Article Directory
I. Introduction
I wrote an article about the function of scrapping before, but now I look at the previous test data article again, and the idea is not very clear. It is more biased towards technology to test and verify, and I did not write from the perspective of the business reasons for the scrapping business, so I will summarize it again today. one time. If there is something wrong, please correct me.
Previous article address: https://blog.csdn.net/Wang_Deji/article/details/128021857
2. Scenario overview:
As a production planner or scheduler, in order to ensure the on-time and on-demand delivery of customer orders, we need to forecast product output and meet the production plan based on sales order status and production capacity. When the production process is very complicated, and there will be a loss of production due to waste of work and materials. These factors need to be considered in advance during the planning stage in order to ensure final product delivery.
3. Types of scrapping:
3.1. Assembly scrap
This situation means that after the production of the product is generally completed, there will be a certain number of unqualified products. For example, for every 100 products produced by the production line, 3 products will be unqualified. When issuing the production plan, the product qualification rate must be considered to meet the delivery needs. When placing a certain order, it is necessary to consider the planned quantity in large quantities.
3.2. Component scrapping
For certain materials required in the production process, some materials cannot be used in the production process, for example, 3 out of 10,000 screws cannot be used. This situation is generally caused by scrapping due to the normal loss range of tools or production processes, or failure to perform all quality inspections and random inspections when materials are put into storage. When releasing the plan, additional consumption needs to be considered for material consumption.
3.3. Process scrap-material waste
During the production process, the operation of the process will cause a certain amount of material loss. For example, when every 1,000 products go through the process, it will cause the loss of 2 pieces of some kind of material. Then this belongs to the loss caused by the number of processes.
3.4. Process scrap-work waste
In the production process, process processing will cause unqualified products to be scrapped, resulting in a reduction in the quantity received by the next process. For example, every 1,000 products go through this process, only 999 qualified products go to the subsequent process.
4. Data maintenance:
In order for the system to consider different business scenarios arising from scrapping during the MRP or CRP phase, we need to set different dimensions of the data according to the actual situation.
4.1. Assembly scrap
It is maintained in the MRP1 view of the material master data. When an order is placed, the order quantity is increased by a certain amount according to the scrap rate. And the number of components will also increase after being calculated according to the proportion in the BOM according to the final quantity of the product.
When the order is placed, fill in the quantity of 100, and after pressing Enter, the system will update the order quantity to 110 according to the scrap rate
The required quantity of components will also be calculated according to the final 110. And update the scrap quantity and scrap rate. If there is an assessment report, the data here can be used as the planned amount for comparison.
4.2. Component scrap (Component scrap)
在物料主数据MRP4视图中维护，订单下达后，根据产品数量和BOM组件的比例计算组件的数量，然后根据报废率计算材料的报废数进行增加。
The product and component materials in the BOM are 1:1. When 100 product orders are placed, the demand data for components is 100 pieces. Considering the 10% scrap rate, the quantity is 110.
4.3. Process scrap-material waste (Operation Scrap, net indicator)
Components are maintained in the BOM. BOM ratio 1:1, scrap rate 10%
Place a product order and the product quantity is 10000, then the components need 11000
== PS: Because the net value flag is checked, the scrapping of the product will not cause the scrapping of this material. Therefore, even if the assembly scrap rate of the product is maintained, the demand for materials for the scrapped product balance is not considered here. ==
As shown in the figure below, if the net value is not checked, the normal demand calculated according to the BOM is 11000, and the scrap rate is 10%, then the total demand = 11000+1100 (assembly waste demand) = 12100
4.4. Operation Scrap - Operation Scrap
Carry out maintenance for the process, as shown in the figure below, the maintenance scrap rate for 10 processes is 10%
The number of orders placed is 100. Considering that the product assembly scrap rate is 10%, the total number of orders is 110. According to the process route system, the number of process 0010 is 110, and the number of scrapped processes is 11.
The number of the next process is changed from 110 because 10 of the 0010 process are scrapped and cannot be transferred to the next 0020 process. So the number of 0020 process becomes 99
