LO720 - QM in Discrete and Repetitive Manufacturing

LO720 QM in Discrete and Repetitive
Manufacturing
LO720
LO
QM in Discrete and Repetitive

Manufacturing
SAP AG 2001
SAP AG
Copyright
Copyright 2001 SAP AG. All rights reserved.

No part of this publication may be reproduced or transmitted in
any form or for any purpose without the express permission of
SAP AG. The information contained herein may be changed
without prior notice.
All rights reserved.
SAP AG 2001
Quality Management (QM)

Level 2
Level 3
LO715
3 days
QM in
Procurement
LO170
3 days
Quality Management
LO705
3 days
Quality Inspections
LO710
3 days
Quality Notifications
LO720
2 days
QM in Discrete and
Repetitive
Manufacturing
LO721
3 days
QM in the Process
Industry
LO725
2 days
QM in Sales and
Distribution / Quality
Certificates
SAP AG 1999
LO750
3 days
QM Organization and
Configuration
Course Prerequisites
LO050 - Planning & Execution for Discrete and

Repetitive Manufacturing
LO705 - Quality Inspections
SAP AG 1999
Target Group
Audience:
Project leaders and members of the project team, who

have experience of quality management and production.
Duration: 2 days
SAP AG 1999
Course Overview
Contents:
Course Goals
Course Objectives
Course Content
Course Overview Diagram
SAP AG 1999
SAP AG
Course Goals
This course deals with:

The integration of the Quality Management
component in PP processes
QM-specific features of a quality inspection for orders
(production orders, run schedule headers,

maintenance orders/calibration orders)
Uses for QM functions
The most important settings for orders in QM
processes
SAP AG 1999
SAP AG
Course Objectives
At the conclusion of this course, you will be

able to:
Describe the integration of the QM component in PP,
based on different manufacturing types

Plan and perform an inspection during production
and an inspection at the end of the production

process
Use control charts to monitor your processes
Plan and process inspections in repetitive
manufacturing
Plan and perform a calibration inspection
SAP AG 1999
Course Content
Preface
Unit 1
Course Overview
Unit 5
Unit 2
Inspection During
Production
Quality Inspection for

External Processing
Unit 6
Unit 3
QM in Repetitive
Manufacturing
Inspection at the End of

the Production Process
Unit 7
Unit 4
Test Equipment
Management
Comparison of
Manufacturing Types
SAP AG 1999
Course Overview Diagram (1)
Course Overview
Inspection During Production
QM in Repetitive Manufacturing
Test Equipment Management
Quality Inspection for External Processing
Inspection at the End of the Production Process
Comparison of Manufacturing Types
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START
Contents:
Defects Recording for an Order
Results Recording by Characteristic for an
Order
Inspection Point Processing
SPC - Statistical Process Control
Integration of the QM and PP Components
SAP AG 1999
Inspection During Production: Unit Objectives
At the conclusion of this unit, you will be

able to:
Plan and implement an inspection during
production
Use different QM variants for an inspection
during production
Use SPC functions to control your
processes
Describe the integration of the QM and PP

components
SAP AG 1999
Introduction

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Results Recording by Characteristic for an Order

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Defects Recording for an Order: Objectives
At the conclusion of this topic, you will be able to:

Plan an inspection during production in the material
master
Create an inspection lot for an order
Record defects
Make a usage decision for an inspection during
production
SAP AG 1999
SAP AG
Defects Recording for an Order: Business Scenario
You manufacture shafts using PP orders. You

want to record any defects that are identified
during production, and to inform the vendor, if
necessary.
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Procurement
Production
Sales
Service
Integrating insp. planning/production operations
QM tasks
Integrating order processing

Controlling inspections during production
Statistical process control (SPC)
Processing internal problem notifications
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Inspection Lot Origins in Production (1)
Inspection
Inspection lot
lot origin
origin 03
03
Discrete
DiscreteManufacturing
Manufacturing
Inspection
Inspection lot
lot origin
origin 13
13
Repetitive
RepetitiveManufacturing
Manufacturing
Inspection
Inspection lot
lot origin
origin 03
03
Process
ProcessManufacturing
Manufacturing
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Inspection Lot Origins in Production (2)
Inspection lot origin 03 / 13

Kanban
Kanban
Inspection lot origin 04

GR
GRfor
forOrder
Order
Inspection lot origin 14
Plant
PlantMaintenance
Maintenance
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Integration in the Production Process (1.1)
Order
Manufacture Manufacture
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
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Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot
Order
Manufacture
Manufacture
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
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Inspection
lot
Defect
For inspection lot

For operation
(For characteristic)
Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Q-notification
Inspection
lot
Defect
For inspection lot

For operation
Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Integration in the Production Process (1)
Q-notification
Inspection
lot
Defect
For inspection lot

