quality cycle

Quality Management Overview

Elements of SAP Quality Management

QM Integration with other SAP Modules

QM Processes in Logistics Supply Chain

Procurement, Production & SD

- Objectives

Functions In Quality Management Module

Elements of Quality Management Modules

Quality Planning

Quality Planning covers the following functions:

General master data (for example, material master, batch data, vendor master records)

QM specific master data (for example, master inspection characteristics, inspection methods, sampling procedures)

Inspection planning functions (for example, inspection plan, material specification)

Quality Planning will be covered in Detail In QM Master Data....

Quality Planning

Quality Inspection

Quality Inspection- Lot Creation

With Inspection Plan Without Inspection Plan

Create Inspection lot

Select inspection planCalculate samplesPrint Shop Papers

Record characteristic results

Record defect data

Specify Sample size

Make Usage decision

Calculate Quality ScoreUpdate Quality Level

Carry out follow-up action

Specify Quality Score

QM Inspection Processing- Work Flow

The inspector can :

Record the Results for Planned or Unplanned Inspection Characteristics

Record the Confirmed Defects

Valuate the characteristics

Quality Inspection- Recording Inspection results

Quality Inspection- Recording Inspection results-QA32

Quality Inspection- Recording Inspection results-QA32

Quality Inspection- Recording Inspection results-QA32

Quality Inspection- Defects Recording

Quality Inspection - Usage Decision

Quality Inspection - Usage Decision-QA32

Quality Control

Quality Control – SPC Quality Control Charts

Quality Notification

Quality Notifications are used to for recording, correcting

& preventing Nonconformities during

Procurement (Q1)

Production (Q2)

Customer complaints(Q3)

Quality Notification

Problem Management via Notifications

Execution Inspection

TasksProblem

description

Defects Causes

AnalysisSolutions

Process improvement

Quality Certificate

Quality Certificates

QMIS

STANDARD ANALYSES FLEXIBLE ANALYSES

lots

vendor

material

customer

Information Structures

defects

notifications

Quality Management Information System

QMIS – Info Structures & Standard Analysis

PPPPMMMM

PurchasingPurchasing RequisitionRequisition

Inventory mgmt

Goods receiptStock transferGoods issue

Inventory mgmt

Goods receiptStock transferGoods issue

ShippingBilling

ShippingBilling

SDSD

Invoiceverification

Invoiceverification

Warehousemanagement

Warehousemanagement

Inspection lotInspection lot

QMQM Inspection lotInspection lot

Print insp. instructionPrint insp. instruction

Results recordingResults recording

Usage decisionUsage decision

Basic dataBasic dataBasic data

Test equipmentmanagement

Test equipmentmanagement

PMPM

Productionplanning

Productionplanning

Reqt planningR-cut capacity

planning

Reqt planningR-cut capacity

planning

PlannedOrders

PlannedOrdersOpeningperiod

Openingperiod

Order:-C reation- Release-C onfirmation

Order:-C reation- Release-C onfirmation

Shop floorcontrolCapacityleveling

Shop floorcontrolCapacityleveling

CAMCAM

MaterialsMaterials

VendorsVendors

RoutingsRoutings

DocumentsDocuments

Inspection plan

Characteristics

Insp. methods

Insp. catalogs

Test equipment

QM Integration within Logistics Chain

QM Processes in Logistics Supply Chain

Procurement Production Sales Service•Release Vendor•Manages the release status of supply relationship•Triggers goods receipt in inspections.•Quality Score•VendorEvaluation•Quality certificates/Notifica tions•Manages problems in procurement•Manages vendor related technical delivery terms & quality assurance plan•Quality Audit

•Integrates inspection planning & work scheduling•Triggers inspection during production•Supports integrated confirmation of quality/operating data•Inspection points•Partial lots•Control charts•Problem notification

•

Triggers inspection lots at delivery.•Quality certificates.•Customer complaints

Technical delivery terms

Vendor evaluation:

quality score

audits

complaints

QA agreements

Certificates

Vendor release (Q-Info)

Inspection at the vendor’spremises

GR inspection

Dynamic modification

Inspection stock

Defects, Nonconformities

Q-Notifications

The procurement chain

QuotationQuotation Vendor selectionVendor selection Purchase orderPurchase order Goods receipt

