Scrap factors 07.04.2019

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Requirements for this Tutorial You will need a good grasp of: The basics of SAP and be.as 4/7/2019

Learning Targets After working through the lesson, you will be able to: Use the different scrap factors and offcut values. 4/7/2019

Scrap factors Terms: Offcut and scrap Scrap (reject) Additional production causes an increase of required material and time. Offcut (Remains at the cutting) only additional material is required

Scrap factors Terms: Offcut and scrap User „Scrap“ „Offcut“ There are several terms with different uses depending on the industry: waste, scrap factor, additional requirement, offcut, etc. be.as provides various scrap and offcut factors. The difference is made at the input, not at calculation. The values are deposited differently. = Be.as = Where are the values deposited ? 07.04.2019

Scrap factors Different specifications of additional requirements In the item master in „Assembly“ In the item master in „Material“ Scrap : Additinal requirement in manufacturing Offcut: Link on the item master to the offcut table Offcut table Scrap: Additional requirement of material (average material loss) Deposit in „scrap quantity“ 5 10% 10 6% 30 3% It is decisive, where in be.as the entry is made: In the item master in „Assembly“ Scrap: Additional requirement in manufacturing. Deposited in “scrap quantity“ and added to the total requirement. This has impact on materials and labor (time). Offcut: a reference in the item master to the offcut table. The additional requirement is depending on quantity. In the item master in „Material“ Scrap: additional requirement of the material (eg in chemical industry: loss through evaporation, sticking to the housing, removal for QC or average material loss). Only referring to material. Offcut: A reference in the item master to the offcut table. The additional requirement is depending on quantity. Total requirement + Material + Time Total requirement + Material 07.04.2019

Scrap factors Possible appearances of additional requirements BOM position: fix material surcharge: Additional requirement for setup (in printing industry), for QC-sampling (Chemistry), average evaporation or additional requirement due to offcut. Only material is affected. 20 kg material 100 kg material Offcut related to an operation: Deposited in the operation, it affects only material. Enable in configuration wizard first. X% 100 kg material 90 kg material 10% Operation 07.04.2019

Scrap factors Use in be.as Scrap factor Offcut factor No difference in calculation Scrap factor 1,08 (fix) Offcut table (variable) Base quantity Additional requirement 10 2,7 50 14,4 100 35,5 2% 5% 8% Additional requirment = Basic amount*1,08 07.04.2019

Scrap factors Use in be.as Enter directly in the item master : scrap / offcut Important: The stored values can represent both scrap factors and offcut factors. Because of the different input (offcut in table, scrap as a percentage) the fields are named differently. However, they are free to use. Note: The pre-calculation is currently not supporting the offcut table for purchase parts. It is therefore recommended to enter a scrap factor. 07.04.2019

Scrap factors Use in be.as Administration – Scrap You can deposit any default settings. For each setting arbitrary quantities ( fix and percentage) can be chosen. Quantity = firmly defined additional requirement Prozent = additional requirement % Additional requirement can be defined freely. 07.04.2019

Scrap factors Additional requirement: Purchase parts The additional requirement has a direct impact on the purchase part. Assembly Assembly (unchanged) 10% Scrap Total requirement 11 pcs Requirement 10 pcs Purchase parts: If the purchase part appears as material of an assembly, only the material is affected by the surcharge value, the quantity of the assembly or the expenditure of time remains unchanged 07.04.2019

Scrap factors Additional requirement: Assemblies Additional requirement affects BOM and routing. Assembly Assembly Planned requirement unchanged 10% Scrap Time Actual: 110 min Material requirement Actual: 11 pcs Time planned: 100 min Material requirement planned: 10 pcs Assembly The additional requirement affects only the BOM and the routing of the assembly. The planned requirement is not increased, because scrap is not reported. But there is an additional requirement of time and material, more needs to be produced. 07.04.2019

Scrap factors Additional requirement : Assembly Scrap 0%; Offcut 10% Additional requirement affects only BOM. Assembly Assembly Planned requirement unchanged 10% Offcut Time Actual: 100 min Material requirement Actual: 11 pcs Time planned: 100 min Material requirement planned: 10 pcs Example: Cutting a board Job time remains unchanged, offcut causes additional requirement. 07.04.2019

Scrap factors Fix quantity surcharge A one time fix quantity surcharge can abe deposited directly in the BOM. Setup process with material Materialverbrauch Beispiel Druckerei: Independent of the quantity to be printed, always 10 m of paper are used for test. The fix quantity surcharge is independent of all production quantities of the work order 07.04.2019

Scrap factors scrap related to a certain operation The actual total requirement of material is computed at a known loss rate Unit of measure (uom) scrap related to a certain operation : Op. Sequ. 1 10% Op. Sequ. 2 15% 10% Material A: 1uom Material A: 1,1 uom Material B: 1 uom Material A : 1,26 uom Material B: 1,15 uom 15% Base requirement Actual requirment Mat A 1 uom 1,26 uom Mat B 1 uom 1,15 uom Operation 1: Material A is needed, 10% scrap, result: 1,1 uom Operation 2: Now 15% are lost, 1,1 pcs + 15% additional requirement= 1,26 uom are needed Material 2 was not used in operation 1. Only with the second operation material has been lost: 1 uom base requirement + 15% scrap = 1,15 uom are needed to produce 1 piece. Op.Sequ.1 Op.Sequ.2 15% 07.04.2019

Scrap factors scrap related to a certain operation If you wish to use the function „Scrap related to a certain operation“ you need to enable it first : Configuration Wizard – Master data – Routing – Material scrap The expected scrap for this operation can now be entered. This value is related only to this operation. 07.04.2019

Scrap factors Calculation of total scrap The total material requirements of all operations from the selected one is calculated  The calculated scrap is deposited in the BOM manufacturing at the moment the work order is created. This entry cannot be changed.  There is no recalculation in case of a subsequent change in a operation sequence  Exception: The switch “update work order" Pressing this button, BOM and routing are re-imported. 07.04.2019

Summary Now you can: Use the different scrap factors and offcut values. 07.04.2019

Thank you for your cooperation! 07.04.2019