3 PM Refurbishment Orders for Material Repairs 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.
4 PM Refurbishment Orders for Material Repairs UseRefurbishment orders are used to:plan & execute the actual repair of a materialaccumulate the repair costs (labor & material)Settlement of the order will transfer the costs of the order to the material.
5 PM Refurbishment Orders for Material Repairs Use of Split Valuation for MaterialConfigured (for Bayer):Global Valuation Category: S - ConditionGlobal Valuation Types: New, Repaired, DefectiveThe Valuation Category S is activated for the plant(s) where the repairable materials are managedValuation 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
6 PM Refurbishment Orders for Material Repairs Configuration for Order TypesSample list:Allocation structure and Settlement profileOrder type (flagged as Refurbishment)Number ranges for order typesAssign order type to plantsAssign maintenance activity type to order typeControl parameters for completion confirmationsDefine checking controls (material availability)Define valuation of goods received
7 PM Refurbishment Orders for Material Repairs Process FlowforRefurbishment Orders
8 Refurbishment Order - Process Flow InventoryDisplay Material Master: Mov. avg. price is updated for “Repaired”PM Work Order to replace non-functioning spare in service9. Order Settlement $$$ (to G/L acct)valuation typeNewSLoc CP018. Order Completion - TECOGoods Issue (reversal) for inventory receipt batch “Defective”Goods Issue for replacement spare - batch “New” OR “Repaired”7. Goods Receipt for refurbished spare - batch “Repaired” (IW8W)Display Material Master: Qty is increased for “Repaired”valuation typeRepaired SLoc CP016. Confirmation of man hours $$$valuation typeDefective SLoc CP075. Goods Issue from Inventory -“Defective” spare (and other required parts) $$$4. Change OrderAdd operations and components, put in process1. MRP is run for Plant (SLoc 0002 excluded)2. Evaluation of MRP List - Collective Display (Plant/MRP controller)3. Create Refurbishment Order (IW81)
9 Material Requirements Planning (MRP) PM Refurbishment Orders for Material RepairsMaterial Requirements Planning (MRP)andRefurbishment OrderinSAP R/3 4.6b
12 T-code IW81 Create Refurbishment Order Special Order Type YFZ1 configured
13 T-code IW81 Create Refurbishment Order (Header data) Storeroom person... updates title and groups- Person responsible- Quantities- Refurbishment- Dates...then saves the orderConfigured as “default” for order type YFZ1“Val. type” only appears if material is set up with split-valuation
14 T-code IW32 Change Order (Operations) Selects “Put in Process”. This will print all selected shop papers (including the “pick list”) and save the order.Maintenance planner updates the Operations tab with an estimate for labor.
15 T-code IW32 Change Order (Operations) The defective material is automatically added to the Components tab.
16 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.
17 Designated storage location for “Defective” spares Pick list printed in storeroom for defective spareDesignated storage location for “Defective” spares
18 Note the batch “Defective” T-code MB1A Goods Issue (to Order)Note the batch “Defective”
19 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.
20 Pick list printed in storeroom for required spare parts
21 T-code MB1A Goods Issue (to Order for spare parts)
22 T-code IW41 Individual Time Confirmation The actual time it took to repair the pump is entered for the order
23 T-code IW33 Display Order (Costs) Note:Total (actual) cost
24 T-code IW33 Display Order (Costs before GR) Balance = Actual totalAct. qty = blank
25 MM03 Material’s total stock/price before GR & Settlement Note:Quantity is 1Mov.avg.price is $258.63
26 T-code IW8W Refurbishment Goods Receipt Order number was entered on the Initial Screen. Field values are defaulted from that number.
27 MM03 Material’s total stock/price after GR & before Settlement Note:Quantity increased to 2Mov.avg.price - unchanged
28 Select button (see next screen) Note new entry for Goods Receipt T-code IW33 Display Order (costs after GR - before Settlement)Select button (see next screen)Note new entry for Goods Receipt
29 “Act. Qty” now displays 1 PCE T-code IW33 Display Order (costs after GR - before Settlement)Balance of Actual cost is reduced by the material’s current moving average price from the GR.“Act. Qty” now displays 1 PCE
30 T-code KO88 Order Settlement NOTE: should be performed soon after the Goods Receipt is done
31 T-code KO88 Order Settlement (continued) Message pop-up SHOULD appear with green status lights...
32 Select icon to see details of the settlement T-code KO88 Order Settlement (continued)Select icon to see details of the settlement
33 T-code KO88 Order Settlement (compared to Order costs) Note:Settlement amount = Balance of order
34 T-code IW33 Display Order (Costs after settlement) Note:Balance is now -0- (blank);Order is then closed
35 MM03 Material’s total stock/price after GR & Settlement New Mov. avg. price =$399.32(old)(new)/ 2
36 Displaying actual costs for the order From SettlementFrom GR for Order
37 Displaying Accounting Documents From GR for OrderFrom Settlement
38 Configuration done for Refurbishment Order (for Bayer)
41 Configuration example for Allocation Structure The allocation structure created and then assigned to the Settlement profile.
42 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
43 Configuration example for Order Types From previous config example.
44 Configuration example for Split Valuation (for material) Created Valuation Types Defective,New and Repaired
45 Configuration example for Split Valuation Created Valuation Category S “Condition” and assigned Valuation Types New and Repaired
46 Configuration example for Split Valuation The valuation types Defective, New and Repaired are activated for valuation category S
47 Configuration example for Split Valuation The valuation category S is activated for the plants where the repairable material is managed.
48 PM Refurbishment Orders for Material Repairs Questions...
49 Thank you for attending! Please remember to complete and return your evaluation form following this session.Session Code: 3606