For operation
Usage
decision
Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Prerequisites for Inspection During Production

with Defects Recording
Material
Other master data
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Inspection type for

origin 03 or 13 is active
Catalogs
Defect catalog
Usage decision catalog
Inspection Results
Inspection
lot
Recording inspection results
Defect data
Characteristic results
Qualitative chars
Activate
Quality notification
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Quantitative chars
Automatic Usage Decision
Prerequisites
Selection options
General UD
Consider
skip lots
Order completed
Consider completed
lots
Order technically
completed
Consider long-term
characteristics
Order
confirmed
No defects
No rejection
Queue time
No characs outstanding
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UD for Orders


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Results Recording by Characteristic for an Order:

Objectives

Add the QM data required for a quality inspection to a
routing
Record results for an inspection during production
SAP AG 1999
Results Recording by Characteristic for an Order:

Business Scenario
You manufacture shafts using PP orders.

Once the operations 'anneal' and 'lathe' have been
completed for the shafts, they are to be subject to a
quality inspection by the workmen. The inspection
results are to be confirmed for process control and
documentation purposes.
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Order
010
020
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Inspect
Manufacture
030
040
+
manufacture
Goods receipt
Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot
Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot
Inspection
Inspection
Results
results
Order
010
020
Inspect
Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot
Inspection
results
Usage
decision
Order
010
020
Inspect Manufacture
+ 030
040
manufacture
Goods receipt
SAP AG 1999
Prerequisites for an Inspection During Production

with Results Recording
Inspection setup
Origin 03 or 13 is active
Inspect with task list
Inspect by characteristic
Material
Other
master data
SAP AG 1999
QM-relevant data in
routing/recipe
Inspection characteristics
Inspection method
Additional QM basic data
Specifications from the Task List
Material
A
Material
Header
Operation 20
Operation 10
Insp. characteristics
Prod. resources/tools
Work center
Material components
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Inspection Results
Inspection
lot
Recording inspection results

for insp. lot (based on operation)
Defect data
Characteristic results
Qualitative chars
Activate
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Quantitative chars
Recording Steps
Operation 10
Record results
Insp. charac. 1
Valuate
characteristic
Complete
characteristic
Make usage decision

for inspection lot
SAP AG 1999

SAP AG 1999
Inspection Point Processing: Objectives

Plan and implement multiple inspections for an
operation using inspection point processing
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Inspection Point Processing: Business Scenario
You manufacture shafts using PP orders. The shafts are

manufactured in wire baskets of 50. Once the operations
'lathe' and 'anneal' have been completed, 5 shafts from
each wire basket are to be inspected for quality.
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Order
Inspection
lot
040
030
020
010
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Quality inspection at
regular intervals during
each operation
Prerequisites for an Inspection During Production

with Inspection Points
Inspection setup
Material
Other
master data
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Origin 03 or 13 is active
Inspect with task list
Inspect by characteristic
QM-relevant data in
routing/recipe
(e.g. insp. point)
Additional QM basic data
Time-Based Inspection
Char.
Insp. freq.
10
20
30
Inspection point
S
S
t
8.00
9.00
10.00 11.00 12.00 13.00 14.00
Operation: Default split 1 h

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= SKIP
Quantity-Based Inspection
Char.
Inspection point
S
S
50
100
S
S
150
200
250
Operation: Default split 50 pcs

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Insp. freq.
10
20
30
300
350
Cumulative quantity
manufactured
= SKIP
Inspection During Production - with Inspection

Points
Operation 30: Manuf. + inspect

Basket
Qty.
001
50
Basket
Qty.
002
55
Basket
Qty.
Yield
Scrap
Rework
Inspect every 50 pcs
SAP AG 1999
...
Operation 90: Inspect
003
52
47
3
2
Basket
Qty.
001
50
Basket
Qty.
002
55
Basket
Qty.
003
49
Inspection Point Settings in the Task List
Task List
Header
Operation
Characteristic
Inspection point
user fields
Default split
Time reference
Qty. reference
Freely defined
Sampling procedure
with inspection
points and
inspection frequency
Partial lot
assignment
Sample-drawing
procedure
Variant for inspection

completion
Last partial lot
assignment indicator
Partial lot quantity

indicator
SAP AG 1999
Variants for Inspection Completion
Quantity,
Quantity, valuation,
valuation, confirmation
confirmation
Quantity,
Quantity, valuation
valuation
Valuation
Valuation
Valuation
Valuation (automatic)
(automatic)
SAP AG 1999
Settings for the Inspection Point (1)

Field combinat.
Z10
Valuation
Function modules
Predefined field (dependent on insp. point type)
Field act.
Field act.
Keyword
Text length 18
Text length 10
Number length 10
Number length 3
Date
Time
Container
Shift
No. insp. points for char. summmariz.

