17

Displaying the Moving Average Price After Settlement.....................................................................19

Displaying Costs on the Refurbishment Order..................................................................................20

Changing the Material Price..............................................................................................................21

Appendix 1 - Cost Overview Report..................................................................................................23



Refurbishment ProcessingPurposeThis scenario demonstrates the process of refurbishment.

It demonstrates how a planner creates a refurbishment order, requisitions the required spares, and returns the renovated material to the warehouse. Additionally, the associated material management issues, such as valuation and stock availability are also described.

PrerequisitesThis scenario is not dependent on any other maintenance scenario.

To run this scenario you need master data. If this is the first time you run through a mining scenario, you will need to run the master data catalog TK_MIN_472_MASTER_DATA_CATTS before you proceed. Described below you will find a detailed description for how to run the catalog.

For all of the mining scenarios CATT procedures are used to generate user specific master data – the names of the master data have a user defined suffix. In this scenario all master data has the default suffix “nn”, for example CONC_nn. When you go through it, make sure you use your individual suffix created by the CATT procedures. For more detailed information about the Mining CATT concept please refer to the document “Instructions for Running Mining Scripts” which is delivered with note 737628.

Keep in mind that the figures that result from the different transactions described in this scenario, such as stock quantities or standard prices, refer to the initial ”walk through“ of the script. These figures may change when the corresponding transaction is run several times. You may want to re-run the master data catalog to create a “fresh” set of data.

Procedure for executing the Master Data Test Catalog

1. From the SAP Easy Access screen select the following menu path or enter the transaction code:

Menu Tools ®ABAP Workbench ®Overview ®Object navigator

Transaction Code SE80

2. On the Object Navigator screen select the following menu path Utilities ®Settings

3. Choose tab SAPSCRIPT

4. Set box left of “Graphical PC Editor” to “blank”

5. From the SAP Easy Access screen select the following menu path or enter the transaction code:

Menu Tools ®ABAP Workbench ®Test ®Test Workbench ®Test

Organizer ® Test Catalog Management

Transaction Code STWB_1

6. From the Test Organizer: Test Catalog Management screen, perform the following steps:

Field name Description Req Opt

User action

Test catalog RClick

In the Title field, type *TK_MIN_472*



Click

R Select TK_MIN_472_MASTER_DATA_CATTS

Click

Select

Screen name Display test catalog TK_MIN_472_MASTER_DATA_CATTS

R Position the cursor on the highest level of the catalog structure, line TK_MIN_472_MASTER_DATA_CATTS.

R Click Test Case

Dialog Box Start CATT Test cases local

R Select Background radio button.

SUFFIX_MIN R Enter a 2-digit suffix in the unmarked field. For example AA

If you are using alpha characters as a suffix they must be in uppercase

R Click

Screen name: CATT: Test Plan Log for Run nnnnnnnn

Note The CATT procedures are executed in the background and after execution a test plan log is displayed. CATTS executed without errors are shown in green in the log. Errors are shown in red.

RClick to return to the SAP Easy Access Screen.

OverviewEn este escenario, nos demuestran la renovación de un material procedente de un estado defectuoso a un estado reformado. En el componente de gestión de materiales, los materiales representan objetos con características similares. Para identificar de forma exclusiva un objeto, el material número se ve aumentada por un número de serie. En el módulo de mantenimiento de las plantas, mantener un objeto es típicamente identificados como equipo. Un material con un número de serie puede ser asignado a una pieza de equipo, proporcionando una identificación exclusiva de un objeto en el mantenimiento y materiales de los módulos. La solución SAP Mining asume que el componente es siempre almacenados en el inventario, independientemente de si el componente es nuevo, reformado o en espera de reparación. El uso de los materiales de valoración permite diferentes tipos de valoración del material, dependiendo de su estado (nuevo, reformado, a la espera de la reparación, para ser desguazados, y así sucesivamente) y proporciona visibilidad de las existencias disponibles en cada uno de los estados. El proceso de remodelación tiene un material en espera de la reparación de



la tienda (o almacén), las reparaciones materiales y devuelve el material a la tienda, donde es almacenado hasta que el material se emitió más tarde para su instalación. El proceso de remodelación escenario muestra sólo el proceso de reacondicionamiento, por ejemplo, un elemento en una ubicación de almacenamiento con la valoración de tipo C3 (defectuoso) es renovado a la valoración de tipo C2 (reformado) por el proceso de sustitución de partes y la adición de trabajo.

