Download - 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