WELCOME TO QUALITY MANAGEMENT MODULE Sanjay Kumar

25th June 2008

QM Module

QM Module General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Business Scenari o: o M ain Business Scenari
 In d ustrial c omp anies p erf o r m quality ins p ectio ns o n

p r od ucts at vario us stages in the lo gistics su pp ly chain.

 They nee d t o m aintain ins p ectio n s p ecificatio ns,

rec o r d ins p ectio n results, an d can p erf o r m evaluatio ns using this d ata.

SAP AG 1999

QM Integration
Basic data
Materials Vendors Routings Documents Inspection plan Characteristics Insp. methods Insp. catalogs Test equipment Results recording Print insp. instruction

MM
Purchasing Inventory mgmt Goods receipt Stock transfer Goods issue Requisition Invoice verification Warehouse management

PP
Production planning Reqt planning R-cut capacity planning Planned Orders Opening period Order: - Creation - Release - Confirmation Shop floor control Capacity leveling CAM

QM

Inspection lot
Inspection lot

PM
Test equipment management Usage decision

SD
Shipping Billing

QM Overview

Planning

Inspection

Control
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QM Overview
Q uality Planning: Activities
Q uality p lanning Q uality insp ecti o n Q uality co ntro l Q uality certificates Q uality n o tificati o ns T est equipm ent m g m t. Creating an d m anaging the m aster d ata that is required ( a mo ng o ther ite m s) to p lan an d execute quality ins p ecti o ns.

     

QM Overview
Qualit Inspe tion:
     

tivities
Determining w et er t e units inspe ted fulfill t e predefined ualit re uirements.

Qualit planning Qualit inspection Qualit control Qualit certificates Qualit notifications Test equipment mgmt.

QM Overview
Qualit
     

ontrol: ctivities
Implementing different preventive, monitoring and corrective activities. These activities are based on the specifications from qualit planning and the evaluations of qualit inspections and qualit notifications.
398 398 157 157
np np

Qualit planning Qualit inspection Qualit control Qualit certificates Qualit notifications Test equipment mgmt.

005 005

QM Overview
Qualit ertificates: ctivities
Certif ing the qualit of a material or product. Qualit certificates contain specification values, and inspection results. te ts,

     

Qualit planning Qualit inspection Qualit control Qualit certificates Qualit notifications Test equipment mgmt.

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QM Overview
Quality Notification : Activities
Recording the Non-Conformance
     

Q uality planning Q uality inspection Q uality control Q uality certificates Q uality notifications Test equipment mgmt.

or product. Investigation and analysis of defect Record Cause , Task and activities , etc.,

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QM Overview
Test Equi pm ent M anage m ent: Activities
Q uality p lanning Q uality ins p ecti o n Q uality c o ntro l Q uality certificates Q uality n o tificati o ns T est equipm ent m g m t.
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M anaging m aster d ata as w ell as the p lanning an d p r o cessing cali ratio n ins p ectio ns f o r test an d m easure m ent equipm ent.

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QM Module - General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Q uality Planning: Activities
Q uality p lanning Q uality insp ecti o n Q uality co ntro l Q uality certificates Q uality n o tificati o ns T est equipm ent m g m t. Creating an d m anaging the m aster d ata that is required ( a mo ng o ther ite m s) to p lan an d execute quality ins p ecti o ns.

     

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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
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Quality Planning
QM Basic Data and Inspection Plan Structure

Inspection Plan Structure :

Material master record Vendor master record Customer master record

Insp. plan

Header

Inspection characteristic

Operation

Work center

Production resources/tools
SAP AG 2001

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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.).

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Quality Planning
M aster Inspection Characteristic

Basic Data : Master Inspection Characteristics

Characteristic control

What is to e inspected?

General data

References to master records

Administrative data

SAP AG 1999

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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.

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Quality Planning
Basic Das tage : of sa ge Catalog C ataof logs
C rr a cke d C a cke d

D a m a ge d D a m a ge d

Sc rr a tt che d Sc a che d

a rr pe d a pe d

CODING
1001 1002 1003 1004
SAP AG

Warped Damaged Cracked Dented

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Quality Planning
Cat Type Codes Codes Grp Selected Set Selected Set Codes

9 6 5 4 3 2 1

Defects Defect consequences Causes Events Usage decisions Task Characteristic attri utes
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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
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Qualit Planning
Basic Data : Inspection Method
Inspection Method: General

Qualification

What kind of inspection is to be performed?

alidit

Texts

Classification

SAP AG

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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

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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

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QM Module General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Qualit Inspection:
     

ctivities
Determining whether the units inspected fulfill the predefined qualit requirements.

