Quality cycle


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SAP QM Overview

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Quality cycle

  1. 1. Quality Management Overview Elements of SAP Quality Management QM Integration with other SAP Modules QM Processes in Logistics Supply Chain Procurement, Production & SD - Objectives
  2. 2. Functions In Quality Management Module
  3. 3. Elements of Quality Management Modules
  4. 4. Quality Planning
  5. 5. 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
  6. 6. Quality Inspection
  7. 7. Quality Inspection- Lot Creation
  8. 8. With Inspection Plan Without Inspection Plan Create Inspection lot Select inspection plan Calculate samples Print Shop Papers Record characteristic results Record defect data Specify Sample size Make Usage decision Calculate Quality Score Update Quality Level Carry out follow-up action Specify Quality Score QM Inspection Processing- Work Flow
  9. 9. The inspector can : Record the Results for Planned or Unplanned Inspection Characteristics Record the Confirmed Defects Valuate the characteristics Quality Inspection- Recording Inspection results
  10. 10. Quality Inspection- Recording Inspection results-QA32
  11. 11. Quality Inspection- Recording Inspection results-QA32
  12. 12. Quality Inspection- Recording Inspection results-QA32
  13. 13. Quality Inspection- Defects Recording
  14. 14. Quality Inspection - Usage Decision
  15. 15. Quality Inspection - Usage Decision-QA32
  16. 16. Quality Control
  17. 17. Quality Control – SPC Quality Control Charts
  18. 18. Quality Notification
  19. 19. Quality Notifications are used to for recording, correcting & preventing Nonconformities during Procurement (Q1) Production (Q2) Customer complaints(Q3) Quality Notification
  20. 20. Problem Management via Notifications Execution Inspection Tasks Problem description Defects Causes Analysis Solutions Process improvement
  21. 21. Quality Certificate
  22. 22. Quality Certificates
  23. 23. QMIS
  24. 24. STANDARD ANALYSES FLEXIBLE ANALYSES lots vendor material customer Information Structures defects notifications Quality Management Information System
  25. 25. QMIS – Info Structures & Standard Analysis
  26. 26. PPPPMMMM PurchasingPurchasing RequisitionRequisition Inventory mgmt Goods receipt Stock transfer Goods issue Inventory mgmt Goods receipt Stock transfer Goods issue Shipping Billing Shipping Billing SDSD Invoice verification Invoice verification Warehouse management Warehouse management Inspection lotInspection lot QMQM Inspection lotInspection lot Print insp. instructionPrint insp. instruction Results recordingResults recording Usage decisionUsage decision Basic dataBasic dataBasic data Test equipment management Test equipment management PMPM Production planning Production planning Reqt planning R-cut capacity planning Reqt planning R-cut capacity planning Planned Orders Planned Orders Opening period Opening period Order: -C reation - Release -C onfirmation Order: -C reation - Release -C onfirmation Shop floor control Capacity leveling Shop floor control Capacity leveling CAMCAM MaterialsMaterials VendorsVendors RoutingsRoutings DocumentsDocuments Inspection plan Characteristics Insp. methods Insp. catalogs Test equipment QM Integration within Logistics Chain
  27. 27. QM Processes in Logistics Supply Chain Procurement Production Sales Servic •Release Vendor •Manages the release status of supply relationship •Triggers goods receipt in inspections. •Quality Score •Vendor Evaluation •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
  28. 28. Technical delivery terms Vendor evaluation: qualityscore audits complaints QAagreements Certificates Vendor release (Q-Info) Inspection at the vendor’s premises GR inspection Dynamic modification Inspection stock Defects, Nonconformities Q-Notifications The procurement chain QuotationQuotation Vendor selectionVendor selection Purchase orderPurchase order Goods receipt QM – Procurements
  29. 29. GRGR Inspection Lot Inspection Lot Sampling Scheme Sampling Scheme Inspection Plan Inspection Plan InspectionInspection Results Recording Results Recording Usage Decision Usage Decision Followup Action Followup Action MIC I. Methods QM in Procurements – Business Process View
  30. 30. Production Planning and Control Result recording Usage Decision Stock movements ProductionProduction planningplanning Production order Order confirmation Goods receipt Routings Inspection lots with insp. Points Sample calculation Process control QM in Production