Last inspected sample is valid
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Inspection point type

dependent on the
application (e.g. freely
defined, for phys. sample,
for equipment)
Keyword
User fields
Stored in the task list header
Freely defined inspection point
InspPt type
Fields
Inspected object: Container
You can freely

define user fields to
identify the
inspected object
Restriction of number
of sample results (for
example for performance
reasons)
For example, for "Phys.

-sample drawing until target
value reached"

Field combinat.
Z10 Inspected object: Container

InspPt type
Fields
Function modules
Valuation
Default for valuating inspection point
Plant
0001 Selected set
03
Default when all chars are accepted
Code
Code group
03
Default when at least one char. is rejected
Code
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Code group
03

Field combinat.
InspPt type
Fields
Z10 Inspected object: Container

Valuation
Name of the function module
Function modules
User-defined function modules for inspection point processing

QAPP_CUST_IP_CREATE
Use func module
Automatic creation of inspection points and partial lots
QAPP_CUST_IP_PROPOSAL
Activation of the function

module
Use func module
Proposal of user fields in results recording
QAPP_CUST_IP_CHECK
Use func module
Verification of user fields in results recording
QAPP_CUST_IP_F4
List of user fields in input help for results recording
SAP AG 1999
Use func module
Function module
documentation
Inspection During Production - with Batches
Operation 30: Manuf. + inspect

Basket 001
Qty.
50
Ptl. lot
1
Basket 002
Qty.
55
Ptl. lot
1
...
Basket 003
Qty.
52
Ptl. lot
2
Operation 90: Inspect

Basket 001
Qty.
50
Ptl. lot
1
Basket 002
Qty.
55
Ptl. lot
1
Basket 003
Qty.
49
Ptl. lot
2
Ptl. lot 2
Batch 2
Ptl. lot 1
Batch 1
Inspect every 50 pcs
Ptl. lot = Partial lot
SAP AG 1999
Ptl. lot 2
Batch 2
SPC

SAP AG 1999
SPC: Objectives

Name the control charts in the SAP System
Plan an SPC characteristic
Display and process a control chart
Make settings for control charts in Customizing
SAP AG 1999
SPC: Business Scenario
You manufacture shafts using PP orders. To monitor the

process, the length of five shafts in each wire basket is
to be inspected after the 'lathe' operation. The mean
value and standard deviation for the samples are to be
displayed in a control chart.
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Statistical Process Control (SPC)
Control charts
Process capability
Results history
Histogram
Run-chart
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Mean value
Control Charts
Time
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Control Charts
Mean value
Specific influence
General influence
Time
SAP AG 1999
Control Charts
Mean value
Specific influence
General influence
Time
SAP AG 1999
Control Charts
Mean value
Specific influence
General influence
Process change
Time
SAP AG 1999
Control Charts
The control chart is a graphical tool that helps you to differentiate

systematic changes in a quality characteristic from random
fluctuations.
Mean value
Specific influence
General influence
Process change
Time
SAP AG 1999
Control Chart Types
Quantitative characteristics
Mean value chart with consideration of tolerance (acceptance chart)
Mean value chart without consideration of tolerance (Shewhart chart)
Standard deviation chart (Shewhart chart)
Moving average chart
EWMA chart (for mean values with exponential weighting)
Original value and moving range chart for sample size n = 1
Qualitative characteristics
np-chart for the number of nonconforming units
p-chart for the fraction of nonconforming units
c-chart for the number of defects
u-chart for the number of defects in each sample unit
SAP AG 1999
Planning Control Charts
Sampling procedure
Control chart type
Valuation mode
Inspection Characteristic in
Task List
Control indicator
Sampling procedure
SPC criterion
You use the SPC
criterion to plan the
number of control charts
for a characteristic
SAP AG 1999
[Codes for automatic defects

recording]
SPC Criteria
Task List Characteristic
Task list characteristic
Task list characteristic/material
Task list characteristic/inspection lot
Task list characteristic/material/work center
...
Task list characteristic/equipment, functional location
Master Inspection Characteristic
Master inspection characteristic
Master inspection characteristic/material
Master inspection characteristic/equipment, functional location
SAP AG 1999
Using Control Charts
Transactions
Results recording
Control charts for inspection lots
Control charts for task list characteristic
Control charts for master inspection characteristic
Functions
Calculating action limits
Defining action limits
Valuating samples
Closing control charts
Setting color/legend options for OCX graphics
SAP AG 1999
Customizing for Control Charts

