Control Plan

CAPGEMINI

CONTROL PLAN SAP Help rrupak 2/27/2014

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Contents

CONTROL PLAN  ....................................................................................................................................... 3 CONTROLLING THE PRODUCTION PROCESS USING THE CONTROL PLAN  ......................... 7  ACCESSING  ACCESSING A CONTROL CONTROL PLAN OR FMEA FROM A QUALITY NOTIFICATION NOTIFICATION  ........................ 9 EDITING THE CONTROL PLAN   ........................................................................................................... 11  ASSIGNMENT  ASSIGNMENT OF A PROJECT PROJECT NUMBER NUMBER IN THE CONTROL CONTROL PLAN ........................................... 13 COPYING FMEA INTO A CONTROL PLAN   ....................................................................................... 15 COPYING CHARACTERISTICS  ........................................................................................................... 17 PERFORMING A CONSISTENCY CHECK  ......................................................................................... 21 CREATING A TASK LIST OR INSPECTION PLAN USING THE CONTROL PLAN  .................... 23 CHANGE TASK LIST OR INSPECTION PLAN BASED ON CONTROL PLAN  ............................ 25

CONTROL PLAN The control plan (CP) describes how products and processes are monitored. It contains actions that are executed for each phase of the process. In addition, the requirements for goods entry and goods issue inspections, for process controls, and for recurring inspections and controls are stored in the control plan so that the process can be controlled. The Control Plan contains tasks for inspecting and monitoring products and processes during product development. These tasks cover goods receipt, goods issue, process requirements, and periodic receivables for the inspection and for monitoring. Together with the FMEA, the control plan provides an overview of the critical characteristics that are included in all relevant inspections for an end product. This also includes all product components contained in the end product. Control plans can be created with or without a material. They are used in three production phases. The following control plan types are provided for each phase. These are defined in Customizing: 

Prototype



Pre-launch



Production

Structure The control plan comprises of a control plan header and a processing and display field that is operated via the tab page.

Control plan screen areas Control plan header  The control plan ID and the language is displayed in the control plan header. Tab pages and processing or display fields The following table gives an overview of the individual tab pages and the corresponding processing or display fields: Tab

Processing or display fields

Basic data All of the basic data defined for a control plan is visible at a glance, for example, short text, project number, material and system status. You can select the data using the mouse, or you can open the input help and process it here.

Tab

Processing or display fields

Long text

You can create a long text from the control plan to give more details.

Partners

You can choose business partners and their specific role for the control plan.

Structure

All of the objects that belong to the control plan are displayed. You can expand the structure. The last level expanded can be a recursive object. Note In Customizing, you can use the structure type defined with the control plan type to define flexible assignment of various master data. The master data is linked using processes. End of the note. You can copy the characteristics from here.

(Control  A piece list is normally not available in the “Prototype” production plan items) phase. You can define control plan items for the product component and process these items, without having to set up material numbers. Note You must always assign process types to a control plan item. If this assignment is missing, the control plan item is process-dependent and is listed in the structure of all processes. End of the note. FMEA

An overview of all the FMEAs that are assigned to the control plan is displayed. Two status displays are available: 



 A traffic light status shows whether the control plan contains all FMEA characteristics.  A further traffic light status shows whether the lower-level FMEAs are referenced in the control plan.

You can branch to the FMEA from the display field. Print preview

In the print preview, you can display and print the control plan as a PDF-based print form, according to the international standard QS 9000.

Integration The control plan is integrated with the following components: 

Failure Mode and Effects Analysis (QM-PT-FA) You can copy a FMEA and all its lower-level FMEAs into a control plan. You can also switch between the control plan display and the FMEA display for processing or adjusting FMEAs. For more information, see Copying an FMEA into a Control Plan .



Task lists (PP-BD-RTG) and inspection plans in inspection planning (QMPT-IP): You can create and change task lists and inspection plans based on the control plan. For more information, see Creating a Task List or Inspection Plan based on the Control Plan or Changing a Task List or Inspection Plan based on the Control Plan .



Quality Notification (QM-QN) You can branch to the corresponding control plan or FMEA from a quality notification and back. Here you can carry out inspections or make adjustments. For more information, see Accessing a Control Plan or FMEA from a Quality Notification.

