Variant confg

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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