PM Refurbishment Orders for Material Repairs

Session 3606

Gail McKeeBayer Corporation

Bayer

• Bayer Chemicals

• Bayer CropScience

• Bayer HealthCare

• Bayer Polymers

• Bayer Corporation Business Services

Definition

The Refurbishment Order is a special type of maintenance order that is used to refurbish (repair) repairable spares and for which an order type must be specially indicated.

PM Refurbishment Orders for Material Repairs

PM Refurbishment Orders for Material Repairs

Use

Refurbishment orders are used to:

Settlement of the order will transfer the costs of the order to the material.

• accumulate the repair costs (labor & material)

• plan & execute the actual repair of a material

PM Refurbishment Orders for Material Repairs

Use of Split Valuation for Material

Configured (for Bayer): Global Valuation Category: S - Condition Global Valuation Types: New, Repaired, Defective

The Valuation Category S is activated for the plant(s) where the repairable materials are managed

Valuation category S is assigned to a repairable material’s Accounting view (at plant level)

Additional “Accounting views” are created for each Valuation Type for each repairable material

PM Refurbishment Orders for Material Repairs

Sample list:• Allocation structure and Settlement profile• Order type (flagged as Refurbishment)• Number ranges for order types• Assign order type to plants• Assign maintenance activity type to order type• Control parameters for completion confirmations• Define checking controls (material availability)• Define valuation of goods received

Configuration for Order Types

PM Refurbishment Orders for Material Repairs

Process Flow

for

Refurbishment Orders

Refurbishment Order - Process Flow

1. MRP is run for Plant (SLoc 0002

excluded)

PM Work Order to

replace non-functioning

spare in service

valuation type

Repaired SLoc CP01

valuation type

Defective SLoc CP07

valuation typeNewSLoc CP01

Inventory

Goods Issue for replacement spare -

batch “New” OR “Repaired”

2. Evaluation of MRP List - Collective Display (Plant/MRP controller)

Goods Issue (reversal) for inventory receipt batch “Defective”

3. Create Refurbishment Order (IW81)

6. Confirmation of man hours $$$

4. Change OrderAdd operations

and components, put in process

Display Material Master: Mov. avg. price is updated

for “Repaired”

7. Goods Receipt for refurbished spare - batch “Repaired”

(IW8W)

Display Material Master: Qty is increased for

“Repaired”

5. Goods Issue from Inventory -“Defective”

spare (and other required parts) $$$

8. Order Completion - TECO

9. Order Settlement $$$ (to G/L acct)

PM Refurbishment Orders for Material Repairs

Material Requirements Planning (MRP)

and

Refurbishment Order

in

SAP R/3 4.6b

T-code MD07 Stock/Reqmnts Coll. Display (after MRP run)

“New” & “Repaired” (functional) spares

“Defective” spares

Highlight item & select button for details

T-code MMBE Stock Overview

“New” & “Repaired” (functional) spares

“Defective” spares

T-code IW81 Create Refurbishment Order

Special Order Type YFZ1 configured

T-code IW81 Create Refurbishment Order (Header data)

Storeroom person... updates title and groups- Person responsible- Quantities- Refurbishment- Dates...then saves the order

Configured as “default” for order type YFZ1

“Val. type” only appears if material is set up with split-valuation

T-code IW32 Change Order (Operations)

Maintenance planner updates the Operations tab with an estimate for labor.

Selects “Put in Process”. This will print all selected shop papers (including the “pick list”) and save the order.

T-code IW32 Change Order (Operations)

The defective material is automatically added to the Components tab.

T-code IW33 Display Order (Settlement rule)

From configuration of the order type and the entry of the material number on the initial screen, the settlement

rule is generated automatically.

Pick list printed in storeroom for defective spare

Designated storage location for “Defective”

spares

T-code MB1A Goods Issue (to Order)

Note the batch “Defective”

T-code IW32 Change Order (add Components)

After inspecting the defective pump, it is found that a mechanical seal and 2 bearings are required for the repair.