CONTROLLING THE PRODUCTION PROCESS USING THE CONTROL PLAN This process provides an overview of the way in which you implement the control plan as part of the processes in a comprehensive inspection plan.  A control plan is created in different production phases; from the prototype phase to prelaunch and production. You can access a control plan in every phase of this process, and you can adjust it as required. Prerequisites You have assigned the control plan to a project. Failure Mode and Effects Analyses (QM-PT-FA) are already determined. Process 1. An expert team in your organization conducts a Failure Mode and Effects  Analsyis. The team determines critical characteristics for the product that indicate a high risk of defects. They specify relevant actions to avoid these defects. 2. You use the control plan to create new task lists or inspection plans, or suitable task lists or inspection plans that you can asign in the control plan already exist in the system. 3. You copy the characteristics identified in the FMEA to a control plan. The integration of the FMEA and the control plan in the SAP ERP Central Component enables you to link objects directly from other processes, such as, materials, BOMs, quality notifications or task lists. 4. You check the status of the FMEA characteristic. This is displayed in the traffic light status. Finally, you use a consistency check to see whether the control plan (relevant inspection plans and task lists) contains the characteristics.

5. You can start production of a new product in the prototype phase, or in the prelauch or production phases. The control plan ensures that all of the inspections required for the identified characteristic are carried out. Comprehensive inspection planning is still adhered to, since new results from customer complaints or problem messages can be compared and checked with the preventive actions previously defined. If a characteristic needs to be changed, adjust the control plan to match the new result status. Result You have copied the results of the Failure Mode and Effects Analysis (FMEA) into the control plan. You have then checked these results, and, if necessary, included customer complaints. You have created a basis for optimizing your production processes. You can close the “Prototype” or “Prelauch” phase and move to the next production phase.

ACCESSING A CONTROL PLAN OR FMEA FROM A QUALITY NOTIFICATION You can access a control plan (CP) or a Failure Mode and Effects Analysis (FMEA) from a quality notification. This means that you can branch directly to a control plan or FMEA when you receive a problem message, for example, a customer complaint, where a certain material is affected. For example, you can check whether a probable defect has already been identified, and make adjustments as required. Prerequisites You have performed the following IMG activities in Customizing, under Management  Quality Notification Notification Processing   Additional Notification Functions Define Action Box  . 

Quality

You have maintained the following activities for the notification type (for example, Q3), under Define Functions for the Action Box : o

o

Control Plans for Material (SAP function module QMQP_ND_FIND_CPLAN) FMEAs for Material (SAP function module QMQP_ND_FIND_FMEA)

You have specified a quality notification for a notification type (for example, Q3). Procedure 1. Call up the quality notification for the notification type in the following way: On the SAP Easy Access Screen, choose Logistics Quality Management  Quality Notification Display  . The system displays the initial screen for the quality notification. 2. In the Activity Box  screen area, you can select and display control plans or FMEAs for the material.

o

To choose a control plan, select Control Plans for Material .  A dialog box for restricting the value range appears.

o

To choose an FMEA, select FMEA for Material . The selection screen for the FMEA monitor appears.

3. Select one of the following steps for the Control Plan or FMEA: o

Control Plan: The material affected and the plant are displayed in the dialog box. Choose (Start Search). The control plans for the material and the plant are displayed in a list.

o

FMEA: The material that is affected is displayed as an FMEA object on the selection screen for the FMEA monitor. The default FMEA type is System FMEA Product . Choose

(Execute).

The FMEAs for the material are displayed in a list. 4. To select a control plan or FMEA, double click on it in the list. Result You branched from a quality notification to a certain material when processing a control plan or FMEA. You can now make changes to the inspection data in a control plan or in an FMEA. For example, you can include new characteristics.

EDITING THE CONTROL PLAN The following options are available for editing a control plan (CP): Depending on the employee's role in company, you can allocate different authorizations for editing a control plan. The following table contains a summary of the functions for editing control plans. Procedure To call the individual functions in the table, on the SAP Easy Access screen, choose Logistics Quality Management  Quality Planning  Control Plan Cockpit  . Function

Icon

Additional Information

Create control Choose To create a control plan, specify an ID for the plan (Create control plan in the Control Plan input help. Use the Control Plan). input help to choose, for example, a Plan Type. Create inspection plan with template

Choose (Create With Template).

To create a control plan with a template, specify an ID for the control plan in the Control Plan data field. Use the input help in the Template field to to choose, for example, a template. You can also select a Plan Type.

Change control plan

Choose To change a control plan, enter the control plan ID (Change in the Control Plan field. Control Plan).

Display control Choose To display a control plan, enter the control plan ID plan (Display in the Control Plan field. Control Plan). Simulate control plan

Choose This function is provided so that certain user (Simulate groups can test the control plan functions by Control Plan). creating and changing a control plan without

Function

Icon

Additional Information needing authorization. Choose the required plan type in the Plan Type input field. You can use the input help to help you. Caution The data that you enter is only intended for test purposes. The system does not save any data in the simulation mode.

