Qm overview

transcript

QM Module

Santosh

QM Overview

QM Module General

Quality Planning

Quality Inspection

Quality Certificate

Quality Notification

Test Equipment management

QM Integration with Other Modules

Standard Reports

Benefits

Processes

SAP AG 1999

Main Business Scenario

Industrial companies perform quality inspections on products at various stages in the logistics supply chain.

They need to maintain inspection specifications, record inspection results, and can perform evaluations using this data.

QM Overview

Business Scenario :

QM Integration

PPPPMMMM

PurchasingPurchasing RequisitionRequisition

Inventory mgmt

Goods receiptStock transferGoods issue

Inventory mgmt

ShippingBilling

Invoiceverification

Warehousemanagement

Inspection lotInspection lot

QMQM Inspection lotInspection lot

Print insp. instructionPrint insp. instruction

Results recordingResults recording

Usage decisionUsage decision

Basic dataBasic dataBasic dataBasic data

Test equipmentmanagement

Productionplanning

Reqt planningR-cut capacity

planning

PlannedOrders

PlannedOrdersOpeningperiod

Openingperiod

Order:- Creation- Release- Confirmation

Shop floorcontrolCapacityleveling

CAMCAM

MaterialsMaterials

VendorsVendors

RoutingsRoutings

DocumentsDocuments

Inspection plan

Characteristics

Insp. methods

Insp. catalogs

Test equipment

Control

Planning Inspection

QM Overview

Quality planning

Quality inspection

Quality control

Quality certificates

Quality notifications

Test equipment mgmt.

Quality Planning: Activities

Creating and managing the

master data that is required

(among other items) to plan

and execute quality

inspections.

QM Overview

Quality Inspection: Activities

Determining whether the units

inspected fulfill the predefined

quality requirements.

Quality planning

Quality inspection

Quality control

QM Overview

Quality Control: Activities

Implementing different

preventive, monitoring and

corrective activities.

These activities are based on the

specifications from quality

planning and the evaluations of

quality inspections and quality

notifications.

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Quality planning

Quality inspection

Quality control

QM Overview

Quality Certificates: Activities

Certifying the quality of a material

or product.

Quality certificates contain texts,

specification values, and

inspection results.

Quality planning

Quality inspection

Quality control

QM Overview

Quality Notification : Activities

Recording the Non-Conformance

or product.

Investigation and analysis of defect

Record Cause , Task and activities , etc.,

Quality planning

Quality inspection

Quality control

QM Overview

Test Equipment Management: Activities

Managing master data as well as

the planning and processing

calibration inspections for test

and measurement equipment.

Quality planning

Quality inspection

Quality control

QM Overview

QM Module - General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

QM Overview

Quality planning

Quality inspection

Quality control

Quality Planning: Activities

Creating and managing the

master data that is required

(among other items) to plan

and execute quality

inspections.

Quality Planning

Inspection Planning Inspection Plan Master Recipes

Basic Data Catalog / Selected Sets Master Inspection Characteristics Class Characteristics Inspection Method Sampling Procedure / Sampling Scheme Work Center

Logistic Master Data Material master QM-View Quality Info Record

15 SAP AG 2001

QM Basic Data and Inspection Plan Structure

Operation

Header

Insp. plan

Material master record

Vendor master record

Inspection characteristic

Work center

Production resources/tools

Customer master record

Quality Planning

Inspection Plan Structure :

Quality Planning

Inspection Plan : Inspection plans is used to describe how a quality inspection should be performed for one or more materials.

Define in the inspection plan in which order individual inspection operations should occur and which inspection characteristics should be inspected, using which inspection specifications.

Inspection plans for different uses (for Example goods issue inspection, Inprocess Inspection, Inspection during Sales etc.).

SAP AG 1999

What is to be inspected?

General data

Characteristiccontrol

References to master records

Administrative data

Master Inspection Characteristic

Quality Planning

Basic Data : Master Inspection Characteristics

Quality Planning

Master Inspection Characteristics :

Inspection characteristic describes WHAT needs to be inspected.

MIC can be either Qualitative or Quantitative and intended for repetitive use.

Catalogs & inspection Methods are assigned to MICs

Defect Catalogs are assigned in case Defect Recording is required.