The order is updated to add two materials and the pick list is printed

for those 2 additional items.

Pick list printed in storeroom for required spare parts

T-code MB1A Goods Issue (to Order for spare parts)

T-code IW41 Individual Time Confirmation

The actual time it took to repair the pump is entered for the order

T-code IW33 Display Order (Costs)

Note:Total (actual) cost

T-code IW33 Display Order (Costs before GR)

Act. qty = blank

Balance = Actual total

MM03 Material’s total stock/price before GR & Settlement

Note:Quantity is 1Mov.avg.price is $258.63

T-code IW8W Refurbishment Goods Receipt

Order number was entered on the Initial Screen. Field values are defaulted from that number.

MM03 Material’s total stock/price after GR & before Settlement

Note:Quantity increased to 2Mov.avg.price - unchanged

T-code IW33 Display Order (costs after GR - before Settlement)

Note new entry for Goods Receipt

Select button (see next screen)

T-code IW33 Display Order (costs after GR - before Settlement)

“Act. Qty” now displays 1 PCE

Balance of Actual cost is reduced by the material’s current moving average

price from the GR.

T-code KO88 Order Settlement

NOTE: should be performed soon after the Goods Receipt is done

T-code KO88 Order Settlement (continued)

Message pop-up SHOULD appear with green status lights...

T-code KO88 Order Settlement (continued)

Select icon to see details of the settlement

T-code KO88 Order Settlement (compared to Order costs)

Note:Settlement amount = Balance of order

T-code IW33 Display Order (Costs after settlement)

Note:Balance is now -0- (blank);Order is then closed

MM03 Material’s total stock/price after GR & Settlement

New Mov. avg. price =$399.321 @ 258.63 (old)1 @ 540.01 (new)2 @ 798.64 / 2

Displaying actual costs for the order

From GR for Order

From Settlement

Displaying Accounting Documents

From GR for Order

From Settlement

Configuration done for Refurbishment Order (for Bayer)IMG Object: Menu Path Settings

CO_SSTRUC

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Basic Settings > General Order Settlement > Maintain Allocation Structures

Allocation Structure = YF (Bayer PM Refurbishment)Assignment = All (All Cost Elements); Source (COArea); Cost elem group = CN;Settlement cost elements: (No settings made)

TKB1V

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Basic Settings > General Order Settlement > Maintain Settlement Profiles

Settlement Profile = YF05 (Bayer PM Refurbishment)To be settled in full; Allocation structure = YF; Default object type = MAT;Indicators = 100%-validation, %-Settlement; Valid receivers: Material = 1;Document type = SA; Max.no.dist.rls = 2, Residence t

V_T003O_I

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Configure Order Types

Order Type = YFZ1 (Refurbishment Material Order)Commitment managmt. = checked; Settlement profile = YF05;Reorganization = 6 and 1; Release immediately = unchecked.

V_T350_RSORD

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Indicate Order Types for Refurbishment Processing "Refurbishment order" box is checked for Order Type YFZ1

OION

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Configure Number Ranges Include element YFZ1 in Group PM: Plant Maintenance

V_T350W

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Assign Order Types to Maintenance Plants Assign YFZ1 to Maintenance Planning Plants

V_T350_P

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Define Default Value for Planning Indicator for Each Order Type

For Order Type YFZ1:"Unplanned Order" is selected

V_TPMP_A

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Default Values for Task List Data and Profile Assignments

FAMOUS Planning Plants/Order Type = YFZ1:ExternProfile = YFSxxxx; Mat.Profile = YFMxxxx; MaintProfile=Y000001; MeasUnitExternOper = H; Task list data = 1st four checked.