ASSIGNMENT OF A PROJECT NUMBER IN THE CONTROL PLAN You can assign an external project number to the control plan (CP) in your system. If the connection to cProjects is set up in Customizing, you can call SAP Collaboration Projects (cProjects) to display projects and to call up the input help for the project number. Note End of the note. You can only link your cProjects project to a control plan using an object link. For more information, see Creating an Object Link. Recommendation We recommend that you use the control plan from the ERP system to make sure that inspection planning is integrated in the Advanced Product Quality Planning (APQP). The control plan provides integration in the relevant master data for logistics. Alternatively, you can use the “Control Plan” available in cProjects. However, the functions in this control plan are limited. End of the recommendation. Prerequisites You have created a project with a project number in cProjects. Features In the control plan screen area on the Basic Data tab page, you can use the Project Number  input field. You can use the input help to select the desired project from cProjects. Note

You can enter a project from another project management system in the Project Number  input field.

COPYING FMEA INTO A CONTROL PLAN You can copy a Failure Mode and Effects Analysis (FMEA) into the control plan (CP). The system checks in the control plan, to see whether all FMEA characteristics from the copied FMEA and all subordinate FMEAs are completely copied. Procedure 1. Choose the FMEA tab page in the edit mode for the control plan. You can choose new FMEAs from a table, or FMEAs that you have already used are displayed. 2. Choose an empty row in the FMEA column, and use the input help to select the desired FMEA. 3. To display all lower-level FMEAs, choose

(Copy Lower-Level FMEAs).

4. The two traffic light statuses in the table indicate whether the control plan contains the FMEA characteristics and all lower-level FMEAs. If you want to branch directly to the FMEA, choose the Display FMEA column.

(Display FMEA) in

If you want to copy another FMEA, repeat steps 2 to 3. If you want to delete a FMEA from the table, select the row for the FMEA that is to be deleted and choose (Delete Row ). Result You have copied a FMEA into a control plan. You can now assign FMEA characteristics to the relevant operations in the task lists and inspection plans. For more information, see Copying Characteristics. You can also perform a consistency check to display objects that may be missing.

COPYING CHARACTERISTICS When you copy critical characteristics from a Failure Mode and Effects Analysis (FMEA) to the control plan (CP), you can link the FMEA characteristics to the inspection characteristics that belong to the corresponding inspection plans and task lists. Prerequisites 

You have assigned a task list and an inspection plan to a control plan item for the prototype phase. From the control plan, you can also create a new task list or inspection plan for a control plan item.



You have specified all of the objects (such as material, plant, key date, inspection plan or task list) that are relevant for the control plan in the prelauch and production phases. From the control plan, you can also create a new task list or inspection plan for a process.



In the task list or inspection plan, you have specified operations for which the characteristic is planned.

Note If there are not yet any operations specified in the task list or inspection plan, you can branch from the CP structure view to a task list or inspection plan. Here you can specify operations in edit mode: 1. Choose Show Plan Header  in the context menu of the task list or inspection plan. The plan header is displayed in the Engineering Workbench (EWB). 2. Switch to change mode and choose operations overview.

Plans Operations in the

3. Create the required operations. For more information, see Processing Inspection Operations. 4. Finally, choose

(Back ) to return to the CP structure display.

5. Choose

(Refresh) to update the structure display.

End of the note. Procedure 1. Choose the Structure tab page in the edit screen for the control plan. The tree structure shows an overview of all of the inspection plans that belong to the control plan. 2. Choose an inspection plan or task list by placing your cursor on the relevant symbol. 3. Choose Copy Characteristic  in the context menu of the task list or inspection plan. The system displays the screen for copying characteristics to the control plan. You see an overview of the plan structure for the task list or inspection plan. You also see a table containing FMEA characteristics and a table containing inspection characteristics. 4. Select an FMEA in the Characteristic Origin input field. Note If you want to use other characteristic origin, apart from the FMEA, you must first specify these in Customizing using the BAdI Define Characteristic Origin. You will then be able to use additional characteristic origins, which will appear in a dropdown list in the Characteristic Origin input field. End of the note. Select an FMEA in the FMEA input field. 5. Choose Load Characteristics. The FMEA characteristics are listed in the FMEA Characteristics table. 6. Choose the characteristic that you want to use from the list. In the plan structure for the operations, select the operation t hat you want to assign the characteristic to. 7. Choose

( Add Characteristic to Plan).

 Alternatively, you can use drag and drop to assign the characteristic to the desired operation in the plan structure.  A characteristic can be used multiple times for different operations. The new characteristic to be copied is displayed in the Inspection Characteristic  table. Note You can only specify new characteristics in a task list or inspection plan. You cannot process characteristics that are already in a task list or inspection plan. End of the note. 8. In the Inspection Characteristics table, enter an inspection characteristic number in the Inspection Characteristic  column. This allows you to identify the inspection characteristic in the operation. It also, for example, allows you to determine the order used for the display of the characteristics in the control plan. You can also enter additional data, such as Unit of Measure, Lower Limit Value or Upper Limit Value. 9. Check all of the copied characteristics. To do this, choose (Check Copied Characteristics). The system displays a log. This shows whether the characteristics can be copied. 10.