Qualit planning Qualit inspection Qualit control Qualit certificates Qualit notifications Test equipment mgmt.

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Quality Inspection


Inspection Lot Creation

 

Manual / Automatic Lot Stock / Non-Stock relevant Lot Quantitative / Qualitative / Calculated chars Single/Multiple recording Valuation with specification Manual / Auto creation Continued with notification : Background process UD code / Stock Posting / Quality Score Calculation
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Result Recording
  

Defect Recording : For deviation

 

Usage Decision


Quality Inspection
Inspection ot :
Inspec tio n Lot : B u s iness Scen a rio

Inspec tio n lot

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

Quality Inspection
Inspecti o t :o General Ins pn ectio on t: General
Maintenance order Goods movement Production order Customer order Delivery

Inspection lot

Quality inspection

Deadline monitoring Manual

SAP AG 2001

11 10

12

1 2

9
8 7 6 5 4

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Quality Inspection
Inspection rocess : Result Recording
QM Inspection rocess: esults ecording

Even t

Inspec tio n lot

S a m p l e d e t e rmi n atio n En t e r r es u lt s

Resu lt s recording
De f ec t s r ec ordi ng

V a l ua tio n C om p l e tio n

Us a ge d ec i s io n

Ev a l ua tio n

SAP AG 

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Quality Inspection
Defect recording usiness scenario :
Defects Recording: Business Scenario

SAP AG 1999

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Quality Inspection
Usage Decisi on Effects : Usage Decision: Effects

Vendor

Stock
A

A B C D

Purchasing

!
Units t

Production

Insp ectio n stage

Statistics
SAP AG 1999

Quality level
Time

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Qualit Certificates: ctivities
Certif ing the qualit of a material or product. Qualit certificates contain specification values, and inspection results. texts,

     

Qualit planning Qualit inspection Qualit control Qualit certificates Qualit notifications Test equipment mgmt.

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Quality Certificate
 Incoming
 Vendor certificate against Good receipt

 Outgoing
 Certificate Profile - Certificate Planning - Certificate Processing

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Quality Certificate

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
38

QM Overview
Quality Notification : Activities
Recording the Non-Conformance
     

Q uality planning Q uality inspection Q uality control Q uality certificates Q uality notifications Test equipment mgmt.

or product. Investigation and analysis of defect Record Cause , Task and activities , etc.,

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Quality Notification
 Notification Type
  

Vendor problem Internal problem Customer complaint Automatic trigger from defect recording / Manual creation.
-

Notification Process
 

Predefined codes as per catalog used in Item / Task / Activity

  

Catalog maintained at client level. Task completion for notification closure Standard report for notification.
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Quality Notification
Elements:
Archive ink Description

Workflow

Defects analysis

Evaluations Controlling

Q Notification

Tasks

Nonconformity costs QM costs Actions

Status management

Quality Notification
Notification Purpose :
 To record & process different types of problems..  To analyze the defects & monitor the correction of these defects.

Complaint Details Complaint type and rejection details Partners and Coordinator Internal and External failures Causes (Root Cause) Tasks (Corrective Action ) Activities (Preventive Action)

Task Completion and Notification closure Report

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment Management QM Integration with Other Modules Standard Reports Benefits Processes
43

QM Overview
Test Equi pm ent M anage m ent: Activities
Q uality p lanning Q uality ins p ecti o n Q uality c o ntro l Q uality certificates Q uality n o tificati o ns T est equipm ent m g m t.
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M anaging m aster d ata as w ell as the p lanning an d p r o cessing cali ratio n ins p ectio ns f o r test an d m easure m ent equipm ent.

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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.

