1
25th June 2008
WELCOME TO QUALITY MANAGEMENT
MODULESanjay Kumar
2
QM Module
3
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
4
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
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 dataBasic data
Test equipmentmanagement
Test equipmentmanagement
PMPM
Productionplanning
Productionplanning
Reqt planningR-cut capacity
planning
Reqt planningR-cut capacity
planning
PlannedOrders
PlannedOrdersOpeningperiod
Openingperiod
Order:- Creation- Release- Confirmation
Order:- Creation- Release- Confirmation
Shop floorcontrolCapacityleveling
Shop floorcontrolCapacityleveling
CAMCAM
MaterialsMaterials
VendorsVendors
RoutingsRoutings
DocumentsDocuments
Inspection plan
Characteristics
Insp. methods
Insp. catalogs
Test equipment
6
Control
Planning Inspection
QM Overview
7
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.
8
QM Overview
Quality Inspection: Activities
Determining whether the units
inspected fulfill the predefined
quality requirements.
Quality planning
Quality inspection
Quality control
Quality certificates
Quality notifications
Test equipment mgmt.
9
QM Overview
R
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.
npnp
157157 005005
398398
Quality planning
Quality inspection
Quality control
Quality certificates
Quality notifications
Test equipment mgmt.
10
QM Overview
R
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 certificates
Quality notifications
Test equipment mgmt.
11
QM Overview
R
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
Quality certificates
Quality notifications
Test equipment mgmt.
12
QM Overview
R
Test Equipment Management: Activities
Managing master data as well as
the planning and processing
calibration inspections for test
and measurement equipment.
30
Quality planning
Quality inspection
Quality control
Quality certificates
Quality notifications
Test equipment mgmt.
13
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
14
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.
15
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
16 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 :
17
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.).
18
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
19
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.
20SAP AG 2001
CODING
ScratchedScratched
WarpedWarped
DamagedDamaged
CrackedCracked
Usage of Catalogs
1001 Warped1002 Damaged1003 Cracked1004 Dented
Quality Planning
Basic Data : Usage of Catalog
21
Quality Planning
Defects
Defect consequences
Causes
Events
Usage decisions
Task
Characteristic attributes
Selected
Set
Codes
Cat
Type
Codes Codes
Grp
Selected
Set
9
6
5
4
3
2
1
22
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
23 SAP AG 2001
Inspection Method: General
What kind of inspection is to be performed?
Validity
Qualification
Texts
Classification
Quality Planning
Basic Data : Inspection Method
24
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
25
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
26
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
27
QM Overview
Quality Inspection: Activities
Determining whether the units
inspected fulfill the predefined
quality requirements.
Quality planning
Quality inspection
Quality control
Quality certificates
Quality notifications
Test equipment mgmt.
28
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
29
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 :
30
SAP AG 2001
12
9
6
3
11 1
7 58 4
210
Goodsmovement
Productionorder
Customerorder
Delivery
Deadlinemonitoring
Manual
Inspectionlot
Maintenanceorder
Inspection Lot: General
Qualityinspection
Quality Inspection
Inspection Lot : General
31
SAP AG 1999
QM Inspection Process: Results Recording
Event
Sample determination
Usage decision
Evaluation
Defects recording
Inspection lot
Enter results
Valuation
Completion
Results recording
Quality Inspection
Inspection Process : Result Recording
32
SAP AG 1999
Defects Recording: Business Scenario
Quality Inspection
Defect recording business scenario :
33
SAP AG 1999
!!Purchasing Production
Vendor StockA
A BCD
Statistics
Units
t
Quality levelInspection stage
Time
Usage Decision: Effects
Quality Inspection
Usage Decision – Effects :
34
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
35
QM Overview
R
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 certificates
Quality notifications
Test equipment mgmt.
36
Quality Certificate
Incoming Vendor certificate against Good receipt
Outgoing Certificate Profile
- Certificate Planning
- Certificate Processing
37
Quality Certificate
38
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
39
QM Overview
R
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
Quality certificates
Quality notifications
Test equipment mgmt.
40
Quality Notification
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.
Quality Notification
Statusmanagement
Nonconformity costs
QM costs
Q Notification
Actions
Defects analysis
TasksEvaluations
Controlling
Workflow
DescriptionArchive LinkElements:
42
Quality Notification
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.
43
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
44
QM Overview
R
Test Equipment Management: Activities
Managing master data as well as
the planning and processing
calibration inspections for test
and measurement equipment.
30
Quality planning
Quality inspection
Quality control
Quality certificates
Quality notifications
Test equipment mgmt.
45
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.
