Material Reconciliation (SAP Library - Handling Units in Process Manufacturing)

Material Reconciliation

Use

You use material reconciliation to analyze and verify ingredients at the end of a production process. It allows you to compare the material quantity that actually flowed in with the planned quantity or the quantity of the material produced. Furthermore, other information about the ingredients can be displayed via the movement types.

Reconciliation of the ingredients can ensure that there are no discrepancies outside of the valid range in the relationship between the input and yield.

Integration

The goods movements for the production order, for example, all goods receipts with all returns and all reversals, as well as all goods withdrawals with all returns and all reversals, are the basis for material reconciliation.

You can define all the goods movements that are to be included in the reconciliation. Material types that you define yourself can also be used for reconciliation.

Note

If you want to integrate the WM movement types into material reconciliation a well, you can use customer exit SMRZ0001 (Customer-Exit for WM Movement Types).

You can choose the components that are to be reconciled. The components must be classified with reconciliation class 050. You do this in the R/3 classification system.

For more information, see Classification System.

Prerequisites

To be able to generate the necessary material documents, you must have made the following settings in Customizing:

In Customizing, choose Production Planning for Process Industries ® Process Order ® Master Data ® Order ® Define Order-Type Dependent Parameters:
On the detail screen, choose Implementation ® Documentation of goods movements for the relevant process order category.
Select the following fields:

Goods receipt for process order
Planned goods issue
Unplanned goods issue

In Customizing, you must have made the following settings under Production Planning for Process Industries ® Process Data Documentation ® Material Reconciliation:

Create formula parameters

Assign movement types to parameters

Create formulas

Material reconciliation takes place using standard process instruction category RECON, which must be assigned to the master recipe. This involves a dynamic function call.

The process instruction RECON for material reconciliation must not be changed, but rather the standard version should be copied.

You have created a class of class type 050 (material reconciliation).

In the master recipe/process order, the components are classified with class type 050 for material reconciliation.

Features

Results report for material reconciliation

This provides you with information about:

The parameters for the produced quantity (if defined):

Value of this parameter
The goods movements that were assigned to the parameter for the produced material.

The individual components:

All goods movements that were assigned to a parameter and were used in this production order

The values of the formula parameters used

The elements of the calculation in line with the definition

The results of the formula calculation

Information about whether the result is within the defined interval.

Miscellaneous:

The sum of materials within the defined interval, and the sum of materials outside the defined interval. This information is transferred back to the PI sheet, providing you can call it up from there.

All parameters and the movement types assigned to them that are used for a production order.

Co-products are reconciled in the same way as ingredients.

Messages to the batch record (EBR)

If material reconciliation is called up from a PI sheet, a message is sent to the batch record each time it is called up.

This message contains the following information:

Process order number
Name of the user
Date, time.
Material number and material short text
BOM items
Result of calculation
Upper and lower limit
Number of materials for which the result of the calculation is within the upper and lower limits.
Number of materials for which the result of the calculation is outside the upper and lower limits.

If the message does not reach the batch record (for example, because some of the goods movements for the order have not yet been posted), call up material reconciliation by choosing the following menu path:

Logistics ® Production Process ® Process Order ® Tools ® Process Data Document ® Material Reconciliation ® For Process Order
Batch usage with material reconciliation

You can use batch usage for a raw material, for example, to find out into which batch of the semi-finished or finished product this raw material flowed. Furthermore, you can display the material reconciliation for the raw material.

You can display parts of the batch usage separately if, for example, you want to trace the semi-finished and finished product further in the batch process. Position the cursor on the batch and choose Material reconciliation ® New expansion.

By choosing Documents, you can display all individual postings for a batch.

For more information on batch usage, see Batch Where-Used List.

Integration of material reconciliation in the electronic batch record

If you use material reconciliation and the electronic batch record, you can choose "not OK" to display reconciled materials in the deviation list.

In Customizing, choose Production Planning for Process Industries ® Process Documentation ® Batch Record ® Define Material-Dependent Complete Record and make the following settings:

Program	PPPI_DEVI_CHECK_MR
Form routine analysis	PPPI_DEVI_CHECK_MR
Form routine print	PPPI_DEVI_PRINT
Form	PPPI_EBR_DEVI_MR

If at least one material was reconciled with "not OK", the system issues the following information in the deviation list:

For all materials:

Person who carried out material reconciliation
Date and time of material reconciliation
Number of reconciled materials
Number of materials reconciled with "not OK"

For each material that was reconciled with "not OK":

BOM item
Material number
Material short text
Result of calculation
Lower limit
Upper limit

If you have carried out material reconciliation several times for a process order, the system only displays the results of the most recent material reconciliation.

Activities

You can call up material reconciliation

From the PI sheet

By choosing Production Process ® Process Order ® Tools ® Process Data Documentation ® Material reconciliation ® For Process Order

In combination with batch usage for raw material batches by choosing Production Process ® Process Order ® Tools ® Process Data Documentation ® Material Reconciliation ® Acc. Batch usage

You can carry out material reconciliation at any time as long as at least one goods movement has been posted for the order.