Flujo de ProcesoA los efectos de este escenario, se ha supuesto que el elemento defectuoso ha sido desmantelado y uno nuevo o renovado instalado como parte de un proceso de orden correctiva o preventiva. Las medidas típicas a continuacion incluyen: 1. Crear orden de renovacion. 2. Planificar la orden. Típico de planificación de tareas incluyen la creación de operaciones, hacer la reserva de piezas de repuesto, la planificación y los plazos de ejecución. Desde el reacondicionamiento es un reacondicionamiento actividad, es común utilizar listas de tareas. 3. Calendario de la orden, incluida la disponibilidad comprobar, la provisión de capacidad, para la impresión de documentos. 4. Ejecutar los trabajos solicitados, así como el retiro de piezas de repuesto desde el almacén y ejecución de la orden. 5. Llevar a término los trabajos realmente ejecutados, con la finalización de confirmación y comprobaciones técnicas para registrar el estado del objeto técnico y los posibles daños. La orden es liquidada en los asuntos Controlling.



Transactional Process Flow

ResultAs a result of this process, one or more defective materials have been taken from store (or warehouse), refurbished, and returned to the store. Stock levels and inventory valuation has also been automatically adjusted.



Displaying an Overview of Rotable Before Refurbishment

PurposeIn this task, the stock on hand is displayed by material number and valuation type.

PrerequisiteRunning the MASTER DATA CATT procedure should have created all master data.

Procedure1. From the SAP Easy Access screen select the following menu path or enter the transaction code:

Menu Logistics ® Materials Management ® Material Master ® Material ® Display ® Current

Transaction Code

MM03

2. From the Display Material: (Initial Screen), enter data as shown or perform necessary actions.

Field name Description Req/Opt

User action

Material R Enter ENGIN_nn

R Choose

R The Select View(s) dialog box appears.

R Select Accounting 1 view by clicking the tile to the left.

R Choose Organizational levels.

The Organizational Levels dialog box appears.

Plant R Enter MP12

Valuation type R Enter C2 (Refurbished)

R Choose

NoteIn the Current Valuation section, V in the Price control field indicates the moving average price.

Also note the total stock on hand.

R Confirm the details in the table below.

R To return to the Display Material Initial Screen,

choose .

3. Repeat the display process for defective materials.

Screen name Display Material: Initial Screen


R Choose

R The Select View(s) dialog box appears.



R Select the Accounting 1 view by clicking the tile to the left.



Plant R Enter MP12

Valuation type R Enter C3 (Defective)

R Choose

NoteIn the Current Valuation section, S in the Price control field indicates Standard Price.

Also note the total stock on hand.

R Confirm the details in the table below.

R To return to the SAP Easy Access screen,

choose .

Result

Val TypeBefore Refurbishment

Issued to workshop

Refurbished & returned to store

After settlement

MAP Qty MAP Qty MAP Qty MAP Qty

C2 (Refurb)

$80.00 10

C3 (Defect)

$20.00 10



Creating a Refurbishment Order

PurposeA refurbishment order supports the re-manufacturing process of materials. The processed materials are withdrawn from store, refurbished, and returned to the store for safe keeping until they are required. This is in contrast to a maintenance order that is used to record, operating costs of maintaining plant and equipment.

PrerequisitesYou have completed the previous activity of the Refurbishment Processing scenario.

Procedure 1. From the SAP Easy Access screen select the following menu path or enter the transaction code:

Menu Logistics ® Plant Maintenance ® Maintenance Processing ® Order ® Create (Special) ® Refurbishment Order

Transaction Code

IW81

2. From the Create Order: Initial Screen, enter data as shown or perform necessary actions.


User action

Order Type R Enter PM04 (Refurbishment Order).