Control Charts
You can define your own control chart types
Simulation of control charts
Definition of reference axis (time/object)
Definition of number of samples for each dialog box (in

modal display only)
Control Chart Tracks
You can add new tracks
Formulas and parameters for calculating the action limits can

be changed using function modules
Hide or show tolerance limits
Make settings to manually change control limits
SAP AG 1999
Insp. lot
2306
SAP AG 1999
Insp. lot
2306
SAP AG 1999
Insp. lot
2306
SAP AG 1999
Insp. lot
2306
SAP AG 1999
Insp. lot
2501
Insp. lot
2583
Insp. lot
2306
SAP AG 1999
Insp. lot
2501
Insp. lot
2583
Insp. lot
2644
Insp. lot
2306
Insp. lot
2501
SAP AG 1999
Insp. lot
2583
Defects recording
Insp. lot
2644
Process Capability
Cpk = 0.87
SAP AG 1999
Results History
Results history
Results
5001
4651
4610
Process capability
indices
Single value list

...
...
Cpk = 1.23
...
MS Excel
Run-chart
18
16
14
12
Histogram
22:15 23:00 23:35 00:05
SAP AG 1999
...
QM-STI statistical
evaluations

SAP AG 1999
Integration of the QM and PP Components:

Objectives

Describe the integration of the QM and PP components
Send confirmations to the PP component directly from
the results recording function and forward inspected

quantities to goods receipt
Control the release of follow-up operations from QM
Trigger rework for an operation from QM and plan a
quality inspection for this rework
SAP AG 1999
Integration of the QM and PP Components:

Business Scenario
You manufacture shafts using PP orders. The costs

incurred in production and in the quality inspection are
to be recorded and valuated.
The 'spray paint' operation is only to be released for
processing, once the previous operation has been
inspected.
If rework is required, this is to be planned as an

additional operation.
SAP AG 1999
Features of the Integration

Quality Management
Planning
Task list types, authorization
Processing
Order types
Quality inspections during production
Quality inspections for external processing
Quality inspections for the withdrawal of components
Confirmation of activities, times ...
Trigger points
Co-products
Quantity proposal at goods receipt for the order
Quality inspections at goods receipt
Other
Material requirements planning
SAP AG 1999
Production Planning
Confirmations
Time ticket confirmations for the operation

Confirmation* from within
Results recording
Quantities, activities, dates ...
Inspection point processing
Quantities, target costs (in background)

Quantities, activities, dates ...
Check whether characteristic results exist, when

confirmations are made in PP
* Incl. retrograde withdrawals and automatic GR

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Trigger Points
Are assigned to the operation in the routing

or in the production order
Functions
Adding a reference operation set
Creating an order
Triggering a Workflow
Releasing operations
Controlled by status changes
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Co-Products
Co-products are basic materials that are

created together with other basic materials in
a joint process.
Their material number differs from that of the
production material.
Inspection points/partial lot processing allow
you to represent co-products in the QM
component.
These materials are taken into consideration at

automatic batch classification from QM and at
certificate creation.
SAP AG 1999
Inspection During Production:

Summary
You can now describe the various types of
inspections during production.

You can use control charts to monitor your
processes.
You can describe the integration of the QM
and PP components
SAP AG 1999
Data for the Exercises
Inspection During Production: Exercises

Unit: Inspection During Production
Inspection During Production: SolutionsUnit: Inspection During

Production
Topic: Defects Recording for an Order
Contents:
Processing and Features of Quality Management Tasks

in Repetitive Manufacturing
SAP AG 1999
QM in Repetitive Manufacturing: Unit Objectives
At the conclusion of this unit, you will be able to:

Create inspection lots for production versions
Explain features of quality management used in

repetitive manufacturing
SAP AG 1999
Introduction
External Processing of Operations
SAP AG 1999
QM in Repetitive Manufacturing: Business

Scenario
You manufacture personal computers using
repetitive manufacturing.
Inspections during production are performed at
regular intervals.
SAP AG 1999
Inspection Lot Monitor (1)
Create
New
production version
for material 4713
SAP AG 1999
Inspection Lot Monitor (2)

Create
New
production
version
for material 4713
Monitor
Create insp. lot
Material
Plant
Production version
Valid from
4711
1
4712
4713
1
SAP AG 1999
0001
09.24.1999
0001
0001
Material description
Valid to
Can type A
12.31.2001
QM active Insp. lots
Insp. lot no. UD

12000013
Can type B
Can type C
4714
1
0001
03.19.1999
Can type D
12.31.2000
12000014
04.06.1999
12.31.2004
12000015
QM in Repetitive Manufacturing: Process
Insp. lot
4711
New
operation
Insp. lot
4712
Tolerance
change
Production version
Current inspection lot 4713
Inspection Lot Overview

No.
Material
4711 Shaft
4712 ...
4713 ...
...
SAP AG 1999
...
Insp. lot
4713
QM in Repetitive Manufacturing: Unit Summary
In repetitive manufacturing, an inspection lot is

created for a production version.
A monitor is available (transaction MFPR) to
monitor and create inspection lots for a
production version.
If the usage decision has been made for an

inspection lot for a production version, a new
inspection lot can be created for the same
production version. This allows changes to task
list data to be included in an inspection that is in
progress.
SAP AG 1999
QM in Repetitive Manufacturing: Exercises