Control Indicators defines the parameters for Result recording of the MIC & Result analysis.

19SAP AG 2001

CODING

ScratchedScratched

WarpedWarped

DamagedDamaged

CrackedCracked

Usage of Catalogs

1001 Warped1002 Damaged1003 Cracked1004 Dented

Quality Planning

Basic Data : Usage of Catalog

Quality Planning

Defects

Defect consequences

Causes

Events

Usage decisions

Characteristic attributes

Selected

Codes Codes

Selected

Quality Planning

Catalog : The catalog contains unique, non-numerical data in the system that is defined at client or plant level.

Can define our own code groups and codes for each catalog type.

Directly assign catalogs to master inspection characteristics

Use the catalogs to make it easier to record inspection results, defects, and defect locations during inspection lot processing

22 SAP AG 2001

Inspection Method: General

What kind of inspection is to be performed?

Validity

Qualification

Classification

Quality Planning

Basic Data : Inspection Method

Quality Planning

Inspection Method: An inspection method describes how the inspection to be carried out for an inspection characteristic.

Common family of components which are inspected under standard specifications, norms etc can be treated as inspection method which will be assigned to master inspection characteristic

Up to ten inspection methods can be assigned to a master inspection characteristic, however only one inspection method can be assigned to the planned characteristic.

Inspection method is maintained at plant level and validity from effective date.

Inspection method identifier is optional Text, Long Text, Inspector Qualification to be entered on data screen for every inspection method

Quality Planning

Quality Info Record :

When a quotation or purchase order is created, the system checks whether a Q-info record is required and available for the combination of material and vendor. A check is made to determine whether the purchase order can be released

Specify a status profile for releasing the supply relationships as well as the QM system of the material-vendor combination in the Q-info record

This facilitates the inspection or perform a goods receipt inspection and/or source inspections

QM Overview

QM Module General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

QM Overview

Quality Inspection: Activities

Determining whether the units

inspected fulfill the predefined

quality requirements.

Quality planning

Quality inspection

Quality control

Quality Inspection

Inspection Lot Creation Manual / Automatic Lot Stock / Non-Stock relevant Lot

Result Recording Quantitative / Qualitative / Calculated chars Single/Multiple recording Valuation with specification

Defect Recording : For deviation Manual / Auto creation Continued with notification : Background process

Usage Decision UD code / Stock Posting / Quality Score Calculation

SAP AG 1999

Inspection Lot: Business Scenario

Inspection lot

The inspection lot represents the request to a plant to perform a quality inspection on a certain quantity of a material.

Quality Inspection

Inspection Lot :

SAP AG 2001

7 58 4

Goodsmovement

Productionorder

Customerorder

Delivery

Deadlinemonitoring

Manual

Inspectionlot

Maintenanceorder

Inspection Lot: General

Qualityinspection

Quality Inspection

Inspection Lot : General

SAP AG 1999

QM Inspection Process: Results Recording

Sample determination

Usage decision

Evaluation

Defects recording

Inspection lot

Enter results

Valuation

Completion

Results recording

Quality Inspection

Inspection Process : Result Recording

SAP AG 1999

Defects Recording: Business Scenario

Quality Inspection

Defect recording business scenario :

SAP AG 1999

!!Purchasing Production

Vendor StockA

Statistics

Quality levelInspection stage

Usage Decision: Effects

Quality Inspection

Usage Decision – Effects :

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

QM Overview

Quality Certificates: Activities

Certifying the quality of a material

or product.

Quality certificates contain texts,

specification values, and

inspection results.

Quality planning

Quality inspection

Quality control

Quality Certificate

Incoming Vendor certificate against Good receipt

Outgoing Certificate Profile

- Certificate Planning

- Certificate Processing

Quality Certificate

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

QM Overview

Quality Notification : Activities

Recording the Non-Conformance

or product.

Investigation and analysis of defect

Record Cause , Task and activities , etc.,

Quality planning

Quality inspection

Quality control

Notification Type

Vendor problem Internal problem Customer complaint

Notification Process Automatic trigger from defect recording / Manual creation. Predefined codes as per catalog used in

- Item / Task / Activity

Catalog maintained at client level. Task completion for notification closure Standard report for notification.