Material no. R Enter ENGIN_nn

Planning plant R Enter MP12

R Choose

Screen name Create Refurbishment order: Central header


User action

Blank field (Description) R Enter a short description of the work to be done. For example, Engine to be refurbished.

Mn.wk.ctr Main work center R Enter ME01_nn

Target qty No of items to be refurbished

R Enter 1

(Frm) Plant From plant R Enter MP12

(Frm) Stor.loc. From storage location

R Enter 0001

(Frm) Val.type From valuation type

R Enter C3 (from Defective)

(To) Plant To plant R Enter MP12

(To) Stor.loc. To storage location

R Enter 0001

(To) Val.type To valuation type R Enter C2 (to Refurbished)



NoteTypically a task list would be available for the refurbishment of rotable materials. By selecting a task list the resources required to complete this known task as well as the materials required will be defaulted.

Menu Extras ® Task list selection ® Direct entry

R The Task List Direct Input dialog box appears. Complete the following data:

Group R Enter MI-02_nn

R Choose

R The Operation selection using work center/replace work center dialog box appears.

Choose

R The Operation select. dialog box appears.

Choose

Choose

NoteTo identify the materials being refurbished, you need to make a note of the serial number. This allows you to track the movements of individual materials through materials management processing.

The Maintain Serial Numbers dialog box appears.

Serial number R Enter CAT021

Choose

R The Document lines: Display messages dialog box appears.

Choose

R Select CAT021 and choose again to return to Create Refurbishment Order: Central Header screen.

R A dialog box appears.

Ignore this message and choose

Go to the Operations tab.

Screen name Create Refurbishment order: Operation Overview

NoteThe task list has populated the required operations to refurbishment the equipment.

Go to the Components tab.

NoteThe refurbishment order automatically creates the first component item. This creates a reservation for the item to be refurbished.

The Task List has created the other material required to refurbish the equipment.

Typically an analysis of the component is carried out. At this stage a detailed estimate of the labor and spare parts required would be made.



Choose

The Order: Put in Process dialog box appears.

Select W/o print.

R Record the refurbishment order number:

____________________________

To return to the SAP Easy Access screen,

choose .

ResultsWe now have an order to which we can charge our time and book materials. The costs will be settled to the material account, as the re-manufacturing will restore value to the material.



Issuing Defective Material to Work Order

PurposeFrom a business perspective the “to be repaired” material has been held in the store (warehouse) for safe keeping before repair. Now that we have created a refurbishment order we need to remove the material from the store in order to repair it. The “to be repaired” material in this scenario has been valued in the material system under valuation type C3 (defective) with a nominal value of say $20.00.

PrerequisiteYou have completed the previous activities of the Refurbishment Processing scenario.

Procedure1. From the SAP Easy Access screen, select the following menu path or enter the transaction code:

Menu Logistics ® Plant Maintenance ® Maintenance Processing ® Completion Confirmation ® Goods Movement ® Goods Movement

Transaction Code

MB11

2. From the Enter Goods Movement: Initial Screen, enter data as shown or perform necessary actions.


User action

R Choose To Order.

R The Reference: Order dialog box appears.

Enter the refurbishment order number created in previous activity.

In the S Loc field, enter 0001.

Choose

Screen name Enter Goods Movement: Selection Screen

NoteAll the materials required for the repair and the to be repaired material are proposed for withdrawal from the store. Choose Page Down to view all materials. See Entry 1 of 2.

R Choose

NoteThe to be repaired material is identified in the inventory system uniquely by the material number/serial number combination. To identify which engine is being refurbishment, you need to make a note of the serial number of the material being withdrawn.

Serial number R The Maintain Serial Numbers dialog box appears.

Enter CAT021.

Select the CAT021 line.

Choose

To return to the SAP Easy Access screen,

choose .