Unit: QM in Repetitive Manufacturing
QM in Repetitive Manufacturing: Solutions

Unit: QM in Repetitive Manufacturing
Contents:
Master Data
Calibration Planning
Calibration Processing
SAP AG 1999
Test Equipment Management: Unit Objectives

Manage test equipment as master data
Maintain the master data required for calibration
Schedule the calibration
Perform a calibration inspection and analyze

results of previous inspections, if test
equipment is rejected
SAP AG 1999
Course Overview
SAP AG 1999
Test Equipment Management: Business Scenario
You use test equipment in your quality inspection.
This test equipment is managed as a master data

record and calibrated at regular intervals (annually).
SAP AG 1999
PM/QM Integration
Test equipment
management
Quality Management
Equipment
(calibration inspection)
Funct. Locs
Plant Maintenance
SAP AG 1999
Maintenance inspection
(extended recording of
measurement readings
in PM)
Test Equipment Types in R/3
Material
Document
Material
Production
resources/tools
Equipment
PRT master
Inclusion in
task list
SAP AG 1999
Test Equipment Management Functions
QM
Master data
Calibration inspection
(planning)
Calibration inspection
(processing)
SAP AG 1999
Calibration Inspection Planning (1)
Planning
Planning
Create
Create
equipment
equipment master
master record
record
A/101
SAP AG 1999
A/102
A/103
Calibration Inspection Planning (2)
Planning
Planning
Create
Create
equipment
equipment master
master record
record
A/101
A/102
A/103
Define maintenance
strategy
Define
Define maintenance
maintenance task
task list
list
OP.10 Calibrate
Create
Create (master)
(master)
inspection
inspection characteristics
characteristics
Zero-point deviation
General appearance
SAP AG 1999
General appearance
Calibration Inspection Planning
Planning
Planning
Create
Create
equipment
equipment master
master record
record
A/101
A/102
A/103
Define maintenance
strategy
Define
Define maintenance
maintenance task
task list
list
OP.10 Calibrate
Create
Create (master)
(master)
inspection
inspection characteristics
characteristics
General appearance
General appearance
Create
Create maintenance
maintenance plan
plan
Scheduling
30
SAP AG 1999
Test equipment list

101
102
103
Calibration Inspection Processing
Inspection
Inspection lot
lot
creation
creation
Schedule
Schedule maintenance
maintenance plan
plan
By automatic batch program

Manually
SAP AG 1999
Inspection
Inspection lot
lot
creation
creation
Schedule
maintenance plan
plan
Manually
Maintenance
Maintenance order
order is
is created
created
and
released
and released
SAP AG 1999
Inspection
Inspection lot
lot
creation
creation
Schedule
maintenance plan
plan
Manually
Inspection
Inspection lot
lot is
is created
created
Test
Test equipment
equipment list
list
Maintenance
Maintenance order
order is
is created
created
and
released
and released
Insp. lot 35 Balance A
A/101
SAP AG 1999
A/102
A/103
Processing
Processing
Results
Results recording
recording
Op.10 Calibrate
Balance A/101
Gen. appearance
Balance A/102
Op. 20 Calibrate
SAP AG 1999
Processing
Processing
Results
Results recording
recording
Op.10 Calibrate
Balance A/101
Gen. appearance
Balance A/102
Op. 20 Calibrate
SAP AG 1999
Process maintenance order

Time recording
Costs recording
Required materials
Processing
Processing
Results
Results recording
recording
Process maintenance order

Time recording
Costs recording
Required materials

Op.10 Calibrate
Balance A/101
Gen. appearance
Make
Make usage
usage decision
decision
Balance A/102
Follow-up actions
are implemented
Op. 20 Calibrate
SAP AG 1999
Change equip. status

Order technically completed
automat.
Change
cycleBatchprogramm
modification factor
Manuell
(Update measurement docs)
Customer def. follow-up actions
Results History for Equipment/Functional Location
Past
Past
Future
Future
Results history
Charac. 10/Equipment 4711
Trend
Charac. 10/Equipment 4711
Result
Result
Inspection lots
Time
SAP AG 1999
Test Equipment Tracking (1)

In which inspections
was balance 4711-1 used?
Material 4711 'Balance'
Balance 4711-1
SAP AG 1999
Balance 4711-2


Balance 4711-1
Balance 4711-2
Usage list
4711-1
Usage list
4711-2
Period
Usage site
Period
Usage site
01.01.-03.17.
Center A
01.01.-03.28.
Center C
04.01.-07.31.
Center B
04.03.-07.31.
Center D
08.01.-08.18.
Calibration
station
08.02.-08.14.
Calibration
station
08.19.-12.31.
Center A
08.17.-12.31.
Center D
SAP AG 1999

