Date post: | 28-Apr-2015 |
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Variant ConfigurationWhat is Variant Configuration?
It is a tool which helps to simplify the complex manufacturing of final product with more varieties and Variation of theinput material.
e.g. Automobile manufacturingFurniture manufacturing
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Variant Configuration..contdVariant configuration helps
To ensure right choice is delivered
Easy for the sales person to select
Communication is fast and clear
Ensures production of right item
Variant Configuration-super BOM
Super BOM:-
containing all the components for producing all variants of the product.
Advantage:-No need to create a separate BOMOne configurable material to cover variants.
Variant Configuration-super Routing
Super Routing:-
containing all the operations for producing all variants of the product.
Advantage:-No need to create a separate Routing
One configurable material to cover variants.
Configurable Material - BOM
configurable material BOM contains all thecomponents that are required to manufacturethe material. The BOM contains components that are only used in specific variants (variant parts),as well as components that are used in all variants (non-variable parts)
Configurable Material - Routing
A routing (or task list) for a configurable material contains all the operations, operation sequences, and production resources/tools (PRTs) that are required tomanufacture all variants of a configurable material
Variant Configuration-Class
To define the features of a configurable material, use characteristics. To enable to use characteristics to configure a material, assign the material to a class ofclass type 300. The customer can choosefrom among different options for each characteristic (values).
Classification & Characteristic
Various characteristics of the material can beDefined and these characteristics are attachedTo the class. Class is attached to the Material master.e.g Variant class – class type 300
Batch class -- class type 022
Item selection from super BOM
•Enter the variant part as a BOM item and assign object dependency to it.
•Classify the variant part in a class andenter the class as a class item in the BOM.
•Use the classification data of a material as a selection condition.
Object Dependency
Selection of item, Restricting the selection &changing the quantity of an item in the BOM are done through Object dependencies select condition, Precondition and Procedure respectively
Select Condition
Super BOM contains all the required and Variable items. From the variable items required items will be selected which are Matching the characteristic value.
Select Condition e.g.Items in the super BOM are : 1. 70hp engine2. 85hp engine3. 95hp engine
Characteristic: PowerChar.Values: 70hp,85hp & 95hpselect Condition : power = ’70’
Result:- item 70hp engine will be selected.
Pre Condition e.g.Items in super BOM related to emission are : 1. DPCpump2. DPAMpump3. HYDpump
Characteristic1: Engine_PowerCharacteristic2: Emission_levelChar.2 Values : euro1,euro2 & euro3Constrains:-70hp can go with euro1 only;85hp can go with all euro1,euro2 and euro3;95hp can go with euro3 only.
Procedure e.g.If there is a change in quantity depends on any Characteristic value, then Procedure is used.
i.e Depends on number of wheel character, item ‘Fastner’ required quantity per engine may be 8 times the number of wheel.
If no of wheel is 4 then fastner qty should be 32Per product.
Creating Sales Order
When creating a sales order & enter the configurable material as an order item.
see the configuration editor, where assign values to the characteristics of the material. when entering characteristic values, dependencies for the characteristics and values are processed.
Class item in super BOM
Another way to simplify the BOM creation Process is through class item in the BOM
Creation of classCharacteristics are created and attached withClass of class type 300(variant class).
Class will be assigned to the material masterWith characteristic values
Enter this class as a class item (K) in the BOM
Link between class,item & BOM
Link is established as class attached to thematerial master and the same class is enteredAs class item (K) in the BOM.
Item selection via class item
When the particular class is assigned to the Material master and the same class is Entered as a class item in the BOM, whileCreating the sales order
Control on class and characteristics
Classes can be created through Engineering ChangeManagement so that the better control can be Imparted to it. Changes to the characteristic & its effective from dates can be triggered through Engineering change Management.
Variant Configuration - PricingYou can make the price of a variant dependent on the characteristic values assigned (Pricing). You can use variant conditions to define surcharges and discounts for a variant
Variant – Pricing stepsCreate condition record
create a procedure where you enter the reference from the characteristic
Assign the procedures to either the characteristic values
configure the material in the sales order
The net price for the material is displayed
Pricing steps - processIf a value that triggers a variant condition is selected when configuring a material in asales order, the price of the material displayed under Net value is automatically increased or reduced.
In addition, the Conditions pushbutton isdisplayed. On pressing this pushbutton, One can see which conditions have influenced the price.
Making variant make to stockFor variants that are required frequently, you can create material variants, which can be produced without a sales order and kept in stock. When you receive a sales order, you can check whether the variant required is in stock, so that you can deliver immediately.
Variant matching in the SOIf material variants already exist for aconfigurable material, the configurable material can be replaced in the sales orderby a material variant.Material variants that only partly match theconfiguration of the material in the sales order are ignoredNote:-The configuration of the material mustmatch the material variant Exactly
Simulating configurationconfiguration simulation to check configuration model.
In the configuration simulation, one can testwhether it has created the objectscorrectly and whether dependencieswork.
Simulating costingUse the configuration simulation functionalityto determine the costs for manufacturing a specific variant of the configurable material. Please note that this configuration is only a simulation – the costing data for a variant is not saved.
use the function to simulate the costing for different characteristic values
Material AccountingRelevant items are selected from the Super BOM through object dependency.
The selected items form the BOM specific toSO.
Items are copied to Plnd.order,prod.order And issued against the production order.
Example of VCFinished Material : Bolerojeep
Raw Material :- Many items
Characters(structure options)
Engine Power
Emission Level
Seating Capacity
Body Material Thickness & colour
Number of wheels
Character value & constraintsEngine Power –70hp, 85hp, 95hp
Emission Level –Euro1, Euro2, and Euro3
Matching70hp can go with Euro1 only80hp can go with all95hp can go with Euro3 only
Character valueSeating Capacity –6 ,7 and 8
Body Material Thickness & colour --0.5mmwhite;0.6mmwhite;0.7mmwhite0.5mmred;0.6mmred;0.7mmred0.5mmblack;0.6mmblack;0.7mmblack
No.of Wheels – 4 or 5This is to select the qty of fastner
Sales Order Creation
Assigning characteristic values
Selecting characteristic values
Selecting characteristic value for constrain
Selecting characteristic value for constrain-85hp
characteristic values for 85hp Engine Power
Complete characteristic values
View the Sales Order
MRP result Planned order with selected items
Planned order detail
View of Super BOM
View of Super BOM…contd
View of Super BOM…contd
Planning for standard variant
Planning of fast moving product as a standard item and Matching at the time of creating the sales order automatically.
Planning for standard variantexample
95Hp,Euro3,6seater,0.6mmred coloredProduct is fast moving and it needs to bePlanned and produced in advance.When the order is received, at the time Of configuring, it will pickup this Preconfigured item in the sales order.
Planning for standard variantexample
Item code Beuro36seat0.6red for85Hp,Euro3,6seater,0.6mmred coloredproduct
Item code beuro37seat0.6redfor95Hp,Euro3,7seater,0.6mmred coloredproduct
Example-preconfigured..
Configuring in the SO
Automatic replacement in SO
Item available in SO
MRP and Result
Planned order view
Component AccountingFrom Planned orders components are
Copied to production order and issued.
All the items are accounted for consumption
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