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Scrap Calculation
Scrap Calculation
Scrap Calculation
Use
You can calculate and plan the scrap quantity that will result from production.
These scrap quantities are then included in the planning run and in the calculat
ion of production costs.
Prerequisites
Which calculation the system uses depends on the settings in the material master
record or in the BOM.
Features
Assembly scrap
Component scrap
Operation scrap
Assembly Scrap
Use
You use this function to plan the scrap that results from the production of an a
ssembly.
Prerequisites
You have maintained the assembly scrap in the material master (MRP 1 view) as a
percentage in the Assembly scrap field for the assembly header material.
Features
However, the system always uses the estimate yield for the availability calculat
ion for the assembly. Furthermore, the estimate yield of the assembly is always
displayed in the MRP list or in the stock/requirements list.
Assembly scrap increases the order quantity of the assembly and subsequently inc
reases the order quantity for corresponding components. The dependent requiremen
ts of the material components are therefore increased correspondingly.
Example
Estimate yield
200
Assembly scrap
10%
Use
You use this function to plan the scrap of a component that may break during pro
duction of an assembly.
Prerequisites
You have entered values for calculating component scrap in the material master o
r the BOM:
in the BOM on the Item Detail Screen: General Data (data block for quantity data
). This component scrap is only relevant for the individual BOM.
in the material master (view MRP 4) in the Component scrap field. This component
scrap is relevant for all BOMs.
The component scrap quantity maintained for a material component in the BOM has
the higher priority.
Features
Example
Estimate yield
200
Assembly scrap
10%
Component scrap
10%
Operation Scrap
Use
Before high-value components are built into an assembly, the system carries out
a quality control check of the assembly, if necessary. Faulty materials that wer
e taken into account in assembly scrap are not passed on to the next operation.
They are removed.
Therefore, for a high-value component, you plan using operation scrap instead of
general assembly scrap.
Prerequisites
You have maintained the operation scrap in the BOM, on the Items Detail Screen:
General Data, under quantity data. You must also set the operations scrap net in
dicator at the same time.
Features
This scrap quantity refers to the quantity of one component that is to be proces
sed in an operation meaning that the planning run is more exact and you can dete
rmine service and quantity consumption more precisely.
If the component is contained in an assembly, for which an assembly scrap quanti
ty has been maintained, the system only takes the operation scrap into account.
The net indicator instructs the system to calculate the component operation scra
p without taking assembly scrap into account (net usage scrap).
You should also set the net indicator, if operation scrap has not been maintaine
d and assembly scrap has been entered. The assembly scrap should not, however, b
e taken into account.
Example
Assembly scrap
10 %
Component 1
Operation scrap
No entry
Net indicator
Not set => assembly scrap is taken into account
Net indicator
Set => assembly scrap is not taken into account
Before component 2 is built into the assembly, the incorrect assemblies are reje
cted and the system only takes the smaller operation scrap quantity into account
. Therefore, component quantity of component 1 refers to 1,100 pieces to be prod
uced; and the component quantity of component 2 refers to 1,010 pieces to be pro
duced.