SAP PP: Production Confirmation - Intermediate posting for defective units

[kaiwalya_kul]

Greetings SAPians!

We have following scenario, and I am not clear how to map this requirement.

The Routing consists of more than 10 operations. In between many Production Operations, there are Quality Operations. Quality employee conducts inspection during these Q-operations, posts operation confirmation with only defect-free quantity as Confirmed Yield.

For e.g. (see image below) if Order quantity is 10 PC and at an operation (0350) 5 PC were found to be defective, the Q-employee confirms only 5 good quality units as confirmed yield to next operation and defective units are seen under 'Confirmed scrap' column. The issue is this scrap quantity is not posted anywhere. I mean, no material document is generated for these 5 defective units.

The Q-employee creates a Q-notification and physically moves defective units in Blocked Storage, and the decision to rework/scrap the defective parts is taken later after detailed inspection; sometimes even after coordination with Customer, which takes weeks or even months. Hence, from system point-of-view, these 5 defective units remain booked nowhere for evaluation.

The business requirement is to able to see the defective quantity, in which (blocked) storage location they are stored, what is the value of those defective units (process + material consumption costs incurred until defect identification).

Furthermore, at a later date, if it is decided to scrap the defective units, the Q-employee should be able to scrap from Q-notification-Action list (Scrapping Function module).

My primary concern is how to post these defective units to stock. Is there any movemnt type intened for such a posting? Or can I create and assign an intermediate material in BoM and in case of defects, post the defect quantity with movement type 531 in valuated stock with respect to Production Order?

Has anyone encountered and realized such requirement? Any inputs would be appreciated. Thankyou in advance.

SAP ERP, add-on for embedded production planning and detailed scheduling