46
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
QM Integration
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 dataBasic data
Test equipmentmanagement
Test equipmentmanagement
PMPM
Productionplanning
Productionplanning
Reqt planningR-cut capacity
planning
Reqt planningR-cut capacity
planning
PlannedOrders
PlannedOrdersOpeningperiod
Openingperiod
Order:- Creation- Release- Confirmation
Order:- Creation- Release- Confirmation
Shop floorcontrolCapacityleveling
Shop floorcontrolCapacityleveling
CAMCAM
MaterialsMaterials
VendorsVendors
RoutingsRoutings
DocumentsDocuments
Inspection plan
Characteristics
Insp. methods
Insp. catalogs
Test equipment
48
SAP AG 1999
QualityManagement:
Integrationin logisticalprocesses
PM
MM PP
SD
QualityManagement
Position of QM
QM integration
49
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
50
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
51
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
52
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
53
Reports
54
Reports
55
Reports
56
Reports
57
Reports
58
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
59
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.
60
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
61
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
62
1. QM Master Data
63
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
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
only)
Change (many times) Display
(any time)
64
2. Incoming Inspection
65
Incoming Inspection
GR-MIGO Posting by MM
Inspection Lot : Type 01 created and viewed thro
QA32
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
OK
QualityNotification
66
3. In-Process Inspection
67
In-process Inspection
Order create by PP
Inspection Lot : Type 03 created and viewed thro
QA32
Result Recording (QE51n) for inspection
characteristicsResult
Valuation is required on each recording
Defect Recording in RR
Notification Creation (QM01)
Background
Notification processing (QM02)
In-process Materials
Notification Closure
Not Ok
OK
Lot Usage Decision
QualityNotification
68
4. Final Packing Inspection
69
Final Inspection
GR Posting by PP
Inspection Lot : Type 04 created and viewed thro
QA32
Result Recording (QE51n) for inspection
characteristicsResult
Defect Recording in RR
Notification Creation (QM01)
Background
Notification processing (QM02)
Final Inspection
Notification Closure
Not Ok
OK
Usage Decision (QA11)- Stock Posting in Silo- Quality Score updation- UD code Valuation- Inspection lot completion
QualityNotification
70
5. Stock Transfer Inspection
71
Stock Transfer Inspection
Stock TransferGR Posting by MM
Inspection Lot : Type 08 created and viewed thro
QA32
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)
Plant to Plant
Notification Closure
Not Ok
OK
QualityNotification
72
6. Customer complaint and Returns
73
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
Task Completion and Notification closure
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
74
Customer complaint
Task Completion and Notification closure
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
75
7. Miscellaneous Inspection
76
Miscellaneous Inspection
Manual Lot Creationusing QA01
Manual Lot origin :Type 89 created and viewed thro
QA32
Result Recording (QE51n) for inspection characteristics
Result
Usage Decision (QA11)- Quality Score updation- UD code Valuation- Inspection lot completion
Defect Recording in RR
Notification Creation (QM01)
Background
Notification processing (QM02)
Miscellaneous Inspection(Audit/Reverse Engg)
Notification Closure
Not Ok
OK
QualityNotification
77
8. Calibration Inspection
78
Internal Calibration
Calibration Order Searching thro IW39
Inspection Lot list :Type 14 created and viewed thro
QA32
Result Recording (QE51n) for inspection characteristics
Result
Usage Decision (QA11)- UD code Valuation- Inspection lot completion
Defect Recording in RR
Notification Creation (QM01)
Background
Notification processing (QM02)
QC Equipment
Notification Closure
Not Ok
OK
Master Data : • Equipment Master : IE01,IE02,IE03• Maintenance Task list : IA01,IA02,IA03• Maintenance Plan : IP41 • Scheduling : IP10
Master Data : • Equipment Master : IE01,IE02,IE03• Maintenance Task list : IA01,IA02,IA03• Maintenance Plan : IP41 • Scheduling : IP10
QualityNotification
79
External Calibration
Create service entry sheet by MM thro ML81N
Inspection Lot list :Type 14 created and viewed thro QA32
Result Recording (QE51n) for inspection characteristics
Result
Usage Decision (QA11)- UD code Valuation- Inspection lot completion
Defect Recording in RR
Notification Creation (QM01)
Background
Notification processing (QM02)
Lab Equipment to be calibrated by external
Notification Closure
Not Ok
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
Master Data : • Equipment Master : IE01,IE02,IE03• Maintenance Task list : IA01,IA02,IA03• Maintenance Plan : IP41 • Scheduling : IP10
QualityNotification
80
Thank you