11.

Choose (Save Transferred Charact. and Close). The system displays a log. This shows whether the system copied and saved characteristics successfully. Finally, choose

(Back ) to return to the CP structure display.

Caution The characteristics are valid from the moment that they a re copied. If the characteristics are not displayed on the Structure tab page in the CP structure view, check the Selection Date on the Basic Data tab page, under Structure Specifications. If the selection date is after the date on which the characteristic was copied, the characteristic is displayed in the control plan structure.

Result You have copied one or more characteristics from an FMEA to the control plan. You have also assigned these characteristics to an operation in the corresponding task list or inspection plan. You can also perform a consistency check, to check whether the FMEA characteristics were considered in the corresponding inspection plans or task lists.

PERFORMING A CONSISTENCY CHECK You can use the consistency check to check whether the relevant inspection plans and task lists contain all of the characteristics from a Failure Mode and Effects Analysis (FMEA) that were assigned to a control pl an (CP). If you have assigned additional FMEAs to the FMEA for a component, this function also checks that all of the lower-level FMEAs have been copied to the control plan. Prerequisites You have assigned one or more FMEA(s) to the control plan. Procedure To perform a consistency check, proceed as follows: 1. Choose the Basic Data tab page in the control plan screen area. 2. Under Status, choose

(Consistency Check ).

In the Inspection Result  field, you can see the status together with the date and time of the consistency check. The following statuses are used: Status

Pushbutton

Additional Information

OK

Display Inspection The control plan is consistent. Result  (OK ) You can display a detailed log. To do this, choose Display Inspection Result .

Warnings Display Inspection For example, a warning notification text occurred Result  (Warning can indicate that an inspection message occurred ) characteristic from a task list or inspection plan refers to an FMEA characteristic that has been deleted. You can display a detailed log. To do this, choose Display Inspection Result .

Status

Pushbutton

Additional Information The problem class and detailed notification text are displayed for the warning.

Error occurred

Display Inspection For example, an error notification text can Result  (Error indicate that an FMEA characteristic is not occurred ) included in the control plan. You can display a detailed log. To do this, choose Display Inspection Result . The problem class and detailed notification text are displayed for the error.

3. If you see a warning or error message, make the necessary corrections. Result You have performed a consistency check and made any necessary changes to ensure that the control plan is consistent. This means that the corresponding task lists and inspection plans contain all characteristics (such as from an FMEA) that are assigned to the control plan.

CREATING A TASK LIST OR INSPECTION PLAN USING THE CONTROL PLAN From the structure display of the control plan (CP), you can create a task list or inspection plan. The following applies for the production phases described below: 

Prototype You can create new task lists or inspection plans for control plan items.

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Prelaunch/Production You can create new task lists or inspection plans for  processes.

Prerequisites 



You have not yet assigned any task lists or inspection plans to a control plan item for the Prototype phase. For the Prelauch and Production phases, you have assigned the Task List and Inspection Plan component type to the process in Customizing.

Procedure To create a task list or inspection plan in the prelauch, production, or prototype phase, proceed as follows: 1. Choose the Structure tab page in the edit mode for the control plan. 2. For the Prelaunch or Production phase, place your cursor on the symbol for a process. For the Prototype phase, place your symbol on a control  plan item. To do this, choose Create Plan in the process context menu or in the control plan item.  A dialog box appears. 3. Enter the required data for the new task list or inspection plan (for example, a short text and a plant).

4. In the CP structure display, choose display.

(Refresh) to update the structure

Note You can also assign existing task lists or inspection plans to a control plan item. To do this, choose the Items tab page in the processing screen for the control plan. Enter an item in the table. Assign a task list or inspection plan to the item. From the structure display of the control plan (CP), you can change the task list or inspection plan. End of the note. Result You have created a new task list or inspection plan. You can now process the new task list or inspection plan. For more information, see Changing a Task List or Inspection Plan based on the Control Plan .

CHANGE TASK LIST OR INSPECTION PLAN BASED ON CONTROL PLAN From the structure display for a control plan (CP), you can branch to the display mode for a task list or inspection plan. You can then switch to change mode to make the required adjustments. Procedure 1. Choose Structure in the edit mode for the control plan. 2. Place the cursor on the symbol for a task list or inspection plan. Choose Show Plan Header  in the context menu of the task list or inspection plan. This takes you to the control plan display in the Engineering Workbench (EWB). 3. Choose

(Change/Lock ) and make the required changes.

4. To return to the structure display for the control plan, choose

(Back ).