Configuration (continued)

V_T350_HE

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Settlement Rule: Define Time and Distribution Rule

For Order Type YFZ1:"Mandatory for release" and "No special handling of sub-orders"

V_T350W_S

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Control Key > Maintain Default Values for Control Keys for Maintenance Order Types

FAMOUS Planning Plant/Order Type YFZ1:Control key = PM01

V_T350I

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Maintenance Activity Type > Assign Valid Maintenance Activity Types to Maintenance Order Types For Order Type YFZ1: Assign MAT Z99

V_T350

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Maintenance Activity Type > Default Values for Maintenance Activity Type for Each Order Types For Order Type YFZ1: Assign MAT Z99

V_T399X_K

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Costing Data for Maintenance Orders > Assign Costing Parameters and Results Analysis Keys

FAMOUS Planning Plants/Order Type YFZ1:Cstg variant planned = PM01; Cstg variant actual = PM01Results analysis key = YPC

V_T399X_S

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Define Change Docs, Collective Purc. Req. Indicator, Operation No. Interval

FAMOUS Planning Plants/Order Type YFZ1:Increment = 0010, OrdStChgDc = checked, Change document = checked

V_T399X_MB

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Goods Movements for Order > Define Documentation for Goods Movements for the Order

FAMOUS Planning Plants/Order Type YFZ1:All 4 boxes are checked.

Configuration (continued)

V_TCO11

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Functions and Settings for Order Types > Availability Check for Material, PRTs and Capacities > Define Checking Control

FAMOUS Planning Plants/Order Type YFZ1/Business Function 1 & 2:Checking rule = 03; Collect.conv. = 1; PRT Availability:No check = checked; Capacity availability:No avail. check = checked.

V_T350_PRI

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > General Data > Priorities > Define Priority Type for Orders Order Type YFZ1: Priority type = YF

V_TCX00_FAUF

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Maintenance and Service Orders > Scheduling > Set Scheduling Parameters

FAMOUS Planning Plants/Order Type YFZ1/PrCtr *:Adjust dates: Adjust basic dates, adjust dep. reqmts to operation date;Scheduling type: Forwards; Automatic scheduling = checked;Scheduling with breaks = checked; Shift order = checked.

V_TCORU_P

Plant Maintenance and Customer Service Orders > Maintenance and Service Processing > Completion Confirmation > Define Control Parameters for Completion Confirmations

FAMOUS Planning Plants/Order Type YRZ1:Proposed dates, Proposed activities and Confirmable are selected.

V_TCO10Production > Shop Floor Control > Integration > Define Valuation of Goods Received FAMOU Planning Plants are assigned Valuation variant Y02

OMWC

Materials Management > Valuation and Account Assignment > Split Valuation > Configure Split Valuation (select Local definitions button)

Create global valuation types: Defective - Ext. POs = 0; Int. POs = 2; ARef = 0010; New - Ext. POs = 2; Int. POs = 1; ARef = 0010; Repaired - Ext. POs = 1; Int. POs = 2; ARef = 0010.Create global valuation category S (Condition) and assign valuation type New and Defective

OMWC

Materials Management > Valuation and Account Assignment > Split Valuation > Configure Split Valuation (select Local definitions button) FAMOUS Planning Plants: Activate valuation category S (Condition).

OMWB

Materials Management > Valuation and Account Assignment > Account Determination > Account Determination without Wizard > Configure Automatic Postings

GBB (ZBAY): 0001 AUF 3251 3600240 3600240PRD (ZBAY): 0001 PRF 3251 4404250 3404250

Configuration example for Allocation Structure

The allocation structure created and then assigned to the Settlement profile.

Configuration example for Settlement Profile

The settlement profile is created and then assigned to the order type for refurb orders.

From previous config example.

Note additional settings to have order settle to a material

Configuration example for Order Types

From previous config example.

Configuration example for Split Valuation (for material)

Created Valuation Types Defective,New and Repaired

Configuration example for Split Valuation

Created Valuation Category S “Condition” and assigned Valuation Types New and Repaired

Configuration example for Split Valuation

The valuation types Defective, New and Repaired are activated for valuation category S

Configuration example for Split Valuation

The valuation category S is activated for the plants where the repairable material is managed.

Questions...

PM Refurbishment Orders for Material Repairs

Thank you for attending!Please remember to complete and return your evaluation form following this session.

Session Code: 3606