Zero-point
deviation A
Balance 4711-1
Balance 4711-2
Usage list
4711-1
Usage list
4711-2
Period
Usage site
Period
Usage site
01.01.-03.17.
Center A
01.01.-03.28.
Center C
04.01.-07.31.
Center B
04.03.-07.31.
Center D
08.01.-08.18.
Calibration
station
08.02.-08.14.
Calibration
station
08.19.-12.31.
Center A
08.17.-12.31.
Center D
SAP AG 1999
Inspection Plan/Routing
1
Zero-point
deviation B
Characteristic 30,
Characteristic 10,
test equipment
test equipment
(PRT) 4711
(PRT) 4711

Zero-point
deviation A

Balance 4711-1
Usage list
4711-1
Balance 4711-2
Zero-point
deviation B
Characteristic 30,
Characteristic 10,
test equipment
test equipment
(PRT) 4711
(PRT) 4711
Usage list
4711-2
Period
Usage site
Period
Usage site
01.01.-03.17.
Center A
01.01.-03.28.
Center C
04.01.-07.31.
Center B
04.03.-07.31.
Center D
08.01.-08.18.
Calibration
station
08.02.-08.14.
Calibration
station
08.19.-12.31.
Center A
08.17.-12.31.
Center D
Insp. lot
Where-Used List 4711
Period
Insp. lot Work center
01.01.-01.05.
100001
01.10.-01.13.
100010
01.15.-01.20.
100015
....
SAP AG 1999
03.31.-04.10.
120011
04.04.-04.10.
120020
Test Equipment Tracking

Zero-point
deviation A

Balance 4711-1
Balance 4711-2
Usage list
4711-1
Usage site
Period
Usage site
01.01.-03.17.
Center A
01.01.-03.28.
Center C
04.01.-07.31.
Center B
04.03.-07.31.
Center D
08.01.-08.18.
Calibration
station
08.02.-08.14.
Calibration
station
08.19.-12.31.
Center A
08.17.-12.31.
Center D
Test Equip. Tracking: Balance 4711-1

Characteristic
Period
10001
Zero-point deviation A
12011
Zero-point deviation B
....
SAP AG 1999
Zero-point
deviation B
Characteristic 30,
Characteristic 10,
test equipment
test equipment
(PRT) 4711
(PRT) 4711
Usage list
4711-2
Period
Insp. lot
Inspection
lot
Where-Used List 4711
Period
Insp. lot Work center
01.01.-01.05.
100001
01.10.-01.13.
100010
01.15.-01.20.
100015
....
03.31.-04.10.
120011
04.04.-04.10.
120020
Equipment Master Record

Location A
Equipment usage
Location B
Classification
Equipment Master Record

General data
Location data
Maintenance
data
Serialization data
Configuration
Documents/
technical drawings
Multilingual texts
Partner/address
Measuring points
Approvals
Internal note
SAP AG 1999
0471
0123
Structure of Preventive Maintenance
Maintenance plan
Scheduling
Scheduling
parameters
parameters
Maintenance
strategy/cycle
Maintenance items
Equipment no.
12345
Maintenance
task list
SAP AG 1999
Preview of due dates

03.08.97
03.10.97
03.12.97
30
Maintenance orders
Maintenance Strategies
Strategy A
Strategy B
P1
Monthly
P1
1000 readings
P2
Semiannually
P2
2000 readings
P3
Every 2 years
P3
3000 readings
SAP AG 1999
Maintenance Plan
Time-based
MO
TU WE TH
FR
SA SU
1
8
15
21
28
2
9
16
22
29
5
12
19
25
6
13
20
26
3
10
17
23
30
4
11
18
24
31
7
14
21
27
W/OUT Maintenance Strategy
Time-based
single cycle
Performance-based
single cycle
Performance-based
Counter reading: 5000
Measuring points
(counters)
SAP AG 1999
Multiple counter plans
WITH Maintenance Strategy
Inspection Characteristics in the Maintenance Task

List
Structure of
Maintenance Task List
Task list header
Status
REL
Inspection points 510
Operation 0010 Calibration insp.
Text:
Work center PMC05
Target value:
0010
0020
SAP AG 1999
0
Upper tolerance:
0.01
Lower tolerance:
- 0.01
Surface
Suboperation
Char. 0020
No inspection
characteristics
Inspection Lots for Origin 14
Assignment
Insp. type - order type
Default values
for
inspection type
Number ranges for

inspection lot origin 14
Insp. type
identification
of type 1 or 2
Order
release
System
prerequisite
UD code with
follow-up action
Insp. point identification

in task list header
Worklist user
variants
Sampling
procedure
for PM
SAP AG 1999
Assignment of
maintenance task
list to order
Default for insp.

point valuation
Maint. order type:
Release immediately
Test Equipment Management: Unit Summary
You know how the inclusion of inspection processing
in PM procedures forms the basis for test equipment

management.
You are familiar with the inspection processing
functions for equipment and functional locations.