ResultAs a result of processing the goods issue, the stock on hand of the engine to be repaired with a defective (C3) valuation type has been reduced. As with other material issues, the cost of the material is charged to the refurbishment order.

After the material is repaired it will be returned to the warehouse with a refurbished (C2) valuation type and the work order will reflect the value of the refurbished material.

Val TypeBefore refurbishment

Issued to workshop


After settlement


C2 (Refurb)

$80.00 10 $80.00 10

C3 (Defect)

$20.00 10 $20.00 9



Returning the Refurbished Material to the Store

PurposeThe refurbishment of the material has been carried out and all material and labor costs have been charged to the refurbishment order. The refurbished material must now be returned to the warehouse for safe keeping until it is required. Since the refurbished material is suitable for productive use, the value of the refurbished material is no longer a nominal value but a value that reflects the cost of repairs.

PrerequisiteYou have completed the previous activities of the Refurbishment Processing scenario.

Procedure1 From the SAP Easy Access screen select the following menu path or enter the transaction code:

Menu Logistics ® Plant Maintenance ® Maintenance Processing ® Completion Confirmation ® Goods Movement ® Refurbishment Goods Receipt

Transaction Code

IW8W

2. From the Goods Receipt Serial Numbers for Refurbishment Order screen, enter data as shown or perform necessary actions.


User action

Order R Enter the refurbishment order number created in previous activity.

R Choose

Activity R Select Change charge/valuation type + post GR.

Screen name Goods Receipt Serial Numbers for Refurbishment Order nnnnnnn

Deliv compl Delivery Complete

R Select the delivery complete indicator.

Serial number R Select the serialized material to be returned to store by clicking the tile to the left of the serial number.

R Choose and note the system message.


choose .

ResultThe refurbished material has now been returned to the store. Consequently the stock on hand of the refurbished (C2) material has increased. When the refurbishment order is settled, the inventory valuation of the material will change.


Issued to workshop


After settlement




C2 (Refurb)

$80.00 10 $80.00 10 $80.00 11

C3 (Defect)

$20.00 10 $20.00 9 $20.00 9



Settling the Costs on the Refurbishment Order

PurposeTypically, orders are settled automatically at regular intervals. However, in this step we will settle costs for an individual order. Unlike maintenance orders, where the costs of maintenance are settled to a cost object such as a cost center, refurbishment costs increase the value of the material and are therefore settled to the material.

PrerequisiteYou have completed the previous activities of this scenario.

Procedure1. From the SAP Easy Access screen, select the following menu path or enter the transaction

code:

Menu Logistics ® Plant Maintenance ® Maintenance Processing ® Completion ® Individual Processing ® Settle

Transaction Code

KO88

2. From the Actual Settlement screen, enter data as shown or perform necessary actions.


User action

Order R Enter the work order created in previous activity.

Settlement Period

R Enter the current Settlement Period. For example, 5 = May, 6 = June

Posting period R Enter current Posting period.

Fiscal Year Current year R Enter current Year

Test Run R Deselect Test Run option.

R Choose

Screen name Actual Settlement :Order Basic list

NoteThis screen confirms that settlement has been successful and therefore the costs have been transferred to the material.


choose .



ResultThe costs on the Refurbishment Order have been settled to the material master.


Issued to workshop


After settlement


C2 (Refurb)

$80.00 10 $80.00 10 $80.00 11 $76.82 11

C3 (Defect)

$20.00 10 $20.00 9 $20.00 9 $20.00 9



Displaying the Moving Average Price After Settlement

PurposeThis task confirms that the moving average price has adjusted after settlement of a refurbishment order.



Menu Logistics ® Materials Management ® Material Master ® Material Master ® Display

Transaction Code

MM03

2. From the Display Material: (Initial Screen), enter data as shown or perform necessary actions.

Field name Description Req /Opt

User action


R Choose

The Select View(s) dialog box appears.

R Select Accounting 1 view by clicking the tile to the left.