Statusmanagement

Nonconformity costs

QM costs

Q Notification

Actions

Defects analysis

TasksEvaluations

Controlling

Workflow

DescriptionArchive LinkElements:

Notification

Task Completion and Notification closure

Report

Complaint Details Complaint type and rejection details

Partners and Coordinator Internal and External failures

Causes (Root Cause) Tasks (Corrective Action )

Activities (Preventive Action)

Purpose : To record & process different types of problems..

To analyze the defects & monitor the correction of these defects.

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Test Equipment Management

Standard Reports

Benefits

Processes

QM Overview

Test Equipment Management: Activities

Managing master data as well as

the planning and processing

calibration inspections for test

and measurement equipment.

Quality planning

Quality inspection

Quality control

Test Equipment Management

Purpose :

To ensure that the Test Equipment ( which is used for Inspection ) continues to meet the pre-defined specifications.

Process: Creation of

• Equipment• Maintenance task list• Maintenance plan

Scheduling the Plan Processing of Calibration order (Internal / External) Creation of the lot Result recording Defect recording Usage decision Notification processing for any deviation.

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

QM Integration

PPPPMMMM

PurchasingPurchasing RequisitionRequisition

Inventory mgmt

ShippingBilling

Invoiceverification

Warehousemanagement

Inspection lotInspection lot

QMQM Inspection lotInspection lot

Print insp. instructionPrint insp. instruction

Results recordingResults recording

Usage decisionUsage decision

Basic dataBasic dataBasic dataBasic data

Test equipmentmanagement

Productionplanning

planning

PlannedOrders

PlannedOrdersOpeningperiod

Openingperiod

Order:- Creation- Release- Confirmation

Shop floorcontrolCapacityleveling

CAMCAM

MaterialsMaterials

VendorsVendors

RoutingsRoutings

DocumentsDocuments

Inspection plan

Characteristics

Insp. methods

Insp. catalogs

Test equipment

SAP AG 1999

QualityManagement:

Integrationin logisticalprocesses

QualityManagement

Position of QM

QM integration

Material Management Manages quality information for materials, vendors Releases vendors; Monitors their QM systems Manages the release status of delivery relationships, for example

Vendor approval, Sample Approval etc Evaluates vendors on the basis of quality using quality scores from

audits, goods receipt inspections, and problem notifications. Requests quality certificates and monitors their receipt. Tracking of

vendor certificates. Triggers source inspections to be carried out at the vendor’s premises

before the vendor is due to make a delivery - Source inspection. Triggers inspections for goods movements, for example, goods receipt Blocks payments until Inspection Lots are accepted

QM integration

Production Planning Batch management Handles inspection characteristics and setup characteristics for

operations Manages quality inspections for manufacturing orders Handles in-process inspections during production at freely defined

inspection Points- In-process Inspection (Qty/time based) Scrapping procedures Triggers final inspection upon goods receipt from production Confirms quality and quantity information for manufacturing orders Monitors production quality with the help of control charts and determines

process capability. Manages problems in production using quality notifications and by

processing corrective tasks

QM integration

Sales and Distribution Batch allocation during delivery of finished goods Customer Complaints Handling Manages customer-related quality information Triggers an inspection at shipping when the delivery is created-

Lot Creation thro PGI for Sales Inspection Lot Creation thro PGR for Customer Returns Creates quality certificates with the delivery

Plant Maintenance Equipment related data maintenance Calibration

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

Reports

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

Benefits

BENEFITS : Comprehensive master data maintenance by system. Stocks in Quality till inspection is completed. Inspection Results are available on line, hence retrieval is

will be easy and trends/SPC of characteristics can be viewed on line

Quality Score for vendor is based on U D. Standardized methodology for complaint reporting and

analysis. Calibration frequency scheduled by system for instruments. Standard reports for analysis and review.

