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Introduction:
Scrap is an inevitable part of any manufacturing process, but keeping track of it is essential for both cost control and process optimization. Excessive scrap and rework lead to wasted materials, inefficient use of resources, and reduced productivity and profits. It is critical for manufacturers to closely monitor scrap and rework rates to identify problem areas and make improvements.
Traditionally, scrap and rework analysis was done using standard SAP transactional reports and Excel spreadsheets. This approach was tedious, time-consuming, and did not provide an intuitive visualization of the data. With SAP Fiori, there are now powerful tools available to provide interactive scrap analysis and reporting.
In this blog post, we will explore three SAP Fiori apps that can help you analyze and manage scrap in your operations:
Scrap Reasons (F2216)
Operation Scrap (F2034)
Material Scrap (F2035).
Scrap Analysis Reporting with SAP Fiori | |||
App Launcher Title(s) | Scrap Reasons | Operation Scrap | Material Scrap |
App ID | F2216 | F2034 | F2035 |
Application Type | Analytical | Analytical | Analytical |
Device Type(s) | Desktop, Tablet | Desktop, Tablet | Desktop, Tablet |
1. With this application, you can compare the actual scrap data that is recorded in production confirmations with the expected scrap data defined in the material. | 1. This application enables you to compare the actual scrap figures that are recorded in production confirmations with the expected scrap figures defined in the routing operation. | 1. This application sends you alerts on Key Performance Indicators (KPIs) related to scrap in your production process. | |
2. The application enables you to establish a feedback mechanism for updating the expected scrap percentage in the material. | 2. The application allows you to implement a feedback loop for updating the expected scrap percentage in the routing operation. | 2. The application allows you to perform step-by-step data analysis from different perspectives to identify the root causes of scrap. | |
3. The application also displays the materials where the difference between the expected scrap percentage and the actual scrap percentage is the highest. | 3. The application also displays the work centers where the difference between the expected scrap percentage and the actual scrap percentage is the highest. | 3. The report generated by the application provides you with information on the distribution of actual scrap recorded in production confirmations across different dimensions, such as time, work center, material, plant, and reason for the variance. | |
4. As a production engineer, you can analyze the confirmed scrap and rework to identify the reasons or root causes of the greatest loss of production. | |||
5. Analyzing the reasons or root causes of scrap can help you prevent similar problems from occurring in the future. | |||
Before we start talking about our topic, we can learn more about the types of scrap, their impact on the production process and costs, and how to handle each type through this blog.
Scrap Categories and Their Effect in SAP PP/CO
1. Scrap Reasons (F2216)
The Scrap Reasons app allows you to monitor and analyze the causes of scrap in your production process. By identifying the most common reasons for scrap, you can focus your improvement efforts on these areas to reduce overall scrap rates.
Key Features:
Visualize scrap reasons by quantity and value
Filter data by plant, material, work center, and time period
Drill down into specific scrap reasons for a more detailed analysis
Export data to various formats (Excel, CSV, PDF)
Scrap Reasons
Read more in Scrap Reasons
Scrap Reasons (F2216)
2. Operation Scrap (F2034)
The Operation Scrap app enables you to analyze scrap data at the operation level, providing insights into which operations are generating the most scrap. This app is particularly useful for identifying bottlenecks and potential areas for process improvement.
Key Features:
Analyze scrap data by operation, work center, and material
Display scrap quantities and values for each operation
Filter data by plant, order type, and time period
Export data to various formats (Excel, CSV, PDF)
Operation Scrap
Read more in Operation Scrap
Operation Scrap (F2034)
3. Material Scrap (F2035)
The Material Scrap app allows you to monitor and analyze scrap data at the material level. This app is useful for identifying materials with high scrap rates, helping you to focus your improvement efforts on these materials.
Key Features:
Display scrap data by material, including quantities and values
Filter data by plant, material group, and time period
Visualize material scrap data in a bar chart or table format
Export data to various formats (Excel, CSV, PDF)
Material Scrap
Read more in Material Scrap
Material Scrap (F2035)
When confirmation times are carried out enter notions of scrap and also reasons for scrap and what is it a faulty part is it operator mis handling … etc
Has this faulty part been reworked for reuse therefore there are many options to manage this notion of defective parts and reworked parts
Scrap and Rework % by Work Center
Scrap and Rework % by Work Center
Material Scrap by Reason Code
Work Center: Scrap and Rework Qty
Work Center: Scrap and Rework Qty
In conclusion, the Fiori apps for scrap analysis reporting - Scrap Reasons (F2216), Operation Scrap (F2034), and Material Scrap (F2035) - provide valuable insights into your production process, enabling you to identify areas for improvement and reduce overall scrap rates. By leveraging these apps, you can optimize your operations and drive cost savings for your organization.
