Managing Defects: The Rework Process in SAP PP

Every manufacturer strives for zero defects, but unfortunately, even the most efficient production lines encounter occasional quality issues. This is where the SAP Production Planning (PP) rework process comes in. It allows you to manage and effectively bring defective materials up to quality standards.

What is a rework order?

A rework order is a specific production order that captures the additional effort required to fix a defective material. This order tracks the resources dedicated to salvaging the product, such as materials, labor, and machine time.

The Rework Process Flow

Here’s a breakdown of the typical rework process in SAP PP:

1. Create a rework order: You’ll use transaction code CO07 to create a new production order specifically for rework. This order won’t reference a material code, as the focus is on fixing existing items.
2. Define rework details: Specify the order type (often PP03 for rework) and plant where the rework will occur. Enter the number of defective items needing rework and the planned completion date.
3. Assign a reference operation set: Instead of traditional routing, a reference operation set defines the steps required to rework the material. This set can be pre-configured with specific operations and work centers.
4. Component overview: Since rework often requires additional materials, you’ll define them in the component overview. These components are typically issued from inventory using transaction MB1A with movement type 261 (goods issue for production order).
5. Release and confirmation: Once everything is set, use CO02 to release the rework order for production. After completing the rework activities, confirm the production order using CO11N to update inventory and production data.

Benefits of using rework orders:

• Improved quality control: Tracking rework efforts can identify recurring issues and take corrective actions to prevent future defects.
• Accurate cost tracking: Rework orders capture the additional costs associated with fixing defective materials, providing valuable insights for cost analysis and improvement.
• Inventory management: Rework orders ensure proper inventory tracking for defective and reworked materials.

Additional considerations:

• Depending on your scenario, rework might be triggered at different points in the production cycle. You can create rework orders before or after the original production order is completed.
• SAP PP offers flexibility in configuring rework processes. You can customize order types, reference operation sets, and settlement rules to suit your needs.