QM Overview

QM Module : General

Quality Planning

Quality Inspection

Quality Certificate

Standard Reports

Benefits

Processes

QM Processes

1. QM Master Data

2. Incoming Inspection

3. In Process Inspection

4. Final Inspection

5. Stock Transfer Inspection

6. Customer Complaints and Return

7. Miscellaneous Inspection

8. Calibration Inspection

1. QM Master Data

QM Master Data

1. Material master : MM01,MM02,MM032. Inspection Method : QS31,QS32,QS333. MIC : QS21,QS23,QS244. Equipment Master : IE01,IE02,IE035. Catalog : QS41,QS426. Selected Set : QS51,QS527. Sampling Procedure : QDV1,QDV2,QDV38. Inspection plan : QP01,QP02,QP039. Maintenance Task list : IA01,IA02,IA0310.Quality info Record : QI01,QI02,QI03

Create (One time

Change (many times) Display

(any time)

2. Incoming Inspection

Incoming Inspection

GR-MIGO Posting by MM

Inspection Lot : Type 01 created and viewed thro

Result Recording (QE51n) for inspection

characteristicsResult

Usage Decision (QA11)- Stock Posting- Quality Score updation- UD code Valuation- Inspection lot completion

Defect Recording in RR

Notification Creation (QM01)

Background

Notification processing (QM02)

Incoming Insp

Notification Closure

Not Ok

QualityNotification

3. In-Process Inspection

In-process Inspection

Order create by PP

Valuation is required on each recording

Background

In-process Materials

Not Ok

Lot Usage Decision

QualityNotification

4. Final Packing Inspection

Final Inspection

GR Posting by PP

Background

Final Inspection

Not Ok

Usage Decision (QA11)- Stock Posting in Silo- Quality Score updation- UD code Valuation- Inspection lot completion

QualityNotification

5. Stock Transfer Inspection

Stock Transfer Inspection

Stock TransferGR Posting by MM

Usage Decision (QA11)- Stock Posting- Quality Score updation- UD code Valuation- Inspection lot completion

Background

Plant to Plant

Not Ok

QualityNotification

6. Customer complaint and Returns

Customer Rejection

Post Goods Receipt to storage loc using VL01n

for Inspection lot creation.

Create Notification

Result Recording for investigation finding

Defect Recording

Create Return Sale Orderby SD thro VA01

Inspection Lot : Type 05 created and viewed thro QA32

Generate Report

Usage Decision for the Lot

Notifications Process contains :•Customer Details / Sale order•Complaint type and rejection

details•Partners and Coordinator•Internal and External failures•Causes (Root Cause)•Tasks (Corrective Action )•Activities (Preventive Action)

Classification of customer complaint

Customer complaint

Generate Report

Notification Raised by SD

Notifications Process contains :•Customer Details / Sale order•Complaint type and rejection

details•Partners and Coordinator•Internal and External failures•Causes (Root Cause)•Tasks (Corrective Action )•Activities (Preventive Action)

Send to Concerned Personnel for actions

7. Miscellaneous Inspection

Miscellaneous Inspection

Manual Lot Creationusing QA01

Manual Lot origin :Type 89 created and viewed thro

Result Recording (QE51n) for inspection characteristics

Result

Usage Decision (QA11)- Quality Score updation- UD code Valuation- Inspection lot completion

Background

Miscellaneous Inspection(Audit/Reverse Engg)

Not Ok

QualityNotification

8. Calibration Inspection

Internal Calibration

Calibration Order Searching thro IW39

Inspection Lot list :Type 14 created and viewed thro

Result

Usage Decision (QA11)- UD code Valuation- Inspection lot completion

Background

QC Equipment

Not Ok

Master Data : • Equipment Master : IE01,IE02,IE03• Maintenance Task list : IA01,IA02,IA03• Maintenance Plan : IP41 • Scheduling : IP10

QualityNotification

External Calibration

Create service entry sheet by MM thro ML81N

Inspection Lot list :Type 14 created and viewed thro QA32

Result

Usage Decision (QA11)- UD code Valuation- Inspection lot completion

Background

Lab Equipment to be calibrated by external

Not Ok

Service Entry Sheet completion / MIRO Processing by QM

Create Purchase Order and Gate Pass by MM thro ME21N

Calibration Order Searching thro IW39 Calibration Order Processing thro IW32

If Inspection Lot not required

Master Data : • Equipment Master : IE01,IE02,IE03• Maintenance Task list : IA01,IA02,IA03• Maintenance Plan : IP41 • Scheduling : IP10

QualityNotification

Thank you

Qm overview

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