QM – Procurements

GRGRInspection

Lot

InspectionLot

SamplingScheme

SamplingScheme

InspectionPlan

InspectionPlan

InspectionInspection ResultsRecording

ResultsRecording

Usage Decision

Usage Decision

Follow up Action

Follow up Action

M I C I. Methods

QM in Procurements – Business Process View

Production Planning and Control

Resultrecording

Usage Decision Stock

movements

Production Production planningplanning

Production order Order confirmat ion Goods receipt

Routings Inspection lots with

insp. Points Sample

calculation Process

control

QM in Production

QM in Production – Business Process View

Qualityinformation

Inspectionlots

Certificates

CustomerComplaints

Service

Sales and Distribution

Sales order Delivery Service

QM – Sales and Distribution / Service

Quality Inspection in SD

We have understood the following :

Elements of SAP Quality Management

QM Integration with other SAP Modules

QM Processes in Logistics Supply Chain

Procurement, Production & SD

Summary

QM Master Data

At the end of this session You will understand the details on QM Master Data:

Material Master -QM View

Basic Data -

Catalogs, Inspection Methods, Master Inspection Characteristics

Inspection Plan

Objectives

Master Data in QM

Views of a Material Master Record

Quality Management View

Quality Management View – General Data

Quality Management View – Procurement View

Material Master - Summary

QM specific data is maintained at the plant level For every inspection type appropriate indicators are selected. Default settings for each inspection type are set. Inspection type specifies how an inspection to be carried out.The inspection type is assigned to inspection lot origin For the inspection lot origin, goods receipt for PO, you can find the following inspection types.-Model series-Preliminary series-Production series

Inspection catalogs are created in QM module

Components of catalogs are

- Codes, Code groups, Selected sets & Codes

Unstructured Description of inspection results, observations, ordecisions made during inspection are coded to evaluate similar information. Easy to evaluate such non numeric data in codes.

Evaluate descriptions such as cracked, dented, damaged, defectives in terms of codes.These coded descriptions are managed in catalogs.

Assign these codes to master inspection characteristic & characteristics in the inspecti on plan.eg. Using code groups & selected set codes.

Codes are used to record inspection results/defects/defect location.

Codes are used to make usage decision and carry out evaluation.

Codes for Task,Events,Causes, etc are used in notifications.

CATALOGS

Surface attribute Color Packaging Material

Code group 1

Catalog Type 1Characteristic

attribute

Gr. Code 1Clear

Gr. Code 1White

Gr. Code 1Foam

Gr. Code 2Frosted

Gr. Code 2Red

Gr. Code 2Wood-wool

Code group 2 Code group 3

Hierarchy of Catalog

Code Groups and Codes

Code groupValuation

all OKOK - othernot OK - other

dirty all OK soakedsticky OK - other dented

not OK - other undamagedtornSet codes for the selected set

"Condition of pencil packaging"

Selected set

Code groupStructure

soliddamaged crushedhas holes

Code groupSurface

evendirtystickysmooth

Characteristic attributes

Catalog type 1

Selected Sets

Selected Sets and Set Code

Inspection Method

Version 1 Version 2

Time axis

Valid from01-01-02

Today Valid from20-02-02

Validity of an Inspection Method

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.

Master Inspection Characteristics

Master Inspection Characteristics

Create Master Inspection Characteristics

Control Indicators for the InspectionCharacteristic

Assign. the insp. cat. to master insp. char.

Validity of an MIC Version Management

Version 1 Version 2

Time axis

Valid from01-01-12

Today Valid from20-02-12

An inspection characteristic describes the inspection requirements for materials,parts and products.

To standardize inspection planning, master inspection characteristic can be defined.These can be used in different inspection plans.

Where used lists and replacement functions support the inspection planner in the maintenance of master data.

Changes are documented using version management.

Master Inspection Characteristics - Summary

A sampling procedure is a procedure by which the sample size is determined for an inspection

Sampling procedures are defined at characteristic level

Sampling procedures are maintained at client level.

Sampling Procedure

•Description/Identifier

Initial screen

Assignments

•Texts

•Sample Type

•Valuation mode

•With inspection points

•Block indicator

Special conditions

•Sampling scheme

•Control chart

•No stage change

•Independent multiple samples (no.of samples)

.