Plant R Enter MP12

Valuation type R Enter C2 (Refurbished)

R Choose

NoteIn the Current Valuation section, note that the moving average price has been adjusted to AUD 76.82 and the stock on hand is now 11.


choose .

ResultRecalculation of the moving average price confirmed.



Displaying Costs on the Refurbishment Order

PurposeThis activity demonstrates how to display costs on the refurbishment order using the order costs display (including the “Report planned/actual”).



Menu Logistics ® Plant Maintenance ® Maintenance Processing ® Order ®Display

Transaction Code

IW33

2. From the Display Order: Initial Screen, enter data as shown or perform necessary actions.


User action

Order Order number R Enter order number from previous activity.

R Choose Costs.

Screen name Display Refurbishment order nnnnnnnn: Cost Overview

NoteIn our example we have not “booked” labor hours and only used one spare part. A more realistic cost overview is included at the end of this scenario as an appendix.

R To display a cost element breakdown, choose Report planned/actual.

NoteThe system displays a detailed cost report by individual cost elements. In particular note the cost element that costs have been settled to.

ResultThe order costs were displayed.



Changing the Material Price

PurposeEsta actividad le permite actualizar los precios de los materiales y revalorizar los materiales. Permite a los usuarios entrar en un Material / Tipo de valoración y el nuevo precio. El sistema revalora el stock existente sobre la base de estos insumos. Esta transacción se utiliza cuando es necesario actualizar el material de precios, por ejemplo, si el proveedor ha aumentado el precio. En este caso, esta transacción sería ejecutado para cada tipo de valoración.

PrerequisiteHa completado las actividades anteriores de este escenario.

Procedure1. From the SAP Easy Access screen select the following menu path or enter the transaction code:

Menu Logistics ® Materials Management ® Valuation ® Actual Costing/Material Ledger ® Material Ledger ® Set Prices ® Change Material Prices

Transaction Code

MR21

2. From the Price Change – Overview Screen, enter data as shown or perform necessary actions.


User action

Posting date R Leave as today’s date.

Plant R Enter MP12

R Choose

Screen name Price Change – Overview Screen


Valuation type R C2

New price R 90

R Choose

ResultThe moving average price of the material is updated.



Appendix 1 - Cost Overview Report

Before Settlement12.04.2001 Dynamic List Display

Order 5000091 Refurbish engine

Order Type PM04 Refurbishment order

Plant MP12 Mine Open

Planned quantity 1 EA each

Actual quantity 1 EA each

Plan version 0 Plan/Act - Version

Company code cur./Object cur.

Cost elem. Cost elem. Total plan Ttl actual Variance P/A var(%) Curr.

404000 Spare parts 270,00 270,00 0,00 SAP

601600 Maintenance labor 9.450,00 9.450,00 0,00 SAP

* Debit Debit 9.720,00 9.720,00 0,00 SAP

895000 Inventory change-production order factor 1,82- 1,82- 0,00 SAP

* Delivery Delivery 1,82- 1,82- 0,00 SAP

** 9.718,18 9.718,18 0,00 SAP



After Settlement12.04.2001 Dynamic List Display

Order 5000091 Refurbish engine

Order Type PM04 Refurbishment order

Plant MP12 Mine Open

Planned quantity 1 EA each

Actual quantity 1 EA each

Plan version 0 Plan/Act - Version

Company code cur./Object cur.

Cost elem. Cost elem. Total plan Ttl actual Variance P/A var(%) Curr.

404000 Spare parts 270,00 270,00 0,00 SAP

601600 Maintenance labor 9.450,00 9.450,00 0,00 SAP

* Debit Debit 9.720,00 9.720,00 0,00 SAP

895000 Inventory change-production order factor 1,82- 1,82- 0,00 SAP

* Delivery Delivery 1,82- 1,82- 0,00 SAP

895000 Inventory change-production order factor 0,00 9.718,18- 9.718,18- SAP

* Settlement Settlement 0,00 9.718,18- 9.718,18- SAP

* 9.718,18 0,00 9.718,18- SAP


Documents

SAP PM Proceso de Remanufacturados