  31. 31. QM in Production – Business Process View
  32. 32. Quality information Inspection lots Certificates Customer Complaints Service Sales and Distribution Sales order Delivery Service QM – Sales and Distribution / Service
  33. 33. Quality Inspection in SD
  34. 34. 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
  35. 35. QM Master Data
  36. 36. 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
  37. 37. Master Data in QM
  38. 38. Views of a Material Master Record
  39. 39. Quality Management View
  40. 40. Quality Management View – General Data
  41. 41. Quality Management View – Procurement View
  42. 42. 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
  43. 43. Inspection catalogs are created in QM module Components of catalogs are - Codes, Code groups, Selected sets & Codes Unstructured Description of inspection results, observations, or decisions 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
  44. 44. Surface attribute Color Packaging Material Code group 1 Catalog Type 1 Characteristic attribute Gr. Code 1 Clear Gr. Code 1 White Gr. Code 1 Foam Gr. Code 2 Frosted Gr. Code 2 Red Gr. Code 2 Wood-wool Code group 2 Code group 3 Hierarchy of Catalog
  45. 45. Code Groups and Codes
  46. 46. Code group Valuation all OK OK - other not OK - other dirty all OK soaked sticky OK - other dented not OK - other undamaged tornSet codes for the selected set "Condition of pencil packaging" Selected set Code group Structure solid damaged crushed has holes Code group Surface even dirty sticky smooth Characteristic attributes Catalog type 1 Selected Sets
  47. 47. Selected Sets and Set Code
  48. 48. Inspection Method
  49. 49. Version 1 Version 2 Time axis Valid from 01-01-02 Today Valid from 20-02-02 Validity of an Inspection Method
  50. 50. 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
  51. 51. Master Inspection Characteristics
  52. 52. Create Master Inspection Characteristics
  53. 53. Control Indicators for the Inspection Characteristic
  54. 54. Assign. the insp. cat. to master insp. char.
  55. 55. Validity of an MIC Version Management Version 1 Version 2 Time axis Valid from 01-01-12 Today Valid from 20-02-12
  56. 56. 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
  57. 57. 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
  58. 58. •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
  59. 59. Sampling Type Valuation Mode ...defines how the sample is determined •Fixed sample •100% Inspection •Sampling scheme • % based sample …defines rules for accepting and rejecting •Attributive inspection based on no.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 of lot size Correlation sampling Type - Valuation Mode
  60. 60. 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
  61. 61. Creating a Sampling Scheme
  62. 62. Example : Determining the Sample Size
  63. 63. 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
  64. 64. Dynamic Modification
  65. 65. Create Dynamic Modification Rule
  66. 66. Dynamic Modification at Lot Creation
  67. 67. 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
  68. 68. 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
  69. 69. 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
  70. 70. Inspection Plan – QM Basic Data & Inspection Plan Structure
  71. 71. Creating Inspection Plan-QP01
  72. 72. Creating Inspection Plan-QP01
  73. 73. Material A KopfOperation 20 Insp. characteristic 20Insp. characteristic Kopf Work Center Header Operation 10 Inspection Plan Structure
  74. 74. 1 2 6 5 4 3 Material Material Plan group counter Usage Planner Group Plan Status Lot Size Plan Header Inspection Plan Header
  75. 75. Inspection Plan – Inspection Operation
  76. 76. 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 ifrequired -Assigning Inspection Planto Material & Plant -Assigning materials vendors/customers at the plant level Preparation of Inspection Plan
  77. 77. 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
  78. 78. An operation is carried out at awork 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 costcenter and the activity types. Inspection Plan- Work Center
  79. 79. Inspection Plan - PRTs/Test Eq 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
  80. 80. 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
  81. 81. 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.
  82. 82. We Have Understood the following : Material Master - QM View Basic Data - Catalogs, Inspection Methods, Master Inspection Characteristics Inspection Plan Summary