Creating a Sampling Procedure

Sampling Type Valuation Mode

...defines how the sampleis determined

•Fixed sample•100% Inspection•Sampling scheme• % based sample

…defines rules for acceptingand rejecting

•Attributive inspection based onno.of nonconforming units/defects•Variable inspection (s- method) •Attributive code•Manual valuation•Mean value within the tolerance•SPC inspection

Sampling Plan

•Sample size n•Acceptance no. c Independent oflot size

Correlation sampling Type - Valuation Mode

A sampling scheme is an arrangement of sampling plans (in sampling tables) for accepting the characteristics of an inspection. A sampling plan defines the sample scope and the acceptance criteria

Acceptance Number and Rejection Number serve as criteria

You assign a sampling scheme to a sampling procedure

Sampling Scheme

Creating a Sampling Scheme

Example : Determining the Sample Size

In order to adapt the inspection to the expected quality level, the inspection scope can be modified dynamically. The inspection scope is adapted to the current quality level with the help of sampling procedures and dynamic modification rules

SAP’s Quality Management (QM) module supports the inspection planner in setting up and maintaining the data needed for monitoring of quality levels. The QM module also takes over the function of maintaining the inspection history

Dynamic Modification Rule

Dynamic Modification

Create Dynamic Modification Rule

Dynamic Modification at Lot Creation

Sampling procedure Dynamic modification rule

•Assignment only to the characteristics

•Assignment

•At header level

•At characteristic level

Inspection Plan

Header

Operation

•Characteristic 1

•Characteristic 2

Dynamic Modification in the Inspection Plan

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

Decision on whether to deactivate the goods receipt inspection or perform a goods receipt inspection and/or source inspections

Quality Information Record

Q Info record is maintained at material,plant,vendor combination level.

Prerequisites:

1)Material for the plant is defined

2)QM in procurement with appropriate control key must be assigned.

3)Vendor must exist in the system.

If a quality assurance agreement or a vendor release is required,you must create a Quality Information record.The Q-info record controls further processing of the material.

Prior to quotation/P.O creation ,system checks availability of Q-info record.System also checks if vendor, material combination is blocked or released for quotation/P.O/G.R

The Q-info record is created only after you maintain the QM data in the material master.The master record for the vendor must also be available.

Q - Information Record

Inspection Plan – QM Basic Data & Inspection Plan Structure

Creating Inspection Plan-QP01

Creating Inspection Plan-QP01

Material

A

KopfOperation 20

Insp. character istic20Insp. character istic

Kopf

Work Center

Header

Operation 10

Inspection Plan Structure

1

2

6

5

4

3

Material

Material

Plan group counter

Usage

Planner Group

Plan Status

Lot Size

Plan Header

Inspection Plan Header

Inspection Plan – Inspection Operation

Following data screens to be filled to create a Inspection plan

-Create Inspection Plan-Initial screen (T.Code QP01)

-Create Inspection Plan-Header Details

-Create Inspection Plan-Operation Overview

-Create Inspection Plan-Characteristic Overview

-Assign PRT to characteristic if required

-Assigning Inspection Plan to Material & Plant

-Assigning materials vendors/customers at the plant level

Preparation of Inspection Plan

Inspection Plan may not get assigned to the lot

-When more than one plan is available

-When there is no plan for the material

Go to the QP03 (display Inspection plan) & verify above.

If Inspection Plan is to be made

-Check whether available generic plan can be assigned,if yes,go to QP02(change Inspection plan) of generic check list &assign the same to the required item.

Assignment of the plan to the inspection lot

-Go to Inspection lot change

-Assign the appropriate inspection plan to the lot(by clicking the next screen.Message indicating inspection plan is revised.Sample calculated should appear).

Assigning an Inspection Plan to the Inspection Lot

An operation is carried out at a work center (a work operation or inspection operation)

The work center is assigned to a cost center in the master record.The output of a work center is valuated by cost rates.Cost ratesare

determined by the assigned cost center and the activity types.

Inspection Plan- Work Center

Inspection Plan - PRTs/Test Equipment

PRTs/Test equipments are assigned to Inspection operation and then to inspection characteristic. The PRTS/test equipment can be printed on the inspection instructions of the corresponding characteristic of a Inspection Plan.

The PRTs/test equipment can be displayed in results recording.

The PRTs master data is maintained as material master data

Production Resource Tool

Task listTask list

Operation 10Operation 10

Operation 20Operation 20

Operation 30Operation 30

PRTs/Equipment 1PRTs/Equipment 1

PRTs/Equipment 2PRTs/Equipment 2

Inspection Plan – Assigning PRTs/ Test Equipment

Inspection Plan - Summary

The Inspection Plan and Routing have identical structure.The inspection plan is selected by the system based on material, plant, vendor,customer,group,group counter,Task list usage &status .The inspection plan is used to specify the inspection operation,the characteristics to be inspected for each operation and the test equipment to be used.The Inspection Plan is assigned to inspection lot for every Inspection Type The Inspection lot is created under each Inspection Type for which Inspection Plan is assigned by the system automatically or manually.

We Have Understood the following :

Material Master - QM View

Basic Data -

Catalogs, Inspection Methods, Master Inspection Characteristics

Inspection Plan

Summary