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
46

QM Integration
Basic data
Materials Vendors Routings Documents Inspection plan Characteristics Insp. methods Insp. catalogs Test equipment Results recording Print insp. instruction

MM
Purchasing Inventory mgmt Goods receipt Stock transfer Goods issue Requisition Invoice verification Warehouse management

PP
Production planning Reqt planning R-cut capacity planning Planned Orders Opening period Order: - Creation - Release - Confirmation Shop floor control Capacity leveling CAM

QM

Inspection lot
Inspection lot

PM
Test equipment management Usage decision

SD
Shipping Billing

QM integration
P o sitio n of QM

Q ualit M anagem ent:

In teg ratio n in log istical p ro cesses

MM
Q ualit M an agem en t

PP

PM

SD

SAP AG

 

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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 vendors 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
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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
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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 createdLot 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

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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Reports

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Reports

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Reports

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Reports

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Reports

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
58

Benefits
BENEFITS :
 Comprehensive master data maintenance y system.  Stocks in Quality till inspection is completed.  Inspection Results are availa le on line, hence retrieval is will e easy and trends/SPC of characteristics can e viewed on line  Quality Score for vendor is ased on U D.  Standardized methodology for complaint reporting and analysis.  Cali ration frequency scheduled y system for instruments.  Standard reports for analysis and review.

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
60

QM Processes
1. 2. 3. 4. 5. 6. 7. 8.

QM Master Data Incoming Inspection In Process Inspection Final Inspection Stock Transfer Inspection Customer Complaints and Return Miscellaneous Inspection Calibration Inspection

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1. QM Master Data

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QM Master Data
Create
(One time only)

Change
(many times)

Display
(any time)

1. Material master 2. Inspection Method 3. MIC 4. Equipment Master 5. Catalog 6. Selected Set 7. Sampling Procedure 8. Inspection plan 9. Maintenance Task list 10.Quality info Record

: : : : : : : : : :

MM01,MM02,MM03 QS31,QS32,QS33 QS21,QS23,QS24 IE01,IE02,IE03 QS41,QS42 QS51,QS52 QDV1,QDV2,QDV3 QP01,QP02,QP03 IA01,IA02,IA03 QI01,QI02,QI03

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2. Incoming Inspection

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Incoming Inspection
Incoming Insp
GR-MIGO Posting y MM

Inspection ot : Type 01 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics Not Ok

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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3. In-Process Inspection

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In-process Inspection
In-process Materials

Order create y PP Inspection ot : Type 03 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics Not Ok

Defect Recording in RR

Resul t
OK

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Valuation is required on each recording

ot Usage Decision

Notification Closure
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4. Final Packing Inspection

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Final Inspection
Final Inspection
GR Posting y PP Inspection ot : Type 04 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics Not Ok

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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5. Stock Transfer Inspection

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Stock Transfer Inspection

Plant to Plant
Stock Transfer GR Posting y MM Inspection ot : Type 08 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics Not Ok

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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6. Customer complaint and Returns

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Customer Rejection
Create Return Sale Order y SD thro VA01

Post Goods Receipt to storage loc using V 01n for Inspection lot creation.

Classification of customer complaint

Inspection ot : Type 05 created and viewed thro QA32

Result Recording for investigation finding

Usage Decision for the ot

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)

Defect Recording Create Notification Task Completion and Notification closure

Generate Report

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Customer complaint

Notification Raised y 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

Task Completion and Notification closure

Generate Report

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7. Miscellaneous Inspection

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Miscellaneous Inspection
Miscellaneous Inspection (Audit/Reverse Engg) Manual ot Creation using QA01 Manual ot origin :Type 89 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics Not Ok

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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8. Calibration Inspection

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Internal Cali ration

QC Equipment

Cali ration Order Searching thro IW39 Inspection ot list :Type 14 created and viewed thro QA32

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

Defect Recording in RR Not Ok

Result Recording (QE51n) for inspection characteristics

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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External Cali ration

La Equipment to e cali rated y external
Cali ration Order Searching thro IW39 Cali ration Order Processing thro IW32
Master Data : Equipment Master : IE01,IE02,IE03 Maintenance Task list : IA01, IA02, IA03 Maintenance Plan : IP41 Scheduling : IP10

Create Purchase Order and Gate Pass y MM thro ME21N Create service entry sheet y MM thro ML81N Inspection Lot list :Type 14 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics

Defect Recording in RR Not Ok

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

If Inspection Lot not required

Service Entry Sheet completion / MIRO Processing y QM

Notification Closure
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Thank you

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