MRO refurbishment thru subcontracting ADSUBCON gaps

[Ramarao]

I normally work in the PP/MM area mostly but have a task of implementing MRO refurbishment process via subcontracting for my company that makes aircrafts. We are on SAP ECC 6 service pack 60302 with DIMP. We use split valuation, and both batch management and serial number management for these parts, and don't have FFMC defined.

The basic process that I am looking at is - as per the following SAP document:
http://help.sap.com/saphelp_di471/helpd ... ontent.htm

We receive parts from customer always as sales order ("E") stock (using movement type 653 E) - mainly there are two scenarios - (i) standard exchange wherein we give our own part as a replacement to the customer; and then (ii) customer owned repair wherein the part stays as E stock and never touches our books for the stock movement all the way through the repair and return process. In the standard exchage, we move the part received immeidately as our own stock (movement type 411-E) then create the PM order, mark the subcontract indicator and material provision indicator to trigger the PurReq, "F" acct assigned PO and so on. In the case of customer owned repair, there is no upfront 411-E as the E-stock itself goes through the PM-order and ADSUBCON processes.

In both cases, we want to receive the REPAIRED part (higher valuation type in split valuation) back into the stock therefore we change the batch number on receipt - while keeping the serial number same in the 101 Goods receipt. In the process, the 543 consumption of CORE valuation (lower valuation type) happens from vendor stock - the cost of the PO for repair hits service order that ultimately settles to the WBS element that's provided on the sales order which triggers it - for cost against the replacement revenue. We also have the default BADI_DIAD_GOODMVT_1 active which should put the part back into stock via movement type 262 when the GR is made for own stock (not E stock) for the REPAIRED back on stock from the direct procurement to the service order.

I am running into quite a few requirements from our end users and don't see these addressed in SAP solution readily - therefore want to ping on other experts who have done this in the past. Specific gaps are in these following scenarios:

In "Own" stock receipt scenario, we have a gap:


1) BADI to put the stock back from PM order when it is own stock - seems to work okay when the PO is marked for unrestricted stock or blocked stock (262 happens accordingly) but not when it is QI stock. We need this to work for QI stock because that keeps our processes normal in receiving and QI - don't know why this should not put back a 262 to QI stock like other stock types.

The following gaps occur only when we need to switch between the scenarios during the middle of process:
Sometime our business has to switch from customer owned repair to standard exchange based on timing of events -- consider this: Customer sends us a part back and wants the same to be repaired and returned (customer owned repair) but while it is being repaired at the vendor place, customer may decide not to wait for it any longer, and ask for our own replacement part rather - thereby making it like a standard exchange. In this case, customer side logistics are completed (sending replacement part, billing, etc.) but at the same moment we need a change in the supply side to reflect this in the system. Specifically, we need the following things:


2) The CORE sent to the vendor for repair should move from Stock provided to vendor (special stock "O") to Subcontractor Sales order stock (special stock "F"), accompanied by a credit for the CORE to the WBS like we would have given if we started it like a standard exchange. Unfortunately, I could not find a movement type in the standard system that can make it - like a 411-F from "F" stock to "O" stock.

I started out (on a treacherous path) to create this movement type myself - and went so far as to make it work Quantitatively but not Valuation-wise. I need the same financial transaction as in 411-E to happen here (this is nothing but 411-E but known late, as far as our business is concerned).

3) The PO should be changed to reflect the stock type change - when I attempt to change the spec2000 tab of the PO from Sales order stock to Normal stock, I am able to save the PO but having issues at GR.
At the time of GR with Spec-2000 of the PO changed subsequently after the 541 movement to vendor, I have an issue with the serialized parts. In the straightforward scenarios for normal or E stock, the PO receipt allows a different batch with a different valuation type be received (101) while consuming the lower valuation type of the CORE (on 543), both with the same serial number. However, when the change of valuation on the stock happens, I am getting a master-batch error related to the serial number master record (IQ02).

Wanted to check with other experts who implemented this process - I am quite convinced about our business need for these processes, including change of special stock type while it is in process -- I already tried to convince our business about the "standard SAP process of reversing the 541E back then make a 411E and send it again as 541" but with our vendors in other countries, ITAR and export controls we can't do that.

Thanks for your time and inputs on this challenging topic.