You can use the maintenance task list and
maintenance plan for processing calibration

inspections.
You are familiar with time-based or performance-based
planning of the maintenance cycles.

You can describe the evaluations and system settings
for a calibration inspection.
SAP AG 1999
Test Equipment Management: Exercises

Unit: Test Equipment ManagementAt the conclusion of this
exercise, you will be able to
Test Equipment Management: Solutions

Unit: Test Equipment Management
Contents:
Planning and Processing a Quality Inspection
for Externally Processed Operations in an Order
SAP AG 1999
Quality Inspection for External Processing: Unit

Objectives

Plan externally processed operations for quality
inspection
Implement quality inspections for external

processing
SAP AG 1999
Introduction
SAP AG 1999
Quality Inspection for External Processing:

Business Scenario
You manufacture shafts using PP orders.

The shafts have to be sprayed. Since your company
does not have its own paint shop, you commission
a vendor to perform the 'spray paint' operation.
When the goods are received, the shade of the paint
is to be inspected.
SAP AG 1999
Production
: order
Materials Management
4713
Material : Shaft
Purchase requisition
Quantity : 1000
Op.
Short text
Control key
10
Lathe
PP01
20
Inspect
PP04
30
Spray (external)
PP02
40
Assemble
PP01
...
...
Purchase order
Goods receipt
Insp. lot : 4712

Material : Shaft
Quantity : 500
SAP AG 1999
Prerequisites and Features
Prerequisites
An inspection type is defined on the external processing screen for

the operation.
The inspection type is active for the finished product in the order.
Features
The inspection type can be defined on the external data screen in the
routing, and can then be copied automatically into the order.
The inspection type belongs to origin 01 (goods receipt).
Inspection plan selection takes place using the inspection type.
Evaluations can be made at inspection type level.
SAP AG 1999
Quality Inspection for External Processing: Unit

Summary
Operations in an order can be externally processed
by vendors. Processing (purchase requisition,

purchase order, goods receipt) takes place in MM
with the material number '0'.
If you want to inspect externally-processed goods,
you can enter an inspection type for origin 01 in the

operation of the task list or order. In the inspection
lot, the material number '0' is then replaced by the
material number for the finished product (from the
order).
The inspection lot that is created is not relevant for
stock.
SAP AG 1999
Quality Inspection for External Processing: Exercises

Unit: Quality Inspection for External Processing
Quality Inspection for External Processing: Solutions

Unit: Quality Inspection for External Processing
Contents:
Planning and Implementing a Quality Inspection
at Goods Receipt for an Order.

Postings to Inspection Stock
SAP AG 1999
Inspection at the End of the Production Process:

Unit Objectives

Activate material for a quality inspection, when
goods produced for an order are received
Process inspection lots from this goods receipt
Control stock using these inspection lots
SAP AG 1999
Introduction
SAP AG 1999

Business Scenario
You manufacture shafts using PP orders. You want

the goods produced for these orders to be posted to
inspection stock and to be inspected. After the
quality inspection, the stock is to be released,
posted to scrap, or submitted for rework.
SAP AG 1999
Quality Inspection Options for Orders
Quality Inspection at Goods Receipt for an Order
Early Goods Receipt Inspection
SAP AG 1999
Types of Inspection at the End of the Production

Process
Quality inspection as final operation of an order

(Origin 03)
Quality inspection, when goods produced for an order are

received
(Origin 04)
Early goods receipt lots

(Origin 04)
SAP AG 1999
Quality Inspection at Goods Receipt for Order
Insp.
Insp.
plan
plan
Material
Unrestr. use
stock?
QM data
Insp. type 04 active
1234
Production
Usage decision
Results recording
Warehouse
receipt
Insp. stock?
Insp. lot
4711
SAP AG 1999
1234
1234
X
96
1750
Posting to Inspection Stock
Setting
Settingthe
thecontrol
controlindicators
indicators
In
Inmaterial
materialmaster
master
Order
In
Inorder
order
At
Atwarehouse
warehousereceipt
receipt
Warehouse
receipt
SAP AG 1999
A Insp. type 04
or
B E.g. op. view
A Insp. type 04
or
B Proposal
A Insp. type 04
or
B Proposal
Quality Inspection Options for Orders
Quality Inspection at Goods Receipt for an Order
SAP AG 1999
Order
creation
Order
release
Release
GR posting
Stock in
quality inspection
Routing
Insp. lot
Origin 04
Insp. lot
SAP AG 1999
Results
recording
Usage decision
Unrestricted-use
stock
Comparison: Origin 03 - Origin 04

