Disassembling Components in Various Scenarios

Objective

After completing this lesson, you will be able to describe the disassembly of components in various scenarios, including those triggered by engineering changes.

Discovering Disassembly Use Cases

This video introduces the key use cases that guide disassembly decisions in SAP S4 HANA PEO, focusing on practical approaches for adapting complex assemblies. It explores various scenarios such as engineering changes, defective parts replacement, reuse, and transport considerations.

Key Takeaways

Engineering Change: Disassembly for engineering change involves updating a product to reflect new design specifications, ensuring it meets quality standards and remains reliable during production.
Defective Parts Replacement: When parts fail functionality tests or are damaged, they are swapped to restore product quality and efficiency.
Disassembly for Reuse: Recover valuable components from assemblies, possibly due to returns, optimizing resource allocation and maintaining cost efficiency.
Locks or Fixtures Removal: Temporary components added for transportation are addressed by creating a new MBOM version, ensuring integration into the production order.
Disassembly for Transportation: Products are broken down into manageable segments to ensure safe delivery while preserving product integrity and reliability for future production.

Disassembly Use Case: Engineering Changes

This video delves into the disassembly process involved in engineering changes, highlighting the various roles and responsibilities that contribute to adapting a product to new specifications. By examining the workflow from start to finish, viewers gain insight into how design updates are effectively integrated into ongoing production.

Key Takeaways

Role of Production Engineer: Initiates the process by managing the unassigned eBOM, assessing impacts, and transitioning eBOM to mBOM, ensuring the engineering change aligns with the new specifications.
Production Operator Responsibilities: Executes operational activities by disassembling components and preparing them for reassembly, focusing on maintaining stock organization.
Supervisory Oversight: The production supervisor oversees the entire process, keeping detailed records through the production action log to ensure transparency and accountability.
Product Genealogy Tracking: Utilizes the product genealogy app to monitor component history with precise serial and batch data, ensuring quality and consistency throughout the production cycle.

Disassembly Use Case:Defective Part Replacement

This video outlines the disassembly process essential for replacing defective parts in ongoing production, highlighting the roles and responsibilities critical for restoring product quality and functionality. Viewers will explore how damaged components are identified and replaced efficiently, ensuring the product meets specifications and the manufacturing process remains reliable.

Key Takeaways

Logging and Analysis of Defects: The process starts with the production operator logging the defect and routing the assembly for rework, followed by the quality engineer who analyzes the defect, identifies its root cause, and records necessary change orders.
Component Replacement: The production engineer updates the component list for replacement, ensuring temporary removal and permanent disassembly are executed to swap out the defective item.
Operational Activities: Operators disassemble the defective parts, route them to quality stock, and reassemble with new components, with all steps captured in the production action log.
Tracking and Evaluation: The product genealogy app tracks component history, while inspection results and quality notifications are managed, ensuring comprehensive oversight and compliance.
Visualization and Documentation: Components are evaluated using work instructions, with detailed inspections highlighted in 3D visuals for instance-specific assessment.

Disassembly Use Case: Disassembly for Reuse

This video delves into the disassembly process for reuse, focusing on the strategic removal and recovery of valuable components from assemblies, often returned due to customer claims. The process aims to optimize resource allocation by ensuring reusable parts are efficiently reintegrated into upcoming production cycles, thereby maintaining cost efficiency and reliability in manufacturing operations.

Key Takeaways

M-BOM Creation: The production engineer initiates the process by using VEMP to create an M-BOM with usage type D for disassembly, retaining positive quantities for reusable components.
Disassembly M-BOM Conversion: Convert the disassembly M-BOM with usage type V for use in production, creating a new header material and adjusting component quantities to facilitate disassembly.
Shop Floor Routing: Establish specialized shop floor routing to manage byproducts and oversee disassembly operations efficiently.
Operation Management: Production operators use the Perform Operation Activity app to manage and document the disassembly process, ensuring accurate tracking and recording.
Quality Inspection: Quality engineers inspect recovered components, ensuring they meet standards before returning them to unrestricted-use stock, ready for future production orders.

Transport Locks/Fixtures Removal

This use case involves additional components like locks and fixtures used temporarily during transportation, not included in the original manufacturing BOM or production order. To address this, you create a new MBOM version using VEMP or the Maintain Bill of Material app, adding non-visual components with positive and negative quantities (by-products). This MBOM version is then integrated into the production order using the order change capability outlined earlier.

Additional Developments to Support Disassembly Scenarios

S/4HANA PEO provides the following developments to support the described disassembly scenarios.

New Action Handlers

The following type handlers are delivered by default and can be viewed in the SPRO customizing activity Define Action Handlers:

CHECK_SERNR_FOR_MATERIAL_RETURN Use this action handler at PRE processing point in combination with the Material Return action to check that the returned serial number exists in the system.

The following class is delivered as a sample action handler, which can be either enhanced or used as is at the customer system.

CL_MPE_OAC_TH_EQUIP_HIERACHY Use this class to create a new action handler to run at a POST processing point in combination with the Component Assembly and Disassembly actions or the Material Return action. The logic implemented in the class will take the recorded serial number with or without reference designator information and send to update the equipment hierarchy with the SN and reference designator information. The result can be viewed in the IQ03 transaction.

Hard-Coded Checks

There are also a couple of hard-coded checks provided in the system to support reassemblies without goods movements (that is, reassembly of temporary disassembled parts). This check on reassembly assures that nothing is reassembled that was not disassembled before. On completion of an operation activity, the system checks that for all reassemblies, exactly what was disassembled is reassembled.

Enhancements to the 3D Viewer for Disassembly in the Perform Operation Activity App

Planned removals are displayed in transparent mode (same as how we show planned assemblies). However, when components get disassembled, they are hidden completely in the 3D viewer.

Summary

This lesson covers various disassembly scenarios in SAP S/4HANA PEO, including engineering changes and defective parts replacement.

Disassembly Use Cases: Includes engineering changes, rework needs, and transportation preparation for component removal.
Engineering Changes: Incorporate new MBOM versions and adjust order-specific routing for disassembly and reassembly.
Defective Parts Replacement: Log defects, update routing, and disassemble defective components for replacement.
Disassembly for Transportation: Split products into chunks, assigning negative quantities for easier shipment.
Additional Developments: Implement action handlers and checks to support disassembly processes in production operations.

Disassemble Components Triggered by Engineering Change

Business Example

John is a consultant with the low-volume A&D company focusing on the final assembly of complex products.

While production on major assemblies has already started, there are still late engineering changes coming in from the engineering department that affect open production orders. John is asked to identify such affected orders and incorporate the BOM change in an order-specific routing. As part of that, he has to do a comparison between the existing and new MBOM and transfer the changes where required. Along with the component change, he also needs to create new operation activities for the disassembly and reassembly of components. After execution of the order-specific routing, he checks the product genealogy and action report to view the performed changes.

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