Feature/Function
Separate planning
Dynamic modification
Stock-relevant
Inspection points
Partial lots
Batch
classification
Direct link
inspection lot - order
SAP AG 1999
Origin 03
Origin 04
(early inspection lot)

Unit Summary
Inspections at the end of the production process can
take place using:

An operation in the order (origin 03)
An inspection lot (origin 04) that is created by the goods
receipt posting for the order

Inspection lots with origin 04 can be relevant for
stock. This allows you to control goods receipt stock

with the QM component.
Early GR lots (origin 04) can be created when the
order is released, and can run in parallel to

inspection lots during production (origin 03).
SAP AG 1999
Inspection at the End of the Production Process: Exercises

Unit: Inspection at the End of the Production Process
Inspection at the End of the Production Process: Solutions

Unit: Inspection at the End of the Production Process
Contents:
Description of QM-Specific Features, Dependent on
Manufacturing Type or Inspection Lot Origin
SAP AG 1999
Comparison of Manufacturing Types: Unit

Objectives
At the conclusion of this unit, you will be able to

describe the effect on the QM component when
you choose a certain order category in PP.
SAP AG 1999
Introduction
SAP AG 1999
Quality Inspection in an Order Environment (1)

Discrete Manufact. Repetitive Manufact.
Process Manufact.
Inspection lot origin
03 / 04*
13
03 / 04*
Task list types
N / Q*
2 / Q*
No. of insp. lots
N**
Stock
No/Yes*
No
No/Yes*
Approval
No/Yes*
No
Yes/Yes*
Insp. point/Ptl. lots
Yes-Yes/Yes-No*
Yes-Yes
Yes-Yes/Yes-No*
Insp. pt. completion
0,1,2,3 / 2*,3*
0,1,2,3
0,1,2,3 / 2*,3*
Worklist
QE51n
QE51n
QE51n
PI sheet
No
No
Yes/No*
Confirmation
Time ticket/
QM order*
Reporting point
Time ticket/
QM order*
*Early GR 04 lots; ** Only one inspection lot may be in process at any one time.
SAP AG 1999
Quality Inspection in an Order Environment (2)

GR for Order
Plant Maintenance
Task list types
E, T, A
Inspection lot origin
04
14
No. of insp. lots
1 or n
Stock
Yes
No
Approval
Yes
Insp. point/Ptl. lots
Yes/No
(Equip., funct. location)/No
Insp. pt. completion
2, 3
2, 3
Worklist
QE51n/QE52*
QE51n/QE53/QE54
PI sheet
No
Confirmation
QM order
*Sample management
SAP AG 1999
No
No
Time ticket
Comparison of Manufacturing Types: Unit Summary
The selection of an order category in PP affects the
way it is processed in QM.
SAP AG 1999

LO720 - QM in Discrete and Repetitive Manufacturing

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LO720 QM in Discrete and Repetitive

QM in Discrete and Repetitive

Copyright 2001 SAP AG. All rights reserved.

All rights reserved.

Quality Management (QM)

LO050 - Planning & Execution for Discrete and

LO705 - Quality Inspections

Project leaders and members of the project team, who

Course Overview Diagram

This course deals with:

(production orders, run schedule headers,

At the conclusion of this course, you will be

based on different manufacturing types

and an inspection at the end of the production

Plan and perform a calibration inspection

Quality Inspection for

Inspection at the End of

Course Overview Diagram (1)

Comparison of Manufacturing Types

Inspection During Production

Inspection During Production: Unit Objectives

At the conclusion of this unit, you will be

Describe the integration of the QM and PP

Course Overview Diagram (2)

Inspection During Production

Comparison of Manufacturing Types

Defects Recording for an Order

Defects Recording for an Order

Results Recording by Characteristic for an Order

Inspection Point Processing

Integration of the QM and PP Components

Defects Recording for an Order: Objectives

At the conclusion of this topic, you will be able to:

Defects Recording for an Order: Business Scenario

You manufacture shafts using PP orders. You

Inspection During Production

Integrating insp. planning/production operations

Integrating order processing

Processing internal problem notifications

Inspection Lot Origins in Production (1)

Inspection Lot Origins in Production (2)

Inspection lot origin 03 / 13

Inspection lot origin 04

Inspection lot origin 14

Integration in the Production Process (1.1)

Integration in the Production Process (1.2)

Integration in the Production Process (1.3)

Integration in the Production Process (1.4)

For inspection lot

Integration in the Production Process (1.5)

For inspection lot

Integration in the Production Process (1)

For inspection lot

Prerequisites for Inspection During Production

Other master data

Inspection type for

Recording inspection results

Automatic Usage Decision

Results Recording by Characteristic for an Order

Defects Recording for an Order

Inspection Point Processing

Integration of the QM and PP Components

Results Recording by Characteristic for an Order: