Plm420 en Col95

PLM420 Quality Management in Production SAP ERP - Operations Support

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Participant Handbook Course Version: 95 Course Duration: 3 Day(s) Material Number: 50101097

An SAP course - use it to learn, reference it for work

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About This Handbook This handbook is intended to complement the instructor-led presentation of this course, and serve as a source of reference. It is not suitable for self-study.

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About This Handbook

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Icons in Body Text The following icons are used in this handbook. Icon

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Contents Course Overview ......................................................... vii Course Goals ...........................................................vii Course Objectives .................................................... viii

Unit 1: Inspection During Production ................................. 1 Defects Recording for an Order.......................................4 Results Recording by Characteristic for an Order ................ 28 Inspection During Production  with Free Inspection Points ...... 62 Inspection During Production with Physical Samples ............ 98 Inspection During Production with Automatic Valuation of Characteristics of a Batch .......................................125 SPC – Statistical Process Control .................................156 Integration Points between Quality Management and Production.........................................................185

Unit 2: QM in Repetitive Manufacturing ........................... 203 QM in Repetitive Manufacturing ...................................204

Unit 3: Quality Inspection for External Processing ............. 215 Quality Inspection for External Processing .......................216

Unit 4: Inspection at the End of the Production Process...... 231 Quality Inspection at Goods Receipt for Order...................232 Early Goods Receipt Inspection ...................................251

Unit 5: Test Equipment Management............................... 277 Test Equipment Management ......................................278

Unit 6: Comparison of Manufacturing Types ..................... 305 Comparison of Manufacturing Types ..............................306

Appendix 1: Digital Signature

..................................... 313

Appendix 2: Approval for Inspection Plan Appendix 3: Batch record

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..................... 325

.......................................... 335


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Course Overview This course provides information on integrating Quality Management into the processes of production planning and shop floor control. Here is an explanation of QM-specific features of quality control in the environment of production orders and process orders as well as orders in the area of plant maintenance and service processing in particular. Inspections in conjunction with repetitive manufacturing as well as the required Customizing settings are also a component of this intensive course. The information in this course refers to the SAP ERP Central Component 6.0 software component, SAP Enhancement Package 5.

Target Audience This course is intended for the following audiences: • •

Project leaders and members of the project team, who have experience with tasks in quality management and production People in consulting

Course Prerequisites Required Knowledge •

SCM100 Planning ERP Overview and SCM300 Production Overview or

• •

SCM340 Process Manufacturing PLM412 Quality Planning and Inspection

Recommended Knowledge •

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Basics of logistical processes


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Course Goals This course will prepare you to: • •

• •

Understand the integration of Quality Management into the processes of production planning and shop floor control Get to know QM-specific features of a quality inspection for orders (production orders, process orders, run schedule headers, maintenance orders/calibration orders) Use the functions illustrated Be able to activate the most important settings for orders in QM processes

Course Objectives After completing this course, you will be able to: • • • • • •

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Describe the integration of Quality Management into production planning and shop floor control based on different manufacturing types Plan and perform an inspection during production and an inspection at the end of the production process Valuate batches from an inspection during production using inspection results Use control charts to monitor your processes Plan and process inspections in repetitive manufacturing Plan and carry out inspections in the environment of plant maintenance and service processing


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Unit 1 Inspection During Production Unit Overview In this chapter, we will demonstrate the quality inspections during production (in-process inspection for an order) using various processes. In addition to a simple process on a pure recording of defects for the order, processes with a one-time inspection as well as with a repeated inspection of inspection characteristics are also explained. The use of control charts in conjunction with an SPC inspection as well as integration aspects between Quality Management and the processes in production are also part of this extensive chapter. The individual lessons illustrate the respective processes using examples with a production order and process order. The inspection lots that arise belong to inspection lot origin 03 and are not stock-relevant. This chapter deals with the integration between the processes in production and those in Quality Management. The inspection specifications for the inspection during production are thus included in the standard routing of production or in the master recipe of process manufacturing.

Unit Objectives After completing this unit, you will be able to: • • • • • • • • •

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Explain the necessary settings in the material master for a quality check during production Create an inspection lot for an order Carry out defects recording using the inspection lot for the order Update the task list for production (standard routing, master recipe) with the required QM data for a quality inspection Implement an inspection results entry for an inspection lot during production Plan a multiple inspection for an operation with inspection point processing. Implement a multiple entry of inspection results for inspection characteristics in the inspection lot. Plan multiple inspections for an operation with sample management. Implement a multiple entry of inspection results for inspection characteristics of samples in the inspection lot.


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Unit 1: Inspection During Production

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Explain planning for a quality check with batch-managed materials. Implement an in-process inspection in the production of a batch-managed material. Describe the value transfer from the master inspection characteristic for the class characteristic of the batch. Explain the control chart types in the SAP system and make Customizing settings Implement an inspection planning for an SPC inspection Use the functions of the control charts in the inspection results recording Explain the most important integration points between Quality Management and Production. Send confirmations to the production or process order directly from the inspection results recording function and forward inspected quantities to goods receipt.

Unit Contents Lesson: Defects Recording for an Order .......................................4 Exercise 1: Defects Recording for the Production Order ............. 15 Exercise 2: Defects Recording for the Process Order ................. 21 Lesson: Results Recording by Characteristic for an Order................. 28 Exercise 3: Characteristic-Based Results Recording for the Production Order ........................................................... 45 Exercise 4: Characteristics-based Results Recording for the Process Order .......................................................................... 51 Lesson: Inspection During Production  with Free Inspection Points ....... 62 Exercise 5: Inspection Point Processing with a Production Order... 75 Exercise 6: Inspection Point Processing with a Process Order ...... 85 Lesson: Inspection During Production with Physical Samples ............ 98 Exercise 7: Inspection during Production with Physical Samples in Production Order .......................................................... 111 Exercise 8: Inspection during Production with Physical Samples in Process Order .............................................................. 117 Lesson: Inspection During Production with Automatic Valuation of Characteristics of a Batch......................................................125 Exercise 9: Inspection during Production with Automatic Valuation of Batch Characteristics in Process Order.................................143 Lesson: SPC – Statistical Process Control ..................................156 Exercise 10: Inspection during Production with Statistical Process Control (SPC) in Production Order......................................169 Exercise 11: Inspection during Production with Statistical Process Control (SPC) in Process Order .........................................177 Lesson: Integration Points between Quality Management and Production........................................................................185

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Exercise 12: Integration Aspects between Quality Management and Production Confirmations for the Production Order ..................189 Exercise 13: Integration Aspects between Quality Management and Production - Trigger Points for the Production Order.................195

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Lesson: Defects Recording for an Order Lesson Overview Defects recording for an order is an easy way to document problems that occur during production in the SAP system. Defects recording can be implemented using an inspection lot (inspection lot origin 03) or using a quality notification (notification origin Q3). This lesson will deal mainly with defects recording using an inspection lot for the order.

Lesson Objectives After completing this lesson, you will be able to: • • •

Explain the necessary settings in the material master for a quality check during production Create an inspection lot for an order Carry out defects recording using the inspection lot for the order

Business Example Different materials are manufactured in production with either production orders or process orders. You want a simple method of recording defects identified during production in the SAP system. It should be possible to evaluate the defects at a later stage using a defect catalog and corresponding defect codes.

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Lesson: Defects Recording for an Order

Plan and execute defects recording for the order

Figure 1: Defects Recording for an Order

Figure 2: Inspection During Production

In production, the Quality Management (QM) component provides important information about the current production quality and allows the production process to be corrected with the help of quality notifications.

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Figure 3: Inspection Lot Origins in Production (1)

Production orders are often used in discrete production (for example, in machine construction). Production versions are generally used during repetitive manufacture (for example, electronic devices). Process orders are often used in the process industry (for example, in the pharmaceutical and foodstuff industries). The inspection lot origin defines the source of the inspection lot. The inspection lot origins that are available are predefined. You can define an inspection type for each inspection lot origin. The inspection type controls how the inspection is to take place. You can define an inspection type for a production order type in Customizing.

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Figure 4: Inspection Lot Origins in Production (2)

Run schedule headers and production orders are used for Kanban production.

Figure 5: Integration in the Production Process (1.1)

The relevant production steps are generally defined in a plan for an order in production. A standard routing or a master recipe is used depending on the production process. The specifications are then transferred from the routing to the order.

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After the planning phase is complete, the orders are released for production. This release stage can depend on a production scheduling profile (entry in the Work scheduling view in the material master) (for example, immediate release when creating an order). Production scheduling profiles can be defined in Customizing: Production → Shop Floor Control → Master Data → Define production scheduling profile or Production Planning for Process Industries → Process Order → Master Data → Define Production Scheduling Profiles

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During the release of the order, an inspection lot is automatically created for materials that require mandatory inspection (inspection type for inspection lot origin 03 is active in the material master). The corresponding inspection lot number is visible in the Assignment tab in the production or process order. The corresponding order number is visible in the tab Data for lot origin in the inspection lot.


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Problems that occur during production can be easily documented for the released inspection lot using Defects Recording. Defect codes are recommended for a better evaluation of defects. Defects can also be documented as free text.


The information entered on the defects are always stored in a quality notification. This quality notification can be used for example to define correction tasks. In general, it is not “mandatory” to process a quality notification.

Figure 10: Integration in the Production Process (1)

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When an order is released, an inspection lot can be created automatically for an inspection during production. You can record any defects that have been identified for the inspection lot, operation, or characteristic. The defects are then transferred to a quality notification for further processing (for example, complaint report). The usage decision completes the inspection lot. It can be made automatically.

Figure 11: Prerequisites for Inspection During Production with Defects Recording

As an example for simple use of SAP Quality Management without extensive planning. A prerequisite for the creation of an inspection lot for an order is that an inspection type with inspection lot origin 03 or 13 is active in the material master of the finished product. Catalogs are the only master data in QM that is required for an inspection during production with defects recording.

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Figure 12: Carrying Out the Inspection

You can record inspection results for an inspection lot, using defect data or characteristic results. A defect data record, (defect type, location, cause...) describes a problem and is stored in a quality notification. If this notification is activated, it can be used for further processing of the problem. You can use the report type to determine the layout (confirmation profile) of results recording as well as the allowed values in the code groups (catalog profile). You can enter the report type in the work center or in the user parameters.

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Figure 13: Automatic Usage Decision

The report program/job Automatic Usage Decision - Orders takes into consideration inspection lots with the following origins: • • •

03 (production) 13 (repetitive manufacturing) 14 (Plant Maintenance)

The report program/job Automatic Usage Decision – General does not take into consideration inspection types with the origins 03, 13 and 14. Since the usage decision in inspection lots for orders usually completes the lot and is therefore of a technical nature, defects and rejections of characteristics are not taken into consideration. Hint: See SAP Note 158455.

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Exercise 1: Defects Recording for the Production Order Exercise Objectives After completing this exercise, 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 a lot that is inspected during production.

Business Example You manufacture shafts using production orders. You want to record any defects that are identified during production, and to inform the vendor, if necessary.

Task 1: Activating quality inspection during production Activate the inspection during production for your material T-BQ6##. 1.

What options are there for maintaining the inspection setup for materials? ______________________________________________________ ______________________________________________________ ______________________________________________________

2.

Which inspection type must you activate for an inspection during production? ______________________________________________________

3.

Do you need to make special settings in the material master to record defects for an inspection lot? ______________________________________________________

Task 2: Create production order with material Create a production order for your material T-BQ6##, release the order and check the inspection lot number in the order header. Use the order type PP01 in plant 1000. The order quantity is 100 pieces (PC). Use the scheduling type Current date (4). 1.

Make a note of the path you use to create the order. ______________________________________________________ ______________________________________________________ Continued on next page

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What is the number of the order you created? ______________________________________________________

3.

What is the inspection lot number? ______________________________________________________

Task 3: Carry Out Defects Recording for an Order Record defects for the order. 1.

What options are there for recording defects for an inspection lot? ______________________________________________________ ______________________________________________________ ______________________________________________________ Hint: Use the report type “00000002” Individual defect report.

2.

Record several defects.

3.

Defects are stored in a quality notification. How is this notification activated and what are the consequences? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

4.

Which setting do you need to make, to allow defects recording for an operation or characteristic? ______________________________________________________ ______________________________________________________

Continued on next page

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Task 4: Complete the inspection lot with the usage decision 1.

Enter the usage decision for the inspection lot. What options do you have for making the usage decision? _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________

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Solution 1: Defects Recording for the Production Order Task 1: Activating quality inspection during production Activate the inspection during production for your material T-BQ6##. 1.

What options are there for maintaining the inspection setup for materials? ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08)

2.

Which inspection type must you activate for an inspection during production? ______________________________________________________ a)

3.

An inspection type for inspection origin 03. In the standard system, this is inspection type 03.

Do you need to make special settings in the material master to record defects for an inspection lot? ______________________________________________________ a)

No, you can record defects at any time (even in an inspection based on characteristics).

Task 2: Create production order with material Create a production order for your material T-BQ6##, release the order and check the inspection lot number in the order header. Use the order type PP01 in plant 1000. The order quantity is 100 pieces (PC). Use the scheduling type Current date (4). 1.

Make a note of the path you use to create the order. ______________________________________________________


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______________________________________________________ a) 2.

Logistics → Production → Shop Floor Control → Order → Create → With Material (CO01)

What is the number of the order you created? ______________________________________________________ a)

3.

Order number

What is the inspection lot number? ______________________________________________________ a)

Inspection lot number


What options are there for recording defects for an inspection lot? ______________________________________________________ ______________________________________________________ ______________________________________________________ Hint: Use the report type “00000002” Individual defect report. a)

Worklist: Logistics → Quality Management → Quality Inspection → Worklist → Inspection → Change Data (QA32) Single recording: Logistics → Quality Management → Quality Inspection → Defects → Record for Inspection Lot (QF11)

2.

Record several defects. a)

3.

Select suitable defects codes or enter text for this defect.

Defects are stored in a quality notification. How is this notification activated and what are the consequences? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ Continued on next page

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______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

A quality notification can be activated by an appropriate setting for the defect class, by triggering it manually when recording defects or making the usage decision, or by manually processing the notification that is not active. The system status DEFR is cancelled when the notification is activated. An active notification with defects recording must be manually completed (that is, the notification is not automatically completed when the usage decision is made on the inspection lot).

4.

Which setting do you need to make, to allow defects recording for an operation or characteristic? ______________________________________________________ ______________________________________________________ a)

Operation-based defect entry is possible by setting the flag Inspect with Task List in the Inspection Setup for the material. If an inspection characteristic is assigned to the operation, characteristic-based defect entry is also possible.


Enter the usage decision for the inspection lot. What options do you have for making the usage decision? _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ a)

Manual Individually Worklists (for example, inspections, collective UD etc.) Automatic usage decision on inspection lots with orders

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Exercise 2: Defects Recording for the Process Order Exercise Objectives After completing this exercise, 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 a lot that is inspected during production.

Business Example You produce tablets using process orders. You want to record defects that are identified during production.

Task 1: Activating quality inspection during production Activate the inspection during production for your material TAB-1##. 1.

What options are there for maintaining the inspection setup for materials? ______________________________________________________ ______________________________________________________ ______________________________________________________

2.

Which inspection type must you activate for an inspection during production? ______________________________________________________

3.

Do you need to make special settings in the material master to record defects for an inspection lot? ______________________________________________________

Task 2: Create process order with material Create a process order for your material TAB-1##, and check the inspection lot number in the order header. Use order type PI01 in plant 1100. The order quantity is 1100 pcs. Use the scheduling type Current date (4). 1.

Make a note of the path you use to create the order. ______________________________________________________ ______________________________________________________ Continued on next page

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What is the number of the order you created? ____________________________________________________________

3.

What is the inspection lot number? ____________________________________________________________


What options are there for recording defects for an inspection lot? ______________________________________________________ ______________________________________________________ ______________________________________________________ Hint: Use the report type “00000002” Individual defect report.

2.

Record several defects.

3.

Defects are stored in a quality notification. How is this notification activated and what are the consequences? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________

4.

Which setting do you need to make, to allow defects recording for an operation or characteristic? ______________________________________________________ ______________________________________________________


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Enter the usage decision for the inspection lot. What options do you have for making the usage decision? _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________

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Solution 2: Defects Recording for the Process Order Task 1: Activating quality inspection during production Activate the inspection during production for your material TAB-1##. 1.

What options are there for maintaining the inspection setup for materials? ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08)

2.

Which inspection type must you activate for an inspection during production? ______________________________________________________ a)

3.

An inspection type for inspection origin 03. In the standard system, this is inspection type 03.

Do you need to make special settings in the material master to record defects for an inspection lot? ______________________________________________________ a)

No, you can record defects at any time (even in an inspection based on characteristics).

Task 2: Create process order with material Create a process order for your material TAB-1##, and check the inspection lot number in the order header. Use order type PI01 in plant 1100. The order quantity is 1100 pcs. Use the scheduling type Current date (4). 1.

Make a note of the path you use to create the order. ______________________________________________________


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______________________________________________________ a) 2.

Logistics → Production - Process → Process Order → Process Order → Create → With Material (COR1)

What is the number of the order you created? ____________________________________________________________ a)

3.

Order number

What is the inspection lot number? ____________________________________________________________ a)

Inspection lot number


What options are there for recording defects for an inspection lot? ______________________________________________________ ______________________________________________________ ______________________________________________________ Hint: Use the report type “00000002” Individual defect report. a)

Worklist: Logistics → Quality Management → Quality Inspection → Worklist → Inspection → Change Data (QA32) Single recording: Logistics → Quality Management → Quality Inspection → Defects → Record for Inspection Lot (QF11)

2.

Record several defects. a)

3.

Select suitable defects codes or enter text for this defect.

Defects are stored in a quality notification. How is this notification activated and what are the consequences? ______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ Continued on next page

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______________________________________________________ ______________________________________________________ ______________________________________________________ ______________________________________________________ a)

A quality notification can be activated by an appropriate setting for the defect class, by triggering it manually when recording defects or making the usage decision, or by manually processing the notification that is not active. The system status DEFR is cancelled when the notification is activated. An active notification with defects recording must be manually completed (that is, the notification is not automatically completed when the usage decision is made on the inspection lot).

4.

Which setting do you need to make, to allow defects recording for an operation or characteristic? ______________________________________________________ ______________________________________________________ a)

Operation-based defect entry is possible by setting the flag Inspect with Task List in the Inspection Setup for the material. If an inspection characteristic is assigned to the operation, characteristic-based defect entry is also possible.


Enter the usage decision for the inspection lot. What options do you have for making the usage decision? _________________________________________________________ _________________________________________________________ _________________________________________________________ _________________________________________________________ a)

Manual Individually Worklists (for example, inspections, collective UD etc.) Automatic usage decision on inspection lots with orders

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Lesson Summary You should now be able to: • Explain the necessary settings in the material master for a quality check during production • Create an inspection lot for an order • Carry out defects recording using the inspection lot for the order

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Lesson: Results Recording by Characteristic for an Order Lesson Overview With characteristic-based results recording for an order, inspection results for inspection characteristics can be documented in the SAP system during prodouction (in-process inspection). Other deviations or problems can also be documented using defects recording. Defects recording can be implemented using an inspection lot (inspection lot origin 03) or using a quality notification (notification origin Q3). This lesson deals with “one-time” entry of inspection results for inspection characteristics in the inspection lot for the order. Hint: “Multiple” entry of inspection results for inspection characteristics in the inspection lot for the order is handled in later lessons in the PLM420 training course.

Lesson Objectives After completing this lesson, you will be able to: • •

Update the task list for production (standard routing, master recipe) with the required QM data for a quality inspection Implement an inspection results entry for an inspection lot during production

Business Example Different materials are manufactured in production with either production orders or process orders. You want to enter the inspection results for specific inspection characteristics during production with an in-process inspection. The inspection results are needed for later process documentation or for quality control. Defects identified during production can also be documented in defects recording.

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Lesson: Results Recording by Characteristic for an Order

In-Process Inspection and Inspection Results Entry for the Order


Inspection specifications from Quality Management can be integrated into the task lists from production (for example, normal routing, standard routing, master recipe) for the in-process inspection. These inspection specifications are assigned in the task list during the relevant processes. For example, the following can be assigned: • • • •

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Master Inspection Characteristics Sampling procedure Dynamic modification rules Codings (selection quantity, code groups, codes)


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When releasing the order, an inspection lot is automatically created for materials that require mandatory inspections. It is also possible to create the inspection lot manually prior to order release with reference to an order number.


The inspection lot is assigned the inspection requirements from the production task list. In addition, unplanned inspection characteristics can also be added when processing the order or when recording the inspection results.

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In addition to entering the inspection results for the inspection characteristics, defects recording is possible if required.


When the production order is released, the system creates an inspection lot, provided that an appropriate inspection type has been entered in the material master and is active. Since the quantity to be inspected is classed as goods in process, the inspection lot is NOT relevant for stock.

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The diagram shows a quality inspection is planned in operation 030. The results for the inspection lot are recorded for the characteristics that are assigned to this operation. The operations can either be work operations or inspection operations. The inspection lot is completed with a usage decision. To automate the usage decision, a job can be scheduled using transaction QA41 in the SAP system. The results for the inspection lot are available for quality control (for example, using transaction QGA4), and are updated in the Quality Management Information System (QMIS).

Figure 19: Prerequisites for an Inspection During Production with Results Recording

To record results by characteristic for the order, the indicators Inspect with task list (or Inspect with material specification) and Check Chars (Inspect by Characteristics) must be set in the inspection type for inspection lot origin 03 or 13 in the inspection setup of the material master (Quality Management view). Dynamic modification data is defined at header level in the task list or recipe, whereas the recording view is defined at operation level. The inspection characteristics are assigned to the operations. Additional QM basic data is, for example, dynamic modification rule and sampling procedure. You can use lots with inspection lot origin 04 (early inspection for a goods receipt) in addition to lots of inspection lot origin 03 and 13.

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Figure 20: Specifications from the Task List

The inspection processes are integrated in the normal routing, standard routing, rate routing or in the master recipe in the inspection during production.

Figure 21: Master Recipe

A master recipe defines all the process steps, resources, material components, data for an in-process quality inspection and control information for the process control level that is required to produce materials. This takes place independently of the order.

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Master recipes contain a planning view and a control view. The planning view covers the planning of operations, materials, resources and inspection characteristics. There are business connections to process production, materials management, and warehouse management as well as to sales processes and quality management. The control view contains information that is required to communicate with the process control level. You can use a master recipe as a copy model for creating process orders. A process order describes a concrete production process and contains all the information that has been collected during the process planning stage, for example, the production deadline and the production quantities. A control recipe contains all the information required by a specific process control system or process operator to carry out a process order. The following organizations have defined the data that must be maintained in the process production master recipe: • • •

The European Batch Forum (EBF) The Instrument Society of America (ISA, with norms S88) Standards Committee for Measuring Methods and Controls (NAMUR)

Figure 22: Structure of a Master Recipe

The recipe header contains data that is valid for the whole recipe. A resource network and the material to be produced are assigned at header level. Operations describe the procedures required for production. The operations can be subdivided into phases to describe these procedures in more detail. Only one primary resource is assigned to each operation. The operation is then to take place at this resource. The assignment of this primary resource applies to all the phases that have been assigned to the operation.

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If required, you can assign additional secondary resources to operations and phases. If material is added at certain stages of the production process, formed temporarily or withdrawn, you assign this as a component of a material list to the corresponding operations or phases. Inspection characteristics define which quality inspections are to be performed during a process. The characteristics can be assigned to operations and phases. You can assign a production resource/tool as test equipment that is required for inspections during production to the relevant inspection characteristic in the task list.

Figure 23: In-Process Inspection - Inspection Lot

The inspection lot for an in-process quality inspection is created, based on the master recipe that forms the basis for the process order. The inspection requirements are defined as inspection characteristics in the master recipe for the corresponding operations or phases. The inspection lot is created either manually before the process order is released or automatically upon release. Prerequisite for the release is the activation of an inspection type (In-process inspection for production order) in the material master of the material to be inspected. The inspection characteristics for the operations or phases in the master recipe are copied into the corresponding inspection operations for the inspection lot. You also have the option of adding unplanned inspection characteristics retroactively from the process order.

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Figure 24: Carrying Out the Inspection

You can record inspection results for an inspection lot, using defect data or characteristic results. You record inspection results for planned characteristics (quantitative or qualitative) on the basis of the planned recording type and you valuate the characteristics according to the predefined valuation rule. You can confirm results for qualitative characteristics with a YES/NO statement or on the basis of attribute codes that implicitly contain a valuation. For quantitative characteristics you can use the following recording methods: • • •

Summarized confirmation of results, for example, mean value and standard deviation Classed confirmation (this means that contents of classes are recorded) Single values (this means that each individual measured value is recorded)

(You can also record summarized, classed and single values for qualitative characteristics). The results are updated in the statistics and can be used for quality control purposes. You can evaluate and monitor this data using the Quality Management Information System (QMIS).

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Figure 25: Recording Steps

You record results in several steps. Once the results have been recorded, the characteristics are valuated and closed. These steps can be automated. There are various modes available for valuating the inspection characteristic (such as valuation based on nonconforming units, SPC inspection, manual valuation…). Processes in the results recording can be changed by the settings in the Recording configuration. Depending on the settings in the QM view in the material master (entry in the field QM material auth.), the digital signature is also used in results entry. Once all characteristics have been closed, the inspection lot is completed by the usage decision.

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Figure 26: Options for Results Recording

Figure 27: Results Recording Using Process Messages

Inspection results can be recorded during production using process notifications automatically using a process control system in the PI-PCS-interface (for details, see the SAP Help Portal [http://help.sap.com] with the search term PI-PCS) or by manually entering a process operator from a PI sheet.

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This type of results recording takes place through the transfer of a process specification (in this case a process data request) to the process control system or the PI sheet. The process values that have been requested are then returned using a process message of type PI_QMSMR Confirmation of inspection results to Quality Management. The process management component controls this exchange of information. QMRES is the process instruction type defined in the process message (PI_QMSMR). It is used to facilitate results transfer in results recording using the possible entries help (F4).

Figure 28: Process Management

The process management component forms the interface between Production Planning for the Process Industry and the systems involved in process control. Its flexible structure allows you to link automated, partially automated and manually controlled lines. Process management comprises the following functions: • • • • •

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Receiving control recipes with process specifications from released process orders Sending control recipes to the process operator or process control system involved Preparation of process specifications in natural language, so that the process operator can display and maintain them on-screen Receiving, checking and sending process messages with actual data about the process Manual entry of process messages


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Figure 29: Transfer of Data to Process Control

You can store information relevant to the control process in the form of process specifications in the process order. You assign this information to the phases in the order. The process specifications are combined in control recipes. These recipes are transferred to the control recipe destination that is defined in the process order. Control recipes can be created for: • •

Process control systems on automated lines Process operators on manually controlled lines

In the latter example, the control recipe in a PI sheet can be prepared on-screen in natural language and processed by the process operator.

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Figure 30: PI Sheet - Structure

A PI sheet contains the following elements: • • • • • • • •

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A header with general data, such as order number, material number and processing group Texts with control information and instructions for the process operator Additional information that you can call up using pushbuttons Processor's comments that you can call up using pushbuttons Input fields (individual or in tables) for actual data that is to be confirmed Fields for calculated results that are to be determined by the system The pushbutton Record inspection results that allows you to switch to the results recording function in QM Pushbuttons that enable you to call function modules to trigger a dialog (for example, order confirmation) or to read data from internal or external applications (for example, from the document management system)


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Figure 31: Transfer of Data from Process Control

During the execution of a process order, actual data from the process control component is confirmed with the help of process messages. These process messages contain, for example, the following information: • • •

The current status of a process order Material consumption Selected process events

The messages allow a batch and production record (EBR) to be created and data in other components (such as, inventory management) to be updated. • •

• •

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The process messages are first sent to the process management component. Here, they are checked and are forwarded to the predefined destination. A process message that is sent to the process management component can contain inspection results that have been recorded. Once the message has been checked, it is forwarded to the inspection lot in QM. You can then call up these values as the default values in the QM results recording function. You also have the additional option of switching directly from the PI sheet to the QM results recording function.


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Figure 32: Process Message for Inspection Result

You can use process messages of type PI_QMSMR to confirm results from inspections during production to QM. There are the following prerequisites for this: • • •

The inspection setup in the material master and the master recipe must be maintained. A corresponding inspection lot has been created for the order. The inspection result that is to be confirmed has been recorded as a summarized measured value.

The inspection lot is automatically created when the order is released, provided that the inspection setup has been maintained in the material master and the master recipe. The process message must contain either the operation number or the phase number. Otherwise, you cannot assign it to an inspection characteristic in the inspection lot. The data that has been confirmed (such as, inspection result, number of inspections and short text for the inspection) is available as a default, when you record results in QM.

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Exercise 3: Characteristic-Based Results Recording for the Production Order Exercise Objectives After completing this exercise, you will be able to: • Maintain inspection characteristics for the operation in the routing • Enter characteristics results for the inspection characteristics of an inspection lot

Business Example You want to record more detailed inspection results for future reference. You therefore want to change from recording defects for material T-BQ6## to recording results by characteristic.

Task 1: Change the inspection setup in the material master Activate the function for recording results by characteristic for your material T-BQ6## in plant 1000. Which flags do you have to set? ____________________________________________________________ 1.

Change your material T-BQ6## .

Task 2: Change Routing for Material T-BQ6## In the routing for your material T-BQ6## (task list with group counter 1), inspection characteristics are already assigned to the operations Anneal Shaft and Check measurements. A visual check should also be performed in the operation Lathe shaft. 1.

Assign a control key to operation 20, which allows you to assign inspection characteristics. Which control key do you use? ________________________________________


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Task 3: Production Order for the Material and Inspection Lot Processing Create and release a production order for your material T-BQ6##. Then enter the inspection results for the in-process inspection for the production order. 1.

Create the production order with the order type PP01 in the plant 1000. The order quantity is 100 PC. Use the scheduling type Current date (4). What order number was given? _______________________________________ What inspection lot number was given? _________________________________

2.

Record the inspection results for the operations 20, 30 and 60, using the worklist for results recording. Use your material number to select the relevant inspection lots T-BQ6##.

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Solution 3: Characteristic-Based Results Recording for the Production Order Task 1: Change the inspection setup in the material master Activate the function for recording results by characteristic for your material T-BQ6## in plant 1000. Which flags do you have to set? ____________________________________________________________ 1.

Change your material T-BQ6## . a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) The flag “Check characteristics” must be set for the inspection type for inspection lot origin 03.

Task 2: Change Routing for Material T-BQ6## In the routing for your material T-BQ6## (task list with group counter 1), inspection characteristics are already assigned to the operations Anneal Shaft and Check measurements. A visual check should also be performed in the operation Lathe shaft. 1.

Assign a control key to operation 20, which allows you to assign inspection characteristics. Which control key do you use?


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________________________________________ a)

Logistics → Quality Management → Quality Planning → Inspection Planning → Routing → Routings → Standard Routings → Change (CA02) or Logistics → Central Functions → Engineering → Engineering Workbench (CEWB) Field name or data type

Values

Material

T-BQ6##

Plant

1000

group counter

1

For example, control key PP06 The indicator 'Insp. char. required' must be set in the control key. b)

Assign the master inspection characteristic 8-106 to the operation. The sample is to be determined according to the sampling procedure FIX5-0. Save the changed routing.

c)


Values

Material

T-BQ6##

Plant

1000

group counter

1

Operation 20, integrate inspection characteristic acccording to the task. Save changed routing


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Create the production order with the order type PP01 in the plant 1000. The order quantity is 100 PC. Use the scheduling type Current date (4). What order number was given? _______________________________________ What inspection lot number was given? _________________________________ a)

Create production order with material: Logistics → Production → Shop Floor Control → Order → Create → With Material (CO01) Field name or data type

Values

Material

T-BQ6##

Production plant

1000

Order type

PP01

Total quantity

100 PC

Scheduling type

4 (current date)

Release production order Assignment tab The inspection lot number is displayed in the assignment screen area. After saving the production order, the inspection lot is also saved. 2.

Record the inspection results for the operations 20, 30 and 60, using the worklist for results recording.


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Use your material number to select the relevant inspection lots T-BQ6##. a)

Results Recording Worklist: Logistics → Quality Management → Quality Inspection → Worklist → Results Recording (QE51N) Field name or data type

Values

Material

T-BQ6##

Plant

1000

Inspection lot origin

03 (entry is optional)

Execute the function key F8. Record the inspection results for the inspection characteristics, and close characteristic processing.

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Exercise 4: Characteristics-based Results Recording for the Process Order Exercise Objectives After completing this exercise, you will be able to: • Plan an inspection during production in the material master • Make settings in the master recipe for in-process control • Assign inspection characteristics in the master recipe • Create an inspection lot for an order • Record inspection results for an inspection during production • Record inspection results in the PI sheet and transfer them to the inspection lot in a process message

Business Example Your company wants to perform inspections during production on the production line and record the results directly in the SAP System

Task 1: Change the inspection setup in the material master Activate the function for recording results by characteristic for your material TAB-1## in plant 1100. Which flags do you have to set? ____________________________________________________________ 1.

Change your material TAB-1## .

Task 2: Display Master Recipe Display your recipe 1 in recipe group TAB-1##, and switch to the inspection characteristic overview in phase 210. 1.

Make a note of the menu path you use to display the master recipe. ____________________________________________________________ ____________________________________________________________

2.

Make a note of the assigned inspection characteristics. ____________________________________________________________ Continued on next page

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____________________________________________________________ ____________________________________________________________ 3.

How can you tell which phase is relevant for quality inspections? ____________________________________________________________

Task 3: Change Master Recipe In your master recipe, add to the process instructions for QM results recording in the PI sheet. 1.

To do this, call up your master recipe in the change mode and switch to the operation/phase overview to the process instruction overview. Enter the process instruction categories in your quality inspection phase 210 ZQ_QMRE1, ZQ_QMRE2 and ZQ_SIGN1 in the given sequence. Which characteristics are relevant for the unique identification of information in the QM component? ____________________________________________________________

Task 4: Process order for material Create a process order for your material TAB-1##, and check the inspection lot number in the order header. 1.

Create the process order with the order type PI01 in the plant 1100. The order quantity is 1100 PC. Use the scheduling type 4 (current date). Make a note of the path you use to create the order. ____________________________________________________________ ____________________________________________________________ What is the number of the order you created? ____________________________________________________________ What is the inspection lot number? ____________________________________________________________


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Task 5: Process Coordination Use the process coordination to send the control recipe, to process the PI sheet, and to send process notifications. 1.

Send your control recipes in the control recipe monitor. What are the control recipe numbers? ____________________________________________________________ ____________________________________________________________

2.

Then call your PI sheet for the processing group "PRODUCTION TABLET (QM)" and process it recording your inspection results. Make a note of the value entered for the sieve size and water content. Sieve size:___________________________________________________ Water content:_________________________________________________ Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password.

3.

Access the process message monitor and display one of the QM-relevant process messages. Then send the PI_QMSMR messages.

Task 6: Record Inspection Results for In-Process Inspection for Process Order Record inspection results for operation 210 in your inspection lot. Use the worklist for results recording. 1.

Use your material number TAB-1## to select the relevant inspection lots. Use the input help function for both characteristics sieve size and water content. Which values are proposed? Sieve size:___________________________________________________ Water content:_________________________________________________ What information do you receive, if you test the input help function for your third characteristic Active ingredient content. ____________________________________________________________ ____________________________________________________________ Record the results for the additional inspection characteristics and close the characteristics.

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Solution 4: Characteristics-based Results Recording for the Process Order Task 1: Change the inspection setup in the material master Activate the function for recording results by characteristic for your material TAB-1## in plant 1100. Which flags do you have to set? ____________________________________________________________ 1.

Change your material TAB-1## . a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) The flag “Check characteristics” must be set for the inspection type for inspection lot origin 03. Inspection type 03 is delivered in the SAP standard release.

Task 2: Display Master Recipe Display your recipe 1 in recipe group TAB-1##, and switch to the inspection characteristic overview in phase 210. 1.

Make a note of the menu path you use to display the master recipe. ____________________________________________________________


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____________________________________________________________ a)

Logistics → Quality Management → Quality Planning → Inspection Planning → Master Recipe → Recipe and Material List → Display (C203) Use the selection criteria material and plant or master recipe group, also enter the recipe group 1.

2.

Field name or data type

Values

Recipe Group

TAB-1##

Recipe

1

Material

TAB-1##

Plant

1100

Make a note of the assigned inspection characteristics. ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

Select Phase 210, Inspection characteristics icon (below the operation/phase overview) Assigned inspection characteristics: N-100 Sieve Size N-200 Water content N-300 Active ingredient content

3.

How can you tell which phase is relevant for quality inspections? ____________________________________________________________ a)

The control key PI02 (inspection characteristics expected) is assigned to the phase that is relevant for quality inspections.

Task 3: Change Master Recipe In your master recipe, add to the process instructions for QM results recording in the PI sheet. 1.

To do this, call up your master recipe in the change mode and switch to the operation/phase overview to the process instruction overview. Enter the process instruction categories in your quality inspection phase 210 Continued on next page

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ZQ_QMRE1, ZQ_QMRE2 and ZQ_SIGN1 in the given sequence. Which characteristics are relevant for the unique identification of information in the QM component? ____________________________________________________________ a)

Logistics → Quality Management → Quality Planning → Inspection Planning → Master Recipe → Recipe and Material List → Change (C202) Use the selection criteria material and plant or master recipe group, also enter the recipe group 1. Field name or data type

Values

Recipe Group

TAB-1##

Recipe

1

Material

TAB-1##

Plant

1100

In the operation/phase overview scree, select Phase 210, and navigate to the Process instruction overview (icon below the operation/phase overview) Assign new process instruction categories (Press enter or use F4 help). Process instruction categories: ZQ_QMRE1 ZQ_QMRE2 ZQ_SIGN1 Process instruction characteristics: PPPI_INSPECTION_LOT PPPI_INSPECTION_CHARACTERISTIC PPPI_INSPECTION_RESULT


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Create the process order with the order type PI01 in the plant 1100. The order quantity is 1100 PC. Use the scheduling type 4 (current date). Make a note of the path you use to create the order. ____________________________________________________________ ____________________________________________________________ What is the number of the order you created? ____________________________________________________________ What is the inspection lot number? ____________________________________________________________ a)

Create process order with material: Logistics → Production - Process → Process Order → Process Order → Create → With Material (COR1) Field name or data type

Values

Material number

TAB-1##

Production plant

1100

Process order type

PI01

Total quantity

1100 PC

Scheduling type

4 (current date)

Assignment tab The inspection lot number is displayed in the assignment screen area. After saving the production order, the inspection lot is also saved. Save your process order. b)

Display process order with material: Logistics → Production - Process → Process Order → Process Order → Display (COR3)


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Task 5: Process Coordination Use the process coordination to send the control recipe, to process the PI sheet, and to send process notifications. 1.

Send your control recipes in the control recipe monitor. What are the control recipe numbers? ____________________________________________________________ ____________________________________________________________ a)

Logistics → Production - Process → Process Management → Control Recipe → Control Recipe Monitor (CO53XT) Field name or data type

Values

Plant

1100

Creation Date

Todaýs date

Send the control recipes to recipients Q1 and Q2. Select the control recipes and press the pushbutton Send 2.

Then call your PI sheet for the processing group "PRODUCTION TABLET (QM)" and process it recording your inspection results. Make a note of the value entered for the sieve size and water content. Sieve size:___________________________________________________


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Water content:_________________________________________________ Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. a)

Logistics → Production-Process → Process Management → PI Sheet → Find (CO60) Field name or data type

Values

Plant

1100

Material number

TAB-1##

The control recipe number matches the PI sheet number. Select the PI sheet, and choose pushbutton Maintain PI sheet, F5. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. 3.

Access the process message monitor and display one of the QM-relevant process messages. Then send the PI_QMSMR messages. a)

Logistics → Production - Process → Process Management → Message → Message Monitor (CO54XT) Field name or data type

Values

Plant

1100

Creation Date

Todaýs date

Select the process messages, and choose the pushbutton Send Messages


Use your material number TAB-1## to select the relevant inspection lots. Use the input help function for both characteristics sieve size and water content. Which values are proposed? Sieve size:___________________________________________________ Water content:_________________________________________________ Continued on next page

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What information do you receive, if you test the input help function for your third characteristic Active ingredient content. ____________________________________________________________ ____________________________________________________________ Record the results for the additional inspection characteristics and close the characteristics. a)


Values

Material

TAB-1##

Plant

1100



Execute the function key F8. The total values entered in the PI sheet for the inspection characteristic sieve size and for the Inspection characteristic water content are suggested by the system in the results recording. Information message when calling input help for the inspection characteristic Active ingredient content: No process messages exist.

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Lesson Summary You should now be able to: • Update the task list for production (standard routing, master recipe) with the required QM data for a quality inspection • Implement an inspection results entry for an inspection lot during production

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  ith Free Lesson: Inspection During Production w Inspection Points Lesson Overview With characteristic-based results recording for an order, inspection results for inspection characteristics can be documented in the SAP system during production (in-process inspection). Other deviations or problems can also be documented using defects recording. This lesson deals with multiple entry of inspection results for inspection characteristics in the inspection lot for the order. For multiple entry of inspection results for the inspection characteristics in the same inspection lot, the SAP system uses inspection points. Hint: Inspection points will be discussed in later lessons in the PLM420 training course. This lesson uses the inspection type Freely-defined inspection point.


Plan a multiple inspection for an operation with inspection point processing. Implement a multiple entry of inspection results for inspection characteristics in the inspection lot.

Business Example Different materials are manufactured in production with either production orders or process orders. You want to enter the inspection results for specific inspection characteristics during production multiple times during the same order with an in-process inspection. The inspection results are needed for later process documentation or for quality control.

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Lesson: Inspection During Production  with Free Inspection Points

Multiple Inspection with “Free Inspection Points” in Production


When an order is released, an inspection lot can be created automatically for an inspection during production. Quality inspections can take place at regular intervals (time-based or quantity-based) or at freely defined intervals (for example, after a tool change). You can record inspection results for a freely defined “object” (such as wire basket number, tank number, shift, time, and so on). You valuate each object (inspection point) after you have recorded results for the characteristics.

Figure 34: Prerequisites for an Inspection During Production with free Inspection Points

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To record results by inspection point for the order, the indicators Inspect with task list (or Inspect with material specification) and Inspect by charac. must be set in the inspection type for origin 03 in the inspection setup of the material master (Quality Management view). The identifier for the inspection point (inspection point user field combination) must be defined in the task list header. This identifier for inspection points (Inspection-User Field combination) is set in Customizing: Quality Management → Quality Planning → Inspection Planning → General → Define Identifier for Inspection Points. The additional master data corresponds to that for a regular inspection by characteristics. Exception: The indicator for inspection points must be set in the sampling procedure. As of Release 4.6, you can also use inspection points outside production.

Figure 35: Time-Based Inspection

In this example, characteristic 10 is to be inspected every hour, characteristic 20 every 2 hours, characteristic 30 every 3 hours. The default split must be set in this example to 1 hour. The split is stored in the QM data for the operation. The inspection frequency is entered in the sampling procedure. This procedure is assigned to the inspection characteristic in the task list.

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Figure 36: Quantity-Based Inspection

In this example, characteristic 10 is to be inspected after every 50 pieces that are manufactured, characteristic 20 after every 100 pieces and characteristic 30 after every 150 pieces. For this example, the default split must be set to 50 pieces. The split is stored in the QM data for the operation. The inspection frequency is entered in the sampling procedure. This procedure is assigned to the inspection characteristic in the task list.

Figure 37: Inspection During Production - with Inspection Points

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An inspection point contains the total quantity of all characteristics that are to be inspected for an operation, based on a partial quantity or a time interval. Each inspection is identified by an inspection point. Keywords can be defined in Customizing to identify the free inspection points. When you enter the results recording, one entry is defined for one keyword. Example for results recording: First inspection point: Keyword: Basket Entry: 001 Second inspection point: Keyword: Basket Entry: 002 Third inspection point: Keyword: Basket Entry: 003 In the example, the inspection is based on quantities and an inspection point is to be created every 50 pcs. In the quality inspection, 3 pcs have to be posted to scrap in operation 30 and 2 pcs require rework. Each inspection point is valuated independently, based on acceptance or rejection. The valuation for the inspection point is proposed by QM Customizing, depending on whether the inspection characteristics are accepted or rejected. The valuation can be changed. The valuation can also take place automatically. You can define keywords in Customizing for the inspection point user fields. These keywords appear when you record results on the initial screen or in the worklist. Examples of keywords: Basket, pallet, shift, date.

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Figure 38: Creation of Inspection Points

This graphic shows the interaction between the inspection points, operations, and the inspection lot. An inspection lot can be created for each production or process order. If you do not confirm any partial quantities during production or do not work with inspection points, the inspection results are recorded for each operation for the entire inspection lot. If an inspection point identification is defined in the master recipe in the recipe header detail screen 'QM data', all inspection results recorded during production are related to the inspection point. Unlike an inspection without inspection points, inspection results can therefore be recorded for inspection characteristics in the same inspection operation several times directly after one another. The interval between such inspection points can be time-based (at specific times), quantity-based (after the production of a certain quantity), or freely defined.

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Figure 39: Inspection Point Settings in the Task List

Figure 40: Inspection Point Completion Variants

The variant for inspection point completion is defined at operation level. If the inspection point completion variant allows confirmation, the system can propose the following: Partial confirmation, final confirmation, no confirmation, according to the production Customizing settings. For special inspection point types (plant maintenance, samples of goods receipts and freely defined inspection points outside production), only the inspection point completion variants “Valuation” or “Valuation (automatic)” are allowed.

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If the inspection point has to be assigned to a partial lot, the system requires a manual valuation, even if the completion variant is “Valuation (automatic)”.

Figure 41: Settings for the Inspection Point (1)

In Customizing, you can define a maximum of 6 fields to identify the inspection point. There are the following inspection point types: • • • •

_ = Freely defined inspection point 1 = Inspection point for equipment 2 = Inspection point for functional location 3 = Inspection point for physical sample

Certain fields are required fields, depending on the inspection point type (for example, the equipment number for inspection points for equipment in a calibration inspection).

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You can define codes as the default valuation of an inspection point. If the valuation of the inspection point takes place automatically (variant 4 for inspection point completion), these codes are used by the system. If no valuation has been defined for the inspection point, the valuation is taken from the Quality Management settings at plant level.


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SAP provides sample function modules that you can use in the following cases: •

•

To generate inspection points automatically when inspection lots are created. (For example, to define an inspection (inspection point) every hour, from the start of an operation until its conclusion). In results recording – – –

• •

To propose user fields as a default To verify entries in user fields To propose a list of values (F4 help) containing allowed entries

The sample programs should be used as copy models and adapted to suit your requirements. The SAP module for automatically generating inspection points contains examples of time and quantity-based inspection points. The SAP modules for default proposals, verification and lists of values for user fields merely describe the interface.

Figure 44: Recording with Inspection Point Overview

Recording screen for tabular characteristic processing of inspection points for an operation. Process-optimized results recording allows you to process characteristic results in tabular form on one screen.

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You can use process-optimized results recording to: • •

Group characteristics flexibly for processing Navigate freely between operations, inspection points, and lots

You can choose between the following recording transactions in the standard system: • • •

Processing characteristics for several inspection lots in tabular form, transaction: QE72 Processing inspection points for an operation in tabular form, transaction: QE71 Tabular processing of all inspection lots for one master inspection characteristic, transaction: QE73

Figure 45: Results Recording by Switching to QM

If a process instruction of type Inspection results request is used, a process operator can switch directly from a PI sheet to QM results recording when recording inspection results during production. In such a case, the inspection results for the corresponding inspection characteristics are entered and valuated directly in the QM results recording function.

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Figure 46: Record Inspection Results

You can use an inspection results request to define that inspection results are to be recorded for one or more operations (QMJMP) or phases (QMJMP_PH) when you execute a process order. You switch directly from the PI sheet to QM results recording for these operations or phases. Prerequisite: An inspection lot with corresponding characteristics exists for the process order.

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Exercise 5: Inspection Point Processing with a Production Order Exercise Objectives After completing this exercise, you will be able to: • Plan inspection point processing in the routing • Record results for the inspection point

Business Example The shafts are now to be produced in larger quantities. They are to be transported in containers. A quality inspection takes place for each container. Inspection results are also to be recorded for each container.

Task 1: Settings in the Routing For the material T-BQ6##, various routings exist in the SAP training system. 1.

Check the routing with the group counter 2 for the material T-BQ6##. For which identification are inspection results to be recorded? What is the user field combination? ____________________________________________________________ ____________________________________________________________ What is the interval for quality inspections for operation 30? ____________________________________________________________ ____________________________________________________________ From now on, operation 30 is to be confirmed using the appropriate production function. In addition, the system should valuate the inspection point automatically. Set the operation accordingly. Make a note of the parameter and its setting. ____________________________________________________________ ____________________________________________________________


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Task 2: Production Order for Material Create and release a production order for your material T-BQ6##. 1.

Create the production order with the order type PP01 in the plant 1000. The order quantity is 200 PC. Use the scheduling type Current date (4). What order number was given? __________________________________ What inspection lot number was given? ____________________________

Task 3: Results recording for inspection points You can carry out inspection results recording several times for the inspection characteristics by using free inspection points. 1.

Record several inspection results for the characteristics in your inspection lot. Use the worklist for results recording. Hint: The inspection results for the characteristic Shaft Length are still needed in the task for the SPC inspection. Hint: If you do not want to confirm the production order when completing the inspection points in Operation 60, set the flag No confirmation in the inspection point valuation screen. Hint: Do not enter a usage decision for this inspection lot. How does the rejection of a characteristic affect the valuation of an inspection point? ____________________________________________________________ ____________________________________________________________

Task 4: Customizing Settings for Inspection Points The inspection point field combination is stored in the header of the routing. Check the settings for the inspection point field combination in Customizing. 1.

Which user fields are active? ____________________________________________________________ ____________________________________________________________

2.

Which code is proposed when all inspection characteristics are accepted, and which is proposed when at least one inspection characteristic is rejected? Continued on next page

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____________________________________________________________ ____________________________________________________________ 3.

Inspection points can be generated automatically when inspection lots are created. In addition, the user fields can be proposed and verified by the system and a range of values (F4 help) can be proposed for each field. What are the function modules (copy models) called that SAP delivers for this purpose? Automatic creation of inspection points: ____________________________________________________________ Proposal of user fields in results recording: ____________________________________________________________ Verification of user fields in results recording: ____________________________________________________________ List of user fields in input help for results recording: ____________________________________________________________

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Solution 5: Inspection Point Processing with a Production Order Task 1: Settings in the Routing For the material T-BQ6##, various routings exist in the SAP training system. 1.

Check the routing with the group counter 2 for the material T-BQ6##. For which identification are inspection results to be recorded? What is the user field combination? ____________________________________________________________ ____________________________________________________________ What is the interval for quality inspections for operation 30? ____________________________________________________________ ____________________________________________________________ From now on, operation 30 is to be confirmed using the appropriate production function. In addition, the system should valuate the inspection point automatically. Set the operation accordingly. Make a note of the parameter and its setting. ____________________________________________________________


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____________________________________________________________ a)

Change routing Logistics → Quality Management → Quality Planning → Inspection Planning → Routing → Routings → Standard Routings → Change (CA02) or Logistics → Central Functions → Engineering → Engineering Workbench (CEWB) Field name or data type

Values

Material

T-BQ6##

Plant

1000

group counter

2

Routing Header Screen area: Parameters for dynamic modification/inspection points Inspection points : 990, Inspection point: Container, date Operations in Routing Details on Operation 30 Screen Area: Quality Management: Inspection Points An inspection is to take place after every 25 annealed shafts. Change with inspection point completion: Select attribute 3 'Automatic valuation according to inspection point definition'. Save the changes to the routing.


Create the production order with the order type PP01 in the plant 1000. The order quantity is 200 PC. Use the scheduling type Current date (4). What order number was given? __________________________________


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What inspection lot number was given? ____________________________ a)


Values

Material

T-BQ6##

Production plant

1000

Order type

PP01

Total quantity

200 PC

Scheduling type

4 (current date)

Release production order Assignment tab The inspection lot number is displayed in the assignment screen area. After saving the production order, the inspection lot is also saved.

Task 3: Results recording for inspection points You can carry out inspection results recording several times for the inspection characteristics by using free inspection points. 1.

Record several inspection results for the characteristics in your inspection lot. Use the worklist for results recording. Hint: The inspection results for the characteristic Shaft Length are still needed in the task for the SPC inspection. Hint: If you do not want to confirm the production order when completing the inspection points in Operation 60, set the flag No confirmation in the inspection point valuation screen. Hint: Do not enter a usage decision for this inspection lot. How does the rejection of a characteristic affect the valuation of an inspection point? ____________________________________________________________


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____________________________________________________________ a)

Results Recording Worklist Logistics → Quality Management → Quality Inspection → Worklist → Results Recording (QE51N) Field name or data type

Values

Material

T-BQ6##

Plant

1000



Execute the function key F8. Manually create inspection points, and enter the inspection results for the inspection characteristics, and complete the characteristics processing. Hint: The valuation of inspection points in Operation 30 is implemented according to the proposed values in Customizing (inspection point completion variant Automatic valuation according to inspection point definition). Hint: The valuation of the inspection points in Operation 60 is implemented in the inspection point valuation screen (inspection point completion variant Quantity, Valuation, Confirmation (Production)). When the inspection point is valuated, a code is proposed for the rejection. This code comes from table TQ79 (Customizing: Definition of inspection points).

Task 4: Customizing Settings for Inspection Points The inspection point field combination is stored in the header of the routing. Check the settings for the inspection point field combination in Customizing. 1.

Which user fields are active? ____________________________________________________________


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____________________________________________________________ a)

Transaction QCCO, then Quality Management → Quality Planning → Inspection Planning → General → Define Identifier for Inspection Points Inspection point-user field-combination 990: Inspection point: Container, date Tab "Fields", active user fields Number length: 10, keyword: Container Date (system field), keyword: Date

2.

Which code is proposed when all inspection characteristics are accepted, and which is proposed when at least one inspection characteristic is rejected? ____________________________________________________________ ____________________________________________________________ a)

Transaction QCCO, then Quality Management → Quality Planning → Inspection Planning → General → Define Identifier for Inspection Points Inspection point-user field-combination 990: Inspection point: Container, date Tab page "Valuation" Accepted: Code A, Code Group 03; Rejection: Code R, Code Group 03;

3.

Inspection points can be generated automatically when inspection lots are created. In addition, the user fields can be proposed and verified by the system and a range of values (F4 help) can be proposed for each field. What are the function modules (copy models) called that SAP delivers for this purpose? Automatic creation of inspection points: ____________________________________________________________ Proposal of user fields in results recording: ____________________________________________________________ Verification of user fields in results recording: ____________________________________________________________ List of user fields in input help for results recording: Continued on next page

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____________________________________________________________ a)

Transaction QCCO, then Quality Management → Quality Planning → Inspection Planning → General → Define Identifier for Inspection Points Inspection point-user field-combination 990: Inspection point: Container, date Tab page "Function modules" Hint: Select the function module with input help. Restrict the selection using QAPP_CUST_IP* Automatic creation of inspection points: QAPP_CUST_IP_CREATE Default for user fields in results recording: QAPP_CUST_IP_PROPOSAL Verification of user fields in results recording: QAPP_CUST_IP_CHECK List of values for user fields in results recording: QAPP_CUST_IP_F4

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Exercise 6: Inspection Point Processing with a Process Order Exercise Objectives After completing this exercise, you will be able to: • Make the required settings for an inspection with inspection points • Plan inspection point processing in the master recipe • Perform several inspections for an inspection characteristic, for example, at regular intervals • Record results for the inspection point

Business Example You produce tablets using process orders. You want to perform time-related inspections on the line.

Task 1: Settings in the Master Recipe For the material TAB-1##, various master recipes exist in the SAP training system. 1.

Check and change the QM-related data in the master recipe for your material TAB-1##, plant 1100; recipe counter 1. You want to record results based on time and you want the inspection points to be generated automatically. What is the user field combination? ____________________________________________________________ In the Quality Management header data for the recipe, enter the inspection point identifier you want to use to record the inspection results. Partial lots are not planned for this exercise. Make the required settings in the master recipe header. ____________________________________________________________ Then define the interval for quality inspections at phase level – 10 mins for phase 210. ____________________________________________________________ In addition, the system should valuate the inspection point automatically, based on the inspection point. Set the QM phase data accordingly. Make a note of the parameter and its setting. ____________________________________________________________ Continued on next page

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Add an inspection characteristic to your master recipe 1 in group TAB-1##. Call up your master recipe in the change mode. Navigate to the operation/phase overview, and select Phase 210 relevant to the quality inspection. Then update the assigned inspection characteristics with a pH-value inspection (inspection characteristic 9-120; Version 1, Plant 1100). The sample is to be determined according to the procedure FIX5-SP1. The task list characteristic/material is to be defined as the SPC criterion. ____________________________________________________________ In phase 210 of the master recipe, assign a new sampling procedure FIX2-P1 that fulfills the requirements for using inspection points, to your inspection characteristics (except for the inspection characteristic 9-120 that you added in exercise 1-5). Save the changes to your master recipe. ____________________________________________________________ Display sampling procedure FIX2-P1. Which setting allows the use of this sampling procedure for the in-process inspection with inspection points. ____________________________________________________________ Hint: If you do not want to change a recipe, you can also display the master recipe with recipe group 2 from the recipe group TAB-1##.

Task 2: Change Process Instruction Categories in the Master Recipe Add the process instruction to your master recipe that allows you to switch from the PI sheet directly to QM results recording. 1.

Goto the process instruction overview for the quality-relevant phase 210. Delete the two process instruction categories ZQ_QMRE1 and ZQ_QMRE2 that were assigned to a different exercise in the PLM420 training course. Then add the process instruction category in the same position to enable "QM-Jump". What is this process instruction called? ____________________________________________________________ Change the text of the process instruction category INSTR in phase 210 to: Quality inspection: - With 10 minute intervals, enter results for: Continued on next page

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used sieve size Water content Potency of Active Ingredient pH Value Save the changes to your master recipe. Hint: If you do not want to change a recipe, you can also display the master recipe with recipe group 2 from the recipe group TAB-1##.


Create the process order with the order type PI01 in the plant 1100. The order quantity is 1100 pieces or 2100 pieces. Use the scheduling type 4 (current date). Make a note of the path you use to create the order. ____________________________________________________________ ____________________________________________________________ What is the number of the order you created? ____________________________________________________________ What is the inspection lot number? ____________________________________________________________

Task 4: Process Coordination Use the process coordination to send the control recipe, and to maintain the PI sheets. 1.

Send your control recipe in the control recipe monitor (or as a batch job). What is the control recipe number? ____________________________________________________________ ____________________________________________________________


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Then call up the relevant PI sheet. Process the sheet as far as the option for calling up the results recording function. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. Record inspection results for each inspection point in your inspection lot, by accessing the results recording function from the PI sheet several times. You use inspection point identifier 999 for inspection date and time. Record inspection results for an additional inspection point that has not been created automatically, by accessing the results recording function directly (without using the Assigned inspection points pushbutton). Hint: The inspection results for the inspection characteristic pH Value are still needed in the task for the SPC inspection in the PLM420 training course. Hint: Do not enter a usage decision for this inspection lot.

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Solution 6: Inspection Point Processing with a Process Order Task 1: Settings in the Master Recipe For the material TAB-1##, various master recipes exist in the SAP training system. 1.

Check and change the QM-related data in the master recipe for your material TAB-1##, plant 1100; recipe counter 1. You want to record results based on time and you want the inspection points to be generated automatically. What is the user field combination? ____________________________________________________________ In the Quality Management header data for the recipe, enter the inspection point identifier you want to use to record the inspection results. Partial lots are not planned for this exercise. Make the required settings in the master recipe header. ____________________________________________________________ Then define the interval for quality inspections at phase level – 10 mins for phase 210. ____________________________________________________________ In addition, the system should valuate the inspection point automatically, based on the inspection point. Set the QM phase data accordingly. Make a note of the parameter and its setting. ____________________________________________________________ Add an inspection characteristic to your master recipe 1 in group TAB-1##. Call up your master recipe in the change mode. Navigate to the operation/phase overview, and select Phase 210 relevant to the quality inspection. Then update the assigned inspection characteristics with a pH-value inspection (inspection characteristic 9-120; Version 1, Plant 1100). The sample is to be determined according to the procedure FIX5-SP1. The task list characteristic/material is to be defined as the SPC criterion. ____________________________________________________________ In phase 210 of the master recipe, assign a new sampling procedure FIX2-P1 that fulfills the requirements for using inspection points, to your inspection characteristics (except for the inspection characteristic 9-120 that you added in exercise 1-5). Continued on next page

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Save the changes to your master recipe. ____________________________________________________________ Display sampling procedure FIX2-P1. Which setting allows the use of this sampling procedure for the in-process inspection with inspection points. ____________________________________________________________ Hint: If you do not want to change a recipe, you can also display the master recipe with recipe group 2 from the recipe group TAB-1##. a)


Values

Recipe Group

TAB-1##

Recipe

1

Material

TAB-1##

Plant

1100

Recipe header, pushbutton Quality Management Screen Area: Parameters for dynamic modification/inspection points. Inspection points (user field combination): 999 Generated inspection point, date and time Partial lot assignment: Partial lots not supported Master Recipe: Operations Select Phase 210 Icon: QM Data in Operation Screen Area: Quality Management: Inspection Points Time-related: x; Time factor: 10 mins.


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Inspection point completion: 3 Automatic valuation based on inspection point definition Master Recipe: Operations Select Phase 210 Icon: Inspection characteristics Field name or data type

Values

Master inspection characteristic:

9-120, pH-value Plant 1100 Version 1

Sampling procedure

FIX5-SP1

SPC criterion

Task list characteristic/Material

Change sampling procedure for inspection characteristics Insp. Characteristic

New sampling procedure

N-100

FIX2-P1

N-200

FIX2-P1

N-300

FIX2-P1

Display sampling procedure Logistics → Quality Management → Quality Planning → Basic Data → Sample → Sampling Procedure → Display (QDV3) Sampling Procedure: FIX2-P1 Screen area Inspection Points: x Free inspection pts

Task 2: Change Process Instruction Categories in the Master Recipe Add the process instruction to your master recipe that allows you to switch from the PI sheet directly to QM results recording. 1.

Goto the process instruction overview for the quality-relevant phase 210. Delete the two process instruction categories ZQ_QMRE1 and ZQ_QMRE2 that were assigned to a different exercise in the PLM420 training course. Then add the process instruction category in the same position to enable "QM-Jump". What is this process instruction called? Continued on next page

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____________________________________________________________ Change the text of the process instruction category INSTR in phase 210 to: Quality inspection: - With 10 minute intervals, enter results for: used sieve size Water content Potency of Active Ingredient pH Value Save the changes to your master recipe. Hint: If you do not want to change a recipe, you can also display the master recipe with recipe group 2 from the recipe group TAB-1##. a)


Values

Recipe Group

TAB-1##

Recipe

1

Material

TAB-1##

Plant

1100

Master Recipe: Operations Select Phase 210 Icon: Process instructions Process instructions to be deleted: ZQ_QMRE1 ZQ_QMRE2 Process instruction for “QM Jump”: QMJMP_PH Change the process instruction category INSTR to Phase 210. Continued on next page

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There are two ways to make these changes: Select the process instruction category, then the detail for the process instruction. Select the characteristic: PPPI_INSTRUCTION, then: Valuation or Select the process instruction, then assistant; select the control instruction 010, then Change. Text: Quality inspection: - With 10 minute intervals, enter results for: used sieve size Water content Potency of Active Ingredient pH Value Save the changes to your master recipe.


Create the process order with the order type PI01 in the plant 1100. The order quantity is 1100 pieces or 2100 pieces. Use the scheduling type 4 (current date). Make a note of the path you use to create the order. ____________________________________________________________ ____________________________________________________________ What is the number of the order you created? ____________________________________________________________ What is the inspection lot number?


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____________________________________________________________ a)


Values

Material number

TAB-1##

Production plant

1100

Process order type

PI01

Total quantity

1100 PC or 2100 PC

Scheduling type

4 (current date)




Send your control recipe in the control recipe monitor (or as a batch job). What is the control recipe number? ____________________________________________________________


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____________________________________________________________ a)


Values

Plant

1100

Creation Date

Todaýs date

Send the control recipes to recipients Q1 and Q2. Select the control recipes and press the pushbutton Send. 2.

Then call up the relevant PI sheet. Process the sheet as far as the option for calling up the results recording function. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. Record inspection results for each inspection point in your inspection lot, by accessing the results recording function from the PI sheet several times. You use inspection point identifier 999 for inspection date and time. Record inspection results for an additional inspection point that has not been created automatically, by accessing the results recording function directly (without using the Assigned inspection points pushbutton). Hint: The inspection results for the inspection characteristic pH Value are still needed in the task for the SPC inspection in the PLM420 training course. Hint: Do not enter a usage decision for this inspection lot. a)


Values

Plant

1100

Material number

TAB-1##

The control recipe number matches the PI sheet number.


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Select the PI sheet, and choose pushbutton Maintain PI sheet, F5. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. In your PI sheet, use the pushbutton highlighted in yellow: Record Inspection Results. On the initial screen: Record results for the inspection point, use the pushbutton assigned inspection points. Select the first inspection point that was generated and choose the ENTER key. Alternatively: Double-click on the generated inspection point. The results recording screen for your first inspection point appears. Valuate the four inspection characteristics and valuate and complete the inspection point (with the save function). Record results for the additional inspection points in the same way. Results recording for inspection points You record inspection results for additional inspection points that have not been created automatically, by accessing the results recording function directly (without using the Assigned inspection points pushbutton). There are several ways to do this: •

•

Using the link from the PI sheet, press ENTER on the initial results recording screen (instead of choosing the Assigned inspection points function). Using the QM menu, choose: Logistics → Quality Management → Quality Inspection → Worklist → Results Recording (QE51N) Hint: The inspection results for the inspection characteristic pH Value are still needed in the task for the SPC inspection in the PLM420 training course. Hint: Do not enter a usage decision for this inspection lot.

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Lesson Summary You should now be able to: • Plan a multiple inspection for an operation with inspection point processing. • Implement a multiple entry of inspection results for inspection characteristics in the inspection lot.

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Lesson: Inspection During Production with Physical Samples Lesson Overview This lesson deals with multiple entry of inspection results for inspection characteristics in the inspection lot for the order. For multiple entry of inspection results for the inspection characteristics in the same inspection lot, the SAP system uses inspection points. By using Sample Management, you can plan multiple recording of inspection results using a detailed sampling procedure. Results recording for the inspection characteristics for all samples is mandatory in this case. Hint: Inspection points will be discussed in later lessons in the PLM420 training course. This lesson uses the inspection type Inspection point for physical sample.


Plan multiple inspections for an operation with sample management. Implement a multiple entry of inspection results for inspection characteristics of samples in the inspection lot.

Business Example Different materials are manufactured in production with either production orders or process orders. You want to enter the inspection results for specific inspection characteristics during production multiple times during the same order with an in-process inspection. The inspection results are needed for later process documentation or for quality control.

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Lesson: Inspection During Production with Physical Samples

In-Process Inspection with Physical Samples in Production

Figure 47: Sample management

Figure 48: Inspection During Production with Physical Samples: Possible scenarios

You can record inspection results for planned and unplanned physical samples, or a combination of both.

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Figure 49: Physical-Sample Drawing in Production (Planned)

You can use Sample Management in an inspection during production to: • •

Plan the drawing and inspection of physical samples at operation/phase level Record inspection results for physical samples and valuate the samples

In preparation, you activate the use of inspection points in the header of the master recipe, and assign an appropriate sample-drawing procedure with one or several sample-drawing items. You then enter information for inspection point completion in the QM data for the operation or phase and, if required, assign corresponding partial sample numbers in the task list characteristics for each operation or phase. When the order is released, the inspection lot and its corresponding planned physical-sample records are created, together with the planned inspection specifications. If necessary, you can create additional data records manually for unplanned physical samples. You record results for each sample and these samples are then valuated.

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Figure 50: Automatic Creation of Physical Samples

3 Physical samples were planned using the sample-drawing procedure in the relevant master recipe. When the process order is released, the system creates the inspection lot and its 3 corresponding physical samples. The inspection results for the planned physical samples are to be confirmed for the operations and phases 10 and 20. (Controlled by partial sample Number in the task list characteristic). An optional characteristic was defined in operation/phase 30. No physical sample records could therefore be created automatically. You can record inspection results for the physical samples using the corresponding process specifications or the worklist for results recording. All physical samples that were automatically created appear automatically in the worklist and can be directly processed, provided that their status allows this.

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Figure 51: Planned Physical Samples with Inspection Specifications from Sample-Drawing Procedure (1)

The central planning object in sample management is the sampling procedure. This is entered in the routing header or recipe header. The sampling-drawing procedure contains at least one sample-drawing item. The details on the sample (for example, number of samples (inspection points)) are defined in the sample-drawing item.

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Figure 52: Planned Physical Samples with Inspection Specifications from Sample-Drawing Procedure (2)

The sampling instruction can also refer to partial sample numbers. These partial sample numbers are entered in the inspection characteristics in the plan.

Figure 53: Results Recording for Physical Samples

When the process order is released, the system creates the inspection lot.

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You can record results for planned and unplanned physical samples. Selection of the physical samples for results recording takes place using the worklist or using specific transactions for sample management. All physical samples that were automatically created appear automatically in the worklist and can be directly processed, provided that their status allows this. If you record results for an additional, unplanned physical sample, the sample must first be manually created, together with the reference to the inspection lot, and then be released. (Function within results recording).

Figure 54: Physical-Sample Drawing in Production (Unplanned)

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Figure 55: Manual Creation of Physical Samples

No physical samples were planned in the corresponding master recipe (using sample-drawing items in a sample-drawing procedure). When the process order is released, the system creates the inspection lot and sample automatically. To record results for an unplanned physical sample, you must first create the sample manually, together with the reference to the inspection lot, and then release the sample if necessary. In the example above, unplanned sample 1 is to be drawn for operation/phase 10 and unplanned samples 2 and 3 are to be drawn for operation/phase 20. You can select the physical samples that are to be drawn manually using: • • •

Corresponding process specifications The worklist for results recording Using specific transactions for sample management

You can record inspection results for the physical samples using the corresponding process specifications or the worklist for results recording.

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Figure 56: Physical-Sample Drawing in Production (Planned and Unplanned)

The assignment of physical samples to inspection characteristics or inspection operations/phases takes place by allocating a partial sample number, (which can be entered in the general data for the task list characteristic). Example: In operation/phase 10 the same partial sample number (e.g. 10) was defined for task list characteristics 1 and 2. In operation/phase 20, an additional partial sample number (e.g. 20) was entered that was different from the number entered in operation/phase 20. Task list characteristic 4 was defined as an optional characteristic in operation/phase 30. No physical sample records could therefore be created automatically. Two sample-drawing items are planned in the sample-drawing procedure. One physical sample is planned up to partial sample 10, and two physical samples are to be created up to partial sample 999. The physical samples 1-3 that were planned using the sample-drawing procedure were generated automatically, when the inspection lot was created. Physical samples 4 and 5 were not planned and were therefore added manually (for example, using the corresponding process specification or in the results recording function).

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Figure 57: Automatic and Manual Creation of Physical Samples

3 Physical samples were planned using the sample-drawing procedure in the relevant master recipe. When the process order is released, the system creates the inspection lot, the physical-sample drawing, and its three corresponding physical samples. The inspection results for the planned physical samples are to be confirmed for the operations/ phases 10 and 20. (Controlled in the task list characteristic using the partial sample number, or an optional/required characteristic, since physical-sample records are only automatically created for required characteristics). Two additional, unplanned samples are taken at a later stage, created manually in the system and then assigned to the corresponding operations/phases in the inspection lot. You can record inspection results for the physical samples using the corresponding process specifications or the worklist for results recording.

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Figure 58: Drawing Physical Samples from the PI Sheet

From the PI sheet, you can create new physical-sample drawings and change existing physical-sample drawings. You can also process the corresponding physical-sample records (for example, you can confirm the physical-sample drawing or release of the physical samples, if necessary using a digital signature).

Figure 59: Jump to Physical-Sample Processing

In the standard system, there are the following process instruction categories with dynamic function calls (function modules) that are relevant for sample management: • •

108

Create new sample: QMJMP_NS/QPRS_PI_NEW_SAMPLE_DRAW Maintain sample: QMJMP_SD/QPRS_PI_SAMPLE_DRAW_PROCESSING


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This slide shows an example for defining and executing a function call. You can also find this function call in the SAP reference client. The inspection lot number is transferred to the function module, together with the import parameter. This lot number is used to switch from the PI sheet to the transaction for confirming the physical-sample drawing. Additional functions are supported by the following process instruction categories: • •

Switch to QM results recording for the operation/phase: QMJMP/QMJMP_PH Recording a summarized measured value in the PI sheet or in an external system and transferring this as a default value to QM results recording for the operation/phase: QMRES/QMRES_PH

Figure 60: Process-Optimized Results Recording

Recording screen for results recording for several physical samples within one inspection lot and operation.

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Exercise 7: Inspection during Production with Physical Samples in Production Order Exercise Objectives After completing this exercise, you will be able to: • Draw and inspect physical samples at any time during the production process • Describe the automatic creation of the first physical-sample drawing and physical samples and also the generation of inspection specifications for these physical samples at inspection lot creation

Business Example You manufacture shafts using production orders. In your company, a specific number of physical samples are drawn from the production line to be inspected. Hint: The physical samples also allow multiple recording of inspection results for inspection characteristics in one inspection lot. In the SAP system, the Inspection point type 03 Inspection point for physical sample is used for physical samples.


Create the production order with the order type PP01 in the plant 1000. The order quantity is 600 PC. Use the scheduling type Current date (4). What order number was given? __________________________________ What inspection lot number was given? ____________________________

Task 2: Display Inspection Lot for In-Process Inspection in Production Display the inspection lot for your material T-BQ6##. 1.

How do you know whether an inspection of physical samples has been planned? ____________________________________________________________


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Task 3: Record Inspection Results on the Samples for the In-Process Inspection on the Production Order Record the inspection results for the operations 20 and 60 in your inspection lot, using the worklist for results recording. 1.

Record the inspection results for the planned physical samples that have been created. Optional: Create another unplanned sample from the results recording. Record and valuate the inspection results.

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Solution 7: Inspection during Production with Physical Samples in Production Order Task 1: Production Order for Material Create and release a production order for your material T-BQ6##. 1.

Create the production order with the order type PP01 in the plant 1000. The order quantity is 600 PC. Use the scheduling type Current date (4). What order number was given? __________________________________ What inspection lot number was given? ____________________________ a)


Values

Material

T-BQ6##

Production plant

1000

Order type

PP01

Total quantity

600 PC

Scheduling type

4 (current date)


Task 2: Display Inspection Lot for In-Process Inspection in Production Display the inspection lot for your material T-BQ6##. 1.

How do you know whether an inspection of physical samples has been planned?


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____________________________________________________________ a)

Display Inspection Lot Logistics → Quality Management → Quality Inspection → Worklist → Inspection → Display Data (QA33) or Logistics → Quality Management → Quality Inspection → Inspection Lot → Processing → Display (QA03) Display the physical samples for the physical-sample drawing. Either using the menu path → Goto → Physical Samples or using the Pushbutton Samples The physical samples were planned in the sample-drawing procedure and created automatically by the system. The sample-drawing procedure is entered in the inspection lot on the Insp. specifications tab.

Task 3: Record Inspection Results on the Samples for the In-Process Inspection on the Production Order Record the inspection results for the operations 20 and 60 in your inspection lot, using the worklist for results recording. 1.

Record the inspection results for the planned physical samples that have been created. Optional:


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Create another unplanned sample from the results recording. Record and valuate the inspection results. a)


Values

Material

T-BQ6##

Plant

1000



Execute the function key F8. Record the inspection results for the samples. Create an unplanned sample: In the worklist for the results recording, select the entry Further inspection. Delete the suggested sample number in the entry screen for the inspection point. Then create an unplanned physical sample using the icon "Create physical sample". In the following screen (create physical sample for inspection lot), enter the corresponding data, and save. You can then record results for the physical sample that you have previously created.

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Exercise 8: Inspection during Production with Physical Samples in Process Order Exercise Objectives After completing this exercise, you will be able to: • Draw and inspect physical samples at any time during the production process • Describe the automatic creation of the first physical-sample drawing and physical samples and also the generation of inspection specifications for these physical samples at inspection lot creation

Business Example You produce tablets using process orders. In your company, a specific number of physical samples are drawn from the production line to be inspected. Hint: The physical samples also allow multiple recording of inspection results for inspection characteristics in one inspection lot. In the SAP system, the Inspection point type 03 Inspection point for physical sample is used for physical samples.


Create the process order with the order type PI01 in the plant 1100. The order quantity is 3500 PC. Use the scheduling type 4 (current date). What is the number of the order you created? ____________________________________________________________ What is the inspection lot number? ____________________________________________________________

Task 2: Display Inspection Lot for In-Process Inspection in Production Display the inspection lot for your material TAB-1##. 1.

How do you know whether an inspection of physical samples has been planned? ____________________________________________________________ Continued on next page

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Send your control recipe in the control recipe monitor (or as a batch job). What is the control recipe number? ____________________________________________________________ ____________________________________________________________

2.

Then call up the relevant PI sheet. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. You now have the option of creating an unplanned physical-sample drawing (once you have processed the first part of the sheet. Which process instruction allows this function? ____________________________________________________________ Lock the physical sample drawing from the PI sheet. Which process instruction allows you to process the physical-sample drawing? ____________________________________________________________ Save the PI sheet.

Task 4: Record Inspection Results on the Samples for the In-Process Inspection on the Process Order Record inspection results for operation 210 in your inspection lot. Use the worklist for results recording. 1.

Record the inspection results for the planned physical samples that have been created. Make a note of one of the physical sample numbers. ____________________________________________________________ Create another unplanned sample from the results recording. Record and valuate the inspection results.

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Solution 8: Inspection during Production with Physical Samples in Process Order Task 1: Process order for material Create a process order for your material TAB-1##, and check the inspection lot number in the order header. 1.

Create the process order with the order type PI01 in the plant 1100. The order quantity is 3500 PC. Use the scheduling type 4 (current date). What is the number of the order you created? ____________________________________________________________ What is the inspection lot number? ____________________________________________________________ a)


Values

Material number

TAB-1##

Production plant

1100

Process order type

PI01

Total quantity

3500 PC

Scheduling type

4 (current date)




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Task 2: Display Inspection Lot for In-Process Inspection in Production Display the inspection lot for your material TAB-1##. 1.

How do you know whether an inspection of physical samples has been planned? ____________________________________________________________ a)

Display Inspection Lot Logistics → Quality Management → Quality Inspection → Worklist → Inspection → Display Data (QA33) or Logistics → Quality Management → Quality Inspection → Inspection Lot → Processing → Display (QA03) Display the physical samples for the physical-sample drawing. Either using the menu path → Goto → Physical Samples or Using the Pushbutton Samples The physical samples were planned in the sample-drawing procedure and created automatically by the system. The sample-drawing procedure is entered in the inspection lot on the Insp. specifications tab.


Send your control recipe in the control recipe monitor (or as a batch job). What is the control recipe number? ____________________________________________________________


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____________________________________________________________ a)


Values

Plant

1100

Creation Date

Todaýs date

Send the control recipes to recipients Q1 and Q2. Select the control recipes and press the pushbutton Send. 2.

Then call up the relevant PI sheet. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. You now have the option of creating an unplanned physical-sample drawing (once you have processed the first part of the sheet. Which process instruction allows this function? ____________________________________________________________ Lock the physical sample drawing from the PI sheet. Which process instruction allows you to process the physical-sample drawing? ____________________________________________________________


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Save the PI sheet. a)


Values

Plant

1100

Material number

TAB-1##

The control recipe number matches the PI sheet number. Select the PI sheet, and choose pushbutton Maintain PI sheet, F5. Hint: A signature is required when processing the PI sheet: Enter your user ID (PLM420-##) and password. In the PI Sheet: Yellow subordinate pushbutton Withdrawal of a new sample which calls the QM selection screen → Create New Physical-Sample Drawing with Reference. In the detail data for the physical sample, enter the quantity and unit of measure for the physical sample (for example, 1 PC). Process instruction category: ZQ_QMJNS (jump to QM for new physical-sample drawing) In the PI Sheet: Yellow pushbutton Processed physical sample drawing which allows you to process the physical sample drawing. Select the sample, and block it (using the pushbutton in the application function bar). Process instruction category: ZQ_QMJSD (jump to processing of physical-sample drawing)


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Task 4: Record Inspection Results on the Samples for the In-Process Inspection on the Process Order Record inspection results for operation 210 in your inspection lot. Use the worklist for results recording. 1.

Record the inspection results for the planned physical samples that have been created. Make a note of one of the physical sample numbers. ____________________________________________________________ Create another unplanned sample from the results recording. Record and valuate the inspection results. a)


Values

Material

TAB-1##

Plant

1100



Execute the function key F8. Record the inspection results for the samples. Create an unplanned sample: In the worklist for the results recording, select the entry Further inspection. Delete the suggested sample number in the entry screen for the inspection point. Then create an unplanned physical sample using the icon "Create physical sample". In the following screen (create physical sample for inspection lot), enter the corresponding data, and save. You can then record results for the physical sample that you have previously created.

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Lesson Summary You should now be able to: • Plan multiple inspections for an operation with sample management. • Implement a multiple entry of inspection results for inspection characteristics of samples in the inspection lot.

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Lesson: Inspection During Production with Automatic Valuation of Characteristics of a Batch

Lesson: Inspection During Production with Automatic Valuation of Characteristics of a Batch Lesson Overview With characteristic-based results recording for an order, inspection results for inspection characteristics can be documented in the SAP system during production (in-process inspection). In the case of batch-managed materials, the inspection results can also be used to valuate characteristics of the batch. This lesson handles the planning and implementation of an in-process inspection for batch-managed materials.


Explain planning for a quality check with batch-managed materials. Implement an in-process inspection in the production of a batch-managed material. Describe the value transfer from the master inspection characteristic for the class characteristic of the batch.

Business Example You want to use the inspection results in the in-process inspection for a batch-managed material to valuated the batch characteristics. You want to search for suitable batches for additional production stages or for a delivery using the inspection results from the in-process inspection.

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Planning and Implementing the In-Process Inspection for Batch-Managed Materials

Figure 61: Definition of Terms

The term Batch in the SAP system:   The same production- and inspection specifications are valid for a production lot. A batch is a unique subset of a material. The batches of one material are managed separately in stock. With regard to the production process, a batch is a quantity of a specific material during a given production run. This quantity, therefore, represents a unit with unique specifications. The definition of the term 'batch' influences the definition of the material. All criteria (characteristics) that would allow a batch to be reproduced, should be assigned to a material (object); the batch (object) however should only contain characteristics that are unique to this batch. The characteristic values in this specification denote that the batch cannot be reproduced.

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Figure 62: Functions in the Classification System

When structuring a classification system, you first define characteristics and the allowed characteristic values (characteristic maintenance). Then you define classes, to which you assign characteristics (class maintenance). You assign objects to the classes (such as, materials, batches) and describe these by giving the characteristics in the class object-related attributes. This batch valuation can also take place using the inspection results that have been recorded in QM. You can then use the Classification System to search for classed objects (for example, in batch determination).

Figure 63: Process Flow with Partial Lot Creation and Batch Assignment

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In the process manufacturing, the process order is created based on a master recipe. The data from the master recipe that also contains QM data, is copied into the order. Depending on the Customizing settings, an inspection lot is created when the order is released. The inspection lot can also be created manually. In the production process, quality inspections are carried out that are based on inspection points defined in the recipe. You can form partial lots based on varying quality results. A batch number can be assigned to each partial lot. Partial quantities of the produced material are confirmed and posted to the warehouse.

Figure 64: Inspection Points, Partial Lots and Batches in the Master Recipe

Partial lot assignment in the master recipe header You make settings for the different levels at which you want to control and document the production process: • • •

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Inspection Points Inspection points - partial lots Inspection points - partial lots - batches


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Indicators for the last partial lot assignment at operation/phase level •

This indicator defines the operation that plans the last inspection during production and if necessary the last assignments to the partial lots from a QM standpoint. The quantities in the inspection points/partial lots for this operation are proposed when the goods receipt for the order is posted. A goods receipt can only be posted automatically for operations that have this indicator set.

Indicator for partial lot quantity at operation/phase level •

If time-based inspection points are created in production, this indicator controls whether a quantity is to be assigned to each inspection point, or whether the quantity is only to be determined once for each partial lot.

Figure 65: Creation of Partial Lots

The inspection characteristics for an in-process inspection are included in the operations and phases of the master recipe. You can create new inspection characteristics in the master recipe or can reference existing master inspection characteristics. This graphic shows the interaction between the inspection points and the partial lots. If you have planned inspection points in the master recipe, you record results with reference to these for each inspection during production. Unlike an inspection without inspection points, inspection results can therefore be recorded for inspection characteristics in the same inspection operation several times directly after one another.

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For each production or process order, an inspection lot can be created for which partial lots can be created if necessary. If you do not confirm any partial quantities during production or do not work with inspection points, the inspection results are recorded for each operation for the entire inspection lot. If you produce goods in partial quantities, the system gives you the option of creating a new partial lot or copying the previous one for each inspection point. The decision should depend on whether varying inspection results for the partial quantities produced require these quantities to be assigned to separate partial lots. Several partial lots enable the stock to be separated for inventory management purposes, as a batch can be created from each partial lot.

Figure 66: Inspection Points, Partial Lots and Batches

This graphic shows the interaction between the inspection points, partial lots, and batches. If an inspection point identification is defined in the master recipe in the recipe header detail screen 'QM data', all inspection results recorded during production are related to the inspection point. Unlike an inspection without inspection points, inspection results can therefore be recorded for inspection characteristics in the same inspection operation several times directly after one another. The interval between such inspection points can be time-based (at specific times), quantity-based (after the production of a certain quantity), or freely defined.

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You record results for the inspection characteristics in the inspection lot. Only one inspection lot for an inspection during production can be created for a process order. If partial quantities with different properties are produced in a process order, you can inspect with inspection points and record the inspection results in each inspection point for a corresponding partial lot. Several partial lots can be formed. A partial lot identifies a specific production quantity during production. This quantity undergoes various operations or phases, in which different inspection characteristics are inspected based on inspection points and the results can be assigned to the partial lots. A new partial lot is created when the first inspection lot for this partial lot is processed. If the finished product is handled in batches, you can assign the partial lots to individual batches.

Figure 67: Relationship Between Partial Lots and Batches

If several partial lots are created during production, you can assign an individual batch number to each partial lot. This batch number is then used for the goods receipt from production. In addition, you can combine partial lots to form a batch, when recording inspection results for inspection points. The inspection results for the individual partial lots are the deciding factor in this case. If there is a difference between the values of the partial lots that have been produced, you can manage the stock subsequently in separate batches. You can form partial lots and split batches based on the confirmation of results.

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Figure 68: Assignment of Batch Numbers

You can enter the batch number for the subsequent goods receipt in the following ways: •

• •

For individual partial lots that have been created for an inspection lot and confirmed as partial lots. You can assign a batch number to each partial lot, or can combine several partial lots under the same batch number. At header level in the process order that has been created, if the whole order is confirmed as one quantity. The batch number is only assigned at the goods receipt.

Scenarios: •

•

•

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A) No batch is entered in the process order. An inspection during production takes place using inspection points. Partial lots are formed for this inspection and batches (C1, C2) are created. These batches C1 and C2 are then proposed at goods receipt. In this scenario, the batch could also be entered in the process order and would then be proposed as the default batch in the 1st partial lot. B) When you create a process order, the batch number C1 is specified and no inspection during production takes place with inspection points at batch level. This batch C1 is then given in the goods receipt transaction. C) The batch number is not known when the process order is created and no inspection during production takes place with inspection points at batch level. The product batch can then be created when the goods receipt is posted.


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Figure 69: Co-products

Figure 70: Typical Material Flow in Co-Product Manufacturing

This graphic illustrates a typical material flow in process manufacturing, using the example of two operations in the primary resources 'charging vessel' and 'reactor vessel'.

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The following cases are shown: • •

• • •

Introduction of ingredients The temporary creation of an intermediate product between two process units, which is subject to further treatment within the process; Such materials are represented by the material type INTR intramaterial. The production of waste The use of a catalyst that enters the process at a certain stage and subsequently leaves the process. The manufacture of one or several products; the production of several materials in a production run is known as the manufacture of co-products.

Figure 71: Bill of Material in Manufacture of Co-Products

Co-products can be included in the bill of material in the following way: •

A co-product can be assigned to the bill of material header as a leading material. Additional co-products appear as bill of material items.

Planned orders can be created for a leading material in material requirements planning. A process order must be created (manually if necessary) to create requirements for co-products that are listed as items in a bill of material.

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Prerequisites for the production of co-products are: • •

•

The 'Co-product' indicator must be set in the material master for co-products. The co-product indicator must also be set for the BOM items, to which co-products are assigned. However, it does not need to be set for a leading product in the BOM header. The creation of a process order can either take place for a co-product or for a process material.

Figure 72: Representation of Co-Products in QM

An example for the formation of partial lots is the simultaneous manufacture of co-products for several materials in a process order. Here, each co-product/product can be identified with a partial lot.

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Figure 73: Material Specification - Planning

The class characteristic that is assigned to the master inspection characteristic must be defined either with the format (NUM) or the format (CHAR) with selected sets. The inspection specifications can come from the following sources: •

• • •

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From the master inspection characteristic (the master inspection characteristic is referenced in the material specification and is not linked to a class characteristic). The master inspection characteristic is referenced in the material specification and is not linked to a class characteristic. From the class characteristic (the master inspection characteristic is referenced in the material specification and is linked to a class characteristic). From the batch classification of the relevant material (the linked master inspection characteristic is referenced in the material specification).


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Figure 74: Using a Material Specification

The inspection type in the (QM view) of the material master controls whether goods are to be inspected using the material specification. If you only inspect with the material specification, the default values must be maintained in Customizing for the inspection type. If you inspect with a task list and specification, the specification takes precedence.

Figure 75: Batch Valuation With Material Specification

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The material specification provides a simple template for inspecting a material across all clients. It consists of the assignment of the material and inspection characteristics. In addition to the “normal” specification, the function can be extended so that the inspection results lead to a batch valuation. For this to take place, the material in the material specification must be classified (class type 022/023) and handled in batches, and the master inspection characteristics that are used must be linked to the relevant class characteristics.

Figure 76: Batch Valuation Without Material Specification

You must set the indicator “Batch valuation without material specification” in the plant-dependent settings in Customizing. When using this function, you can no longer control which characteristics from the batch are to be supplied with the QM inspection results based on material. The transfer of inspection results always occurs if there is a link between the master inspection characteristic and the class characteristic [batch characteristic] (independent of material). During inspection lot creation, there must be a link between the master inspection characteristics and the class characteristics in the batch class, so that a batch valuation occurs when making usage decisions or inspection point valuations.

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Figure 77: Time of Batch Evaluation

The system only copies results from master inspection characteristics that are linked to a class characteristic in the batch class. You do not need to inspect with a material specification. In the class characteristic • •

The mean value for quantitative master inspection characteristics The attribute code for qualitative, summarized master inspection characteristics with characteristic attributes

are described for the corresponding inspection characteristic. • •

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The long text for the usage decision logs which class characteristics in the batch class have inspection results. Batch derivation is possible as of Release 4.7. You can use this to transfer data, for example, when you make the usage decision. This may be necessary when several batches of heterogeneous materials are based on one bulk batch.


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Figure 78: Specification for Produced Batches

In an in-process inspection, the inspection requirements are defined using inspection characteristics for the operations and phases that are contained in the master recipe. The process order or inspection lot is based on this master recipe. You can either create new inspection characteristics in the master recipe, or reference master inspection characteristics for this inspection. Master inspection characteristics are master data created in QM. They simplify the standard inspection process and enable a link to the class characteristics of batches. This link allows the automatic transfer of inspection results from the inspection characteristics to the corresponding class characteristics of the batches produced. When you inspect with inspection points, the inspection results are recorded for a specific partial lot in each inspection point. You can assign several partial lots to an inspection lot. A partial lot identifies a discrete production quantity that can be assigned to a batch. The inspection results for an inspection point are transferred to the class characteristics in the batch that are linked to master inspection characteristics, once the inspection point has been valuated.

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Figure 79: The Batch Where-Used List over Several Production Stages

The where-used list tracks the batch, using the Inventory Management functions. From initial posting to deletion from inventory, each batch has its own document journal. In addition, links between batches across all manufacturing levels through to the sales order and batch splits are logged. The lifecycle of a batch is only logged, if an inventory posting has taken place. The numbers of the reference documents, the process order and sales order are stored, as well as the material document. The 'Top down' and 'Bottom up' display variants describe the direction, in which you view the 'family tree' of the batch. You can also display the batch where-used list as a graphic. The Batch Information Cockpit that was developed in 4.6C was enhanced in Release 4.7. Using a customer-specific BAdI, it is now possible to make a customer-specific selection on a selection tab page. This selection tab page is delivered with an example implementation that you can use to select inspection lots.

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Exercise 9: Inspection during Production with Automatic Valuation of Batch Characteristics in Process Order Exercise Objectives After completing this exercise, you will be able to: • Describe the use of terms "Class characteristic" and "Batch" in the SAP System • Describe the connection between batches and partial lot processing • Create batches in the system that are formed during the process or planned batches • Valuate class characteristics for a batch automatically with results from QM

Business Example During the production process, quantities of differing quality are manufactured that have to be handled as batches. Partial lots are therefore created and assigned to a batch for each partial quantity. In this process, new batch master records are also created. You produce tablets using process orders. A batch is manufactured for each order. This batch is classified for batch determination when the delivery note is created. Some of the characteristic values in the batch correspond to inspection results in QM.

Task 1: Display material master Display the Classification view for your material TAB-1## (class type 023). 1.

Which characteristics are contained in the class that has been assigned? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 2: Display master inspection characteristic The coupling between a master inspection characteristic and a class characteristic is required to transfer an inspection result to a characteristic of the batch. 1.

Display the master inspection characteristic N-300 Active ingredient content in change mode (Plant: 1100). Is a class characteristic assigned to this master inspection characteristic, and if so, which one? Continued on next page

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____________________________________________________________

Task 3: Customizing Setting for Batch Valuation from the Quality Management Check the QM default settings at plant level in Customizing. 1.

You can change the settings so that the characteristics results can also be transferred without material specification. What is this setting for Plant 1100? ____________________________________________________________


Create the process order with the order type PI01 in the plant 1100. The order quantity is 4500 PC. Use the scheduling type 4 (current date). What is the number of the order you created? ____________________________________________________________ What batch number is given? ____________________________________________________________ What is the inspection lot number? ____________________________________________________________


Use your material number TAB-1## to select the relevant inspection lot. Have inspection points been automatically created? ____________________________________________________________ If so, how many were generated automatically and how is the number calculated? ____________________________________________________________ ____________________________________________________________


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Valuate the inspection characteristics for the first inspection point and close the characteristics. The values in this case should fall within the tolerances. Once you have saved, the valuation screen for the inspection point appears. A valuation is proposed. Which setting do you make, to have the system propose this default value? ____________________________________________________________ ____________________________________________________________ How do you define whether a quantity is to be confirmed for each inspection point, or only once at the end of the process? ____________________________________________________________ ____________________________________________________________ Create a partial lot for your first inspection point: Partial lot 1; Short text for the partial lot:Group ##-1 Transfer the batch proposal. Create a partial confirmation for the process order.

Task 6: Display the Batch Display the batch master record for your batch from the previous exercise. 1.

Access the Classification information and compare the values with the inspection results that were recorded. What can you see? ____________________________________________________________ ____________________________________________________________

Task 7: Record Additional Inspection Results for In-Process Inspection for Process Order Now record additional inspection results for operation 210 in your inspection lot. Use the worklist for results recording. 1.

Record inspection results for a second inspection point (this time with some outside the tolerances) so that some of the inspection characteristics are rejected at the valuation. However, the inspection result for the Active ingredient content should be between 0-100%. Once you have saved, the valuation screen for the inspection point appears. A valuation is proposed. Continued on next page

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When the results differ from the first inspection point, create a new partial lot Partial lot 2; short text for the partial lot: Group ##-2 and a new batch TL2Grp##. Create a partial confirmation for the process order.

Task 8: Display Batches for the Material TAB-1## Display the batch master records for your batches from the previous exercises. 1.

Access the Classification information and compare the values with the inspection results that were recorded. What can you see? ____________________________________________________________ ____________________________________________________________

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Solution 9: Inspection during Production with Automatic Valuation of Batch Characteristics in Process Order Task 1: Display material master Display the Classification view for your material TAB-1## (class type 023). 1.

Which characteristics are contained in the class that has been assigned? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Display (MM03) View:

Classification

Class type:

023 Batch

Class:

N-005 Tablet characteristics

Class characteristic:

N-006 Active ingredient content

Select class, then the menu path Environment → Display master data, Tab page: Characteristics

Task 2: Display master inspection characteristic The coupling between a master inspection characteristic and a class characteristic is required to transfer an inspection result to a characteristic of the batch. 1.

Display the master inspection characteristic N-300 Active ingredient content in change mode (Plant: 1100). Is a class characteristic assigned to this master inspection characteristic, and if so, which one? ____________________________________________________________ a)

Display the master inspection characteristic N-300 in plant 1100 Logistics → Quality Management → Quality Planning → Basic Data → Inspection Characteristic → Display (QS24) The class characteristic N-006 (Active ingredient content) is assigned to the Master inspection characteristic N-300 (Active ingredient content).


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Task 3: Customizing Setting for Batch Valuation from the Quality Management Check the QM default settings at plant level in Customizing. 1.

You can change the settings so that the characteristics results can also be transferred without material specification. What is this setting for Plant 1100? ____________________________________________________________ a)

Customizing (Transaction QCC0): Then use the Customizing path: Quality Management → Basic Settings → Maintain Settings at Plant Level Plant 1100 Tab page: Inspection lot completion Screen Area: Batch Valuation Batch Valuation Without Material Specification: X Only the coupling between the master inspection characteristic and the class characteristic is needed to transfer an inspection result to the class characteristic of the batch.


Create the process order with the order type PI01 in the plant 1100. The order quantity is 4500 PC. Use the scheduling type 4 (current date). What is the number of the order you created? ____________________________________________________________ What batch number is given? ____________________________________________________________ What is the inspection lot number?


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____________________________________________________________ a)


Values

Material number

TAB-1##

Production plant

1100

Process order type

PI01

Total quantity

4500 PC

Scheduling type

4 (current date)


Display process order with material: Logistics → Production - Process → Process Order → Process Order → Display (COR3) Process order header Goods receipt tab: Batch


Use your material number TAB-1## to select the relevant inspection lot. Have inspection points been automatically created? ____________________________________________________________ If so, how many were generated automatically and how is the number calculated? ____________________________________________________________ ____________________________________________________________ Valuate the inspection characteristics for the first inspection point and close the characteristics. The values in this case should fall within the tolerances. Continued on next page

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Once you have saved, the valuation screen for the inspection point appears. A valuation is proposed. Which setting do you make, to have the system propose this default value? ____________________________________________________________ ____________________________________________________________ How do you define whether a quantity is to be confirmed for each inspection point, or only once at the end of the process? ____________________________________________________________ ____________________________________________________________ Create a partial lot for your first inspection point: Partial lot 1; Short text for the partial lot:Group ##-1 Transfer the batch proposal.


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Create a partial confirmation for the process order. a)


Values

Material

TAB-1##

Plant

1100



Execute the function key F8. Have inspection points been automatically created? Yes Three inspection points were created by the system. The interval defined in the QM data of Phase 210 was 10 mins and a phase duration of 30 mins was entered in the master recipe. (30/10 = 3) The inspection characteristic valuation and completion occurs automatically based on the user settings. Recording configuration !!! The valuation proposal for the inspection point is based on the settings for the user field combination in Customizing for the inspection point. Here, you can enter default codes for acceptance and rejection. Settings in the QM data at operation level in the master recipe: Quan. pt. lot: x Pushbutton Ptl lot (Create new partial lot) Short text for the partial lot: Group##-1; Inspection point valuation: Acceptance Partial confirmation for the process order, for example Yield: 1000 PC

Task 6: Display the Batch Display the batch master record for your batch from the previous exercise. 1.

Access the Classification information and compare the values with the inspection results that were recorded. What can you see? ____________________________________________________________ Continued on next page

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____________________________________________________________ a)

Display batch Logistics → Quality Management → Quality Planning → Logistics Master Data → Batch → Display (MSC3N) or Logistics → Central Functions → Batch Management → Batch → Mass Processing (MSC5N) Field name or data type

Values

Material

TAB-1##

Plant

1100

Batch

if necessary, select batches for the material with input help

Navigate to the Classification tab for your batch. The class characteristic Active ingredient content was valuated with the inspection result for the master inspection characteristic Active ingredient content.

Task 7: Record Additional Inspection Results for In-Process Inspection for Process Order Now record additional inspection results for operation 210 in your inspection lot. Use the worklist for results recording. 1.

Record inspection results for a second inspection point (this time with some outside the tolerances) so that some of the inspection characteristics are rejected at the valuation. However, the inspection result for the Active ingredient content should be between 0-100%. Once you have saved, the valuation screen for the inspection point appears. A valuation is proposed.


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When the results differ from the first inspection point, create a new partial lot Partial lot 2; short text for the partial lot: Group ##-2 and a new batch TL2Grp##. Create a partial confirmation for the process order. a)


Values

Material

TAB-1##

Plant

1100



Execute the function key F8. Record the inspection results for an additional inspection point, some values outside the tolerance limit. Inspection point valuation screen Pushbutton Ptl lot (Create new partial lot) Enter the short text for the new partial lot. Pushbutton Batch (Create batch) Creation of WIP Batches -> No External number assignment for the new batch: TL2Grp## Partial confirmation for the process order, for example Yield: 1500 PC

Task 8: Display Batches for the Material TAB-1## Display the batch master records for your batches from the previous exercises. 1.

Access the Classification information and compare the values with the inspection results that were recorded. What can you see? ____________________________________________________________


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____________________________________________________________ a)

Display batch Logistics → Central Functions → Batch Management → Batch → Mass Processing (MSC5N) Field name or data type

Values

Material

TAB-1##

Plant

1100

Navigate to the Classification tab for your batches. The class characteristic Active ingredient content was valuated with the inspection result for the master inspection characteristic Active ingredient content.

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Lesson Summary You should now be able to: • Explain planning for a quality check with batch-managed materials. • Implement an in-process inspection in the production of a batch-managed material. • Describe the value transfer from the master inspection characteristic for the class characteristic of the batch.

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Lesson: SPC – Statistical Process Control Lesson Overview With characteristic-based results recording for an order, inspection results for inspection characteristics can be documented in the SAP system during production (in-process inspection). You can also plan a quality control chart for the inspection characteristics in the quality planning. This quality control card can be displayed and updated in the inspection results recording. A valuation of the inspection characteristics according to the action limits of a quality control chart is also planned. This lesson will deal with the corresponding planning stages, and record the inspection results for an SPC characteristic.


Explain the control chart types in the SAP system and make Customizing settings Implement an inspection planning for an SPC inspection Use the functions of the control charts in the inspection results recording

Business Example You want to use quality control charts for specific inspection characteristics in the in-process inspection for the order in order to represent the course of the average value and standard deviation in a graph of the results for quantitative inspection characteristics. You also want to make statistical parameters available to quality control.

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Lesson: SPC – Statistical Process Control

Quality Control Charts and Statistical Process Control

Figure 80: Statistical Process Control (SPC)

Statistical process control (SPC) allows you to monitor, control and improve processes. The most important statistical methods are: • • •

Control chart (such as, Shewhart chart) Process capability analyses (such as, Cp and Cpk) Sample evaluations (such as run-chart)

Figure 81: Control charts

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Control charts were developed to differentiate systematic deviations from a target value in a characteristic (signals) from unavoidable random fluctuations of individual measured values (interference). One or two control variables (such as mean value, standard deviation) are determined for the chart based on the inspection results and are displayed on a time axis. Once a preliminary run has been completed, the random dispersion interval of the inspection statistics is determined. The limits of the random dispersion interval form the action limits. If these limits are exceeded, a special influence is assumed and you can intervene in the process. You can also identify a permanent process change from a control chart.

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Figure 86: Control Chart Types

The control chart types currently available in the SAP system are shown in the diagram. Further details on control charts are also available in QM Customizing under Quality Management -> Quality Planning -> Basic Data -> Sample, SPC -> Statistical Process Control For additional information, see the SAP Help Portal (http://help.sap.com) with the search term SPC.

Figure 87: Planning control charts

You make the preparations for a control chart in the sampling procedure and the task list or master inspection characteristic.

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You use control charts to control or monitor one or more processes. In the task list characteristic, you define how these processes are to be combined or separated from one another (which inspection lots refer to a common control chart). You can use the control chart to valuate inspection results. If an appropriate valuation rule is used, a sample can be rejected if at least one of the action limits in the related control chart is exceeded.

Figure 88: SPC Criteria

The SPC criterion controls how processes are combined or separated for a control chart (that is which inspection lots refer to a common control chart).

Figure 89: Using Control Charts

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Figure 90: Customizing for Control Charts

It is possible to set new control charts in Customizing. You can also make changes by adapting or exchanging function modules for the calculation of action limits. Using the graphic functions of OCX, it is possible to improve the display of control charts: • • •

Integrated display, “as in Windows” Automatic update of the data in the graph in results recording Personalized configuration possibilities


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The life cycle of a control chart: • • • • • • • •

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Creating a control chart for the first inspection lot Creating inspection points and recording results Calculating action limits Creating additional inspection lots, inspection points and inspection results Violation of action limits with quality notification and Workflow Violation of action limits with automatic defects recording (documentation) Closing the control chart Automatic creation of a new control chart for the next inspection lot


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Figure 97: Process capability

You can display key figures for process capability in the mean value and qualitative tracks on a control chart. The system calculates these key figures using the inspection results for the control chart (for several inspection lots).

Figure 98: Western Electric Rules

Apart from showing where control limits have been exceeded, control charts can indicate that a process may be running out of control on the basis of unusual patterns. Runs or trends are examples of this. The Western Electric Rules are the criteria used to detect such patterns. As of Release 4.6C, you can test a variety of stability criteria in the worklists for the quality control charts. These criteria are also known as Western Electric Rules.

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On a selection screen you can decide whether: •

•

The testing of the Western Electric Rules is to be performed immediately. In this case, all control charts corresponding to the selection criteria will be checked. You want to receive a list of control charts. You can then choose one control chart from the list to perform a check on.

Figure 99: Western Electric Rules (2)

Violations of the Western Electric Rules are displayed in a list along with the chart number, track, and sample number. From this list, you can branch to the inspection results to display detailed information and to view the control chart.

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Figure 100: Result History

In addition to the control chart, the results history provides another option of displaying summarized results for an inspection characteristic across several inspection lots. There are no specific prerequisites for this function in inspection planning. You can call up the display functions for all or selected inspection lots, samples or inspected units in the results history. As of SAP ERP 6.0, numerous evaluation options for inspection results for quantitative and qualitative inspection characteristics are available in transaction QGA4 (Quality Management → Quality Control → Evaluations of Original Documents → General QM Evaluations). A subsequent evaluation with quality control charts is also possible here.

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Exercise 10: Inspection during Production with Statistical Process Control (SPC) in Production Order Exercise Objectives After completing this exercise, you will be able to: • Plan an SPC characteristic • Call up and process a control chart

Business Example You manufacture shafts using production 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 should be displayed in a control chart.

Task 1: Use Control Chart in Inspection Results Recording After planning the quality control card with the inspection characteristic in the routing, you want to represent the control chart in the results recording, and use this to valuate the inspection characteristic. 1.

Create a new inspection point for the length inspection and record the inspection results. To do this, use an inspection from the previous exercise in the PLM420 training course. Call the control chart for this inspection characteristic Shaft Length in the results recording. Calculate the action limits and activate the control chart. Make a note of the calculated action limits for the mean value track (4 decimal places). ____________________________________________________________ ____________________________________________________________


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Save the inspection results, and the changes you made to the control chart. Hint: The acceptance charts are based on the predefined tolerances and determine the share of scrap in the process. Using these charts, if a long-term reduction in the process variance is achieved, the limits are extended. Hint: With a Shewhart chart, in this case the limits become tighter. These charts only take internal process parameters into account and not external tolerance specifications. In a continuously recurring statistical test, the hypothesis is tested that the established, controlled status of the process has not changed.

Task 2: SPC inspection If the valuation mode 800 SPC inspection is used in the sampling procedure, the inspection characteristic is valuated according to the action limits of the quality control chart after activation. 1.

Create additional inspection points for the length inspection of the shafts and record the inspection results. Note the individual values when these are recorded. The sample is valuated based on the action limits in the control chart. Save the inspection results. Check the changes to the control chart using the control chart worklist. Which menu path did you use?

Task 3: Planning control charts Control charts can be planned for one inspection characteristic in the plan, and to valuate the inspection characteristic. 1.

How do you plan the automatic triggering of an editing process, when the action limits in a control chart have been exceeded? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Continued on next page

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Why is an x-bar/s-chart not advisable for a sample size of n=1? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

Task 4: Customizing for Control Charts Numerous control charts are available in basic Customizing in the SAP standard release. 1.

Check which reference axis has been set in QM Customizing for the control chart used above and the characteristic category, for which the control chart is set. Simulate another control chart.

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Solution 10: Inspection during Production with Statistical Process Control (SPC) in Production Order Task 1: Use Control Chart in Inspection Results Recording After planning the quality control card with the inspection characteristic in the routing, you want to represent the control chart in the results recording, and use this to valuate the inspection characteristic. 1.

Create a new inspection point for the length inspection and record the inspection results. To do this, use an inspection from the previous exercise in the PLM420 training course. Call the control chart for this inspection characteristic Shaft Length in the results recording. Calculate the action limits and activate the control chart. Make a note of the calculated action limits for the mean value track (4 decimal places). ____________________________________________________________ ____________________________________________________________ Save the inspection results, and the changes you made to the control chart. Hint: The acceptance charts are based on the predefined tolerances and determine the share of scrap in the process. Using these charts, if a long-term reduction in the process variance is achieved, the limits are extended. Hint: With a Shewhart chart, in this case the limits become tighter. These charts only take internal process parameters into account and not external tolerance specifications. In a continuously recurring statistical test, the hypothesis is tested that the established, controlled status of the process has not changed. a)


Values Continued on next page

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Material

T-BQ6##

Plant

1000



Execute the function key F8. Manually create inspection points, and enter the inspection results for the inspection characteristics, and complete the characteristics processing. Hint: The characteristic Shaft Length is required for the additional exercises. Create a new inspection point for the length inspection and record the inspection results. Call up the control chart for this inspection characteristic. Use the corresponding pushbutton in the application function bar of the inspection results recording or the corresponding icon in the characteristic overview screen in the line for characteristic 20 in the inspection results recording. Calculate the action limits and activate the control chart. Use the relevant icon in the inspection results recording graph. Icon Enter control limits: Here, you can see the calculated values for the upper and lower tolerance, the upper and lower warning limit, as well as the center line. Save the inspection results. The changes in the control chart are automatically saved.


Create additional inspection points for the length inspection of the shafts and record the inspection results. Note the individual values when these are recorded. The sample is valuated based on the action limits in the control chart. Save the inspection results.


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Check the changes to the control chart using the control chart worklist. Which menu path did you use? a)


Values

Material

T-BQ6##

Plant

1000



Execute the function key F8. Hint: The characteristic Shaft Length is required for the additional exercises. Create a new inspection point for the length inspection and record the inspection results. Note the individual values when these are recorded. The sample is valuated based on the action limits in the control chart. b)

Display Quality Control Chart: Logistics → Quality Management → Quality Inspection → Worklist → Quality Control Chart → For Inspection Lot (QGC1) Field name or data type

Values

Material

T-BQ6##

Plant

1000


03

Execute the function key F8. Note the settings for the control chart status in the selection screen.


How do you plan the automatic triggering of an editing process, when the action limits in a control chart have been exceeded? Continued on next page

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Why is an x-bar/s-chart not advisable for a sample size of n=1? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

Automatic maintenance process if action limits are exceeded: To create a quality notification, the indicator Auto. defects recording must be set in the control indicators for the inspection characteristic. In addition, a 'Defect code for rejection' (general, at the upper or lower tolerance) must be maintained in the catalog for the inspection characteristic. The defect class for the code must have the relevant Customizing setting to automatically activate the created quality notification. The valuation of the characteristic in results recording must take place based on the action limits (valuation mode in the sampling procedure: 800 SPC inspection). The standard deviation (s-chart) for a sample size of n=1 is always zero.


Check which reference axis has been set in QM Customizing for the control chart used above and the characteristic category, for which the control chart is set. Simulate another control chart. a)

Transaction QCCO, then Quality Management → Quality Planning → Basic Data → Sample, SPC → Statistical Process Control → Define Control Chart Type Display details for the control chart type The control chart types 211 and 411 were used in the exercises.

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Exercise 11: Inspection during Production with Statistical Process Control (SPC) in Process Order Exercise Objectives After completing this exercise, you will be able to: • Plan an SPC characteristic • Call and edit a control chart

Business Example You produce tablets using process orders. To monitor the process, the characteristic pH Value should be checked in 10 minute intervals. The mean value and standard deviation for the samples should be displayed in a control chart.

Task 1: Use Control Chart in Inspection Results Recording After planning the quality control card with the inspection characteristic in the master recipe, you want to represent the control chart in the results recording, and use this to valuate the inspection characteristic. 1.

Create a new inspection point for the pH value inspection of tablets and record inspection results. Use the inspection lot from the exercise on the subject inspection point processing - process order in the PLM420 training course. Call the control chart (Shewhart chart) for this inspection characteristic (9-120) in the results recording. Calculate the action limits and activate the control chart. Make a note of the calculated action limits for the mean value track (4 decimal places). ____________________________________________________________ ____________________________________________________________


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Save the inspection results, and the changes you made to the control chart. Hint: The acceptance charts are based on the predefined tolerances and determine the share of scrap in the process. Using these charts, if a long-term reduction in the process variance is achieved, the limits are extended. Hint: With a Shewhart chart, in this case the limits become tighter. These charts only take internal process parameters into account and not external tolerance specifications. In a continuously recurring statistical test, the hypothesis is tested that the established, controlled status of the process has not changed.


Create further inspection points for the pH value inspection of tablets and record inspection results. Note the individual values when these are recorded. The sample is valuated based on the action limits in the control chart. Save the inspection results. Check the changes to the control chart using the control chart worklist. Which menu path did you use?


How do you plan the automatic triggering of an editing process, when the action limits in a control chart have been exceeded? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Continued on next page

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Why is an x-bar/s-chart not advisable for a sample size of n=1? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________


Check which reference axis has been set in QM Customizing for the control chart used above and the characteristic category, for which the control chart is set. Simulate another control chart.

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Solution 11: Inspection during Production with Statistical Process Control (SPC) in Process Order Task 1: Use Control Chart in Inspection Results Recording After planning the quality control card with the inspection characteristic in the master recipe, you want to represent the control chart in the results recording, and use this to valuate the inspection characteristic. 1.

Create a new inspection point for the pH value inspection of tablets and record inspection results. Use the inspection lot from the exercise on the subject inspection point processing - process order in the PLM420 training course. Call the control chart (Shewhart chart) for this inspection characteristic (9-120) in the results recording. Calculate the action limits and activate the control chart. Make a note of the calculated action limits for the mean value track (4 decimal places). ____________________________________________________________ ____________________________________________________________ Save the inspection results, and the changes you made to the control chart. Hint: The acceptance charts are based on the predefined tolerances and determine the share of scrap in the process. Using these charts, if a long-term reduction in the process variance is achieved, the limits are extended. Hint: With a Shewhart chart, in this case the limits become tighter. These charts only take internal process parameters into account and not external tolerance specifications. In a continuously recurring statistical test, the hypothesis is tested that the established, controlled status of the process has not changed. a)

Results Recording Worklist Logistics → Quality Management → Quality Inspection → Worklist → Results Recording (QE51N)


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Field name or data type

Values

Material

TAB-1##

Plant

1100



Execute the function key F8. Manually create inspection points, and enter the inspection results for the inspection characteristics, and complete the characteristics processing. Hint: The characteristic pH Value is required for the additional exercises. Create a new inspection point for the pH value inspection of the tablet and record inspection results. Call up the control chart for this inspection characteristic. Use the corresponding pushbutton in the application function bar of the inspection results recording or the corresponding icon in the characteristic overview screen in the line for characteristic 40 in the inspection results recording. Calculate the action limits and activate the control chart. Use the relevant icon in the inspection results recording graph. Icon Enter control limits: Here, you can see the calculated values for the upper and lower tolerance, the upper and lower warning limit, as well as the center line. Save the inspection results. The changes in the control chart are automatically saved.


Create further inspection points for the pH value inspection of tablets and record inspection results. Note the individual values when these are recorded. The sample is valuated based on the action limits in the control chart. Save the inspection results. Continued on next page

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Check the changes to the control chart using the control chart worklist. Which menu path did you use? a)


Values

Material

TAB-1##

Plant

1100



Execute the function key F8. Hint: The characteristic pH Value is required for the additional exercises. Create a new inspection point for the pH value inspection of the tablet and record inspection results. Note the individual values when these are recorded. The sample is valuated based on the action limits in the control chart. b)

Display Quality Control Chart: Logistics → Quality Management → Quality Inspection → Worklist → Quality Control Chart → For Inspection Lot (QGC1) Field name or data type

Values

Material

TAB-1##

Plant

1100


03

Execute the function key F8. Note the settings for the control chart status in the selection screen.


How do you plan the automatic triggering of an editing process, when the action limits in a control chart have been exceeded? Continued on next page

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____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Why is an x-bar/s-chart not advisable for a sample size of n=1? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ a)

Automatic maintenance process if action limits are exceeded: To create a quality notification, the indicator Auto. defects recording must be set in the control indicators for the inspection characteristic. In addition, a 'Defect code for rejection' (general, at the upper or lower tolerance) must be maintained in the catalog for the inspection characteristic. The defect class for the code must have the relevant Customizing setting to automatically activate the created quality notification. The valuation of the characteristic in results recording must take place based on the action limits (valuation mode in the sampling procedure: 800 SPC inspection). The standard deviation (s-chart) for a sample size of n=1 is always zero.


Check which reference axis has been set in QM Customizing for the control chart used above and the characteristic category, for which the control chart is set. Simulate another control chart. a)

Transaction QCCO, then Quality Management → Quality Planning → Basic Data → Sample, SPC → Statistical Process Control → Define Control Chart Type Display details for the control chart type. The control chart type 116 was used in the exercise.

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Lesson Summary You should now be able to: • Explain the control chart types in the SAP system and make Customizing settings • Implement an inspection planning for an SPC inspection • Use the functions of the control charts in the inspection results recording

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Lesson: Integration Points between Quality Management and Production

Lesson: Integration Points between Quality Management and Production Lesson Overview This lesson will provide another overview of important integration points between Quality Management and Production. In addition to the integrated planning, this lesson also deals with confirmations to the production or process order together with the results recording in the in-process inspection for the order.


Explain the most important integration points between Quality Management and Production. Send confirmations to the production or process order directly from the inspection results recording function and forward inspected quantities to goods receipt.

Business Example After recording the inspection results, you also want to confirm the produced quantities and the required time in the in-process inspection. If necessary, the quality control follow-up processes should also be triggered in production.

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Important Integration Points between Quality Management and Production

Figure 101: Features of the Integration

Figure 102: Confirmations

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Figure 103: Trigger Points

Figure 104: Co-products

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Exercise 12: Integration Aspects between Quality Management and Production Confirmations for the Production Order Exercise Objectives After completing this exercise, you will be able to: • Implement a confirmation for the order operation from the results recording function in Quality Management.

Business Example The activities that were performed for the quality inspection of operation 60 are to be recorded based on cost.

Task 1: Specifications in Routing For the material T-BQ6##, various routings exist in the SAP training system. 1.

Check the specifications in the routing with the group counter 2 for your material T-BQ6##. Which setting requires operation 60 to be confirmed? ____________________________________________________________ ____________________________________________________________ What are the default value, the unit and the activity type for the labor? ____________________________________________________________ ____________________________________________________________

Task 2: Create additional inspection points for the in-process inspection in the production order, and run the confirmation After the results recording for the inspection characteristics, you also want to carry out a confirmation for the production order in connection with the inspection point valuation. 1.

Create a new inspection point for the in-process inspection for the production order, and record the inspection results. To do this, use an inspection from the previous exercise in the PLM420 training course. Accept the proposed inspection point quantity and change the proposed labor (confirmation detail). Continued on next page

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Check the time confirmed. Make a note of the path you use to display the confirmations. ____________________________________________________________ ____________________________________________________________

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Solution 12: Integration Aspects between Quality Management and Production Confirmations for the Production Order Task 1: Specifications in Routing For the material T-BQ6##, various routings exist in the SAP training system. 1.

Check the specifications in the routing with the group counter 2 for your material T-BQ6##. Which setting requires operation 60 to be confirmed? ____________________________________________________________ ____________________________________________________________ What are the default value, the unit and the activity type for the labor? ____________________________________________________________


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____________________________________________________________ a)

Display the Maintenance Task List Logistics → Quality Management → Quality Planning → Inspection Planning → Routing → Routings → Standard Routings → Display (CA03) or Logistics → Central Functions → Engineering → Engineering Workbench (CEWB) Field name or data type

Values

Material

T-BQ6##

Plant

1000

group counter

2

Operations in Routing Details on Operation 60 Details on the control key in Operation 0060 The setting Confirmation in the control key for the operation must plan a confirmation. The default value for the labor is 30 minutes. The activity type is 1421 (labor hours).

Task 2: Create additional inspection points for the in-process inspection in the production order, and run the confirmation After the results recording for the inspection characteristics, you also want to carry out a confirmation for the production order in connection with the inspection point valuation. 1.

Create a new inspection point for the in-process inspection for the production order, and record the inspection results. To do this, use an inspection from the previous exercise in the PLM420 training course. Accept the proposed inspection point quantity and change the proposed labor (confirmation detail). Check the time confirmed. Make a note of the path you use to display the confirmations. ____________________________________________________________ Continued on next page

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____________________________________________________________ a)


Values

Material

T-BQ6##

Plant

1000



Execute the function key F8. Manually create inspection points, and enter the inspection results for the inspection characteristics, and complete the characteristics processing. During the inspection point valuation, carry out a partial confirmation for the production order. Use the details for the confirmation, and change the suggested times. Save your data. b)

Display the confirmation of the production order: Logistics → Production → Shop Floor Control → Confirmation → Display (CO14) Use the production order number from your last production order for the material T-BQ6##.

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Exercise 13: Integration Aspects between Quality Management and Production Trigger Points for the Production Order Exercise Objectives After completing this exercise, you will be able to: • Use trigger points to control your production processes

Business Example Operation 65 “spray paint” should only be started if the quality inspection that took place after operation 60 “Check Measurements” has been completed.

Task 1: Change routing Standard trigger points belong to the master data in production. The later production processes can be be changed with a standard trigger point. 1.

Assign the standard trigger point PLM420 to operation 60 in the routing (group counter 2) for your material T-BQ6##.

Task 2: Production Order for the Material and Inspection Lot Processing Create a production order for your material T-BQ6##. Then enter the inspection results for the in-process inspection for the production order. 1.

Create the production order with the order type PP01 in the plant 1000. The order quantity is 200 PC. Use the scheduling type Current date (4). Hint: Release operations 10 through 60 only. To do this, switch to the operation overview screen. Select the operations 10 through 60. Select the menu path Operation → Release. What order number was given? _____________________________________ What inspection lot number was given? _______________________________ Which system status was set for operation 60 and which status was set for operation 65? Continued on next page

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Operation 60: __________________________________________________ Operation 65: __________________________________________________ 2.

Record results for operation 60. Enter a yield of 200 PC in the inspection point valuation screen. Set the flag for the final confirmation in the inspection point valuation screen. What message appears when you save the results? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Check the release of the follow-up operation. What status is set for operation 65 in the production order?

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Solution 13: Integration Aspects between Quality Management and Production Trigger Points for the Production Order Task 1: Change routing Standard trigger points belong to the master data in production. The later production processes can be be changed with a standard trigger point. 1.

Assign the standard trigger point PLM420 to operation 60 in the routing (group counter 2) for your material T-BQ6##. a)

Display the standard trigger point. Logistics → Production → Master Data → Standard Trigger Points → Standard trigger pt → Display (CO33) Standard trigger point: PLM420 Change routing Logistics → Quality Management → Quality Planning → Inspection Planning → Routing → Routings → Standard Routings → Change (CA02) Field name or data type

Values

Material

T-BQ6##

Plant

1000

Group counter

2

Operations in Routing Operation overview in routing, select Operation 60. Then select the menu path: Goto →Trigger point overview Pushbutton StdTrgPoint (Standard trigger point) in the application function bar Enter standard trigger point PLM420 or select with input help. Save the changed routing.


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Task 2: Production Order for the Material and Inspection Lot Processing Create a production order for your material T-BQ6##. Then enter the inspection results for the in-process inspection for the production order. 1.

Create the production order with the order type PP01 in the plant 1000. The order quantity is 200 PC. Use the scheduling type Current date (4). Hint: Release operations 10 through 60 only. To do this, switch to the operation overview screen. Select the operations 10 through 60. Select the menu path Operation → Release. What order number was given? _____________________________________ What inspection lot number was given? _______________________________ Which system status was set for operation 60 and which status was set for operation 65? Operation 60: __________________________________________________


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Operation 65: __________________________________________________ a)


Values

Material

T-BQ6##

Production plant

1000

Order type

PP01

Total quantity

200 PC

Scheduling type

4 (current date)

Operation Overview in the production order Select operations 10 through 60, and then the menu path Operation → Release System status in Operation 60: ICHA (Planned InspCharacs. Allocated) REL (Released) System status in Operation 65: CRTD (created): Assignment tab The inspection lot number is displayed in the assignment screen area. After saving the production order, the inspection lot is also saved. 2.

Record results for operation 60. Enter a yield of 200 PC in the inspection point valuation screen. Set the flag for the final confirmation in the inspection point valuation screen. What message appears when you save the results? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ Check the release of the follow-up operation.


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What status is set for operation 65 in the production order? a)


Values

Material

T-BQ6##

Plant

1000



Execute the function key F8. Enter the inspection results for the inspection characteristics, close the characteristics processing, and valuate the inspection point. Enter a yield of 200 PC in the inspection point valuation screen, and set the flag for the final confirmation. Trigger point function: Release of subsequent operations Activated by trigger point ............ Release Operation Order ............ Sequence 0 Operation 0060 b)

Display production order Logistics → Production → Shop Floor Control → Order → Display (CO03) Operation Overview in the production order The operation 0065 now has the status REL (released).

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Lesson Summary You should now be able to: • Explain the most important integration points between Quality Management and Production. • Send confirmations to the production or process order directly from the inspection results recording function and forward inspected quantities to goods receipt.

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Unit Summary

PLM420

Unit Summary You should now be able to: • Explain the necessary settings in the material master for a quality check during production • Create an inspection lot for an order • Carry out defects recording using the inspection lot for the order • Update the task list for production (standard routing, master recipe) with the required QM data for a quality inspection • Implement an inspection results entry for an inspection lot during production • Plan a multiple inspection for an operation with inspection point processing. • Implement a multiple entry of inspection results for inspection characteristics in the inspection lot. • Plan multiple inspections for an operation with sample management. • Implement a multiple entry of inspection results for inspection characteristics of samples in the inspection lot. • Explain planning for a quality check with batch-managed materials. • Implement an in-process inspection in the production of a batch-managed material. • Describe the value transfer from the master inspection characteristic for the class characteristic of the batch. • Explain the control chart types in the SAP system and make Customizing settings • Implement an inspection planning for an SPC inspection • Use the functions of the control charts in the inspection results recording • Explain the most important integration points between Quality Management and Production. • Send confirmations to the production or process order directly from the inspection results recording function and forward inspected quantities to goods receipt.

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Unit 2 QM in Repetitive Manufacturing Unit Overview This chapter covers the features for an in-process inspection for production versions in repetitive manufacturing.

Unit Objectives After completing this unit, you will be able to: • •

Create inspection lots for production versions Explain details of Quality Management for the inspection process in repetitive manufacturing

Unit Contents Lesson: QM in Repetitive Manufacturing ....................................204 Exercise 14: Processing Inspections in Repetitive Manufacturing...207

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PLM420

Lesson: QM in Repetitive Manufacturing Lesson Overview This lesson deals with specific elements of the inspection process in repetitive manufacturing. The inspection lots can be created for the production version, and belong to the inspection origin 13.


Create inspection lots for production versions Explain details of Quality Management for the inspection process in repetitive manufacturing

Business Example The company produces personal computers in repetitive manufacturing. Inspections during production are performed at regular intervals.

The Inspection Process in Repetitive Manufacturing

Figure 105: Inspection lots for production version (1)

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Lesson: QM in Repetitive Manufacturing

Figure 106: Inspection lots for production version (1)

You can create inspection lots for a production version, using transaction “MFPR”. A traffic light shows whether inspection lots exist for all production versions for a material, or whether there are production versions without inspection lots for materials requiring inspection (inspection type of origin 13 active).

Figure 107: QM in Repetitive Manufacturing: Process Flow

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If the usage decision has been made for an inspection lot, an additional inspection lot can be created for a production version. This allows the inspection data to be updated, if the planned data has changed, without a new production version having to be created.

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Exercise 14: Processing Inspections in Repetitive Manufacturing Exercise Objectives After completing this exercise, you will be able to: • Create inspection lots for production versions of a material in repetitive manufacturing • Use the monitor for inspection lots for production versions

Business Example You manufacture personal computers using repetitive manufacturing. Inspections during production are performed at regular intervals.

Task 1: Change the inspection setup in the material master Activate the required inspection lot for inspection of the material T-FQ7## in repetitive manufacturing in plant 1200. 1.

Which inspection type do you use? ______________________________________________

Task 2: Create inspection lot for production versions Use the “inspection lot monitor” to create an inspection lot for the production version. 1.

Use the following menu path: Logistics → Quality Management → Quality Inspection → Worklist → Inspection Lot Creation → Inspection Lots for Repetitive Manufacturing (MFPR) or Logistics → Production → Repetitive Manufacturing → Data Entry → Inspection Lots for Prod. Version (MPFR) Field name or data type

Values

Plant

1200

Material number

T-FQ7##

Make a note of the inspection lot number for the production version. Continued on next page

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Production version 0001:_________________________________________ Production version 0002:_________________________________________ 2.

Record results for the inspection lots and make the usage decision. Hint: Inspection points are used during repetitive manufacturing. The rate routing for the Production version 0001 “only” allows for inspection points. The rate routing for the Production version 0002 also allows for partial lots.

Task 3: Change Rate Routing and Create new Inspection Lot for Production Version You want to change the inspection requirements for the in-process inspection for the production version. Then new inspection lots are created for the production versions. 1.

Change the inspection characteristic or the short text for the operation in the relevant rate routing for the material T-FQ7##. Then save the changes.

2.

Create a new inspection lot for the production versions for the material T-FQ7## with the changed routing. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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Solution 14: Processing Inspections in Repetitive Manufacturing Task 1: Change the inspection setup in the material master Activate the required inspection lot for inspection of the material T-FQ7## in repetitive manufacturing in plant 1200. 1.

Which inspection type do you use? ______________________________________________ a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) An inspection type for inspection origin 13. In the standard system, this is inspection type 13.

Task 2: Create inspection lot for production versions Use the “inspection lot monitor” to create an inspection lot for the production version. 1.

Use the following menu path: Logistics → Quality Management → Quality Inspection → Worklist → Inspection Lot Creation → Inspection Lots for Repetitive Manufacturing (MFPR) or Logistics → Production → Repetitive Manufacturing → Data Entry → Inspection Lots for Prod. Version (MPFR) Field name or data type

Values

Plant

1200

Material number

T-FQ7##

Make a note of the inspection lot number for the production version. Production version 0001:_________________________________________ Continued on next page

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Production version 0002:_________________________________________ a)

Logistics → Quality Management → Quality Inspection → Worklist → Inspection Lot Creation → Inspection Lots for Repetitive Manufacturing (MFPR) Field name or data type

Values

Plant

1200

Material number

T-FQ7##

Execute the selection with the function key F8. Select both production versions, choose the pushbutton "Create inspection lots" in the application function bar. 2.

Record results for the inspection lots and make the usage decision. Hint: Inspection points are used during repetitive manufacturing. The rate routing for the Production version 0001 “only” allows for inspection points. The rate routing for the Production version 0002 also allows for partial lots. a)


Values

Material

T-FQ7##

Plant

1200



Execute the function key F8. Record the inspection results for the inspection characteristics, and close characteristic processing. Make the usage decision for these inspection lots.


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Task 3: Change Rate Routing and Create new Inspection Lot for Production Version You want to change the inspection requirements for the in-process inspection for the production version. Then new inspection lots are created for the production versions. 1.

Change the inspection characteristic or the short text for the operation in the relevant rate routing for the material T-FQ7##. Then save the changes. a)

Change the corresponding rate routing for the material. Logistics → Quality Management → Quality Planning → Inspection Planning → Routing → Routings → Rate Routings → Change (CA22) Field name or data type

Values

Material

T-FQ7##

Plant

1200

Change the short text for the operation or the short text for the inspection characteristic. Save the change to the rate routing. 2.

Create a new inspection lot for the production versions for the material T-FQ7## with the changed routing. How do you proceed? ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________


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____________________________________________________________ a)

Choose Logistics → Quality Management → Quality Inspection → Worklist → Inspection Lot Creation → Inspection Lots for Repetitive Manufacturing (MFPR) Field name or data type

Values

Plant

1200

Material number

T-FQ7##

Execute the selection with the function key F8. Select both production versions, choose the pushbutton "Create inspection lots" in the application function bar. It is important that the previous inspection lot for the production version has been completed with the usage decision.

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Lesson Summary You should now be able to: • Create inspection lots for production versions • Explain details of Quality Management for the inspection process in repetitive manufacturing

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Unit Summary You should now be able to: • Create inspection lots for production versions • Explain details of Quality Management for the inspection process in repetitive manufacturing

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Unit 3 Quality Inspection for External Processing Unit Overview This chapter covers the planning and processing of a quality inspection for an external processing of operations in Production.

Unit Objectives After completing this unit, you will be able to: • • •

Plan external processing of operations Plan the quality inspection for external processing Implement external processing with a quality inspection

Unit Contents Lesson: Quality Inspection for External Processing........................216 Exercise 15: Quality Inspection for External Processing ..............219

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Lesson: Quality Inspection for External Processing Lesson Overview This lesson deals with the planning and implementation of the quality inspection for external processing of the operations of an order.


Plan external processing of operations Plan the quality inspection for external processing Implement external processing with a quality inspection

Business Example Shafts are manufactured with manufacturing orders. The shafts have to be sprayed. Since there are no spray-paint plants available, the operation Spray Paint is outsourced to an external company. You want to implement quality control for the paint color at the point of goods receipt for the painted shafts.

External Processing and Quality Control

Figure 108: Quality Inspection for External Processing

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Lesson: Quality Inspection for External Processing

You can plan the operations in an order that are to be performed externally by vendors, using the control key for external processing. In this case, a purchase requisition is created, when the order is created. The purchase requisition is converted into a purchase order. The reference to the order remains. If a quality inspection is planned for an externally-processed operation, an inspection lot is created when the externally-processed goods are received.

Figure 109: Prerequisites and Features

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Exercise 15: Quality Inspection for External Processing Exercise Objectives After completing this exercise, you will be able to: • Plan a quality inspection for externally processed operations • Explain the process of external processing with a quality inspection from the order through to the usage decision.

Business Example The shafts are also to be spray painted during the production process. Since there is no paint shop available in your company, the operation 'spray paint' is to be completed externally.

Task 1: Change the inspection setup in the material master Activate the quality inspection for external processing for your material T-BQ6## in the material master. 1.

Which inspection type do you use? ______________________________________________

Task 2: Change Routing for Material T-BQ6## Change the routing with the group counter 1 for your material T-BQ6##. 1.

From now on, operation 65 'Spray paint' is to be externally processed. Make the following changes: Field name or data type

Values

Control key

PP02

Work center

Delete work center assignment

Inspection Type (external processing 0130 data) Save the change to the routing


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Create the production order with the order type PP01 in the plant 1000. The order quantity is 100 PC. Use the scheduling type Current date (4). What order number was given? __________________________________ What inspection lot number was given? ___________________________________

Task 4: Purchase Request for Spray Painting There is now a purchase requisition for the external process “Spray Paint” for the production order. 1.

Check the purchase requisition on the external processing screen in the order operation. What purchase requisition number was given? ___________________________________________________________

Task 5: Purchase Order with Reference to the Purchase Requisition The purchase requisition for the spray-painting is converted into a purchase order for the vendor. 1.

The purchase requisition is to be converted into a purchase order. Use the following menu path: Logistics → Materials Management → Purchasing → Purchasing Requisition → Follow-On Functions → Create Purchase Order → Automatically via Purchase Requisitions (ME59N). Use the following data to create the purchase order: Field name or data type

Values

Purchasing group

001

Purch. organization

1000

Fixed vendor

TPLM420-##

Plant

1000

Execute the function key F8. What is the number of the purchase order? ____________________________________________________________ Continued on next page

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Task 6: Goods Receipt for Purchase Order The painted shafts arrive at your company. 1.

Post the goods receipt for your purchase order. Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Hint: Select the corresponding purchase order with a reference to the vendor TPLM420-##. Optional: The delivery takes place in partial quantities. Reduce the goods receipt quantity to 50 pcs. Save the goods receipt posting. What is the document number? ____________________________________________________________

Task 7: Display Inspection Lot for External Processing An inspection lot is created by assigning the corresponding inspection type in the material of the final product (Material: T-BQ6##) and by entering the corresponding inspection type in the external processing screen in the operation for the goods receipt. 1.

Which reference documents are displayed on the tab page for Data for lot origin?

Task 8: Record the inspection results, and make a usage decision for the inspection lot Inspect the painted shafts and then make a usage decision on the inspection lot.

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Record inspection results for the created inspection lot. Use the worklist for results recording.

2.

Make the usage decision for the inspection lot.


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Solution 15: Quality Inspection for External Processing Task 1: Change the inspection setup in the material master Activate the quality inspection for external processing for your material T-BQ6## in the material master. 1.

Which inspection type do you use? ______________________________________________ a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) An inspection type for inspection origin 01. The inspection type 0130 Receiving inspection at GR from ext. process. is delivered in the SAP standard system.

Task 2: Change Routing for Material T-BQ6## Change the routing with the group counter 1 for your material T-BQ6##. 1.

From now on, operation 65 'Spray paint' is to be externally processed. Make the following changes: Field name or data type

Values

Control key

PP02

Work center

Delete work center assignment

Inspection Type (external processing 0130 data)


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Save the change to the routing a)


Values

Material

T-BQ6##

Plant

1000

Group counter

1

Operation overview, changes to the Operation 65 according to exercise Details on Operation 65: Screen area external processing, enter inspection type 0130


Create the production order with the order type PP01 in the plant 1000. The order quantity is 100 PC. Use the scheduling type Current date (4). What order number was given? __________________________________


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What inspection lot number was given? ___________________________________ a)


Values

Material

T-BQ6##

Production plant

1000

Order type

PP01

Total quantity

100 PC

Scheduling type

4 (current date)


Task 4: Purchase Request for Spray Painting There is now a purchase requisition for the external process “Spray Paint” for the production order. 1.

Check the purchase requisition on the external processing screen in the order operation. What purchase requisition number was given? ___________________________________________________________ a)

Display production order: Logistics → Production → Shop Floor Control → Order → Display (CO03) Application function bar, icon Operation overview (F5) Details on Operation 0065, tab page External processing


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Task 5: Purchase Order with Reference to the Purchase Requisition The purchase requisition for the spray-painting is converted into a purchase order for the vendor. 1.

The purchase requisition is to be converted into a purchase order. Use the following menu path: Logistics → Materials Management → Purchasing → Purchasing Requisition → Follow-On Functions → Create Purchase Order → Automatically via Purchase Requisitions (ME59N). Use the following data to create the purchase order: Field name or data type

Values

Purchasing group

001

Purch. organization

1000

Fixed vendor

TPLM420-##

Plant

1000

Execute the function key F8. What is the number of the purchase order? ____________________________________________________________ a)

Create purchase order with reference to the purchase requisition: Logistics → Materials Management → Purchasing → Purchasing Requisition → Follow-On Functions → Create Purchase Order → Automatically via Purchase Requisitions (ME59N). Use the data from the exercise description. After executing the function, the created purchase order and the number of the purchase requisition are displayed in the list. After selecting the line with the purchase order number, you can display the details for the purchase order. Hint: One “text position” is occupied here. The text for the item comes from the operation of the routing.

Task 6: Goods Receipt for Purchase Order The painted shafts arrive at your company. 1.

Post the goods receipt for your purchase order. Continued on next page

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Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Hint: Select the corresponding purchase order with a reference to the vendor TPLM420-##. Optional: The delivery takes place in partial quantities. Reduce the goods receipt quantity to 50 pcs. Save the goods receipt posting. What is the document number? ____________________________________________________________ a)

Post a goods receipt. Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Goods Receipt for Purchase Order Plant: 1000 Search help in MIGO (binoculars icon), select the purchase orders for the vendor TPLM420-##. Hint: In MIGO, set the indicator Item ok.

Task 7: Display Inspection Lot for External Processing An inspection lot is created by assigning the corresponding inspection type in the material of the final product (Material: T-BQ6##) and by entering the corresponding inspection type in the external processing screen in the operation for the goods receipt. 1.

Which reference documents are displayed on the tab page for Data for lot origin? a)

Display the inspection lot: Logistics → Quality Management → Quality Inspection → Inspection Lot → Processing → Display (QA03) There is a reference to the purchasing and material documents, as well as to the order.


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Task 8: Record the inspection results, and make a usage decision for the inspection lot Inspect the painted shafts and then make a usage decision on the inspection lot. 1.

Record inspection results for the created inspection lot. Use the worklist for results recording. a)


Values

Material

T-BQ6##

Plant

1000



Execute the function key F8. Record the inspection results for the inspection characteristics, and close characteristic processing. 2.

Make the usage decision for the inspection lot. a)

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Lesson Summary You should now be able to: • Plan external processing of operations • Plan the quality inspection for external processing • Implement external processing with a quality inspection

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Unit Summary

Unit Summary You should now be able to: • Plan external processing of operations • Plan the quality inspection for external processing • Implement external processing with a quality inspection

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Unit 4 Inspection at the End of the Production Process Unit Overview In addition to an in-process inspection during production, an incoming inspection of the goods produced may also occur upon goods receipt in the warehouse. In this case, the system generates an inspection lot upon goods receipt for the order. The inspection specifications for this inspection lot may be defined in an inspection plan (task list type Q) and/or in a material specification.

Unit Objectives After completing this unit, you will be able to: • • • • • •

Explain the material settings for a quality inspection in the goods receipt for the order Process inspection lots from this goods receipt Post the stocks using the inspection lots for the goods receipt for the order Explain the material settings for a quality inspection for early lot creation for the order item Carry out an in-process inspection for the order and an incoming inspection at goods receipt for the order with one inspection lot Post the stocks using this inspection lot

Unit Contents Lesson: Quality Inspection at Goods Receipt for Order ...................232 Exercise 16: Quality Inspection at Goods Receipt for the Production Order .........................................................................235 Exercise 17: Quality Inspection at Goods Receipt for the Process Order .........................................................................243 Lesson: Early Goods Receipt Inspection ....................................251 Exercise 18: Early Goods Receipt Inspection for the Production Order .........................................................................255 Exercise 19: Early Goods Receipt Inspection for the Process Order .........................................................................265

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Lesson: Quality Inspection at Goods Receipt for Order Lesson Overview This lesson deals with the planning and process of a quality inspection during goods receipt for the order. The Inspection lots for inspection origin 04 are created when the goods receipt is posted for the order and these are stock-relevant. The inspection requirements for the inspection can originate from an inspection plan and/or from a materials specification. A simple defects recording is also possible.


Explain the material settings for a quality inspection in the goods receipt for the order Process inspection lots from this goods receipt Post the stocks using the inspection lots for the goods receipt for the order

Business Example The produced goods are delivered to production in the warehouse. A goods receipt check is carried out at this point. Depending on the result of the goods receipt check, the stock is released after the quality inspection has finished.

Inspection at Goods Receipt f  rom Production

Figure 110: Variants of Inspections at the End of the Production Process

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Lesson: Quality Inspection at Goods Receipt for Order

You can plan a final inspection using the last operation (inspection operation) of an order (inspection lot origin 03), or using a quality inspection for produced goods received for an order (inspection lot origin 04). Goods receipt inspection lots can already be created when releasing the order (early inspection lot creation for the order item, inspection origin 04). With inspection lots for inspection origin 04, Quality Management can take over stock control.

Figure 111: Quality Inspection at Goods Receipt for Order

If an appropriate inspection type is entered in the material, an inspection lot is automatically created as soon as the warehouse receipt is posted. From a system standpoint, the quality inspection takes place in inventory management. The inspection characteristics in an inspection lot can come from an inspection plan. You can also just record defects. In this case, an inspection plan is not required. You can post the warehouse receipt to inspection stock for the duration of the quality inspection.

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Figure 112: Posting to Inspection Stock

The “"Post to Inspection Stock"” indicator triggers automatic posting in the inspection stock during the quality inspection. You can set the indicator at various levels. If the indicator is set to the QM view in the material master in the inspection settings (inspection type for inspection origin 04), it can no longer be changed in the order header or at warehouse receipt. With the usage decision, you control whether the inspected quantity is to be posted to unrestricted-use stock, or whether other follow-up postings are to be triggered.

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Exercise 16: Quality Inspection at Goods Receipt for the Production Order Exercise Objectives After completing this exercise, you will be able to: • Activate an inspection at the goods receipt for an order • Perform goods receipt inspections and post quantities using inspection results in the usage decision

Business Example You no longer need an inspection during production for the shafts. Instead, a final inspection is to take place, once you have posted the goods receipt to the warehouse. The goods receipt quantity must not be removed from the warehouse before the usage decision has been made.

Task 1: Change the inspection setup in the material master Enter the inspection type for a goods receipt for an order in the material master of the shaft (T-BQ6##). 1.

Which inspection type do you use? _______________________________________________________________ Which indicator controls whether the GR quantity is posted in the inspection stock? _______________________________________________________________ Hint: Make sure that you set the indicator for the goods receipt inspection, and cancel the indicator for an inspection during production.

Task 2: Goods Receipt for the Production Order After completing production, the shafts are delivered to the warehouse. 1.

In plant 1000, post the goods receipt for a production order for the material T-BQ6## to storage location 0001. Use the following menu path:


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Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Hint: Select the corresponding production orders for the material T-BQ6##. Optional: Post only one partial quantity of the production order Save the goods receipt posting. What document number is given? ____________________________________________________________

Task 3: Stock Overview for the Material After delivery of the goods to the warehouse, the corresponding stocks appear in the stock overview. 1.

Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________ Quantity in inspection stock: ___________________________________

Task 4: Record the inspection results, and make a usage decision for the inspection lot Inspect the shafts on warehouse receipt, and then make a usage decision on the inspection lot. 1.

Record inspection results for the goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number and the inspection lot origin 04.

2.

Make the usage decision for the inspection lot. Optional: Post part of the inspection stock to unrestricted-use stock and the other part to the order. What additional entry do you have to make?

Task 5: Stock Overview for the Material Inspect the stocks again after quality control. 1.

Check the stock for your material T-BQ6##. Continued on next page

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What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________ Quantity in inspection stock: ___________________________________

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Solution 16: Quality Inspection at Goods Receipt for the Production Order Task 1: Change the inspection setup in the material master Enter the inspection type for a goods receipt for an order in the material master of the shaft (T-BQ6##). 1.

Which inspection type do you use? _______________________________________________________________ Which indicator controls whether the GR quantity is posted in the inspection stock? _______________________________________________________________ Hint: Make sure that you set the indicator for the goods receipt inspection, and cancel the indicator for an inspection during production. a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) An inspection type for inspection origin 04. In the standard system, this is inspection type 04. Post to the quality inspection stock: Indicator: Post to the inspection stock with inspection settings for inspection type 04


In plant 1000, post the goods receipt for a production order for the material T-BQ6## to storage location 0001. Use the following menu path:


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Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Hint: Select the corresponding production orders for the material T-BQ6##. Optional: Post only one partial quantity of the production order Save the goods receipt posting. What document number is given? ____________________________________________________________ a)

Post a goods receipt. Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Goods receipt for the order Plant: 1000 Search help in MIGO (binoculars icon), select the orders for the material T-BQ6## Hint: In MIGO, set the indicator Item ok.


Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________


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Quantity in inspection stock: ___________________________________ a)

Display the stocks for the material: Logistics → Materials Management → Inventory Management → Environment → Stock → Stock Overview (MMBE) Field name or data type

Values

Material

T-BQ6##

Plant

1000

Execute the function key F8. Other option: Logistics → Quality Management → Quality Inspection → Inspection Lot → Processing → Display (QA03) Application function bar, pushbutton Stock (Stock overview).


Record inspection results for the goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number and the inspection lot origin 04. a)


Values

Material

T-BQ6##

Plant

1000


04


Make the usage decision for the inspection lot. Continued on next page

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Optional: Post part of the inspection stock to unrestricted-use stock and the other part to the order. What additional entry do you have to make? a)

Double click the inspection lot number in the worklist of the results recording. Make usage decision. On return delivery: Reason for the goods movement for the return delivery for an order and an explanatory text (optional).


Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________ Quantity in inspection stock: ___________________________________ a)


Values

Material

T-BQ6##

Plant

1000


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Exercise 17: Quality Inspection at Goods Receipt for the Process Order Exercise Objectives After completing this exercise, you will be able to: • Activate an inspection at the goods receipt for an order • Perform goods receipt inspections and post quantities using inspection results in the usage decision

Business Example A final inspection should be performed for certain materials instead of or in addition to an inspection during production (in-process control). The goods receipt for the order should be posted to inspection stock, so that the quantity for the completed certificate that is to be stored cannot be withdrawn from the plant before the usage decision is made.

Task 1: Change the inspection setup in the material master Enter the inspection type for a goods receipt for an order in the material master of the tablet (TAB-1##). 1.

Which inspection type do you have to activate if you want to perform a goods receipt inspection for an order? _______________________________________________________________ Which indicator controls whether the GR quantity is posted in the inspection stock? _______________________________________________________________ How do you control that a post-process inspection should be performed in addition to/instead of an inspection during production? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________

Task 2: Goods Receipt for the Process Order After completing production, the tablets are delivered to the warehouse. 1.

In plant 1100, post the goods receipt for a process order for the material TAB-1## to storage location 0001. Continued on next page

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Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Hint: Select the corresponding process orders for the material TAB-1##. Save the goods receipt posting. What document number is given? ____________________________________________________________


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________ Quantity in inspection stock: ___________________________________

Task 4: Record the inspection results, and make a usage decision for the inspection lot Inspect the tablets on warehouse receipt, and then make a usage decision on the inspection lot. 1.


2.

Make the usage decision for the inspection lot. Post the inspection lot quantity to the free stock.


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Continued on next page

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Quantity in unrestricted-use stock: ______________________________ Quantity in inspection stock: ___________________________________

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Solution 17: Quality Inspection at Goods Receipt for the Process Order Task 1: Change the inspection setup in the material master Enter the inspection type for a goods receipt for an order in the material master of the tablet (TAB-1##). 1.

Which inspection type do you have to activate if you want to perform a goods receipt inspection for an order? _______________________________________________________________ Which indicator controls whether the GR quantity is posted in the inspection stock? _______________________________________________________________ How do you control that a post-process inspection should be performed in addition to/instead of an inspection during production? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) An inspection type for inspection origin 04. In the standard system, this is inspection type 04. Post to the quality inspection stock: Indicator: Post to the inspection stock with inspection settings for inspection type 04 If a post-process inspection should be performed in addition to an inspection during production, you must activate both inspection type 03 and 04. If a post-process inspection should be performed instead of an inspection during production, you should deactivate inspection type 03 and activate inspection type 04.


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In plant 1100, post the goods receipt for a process order for the material TAB-1## to storage location 0001. Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Hint: Select the corresponding process orders for the material TAB-1##. Save the goods receipt posting. What document number is given? ____________________________________________________________ a)

Post a goods receipt. Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Goods receipt for the order Plant: 1100 Search help in MIGO (binoculars icon), select the orders for the material TAB-1## Hint: In MIGO, set the indicator Item ok.


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________


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Quantity in inspection stock: ___________________________________ a)


Values

Material

TAB-1##

Plant

1100



Record inspection results for the goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number and the inspection lot origin 04. a)


Values

Material

TAB-1##

Plant

1100


04


Make the usage decision for the inspection lot. Continued on next page

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Post the inspection lot quantity to the free stock. a)

Double-click the inspection lot number in the worklist of the results recording. Make usage decision.


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ______________________________ Quantity in inspection stock: ___________________________________ a)


Values

Material

TAB-1##

Plant

1100


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Lesson Summary You should now be able to: • Explain the material settings for a quality inspection in the goods receipt for the order • Process inspection lots from this goods receipt • Post the stocks using the inspection lots for the goods receipt for the order

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Lesson: Early Goods Receipt Inspection

Lesson: Early Goods Receipt Inspection Lesson Overview This lesson describes the in-process inspection for an order, and the possible incoming inspection for the order in the warehouse with one inspection lot. The inspection requirements are defined in an inspection plant and/or in a material specification. A simple defects recording is also possible.


Explain the material settings for a quality inspection for early lot creation for the order item Carry out an in-process inspection for the order and an incoming inspection at goods receipt for the order with one inspection lot Post the stocks using this inspection lot

Business Example You want to carry out an in-process inspection during production and a possible incoming inspection after delivery of the goods to the warehouse using one inspection lot. The required inspection specifications are to be defined in one inspection plan from Quality Management. You also want to post stock with the inspection lot.

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Early Lot Creation for the Order Item

Figure 113: Early Goods Receipt Inspection

When a production or process order is released, an early goods receipt inspection lot (inspection lot origin 04) can be generated for this order. This inspection lot is created independently of whether an inspection lot with origin 03 exists for the relevant order. You control the creation of the immediate goods receipt inspection lot in the inspection setup in the material master. For inspection types of origin 04, the Control of inspection lot creation indicator has the option Early lot creation for order item. The inspection lot can be used for an inspection during production, as well as an inspection at the end of the production process. Unlike inspection lot origin 03, for this process you can use an inspection plan for an inspection during production. The early goods receipt inspection provides a type of inspection lot summary. Once the goods have been received, the inspection lot becomes stock-relevant and can be used to manage stock. At the time of goods receipt, if the batch or storage location differs from the planned batch or storage location, a new inspection lot (origin 04) is created.

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Figure 114: Comparison: Inspection lot origin 03 - Inspection lot origin 04

If you use early GR lots (inspection lot origin 04), work scheduling (task list type N / task list type 2) and inspection planning (task list type Q) take place separately. You can only control stock using the early inspection lot with origin 04.

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Exercise 18: Early Goods Receipt Inspection for the Production Order Exercise Objectives After completing this exercise, you will be able to: • Activate an early inspection for the goods receipt for an order • Perform an early inspection for the goods receipt and make a transfer posting for the goods receipt quantity, based on the inspection results

Business Example As an alternative to inspection during production with inspection lots for the inspection origin 03, you want to inspect shafts during an early goods receipt inspection with inspection lots for the inspection lot origin 04. The inspection lots should be automatically created when the order is released and the goods receipt quantities for the order are only posted when the usage decision is made.

Task 1: Change the inspection setup in the material master Set an inspection type for the early goods receipt inspection for an order in the material master of the shaft (T-BQ6##). 1.

Which inspection type do you use? _______________________________________________________________ Which setting controls that the inspection lot is created when the production order is released? _______________________________________________________________

Task 2: Change inspection plan An existing inspection plan for the shaft is enhanced for the inspection during production. 1.

The inspection plan that has previously been used to inspect the goods receipt is used for the inspection. Add an additional operation including the inspection characteristic (for example, master inspection characteristic 8-106, and sampling procedure FIX3-0) for the inspection during production.


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Create the production order with the order type PP01 in the plant 1000. The order quantity is 100 PC. Use the scheduling type Current date (4). What order number was given? _________________________________

2.

Record inspection results for the "early" goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number T-BQ6## and the inspection lot origin 04. Record inspection results for the new operation.


In plant 1000, post the goods receipt for a production order for the material T-BQ6## to storage location 0001. Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Save the goods receipt posting. Which material document number is assigned? _______________________________________________________________ Was another inspection lot created? _______________________________________________________________


Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ____________________________ Quantity in inspection stock: ________________________________ Continued on next page

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Then check the quantity to be posted in the inspection (tab Inspection lot quantities).



2.

Make the usage decision for the inspection lot. Optional: Post part of the inspection stock to unrestricted-use stock and the other part to the order. What additional entry do you have to make?


Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ____________________________ Quantity in inspection stock: ________________________________

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Solution 18: Early Goods Receipt Inspection for the Production Order Task 1: Change the inspection setup in the material master Set an inspection type for the early goods receipt inspection for an order in the material master of the shaft (T-BQ6##). 1.

Which inspection type do you use? _______________________________________________________________ Which setting controls that the inspection lot is created when the production order is released? _______________________________________________________________ a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) An inspection type for inspection origin 04. In the standard system, this is inspection type 04. Inspection lot creation for order release: Indicator Control InsLot with the setting Early Lot Creation for the Order Item.

Task 2: Change inspection plan An existing inspection plan for the shaft is enhanced for the inspection during production. 1.

The inspection plan that has previously been used to inspect the goods receipt is used for the inspection.


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Add an additional operation including the inspection characteristic (for example, master inspection characteristic 8-106, and sampling procedure FIX3-0) for the inspection during production. a)

Logistics → Quality Management → Quality Planning → Inspection Planning → Inspection Plan → Change (QP02) or Logistics → Central Functions → Engineering → Engineering Workbench (CEWB) Field name or data type

Values

Material

T-BQ6##

Plant

1000

Group counter

1

Change the inspection plan with the Group counter 1 Create an additional operation with the control key QM02 and the short text Inspection in production. b)

Assign the master inspection characteristic 8-106 to the operation. The sample is to be determined according to the sampling procedure FIX3-0. Then save the changed inspection plan.


Create the production order with the order type PP01 in the plant 1000. The order quantity is 100 PC. Use the scheduling type Current date (4).


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What order number was given? _________________________________ a)


Values

Material

T-BQ6##

Production plant

1000

Order type

PP01

Total quantity

100 PC

Scheduling type

4 (current date)

Release production order Save production order 2.

Record inspection results for the "early" goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number T-BQ6## and the inspection lot origin 04. Record inspection results for the new operation. a)


Values

Material

T-BQ6##

Plant

1000


04



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In plant 1000, post the goods receipt for a production order for the material T-BQ6## to storage location 0001. Continued on next page


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Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Save the goods receipt posting. Which material document number is assigned? _______________________________________________________________ Was another inspection lot created? _______________________________________________________________ a)

Post a goods receipt. Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Goods receipt for the order Plant: 1000 Search help in MIGO (binoculars icon), select the orders for the material T-BQ6## Hint: In MIGO, set the indicator Item ok. No additional inspection lot has been created. The quantity in the existing inspection lot is increased by the GR stock. The posted order quantity exists in the quality inspection stock. The inspection lot is stock-relevant (system status SPRQ), and has a quantity to be posted (tab Inspection lot quantities).


Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ____________________________ Quantity in inspection stock: ________________________________


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Then check the quantity to be posted in the inspection (tab Inspection lot quantities). a)


Values

Material

T-BQ6##

Plant

1000

Execute the function key F8. Other option: Logistics → Quality Management → Quality Inspection → Inspection Lot → Processing → Display (QA03) Application function bar, pushbutton Stock (Stock overview). Tab page Insp. lot quantities


Record inspection results for the goods receipt inspection lot. Use the worklist for results recording.


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Select your inspection lot using the material number and the inspection lot origin 04. a)


Values

Material

T-BQ6##

Plant

1000


04


Make the usage decision for the inspection lot. Optional: Post part of the inspection stock to unrestricted-use stock and the other part to the order. What additional entry do you have to make? a)

Double click the inspection lot number in the worklist of the results recording. Make usage decision. On return delivery: Reason for the goods movement for the return delivery for an order and an explanatory text (optional).


Check the stock for your material T-BQ6##. What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: ____________________________


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Quantity in inspection stock: ________________________________ a)


Values

Material

T-BQ6##

Plant

1000


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Exercise 19: Early Goods Receipt Inspection for the Process Order Exercise Objectives After completing this exercise, you will be able to: • Activate an early inspection for the goods receipt for an order • Perform an early inspection for the goods receipt and make a transfer posting for the goods receipt quantity, based on the inspection results

Business Example An early goods receipt inspection should be performed for certain materials instead of or in addition to an inspection during production (in-process control). The inspection lots should be automatically created when the order is released and the goods receipt quantities for the order are only posted when the usage decision is made.

Task 1: Change the inspection setup in the material master Enter the inspection type for an early goods receipt for an order in the material master of the tablet (TAB-1##). 1.

Which inspection type do you use? _______________________________________________________________ Which setting controls that the inspection lot is created when the process order is released? _______________________________________________–_______________ Hint: If both an inspection during production (inspection type 03) and an early goods receipt inspection (inspection type 04) are active in the inspection setup of the material master, two inspection lots are created when the order is released.

Task 2: Change inspection plan: An existing inspection plan for the tablet is enhanced for the inspection during production. 1.

The inspection is based on the existing goods receipt inspection plan for the material TAB-1## in the plant 1100. Continued on next page

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Insert another operation (in-process inspection) with the master inspection characteristics during production N-100, N-200). Use the operation control key QM02 and the sampling procedure FIX1-0.

Task 3: Process Order for the Material and Inspection Lot Processing Create a process order for your material TAB-1##. Then enter the inspection results for the in-process inspection for the process order. 1.

Create the process order with the order type PI01 in the plant 1100. The order quantity is 1500 PC. Use the scheduling type Current date (4). What order number was given? _______________________________________ Inspection lot(s) for the process order: _________________________________

2.

Record inspection results for the "early" goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number TAB-1## and inspection lot origin 04. Record inspection results for the new operation In-process inspection.


In plant 1100, post the goods receipt for a process order for the material TAB-1## to storage location 0001. Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Save the goods receipt posting. Which material document number is assigned? ____________________________________________________________ Was another inspection lot created? ____________________________________________________________


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Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: _____________________________________ Quantity in inspection stock: _________________________________________ Then check the quantity to be posted in the inspection (tab Inspection lot quantities).



2.

Make the usage decision for the inspection lot. Post the inspection lot quantity to the free stock.


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: _____________________________________ Quantity in inspection stock: _________________________________________

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Solution 19: Early Goods Receipt Inspection for the Process Order Task 1: Change the inspection setup in the material master Enter the inspection type for an early goods receipt for an order in the material master of the tablet (TAB-1##). 1.

Which inspection type do you use? _______________________________________________________________ Which setting controls that the inspection lot is created when the process order is released? _______________________________________________–_______________ Hint: If both an inspection during production (inspection type 03) and an early goods receipt inspection (inspection type 04) are active in the inspection setup of the material master, two inspection lots are created when the order is released. a)

Individual maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Change (MM02) Central maintenance: Logistics → Quality Management → Quality Planning → Logistics Master Data → Material → Inspection Setup (QA08) An inspection type for inspection origin 04. In the standard system, this is inspection type 04. Inspection lot creation for order release: Indicator Control InsLot with the setting Early Lot Creation for the Order Item.

Task 2: Change inspection plan: An existing inspection plan for the tablet is enhanced for the inspection during production. 1.

The inspection is based on the existing goods receipt inspection plan for the material TAB-1## in the plant 1100.


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Insert another operation (in-process inspection) with the master inspection characteristics during production N-100, N-200). Use the operation control key QM02 and the sampling procedure FIX1-0. a)

Logistics → Quality Management → Quality Planning → Inspection Planning → Inspection Plan → Change (QP02) or Logistics → Central Functions → Engineering → Engineering Workbench (CEWB) Field name or data type

Values

Material

TAB-1##

Plant

1100

Create an additional operation with the control key QM02 and the short text In-process inspection. b)

Then assign the master inspection characteristics N-100 and N-200 to the operation. The sample is to be determined according to the sampling procedure FIX1-0. Then save the changed inspection plan.

Task 3: Process Order for the Material and Inspection Lot Processing Create a process order for your material TAB-1##. Then enter the inspection results for the in-process inspection for the process order. 1.

Create the process order with the order type PI01 in the plant 1100. The order quantity is 1500 PC. Use the scheduling type Current date (4). What order number was given? _______________________________________


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Inspection lot(s) for the process order: _________________________________ a)


Values

Material number

TAB-1##

Production plant

1100

Process order type

PI01

Total quantity

1500 PC

Scheduling type

4 (current date)

Save your process order. 2.

Record inspection results for the "early" goods receipt inspection lot. Use the worklist for results recording. Select your inspection lot using the material number TAB-1## and inspection lot origin 04. Record inspection results for the new operation In-process inspection. a)


Values

Material

TAB-1##

Plant

1100


04



In plant 1100, post the goods receipt for a process order for the material TAB-1## to storage location 0001. Continued on next page

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Use the following menu path: Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Save the goods receipt posting. Which material document number is assigned? ____________________________________________________________ Was another inspection lot created? ____________________________________________________________ a)

Post a goods receipt. Logistics → Materials Management → Inventory Management → Goods Movement → Goods Movement (MIGO). Goods receipt for the order Plant: 1100 Search help in MIGO (binoculars icon), select the orders for the material TAB-1## Hint: In MIGO, set the indicator Item ok. No additional inspection lot has been created. The quantity in the existing inspection lot is increased by the GR stock. The posted order quantity exists in the quality inspection stock. The inspection lot is stock-relevant (system status SPRQ), and has a quantity to be posted (tab Inspection lot quantities).


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: _____________________________________ Quantity in inspection stock: _________________________________________


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Then check the quantity to be posted in the inspection (tab Inspection lot quantities). a)


Values

Material

TAB-1##

Plant

1100



Record inspection results for the goods receipt inspection lot. Use the worklist for results recording.


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Select your inspection lot using the material number and the inspection lot origin 04. a)


Values

Material

TAB-1##

Plant

1100


04


Make the usage decision for the inspection lot. Post the inspection lot quantity to the free stock. a)

Double-click the inspection lot number in the worklist of the results recording. Make a usage decision and post the stocks.


Check the stock for your material (TAB-1##). What quantity is in unrestricted-use stock? What quantity is in inspection stock? Quantity in unrestricted-use stock: _____________________________________


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Quantity in inspection stock: _________________________________________ a)


Values

Material

TAB-1##

Plant

1100


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Lesson Summary You should now be able to: • Explain the material settings for a quality inspection for early lot creation for the order item • Carry out an in-process inspection for the order and an incoming inspection at goods receipt for the order with one inspection lot • Post the stocks using this inspection lot

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Unit Summary You should now be able to: • Explain the material settings for a quality inspection in the goods receipt for the order • Process inspection lots from this goods receipt • Post the stocks using the inspection lots for the goods receipt for the order • Explain the material settings for a quality inspection for early lot creation for the order item • Carry out an in-process inspection for the order and an incoming inspection at goods receipt for the order with one inspection lot • Post the stocks using this inspection lot

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Unit 5 Test Equipment Management Unit Overview This chapter deals with inspection processing in the environment of orders from Plant Maintenance and Customer Service. The application example used is an inspection in conjunction with the recurring control of the test equipment. This may be created in the SAP system as equipment.

Unit Objectives After completing this unit, you will be able to: • • •

Manage test equipment as master data in plant maintenance Maintain the necessary master data data for repeat checks of test equipment Carry out repeat checks of test equipment

Unit Contents Lesson: Test Equipment Management.......................................278 Exercise 20: Test Equipment Management .............................295

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Lesson: Test Equipment Management Lesson Overview This chapter deals with inspection processing in connection with orders from Plant Maintenance and Service Processing. The corresponding master data will be discussed and the necessary settings in Customizing explained. The full process from planning through to implementation of the inspection will be presented.


Manage test equipment as master data in plant maintenance Maintain the necessary master data data for repeat checks of test equipment Carry out repeat checks of test equipment

Business Example Test equipment is used during quality inspections. This is regularly managed and checked as master records Plant Maintenance.

Master Data in Plant Maintenance

Figure 115: Test Equipment Types in the SAP System

Test equipment is included in the inspection plan or task list using the functions for production resources/tools (PRTs).

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Lesson: Test Equipment Management

You can manage test equipment as: • • • •

Material master Document master record Separate production resources/tools master record Equipment

The equipment is checked at single unit level (equipment).

Figure 116: Quality Management - Plant Maintenance Integration

To plan and implement test equipment management, Plant Maintenance and Quality Management are integrated. These functions provide extended recording options for measurement readings in classic plant maintenance.

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Figure 117: Test Equipment Management Functions

You use test equipment management to monitor the test equipment you use in inspections.

Figure 118: Create equipment master

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The equipment master record contains the following data groups: • • • • • •

General data  (for example, reference data, manufacturer data, and so on) Location data  (for example, plant, company code, cost center, and so on) Classification  (for example, class, characteristics) Documents Partner Warranty information

In addition, you can set the following additional views by choosing Edit → View Selection from the menu: • • • •

Serial numbers Configuration PRT data Sales data

Figure 119: Structure of Preventive Plant Maintenance

Maintenance planning links the required master data for regular checks, and allows the scheduling of the test equipment monitoring.

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Figure 120: Maintenance Strategies

The maintenance strategy can either be time-based or performance-based. Measuring points form the basis for performance-based maintenance. You record counter readings for these measuring points.

Figure 121: maintenance plan

You can create a maintenance plan with or without a maintenance strategy. A calibration inspection is implemented with the help of a time-based or performance-based maintenance strategy. For a single cycle plan, you do not need to maintain a strategy, but can enter the cycle directly in the maintenance plan. You can also switch directly to the operation overview in the maintenance task list from the maintenance transaction in the maintenance plan.

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Several time-based and performance-based maintenance cycles are combined in a multiple counter plan.

Planning and Implementation of the Inspections

Figure 122: Processing a Calibration Inspection

You process the inspection lot in Quality Management that was created by the planning activities and release of the maintenance order in plant maintenance. The items of equipment assigned in the maintenance item are copied into the inspection lot as objects to be inspected. You record results for the characteristics planned in the equipment task list or in the maintenance task list, valuate the characteristics, and complete the inspection lot by making the usage decision. Once the usage decision has been made, the system use follow-up actions to change the PRT status of the test equipment. The inspection results history allows you to select and evaluate inspection results for equipment or functional locations. You thus have the option of displaying the run of measured values graphically, which allows you to anticipate when tolerances are likely to be exceeded.

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Figure 123: Calibration Inspection Planning (1)

Figure 124: Calibration Inspection Planning (2)

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Figure 125: Planning a Calibration Inspection

Test equipment is managed as an equipment master record. Inspection characteristics can be included in the Equipment task list (plan type E) or in the General maintenance task list (plan type A) in the form of master inspection characteristics or task list characteristics. If inspection results are to be copied to a measurement point for the equipment, you must establish a link to the QM master inspection characteristic, by assigning a corresponding class characteristic. You use the maintenance plan to link the required master data and to schedule the calibration inspection. The orders in plant maintenance are created for items in the maintenance plan. Alternatively, you can determine the calibration intervals using maintenance strategies or a maintenance cycle.

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The transaction IP10 is used for manual scheduling. Quality Management → Test Equipment Management → Calibration Planning → Maintenance Planning → Scheduling (IP10) A variant is created for automatic scheduling with the transaction IP30, and then a job is scheduled for the program RISTRA20. Quality Management → Test Equipment Management → Calibration Planning → Maintenance Planning → Deadline Monitoring (IP30) Job scheduling using: System→ Services → Jobs→ Define Job (SM36)

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The indicator Release immediately should be set for the corresponding order type from plant maintenance in Customizing. Customizing: Plant Maintenance and Customer Service → Maintenance and Service Processing → Maintenance and Service Orders → Functions and Settings for Order Types → Configure Order Types


The maintenance plan is usually scheduled using a batch program. The result of scheduling is an order in plant maintenance. When this order is released, an inspection lot is created. This can take place in a single step.

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The test equipment from the items in the maintenance plan is copied to the inspection lot. The test equipment is mapped as inspection points in the inspection lot. The inspection point type 1 is used for an item of equipment and inspection point type 2 for a functional location. For details on the field combinations for the inspection point types, make the following setting in Customizing: Quality Management → Quality Planning → Inspection Planning → General → Define Identifier for Inspection Points



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In the worklist of the results recording (QE51N), you can select the inspection lots with equipment number. Results are recorded for each item of equipment. Times can be confirmed for the inspection in the plant maintenance order. A change to the equipment status can be carried out with a corresponding follow-up action using the usage decision for the inspection lot.

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Evaluations on the Inspections in Plant Maintenance

Figure 132: Results history for Equipment/functional loc.

Using the results history, you can analyze past calibration results and predict future development. The results history can be called in results recording, in the usage decision, and as a separate transaction. Control charts can also be created for the equipment or for the functional location. Transaction for results history on the equipment/functional location Quality Management → Test Equipment Management → Information System → Equipment → Calibration Results History (QGP2) Evaluations on inspections of equipment and functional locations can also be carried out with the General QM Evaluations: Quality Management → Quality Control → Evaluations of Original Documents → General QM Evaluations (QGA4)

Figure 133: Test Equipment Tracking (1)

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If there are rejections as a result of the calibration, the inspection results that were measured using the test equipment have to be determined.

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A prerequisite for this is that the usage site of the test equipment is stored in the test equipment master, and that the test equipment to be used is planned in the inspection plan or task list. The planning can take place on the basis of the material or of the equipment. You can also use: • • • •

the results history The usage list The where-used list Test equipment tracking

as a means of performing evaluations. Documentation on the measurement equipment actually used is also available directly in the results records as of Release 4.7. In the results history, the measurement equipment used can be displayed both in the summary, and in the individual values display. The corresponding layout for the results history can be defined in the QM Customizing.

Prerequisites for the Inspections

Figure 138: Inspection Lots for Inspection Lot Origin 14

In the standard delivery, the inspection type “14” is intended for carrying out inspections in the environment of orders from plant maintenance and service processing. If an inspection lot is to be created for a maintenance order, an inspection type must be assigned to an appropriate order type.

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The parameters for the inspection type, which are normally determined by the inspection setup in the material master, come in this case from the Customizing default settings for the inspection type.

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Exercise 20: Test Equipment Management Exercise Objectives After completing this exercise, you will be able to: • Name the master data for calibration processing • Maintain and schedule a maintenance plan for a calibration inspection. • Record inspection results for the calibration inspection

Business Example You work in the department for monitoring test equipment and are responsible for calibrating the multimeters in your company. The items of test equipment T-C1## and T-C2## are stored in the system as equipment records. General task list T-CAL## has already been created for calibration. You have to create and schedule the maintenance plan for the multimeter and then calibrate it.

Task 1: Create maintenance plan The maintenance plan is the basis for the regular testing of the equipment. 1.

Create a new maintenance plan (single cycle plan) for the equipment T-C1## and T-C2##. Use the following data: Field name or data type

Values

Maintenance plan category

Plant Maintenance

Description for the maintenance plan

PMV Group ##

Reference object (equipment)

T-C1##

The equipment should be checked every 12 months. The equipment is tested based on a task list from plant maintenance. This task list already exists in the SAP training system: Field name or data type

Values

Task list type

A (General maintenance task list)

Task list group

T-CAL##

Group counter

1 Continued on next page

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Create a second item for the equipment T-C2## in your maintenance plan. Also use the task list (plan type A) from the plan group T-CAL## with the group counter 1 for the second item of equipment. Save the maintenance plan. Use the current date as the cycle type. What number is given to the maintenance plan? Maintenance plan: _________________________________________________

Task 2: Schedule maintenance plan Schedule your maintenance plan manually. 1.

Start the scheduling and enter the current date as the start of the cycle. Use the following menu path: SAP Menu → Logistics → Quality Management → Test Equipment Management → Calibration Planning → Maintenance Planning → Scheduling (IP10) Save the scheduling information. Hint: With the transaction IP30, you can schedule deadline monitoring of the maintenance plans.

Task 3: Record inspection results, and make a usage decision for the inspection lot Record inspection results for the inspection lots and the equipment to be inspected, then complete the inspection lot by making the usage decision. 1.

Use the worklist for the results recording, and select the inspection lots using the equipment number. Hint: As an alternative to making a selection using the equipment number, you can also select your inspection lots using the work place T-CAL##. Then valuate the equipment and complete the inspection lot with the usage decision. Select an appropriate follow-up action.

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Solution 20: Test Equipment Management Task 1: Create maintenance plan The maintenance plan is the basis for the regular testing of the equipment. 1.

Create a new maintenance plan (single cycle plan) for the equipment T-C1## and T-C2##. Use the following data: Field name or data type

Values


Plant Maintenance


PMV Group ##

Reference object (equipment)

T-C1##

The equipment should be checked every 12 months. The equipment is tested based on a task list from plant maintenance. This task list already exists in the SAP training system: Field name or data type

Values

Task list type


Task list group

T-CAL##

Group counter

1

Create a second item for the equipment T-C2## in your maintenance plan. Also use the task list (plan type A) from the plan group T-CAL## with the group counter 1 for the second item of equipment. Save the maintenance plan. Use the current date as the cycle type. What number is given to the maintenance plan? Maintenance plan: _________________________________________________ a)

Create maintenance plan: Logistics → Quality Management → Test Equipment Management → Calibration Planning → Maintenance Planning → Maintenance Plan → Create Single Cycle Plan (IP41) Field name or data type

Values Continued on next page

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PM, Plant Maintenance


PMV Group ##

Maintenance plan header: Tab page Maintenance plan cycle Cycle/unit: 12 months Item in maintenance plan: Tab page: Item Screen area reference object: Equipment: T-C1## Screen area Task List Field name or data type

Values

Task list type


Task list group

T-CAL##

Group counter

1

Create a second item in the maintenance plan: Use the icon Create more items in the Item tab page to create a second item in the maintenance plan. Use the the following data for the second item: Tab page: Item Screen area reference object: Equipment: T-C2## Screen area Routing Field name or data type

Values

Task list type


Task list group

T-CAL##


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Group counter

1

Hint: In the Maintenance plan header, you can enter another Scheduling Period and the call horizon in the Maintenance plan scheduling parameter tab. These entries are used when scheduling the maintenance plan. Save the maintenance plant, and confirm the suggested data for the cycle start.

Task 2: Schedule maintenance plan Schedule your maintenance plan manually. 1.

Start the scheduling and enter the current date as the start of the cycle. Use the following menu path: SAP Menu → Logistics → Quality Management → Test Equipment Management → Calibration Planning → Maintenance Planning → Scheduling (IP10)


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Save the scheduling information. Hint: With the transaction IP30, you can schedule deadline monitoring of the maintenance plans. a)

Schedule maintenance plan: SAP Menu → Logistics → Quality Management → Test Equipment Management → Calibration Planning → Maintenance Planning → Scheduling (IP10) Use the number of your maintenance plan from the first task of this exercise, and select the pushbutton Manual call in the application function bar. Start the scheduling for the current date, and save the scheduling. You can also start the scheduling of the maintenance plan with the pushbutton start in the application function bar, and then save. Hint: The call creates a maintenance order as a call object with the order type PM06. This order is immediately released according to the setting in the order type. When the plant maintenance order is released, the inspection lot for inspection lot origin 14 is created. Hint: A maintenance order is created for each item of the maintenance plan. An inspection lot for inspection lot origin 14 is created for each maintenance order if the corresponding settings are active in the Equipment task list or in the General task list.

Task 3: Record inspection results, and make a usage decision for the inspection lot Record inspection results for the inspection lots and the equipment to be inspected, then complete the inspection lot by making the usage decision. 1.

Use the worklist for the results recording, and select the inspection lots using the equipment number. Hint: As an alternative to making a selection using the equipment number, you can also select your inspection lots using the work place T-CAL##. Continued on next page

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Then valuate the equipment and complete the inspection lot with the usage decision. Select an appropriate follow-up action. a)

Results Recording Worklist: Logistics → Quality Management → Quality Inspection → Worklist → Results Recording (QE51N) Tab page Material: Field name or data type

Values

Plant

1000


14

Tab page Equipment, functional locations: Field name or data type

Values

Equipment

T-C*##

Execute the function key F8. Record the inspection results for the inspection characteristics, and close characteristic processing. Valuate the equipment. Hint: The equipment is mapped using inspection points in the inspection lot. Make the usage decision for these inspection lots.

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Lesson Summary You should now be able to: • Manage test equipment as master data in plant maintenance • Maintain the necessary master data data for repeat checks of test equipment • Carry out repeat checks of test equipment

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Unit Summary

Unit Summary You should now be able to: • Manage test equipment as master data in plant maintenance • Maintain the necessary master data data for repeat checks of test equipment • Carry out repeat checks of test equipment

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Unit 6 Comparison of Manufacturing Types Unit Overview This chapter includes a summary comparison of inspection lot processing in conjunction with orders from production, Plant Maintenance and Customer Service.

Unit Objectives After completing this unit, you will be able to: • •

Explain the inspection process with orders. Illustrate the respective properties of the inspection lots for inspection lot origins 03, 04, 13 and 14.

Unit Contents Lesson: Comparison of Manufacturing Types ..............................306

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Lesson: Comparison of Manufacturing Types Lesson Overview Summary of QM-Specific Features, Dependent on Production Type or Inspection Lot Origin


Explain the inspection process with orders. Illustrate the respective properties of the inspection lots for inspection lot origins 03, 04, 13 and 14.

Business Example Different inspection lot origins can be used for quality inspections in conjunction with orders from production, from plant maintenance, and from service processing. In addition, the inspection requirements can be defined in different task lists. This summary provides another overview of the key elements.

Summary of the Inspection Processes in Conjunction with Orders

Figure 139: Quality Inspection in an Order Environment (1)

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Lesson: Comparison of Manufacturing Types

The task list types are as follows: • • • •

N = Routing Q = Inspection plan R = Rate routing 2 = Master recipe

Variants for inspection point completion are as follows: • • • •

_ = Quantity assignment, confirmation and inspection point valuation required 1 = Quantity assignment and inspection point valuation required 2 = Inspection point valuation required 3 = Automatic inspection point valuation

Figure 140: Quality Inspection in an Order Environment (2)

The task list types are as follows: • • •

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E = Equipment task list T = Task list for functional location A = General maintenance task list


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Lesson Summary You should now be able to: • Explain the inspection process with orders. • Illustrate the respective properties of the inspection lots for inspection lot origins 03, 04, 13 and 14.

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Unit Summary

Unit Summary You should now be able to: • Explain the inspection process with orders. • Illustrate the respective properties of the inspection lots for inspection lot origins 03, 04, 13 and 14.

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Unit Summary

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Course Summary

Course Summary You should now be able to: • • • • • •

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Describe the integration of Quality Management into production planning and shop floor control based on different manufacturing types Plan and perform an inspection during production and an inspection at the end of the production process Valuate batches from an inspection during production using inspection results Use control charts to monitor your processes Plan and process inspections in repetitive manufacturing Plan and carry out inspections in the environment of plant maintenance and service processing


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Appendix 1 Digital Signature

Figure 141: Digital Signature

Figure 142: Digital Signature: Definition (1)

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The digital signature serves the same purpose when processing digital data as the handwritten signature for paper documents.

Figure 143: Digital Signature: Definition (2)

You can specify that a user must provide a digital signature to be able to carry out certain business transactions in the SAP system. The digital signature enables you to meet the security requirements stipulated in the Good Manufacturing Practices (GMP) with regard to the execution of these transactions. The digital signature ensures that: • • •

A transaction is only performed by users with special authorization The user is uniquely identified in a forgery-proof way (for example, with the help of a smartcard-reader) The user's name, the signed transaction, the time and date are documented and cannot be forged

Comments on the digital signature can (or must) be recorded, depending on the application.

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Figure 144: Link to External Security Products

The digital signature has been implemented in the SAP system using the Secure Store and Forward (SSF) interface. SSF allows you to link various external security products that use different identification procedures. In this way, you can use individual digital signatures to protect data and documents, if the latter are stored on data carriers or transferred using communication channels. The identification and signature creation process is supported by the use of chip cards and files. The user-specific data (such as, password and private ID) are encoded on the chip card or in the file. Once the identification has been successfully made, the document data is transferred to the security product. The digital signature is created on the basis of this data and is transferred back to the SAP system. As of Release 4.6, digital signatures can be made with your SAP user and your personal password.

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Figure 145: Processing Digital Signatures

Figure 146: Digital Signature and Authenticity

The digital signature serves the same purpose when processing digital data as the handwritten signature for paper documents. The digital signature is based on a private-public key cryptography. Each signatory receives a unique ID pair made up of a private and public key. The digital signature is closely linked to the signed data. If you change only one bit of the data or the signature, the digital signature is invalid. A digital signature is created using a private key. The signature is checked with the corresponding public key. The only person who knows the private key is the signatory (the private key is stored for example on a chip card). Anyone, who knows the corresponding public key (that can be stored in the SAP system), can check the digital signature of the signatory.

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In electronic commerce, for example, contracts are concluded without the existence of a handwritten signature on paper.

Figure 147: Digital Signature

Figure 148: Digital Signature: Process Flow

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The procedure for executing a digital signature is identical for all transactions that are supported: 1. 2. 3. 4.

• •

•

You choose the function that is used to carry out the corresponding transaction in the SAP system. Based on the settings you have made, the system recognizes that a digital signature is required and switches to the dialog box for signature execution. You insert your chip card in the card reader and enter your user name and password in the dialog box if required. The system checks in your user master record, whether you are authorized to execute a signature for the function you have selected and whether the entries you have made match the data on the chip card. If you have no authorization to enter a digital signature, the function is cancelled. If you have not inserted your chip card in the card reader, or your entries do not match the data on the chip card, the dialog box reappears and you can repeat the entry procedure. The function is cancelled after the third unsuccessful attempt. If the signature is correct, processing continues with step 5.

5. If the signature requires a comment, or if you have chosen “Create comment” in step 4, you now enter your comment. The text is saved when you leave the editor. 6. You can now continue the function you have called in step 1. When you save the processed object, the signature is also saved.

Figure 149: Using Digital Signatures

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The digital signature was implemented for the following transactions: Quality Management area (QM) • • • • •

Saving inspection results for an inspection lot Recording and changing the usage decision for an inspection lot Releasing a physical-sample drawing With business transactions for the header of the quality notification With business transactions for the tasks in the quality notification

Engineering change management area • •

Status changes to the engineering change request/order Status changes to the change objects in the engineering change request/order

The approval procedures for recipes and inspection plans are based on the execution of engineering change requests/orders. •

Process manufacturing area – – –

Completing a work step in the PI sheet Accepting inadmissible values in the input validation for the PI sheet Approving a batch record

Figure 150: Activating the Digital Signature function

To determine whether a digital signature is required for the transactions mentioned above, the digital signature function must be activated in each application. You achieve this as follows:

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In process manufacturing •

•

Set the “Digital signature” indicator for the control recipe destination in Customizing for completing a phase and for accepting inadmissible values in the PI sheet. A digital signature is always required to confirm approval of a batch record.

In engineering change management: •

•

Set the “Digital signature” indicator for change types for object management records to protect status changes in engineering change requests before the engineering change order is executed. Also set this “Digital Signature” indicator to release engineering change orders for change types for object management records in Customizing.

In Quality Management: • • •

For results recording using a “Digital signature required for results recording” setting in the material authorization groups. For the usage decision using a “Digital signature required for making the usage decision” setting in the material authorization groups. For the physical-sample drawing using a “Digital signature required for confirmation of physical-sample drawing” setting in the material authorization groups.

Figure 151: Finding and Displaying Digital Signatures

You can display the signatures that have been executed for an inspection lot, engineering change order, PI sheet, or batch record, from within the corresponding object.

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For evaluations, you can search for digital signatures using the following criteria: • • •

Signatory (first and last name) Creation date and time Object type, for which the signature was used (such as, engineering change order or inspection lot)

The system generates a list of objects for which digital signatures have been executed. From this list, you can jump to the objects and display all signatures executed for them.

Figure 152: Signature Strategy (1)

Depending on the application and setting, a signature can consist of one individual signature (dual control), or of several individual signatures defined in a signature strategy. A signature strategy defines: • • •

Which individual signatures are required, that is which user groups have to sign to confirm the transaction The sequence for the individual signatures The signature or signatures that can complete the signature process

A user can only provide one signature in a signature strategy.

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Digital signature and its use: • • • •

PI sheet: Digital signatures possible with and without signature strategies Batch record: Digital signatures possible with and without signature strategies Engineering change request/order: Digital signatures possible only with signature strategies Quality Management: Signature strategies are supported for digital signatures

Figure 153: Signature Strategy (2)

If a transaction has to be signed by several people, individual signatures from different user groups can be combined to form application-specific signature strategies.

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Figure 154: Signature strategy: Example

Figure 155: Display of Signature Information

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Appendix 2 Approval for Inspection Plan

Figure 156: Approval for Inspection Plan

Figure 157: Engineering change management: Associated Objects

The engineering change management component is a central, integrated part of product data management (PDM) in the SAP System.

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In the QM and process manufacturing areas, engineering change management can, for example, be used in the following: • • • • • •

Material master Material BOM Various task list types: Inspection plan, master recipe Documents Characteristics, class characteristics and classification Object Dependencies

Figure 158: Why Make Changes with Engineering Change Management?

Engineering change management is a central logistics function that can be used to change various master data and to document this change. The valid-from date in the change master record or the engineering change request/order allows the changes to be applied at a specific time and enables you to plan changes on a long-term basis. Engineering change management enables multiple saving of SAP objects (such as, bills of material, inspection plans). This means that all the relevant change statuses are saved. The changes automatically become effective at the defined time in all areas of the logistics process chain (for example, materials planning and shop floor control). You can use engineering change management to combine changes made to several different SAP objects that have been subject to an overall change. The time of the change can be the same for all objects, or the changes can be made at different object-related times. You can store general documentation for the overall change, as well as specific documentation for each individual object change.

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Engineering change management can play an integral part in fulfilling your verification requirement.

Figure 159: Documenting a Change

A change takes effect on a predefined date. The changed object is saved twice; with its status before and after the change. The previous change condition ends as of the valid-from date of the next change. The changes are recorded in a change master record.

Figure 160: Engineering change request/order

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Engineering change orders have all the functions of change master records, as well as the following functions: • • • •

The option of triggering a Workflow task (such as, informing the person responsible for the task by mail) for certain processing stages. An approval and release procedure for changes that allow an unapproved engineering change request to become an approved engineering change order. Like change master records, you create engineering change requests in the engineering change management component. The valid-from date in the engineering change order takes over the function of the key date. The following prerequisites must be fulfilled, for you to be able to display or process the inspection plan with the engineering change order: –

– –

The engineering change order must be approved and must contain at least one object management record with approved changes for the inspection plan. The order must also contain the change type that has been defined in the inspection plan header for the corresponding change rule. The link between status and business transactions controls the processing of engineering change requests and orders. The statuses identify the individual processing stages during an approval procedure. There are both predefined (fixed) system statuses, as well as user-defined statuses. Business transactions trigger the progression from one status to the next.

Figure 161: Changes to Inspection Plans

In the process industry, there are various different requirements relating to the documentation and checking of inspection plans, depending on the sector and product. Requirements range from a relatively flexible inspection plan maintenance, through a detailed, time-based advanced planning and documentation, to strict approval procedures.

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The SAP system provides you with different types of inspection plan maintenance. In the inspection plan, you can use a change rule to define which form of maintenance is to be used for an inspection plan (in the inspection plan header data). You can create or change inspection plans as follows: •

•

•

Without a change number: A prerequisite for this is that you have authorization for the relevant inspection plan transactions. Changes apply to the entire validity period of the changed inspection plan object versions. With a change number: You can use change master records to plan and execute collective creation of and changes to related objects. The validity date is defined using a change master record (synonym: Change number). A new version is created for all inspection plan objects that have been changed. With engineering change order:   Engineering change requests contain an additional function in comparison to change master records - an extensive approval procedure. To specify a particular, user-defined procedure for the approval procedure, you enter a change type.

Once you have used a change rule to define a change procedure for an inspection plan, this plan is locked for any other less-restrictive change procedure. To unlock the inspection plan, you must first run through the change procedure that has been defined.

Figure 162: Approval for Inspection Plans

An approval procedure for master recipes, based on changes made with engineering change requests or orders was already delivered in Release 3.0. This approval procedure was extended to apply to inspection plans from Release 4.0 onwards.

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This slide illustrates the basic steps in the change process using engineering change request. This process provides an approval procedure for a master recipe or inspection plan that has been assigned the change type With engineering change order. Once the processed recipe or inspection plan is released in the approval procedure, it receives the identification Approved for the change period that has been defined by the valid-from date in the engineering change request. You can define that a digital signature is required for the progression of a system status.

Figure 163: Inspection Plan Approval (Status Sequence I)

The link between status and business transactions controls the approval and release of engineering change requests and orders. The statuses identify the individual processing stages during an approval procedure. There are the following statuses: • •

Predefined (fixed) system statuses Company-specific user statuses

Business transactions trigger the progression from one status to the next.

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SAP provides a basic process flow for the approval procedure that is defined by a network of system statuses: 1. 2. 3.

An engineering change request is created that contains a description of planned changes to various objects including an inspection plan. You check the changes for the individual objects and identify them as possible or unnecessary. Once this check has been made, the engineering change request is approved and converted into an engineering change order. The changes can now take place, this means that the inspection plan can be processed, according to the engineering change order.

Figure 164: Inspection Plan Approval (Status Sequence II)

• •

4. Once the changes to all objects have been completed, the entire order is completed. 5. Processing of the engineering change order ends with its release.

The inspection plan is now approved and can be used for inspection lot creation that requires an approved inspection plan. If the standard approval procedure provided by SAP does not meet your requirements, you can add your own company-specific checks at the order header and change object levels. You do this by using the change type to assign an appropriate user status profile to the engineering change order or the change objects. You define status profiles in Customizing for engineering change management and assign these profiles to the change types. The profiles contain a number of company-specific user statuses. These statuses are linked to the business transactions in the status profile and in this way are included in the existing status network.

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You can define that a user must have specific authorization, to set or delete a user status.

Figure 165: Prerequisites

Figure 166: Inspection Lot Approval Procedure

You can include approval requirements from the process industry when changing master data. You define a change rule and a change type in the inspection plan header, to use the approval procedure for the inspection plan. To use the approval procedure in the inspection lot (for a work order), you define an identifier for this approval procedure in the material authorization group.

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To use the authorization objects, the corresponding user master records and the required authorizations must be assigned in Customizing.

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Appendix 3 Batch record

Figure 167: Batch record

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Figure 168: Structure and Content of a Batch Record

Good Manufacturing Practices require a processing record to be created for each batch. This means that the execution of the process order that creates the batch has to be documented in the SAP system. When creating a batch record, the SAP system therefore collects all the quality-related data that has accrued for this process order. You can add to the list of SAP ERP data by using your own customer enhancement in Customizing for process data documentation. You can include optically archived files from external systems in the batch record with the help of the SAP ArchiveLink interface. You can also use the ArchiveLink to transfer data to an optical archive where it can be stored and protected against forgeries. From Release 4.7, you can use the function 21 CFR Part 11 Enhancement on Electronic Records to switch on and switch off the logging of data changes in individual data elements or entire tables according to customer-specific requirements and without modification. In addition, logged data can be evaluated according to selection criteria that you can define.

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Figure 169: Electronic Batch Record (1)

The batch record contains all the quality-relevant planned and actual data for the production of a batch. The structure, content and processing of the batch record conform to the international standards that are laid down in the GMP (Good Manufacturing Practices) guidelines for the pharmaceutical and foodstuff industries. If required, customer-specific lists can form part of a batch record, allowing the inclusion of customer-defined lists/information.


All information relevant to the process order is documented in the batch record (such as, header data for the process order and the material list).

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If the material quantity calculation is active, this data is also displayed in the batch record.


The PI sheet that has been processed, including recorded temperatures or calculated quantities is also included in the batch record.


All inspection characteristics that have been recorded in an in-process or post-process inspection are included in the batch record. The inspection report in the batch record can contain details of the physical-sample drawing, if the sample management component is in use.

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Figure 173: Creating a Batch Record: Prerequisites

If you want to create a batch record for a process order, you must take the following into account when processing the application data: • • •

The process order that produces the batch must be approved. The batch number may only be assigned to one process order (4.0 and 4.5). There must only be one goods receipt inspection lot for the process order (4.0 and 4.5).

You can prevent the creation of several goods receipt inspection lots in the material master of the material to be produced (see Insp. lot for mat. doc. item in the inspection data for the goods receipt inspection). •

The batch record can only be archived, if the following statuses are activated: Order status: Technically completed Inspection lot status Lot locked for batch record in the inspection lot for an inspection during production and a goods receipt inspection – Status in usage decision for post-process inspection lot: Locked for batch record When the order is completed, the system does not check whether all process messages have been sent successfully. To ensure that all messages are included in the batch record, you must therefore check the message log beforehand in the message monitor. – –

•

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Figure 174: Creating a Batch Record: Process Flow

A batch was produced in your plant that requires a batch record. This batch record must be approved, for example, so that you can make the usage decision for the goods receipt inspection lot and the batch status can be changed from Restricted to Released. You generate the batch record. You simulate the batch record using the current data in the system and check whether this data is complete. If necessary, you make sure that any missing data is added. To check, for example, if there are values outside the tolerances, you call up the deviation analysis. If part of the relevant data is stored outside the SAP system, you include archived files from external systems in the batch record, if required. Once the simulation list is complete and the status prerequisites have been fulfilled, you archive the record. You, or another authorized person, approve the archived batch record by executing a digital signature. Result is: The approved record is now available for use a basis for the usage decision and change in batch status.

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Figure 175: Creating a Batch Record

If you want to create a batch record as of Release 4.6, choose the proposed batch from your worklist and execute the function Generate batch record. Each batch record has a header record that manages the version data for the record, its status, approval data, as well as links to archived documents. To archive and approve a batch record, you must first generate this header record. You can also use a background job (program PPPI_MCHP_CREATE) to execute the function Generate batch record. To do this, the following prerequisites must be fulfilled: • •

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There must be at least one released process order for the batch. The process order has the statuses: Approval granted and Batch record required.


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Figure 176: Archiving and Approving Batch Record

Once you have generated the batch record, you can execute the deviation analysis. You define the events that are to be classed as variances in the material and plant-dependent settings in Customizing for the batch record. You also have the option of creating an attachment for the batch record, for example, a document in PDF format. The attachment is assigned to the current version of the batch record. You can enter comments for each version of the batch record. This allows you to store information on the batch record that is not contained in an archived document, for example, comments on the variances documented in the batch record. If all technical and system requirements have been fulfilled, the batch record can be activated and written to an optical archive using the ArchiveLink interface. Finally, the Quality Controller, or a member of the Quality Assurance department can approve the batch record. This process can be supported by an individual digital signature, or by a signature strategy.

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Figure 177: Batch record: Enhancements for Release 4.6

In addition, customers can adapt functions flexibly to suit their requirements: • • •

Closer integration of customer-defined evaluations More flexible structuring of layout Flexible control of data scope

Figure 178: Batch record: Enhancements for Release 4.6

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Figure 179: Deviation Analysis

You use a deviation analysis to determine irregularities that occurred during the production of a batch. The deviation analysis can be triggered automatically in the archiving or approval procedure, or you can trigger it manually at an earlier stage. You can archive the results in the document Deviations.

Figure 180: Customizing for the Deviation Analysis (1)

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Figure 181: Customizing for the Deviation Analysis (2)

Figure 182: Archiving the Batch Record

For the first version of the batch record, the system activates all documents at one time that belong to the record according to the Customizing settings. For all subsequent versions, only the changed documents Contents and Version data are archived, together with documents for objects that have been added to the record at a later stage.

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If new objects are created retroactively for a batch record that has already been archived, the following additional special cases can occur: •

•

If the current version has not been approved, the status Partially archived is given, when you access the objects next time. The documents for the objects that have been added, as well as the changed Contents are archived. If the current version is already approved, the system creates a new version when you access the change mode. You can then archive this version.

Figure 183: Approval Sequence for Batch Record

The batch record is linked to the SAP status management system. The following statuses are important for the approval of the batch record: • • •

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Status Partially approved Status Approval withdrawn Status Approved


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Figure 184: Batch Status and Usage Decision

If necessary, you can define in the material master (work preparation view) that the following operations are only possible for certain materials after the approval of the batch report: • •

Making the usage decision for the batch goods receipt inspection lot Changing the batch status from Restricted to Released

You should produce the materials, for which this indicator is set, using an order type that has the Customizing indicator Batch record required set. • •

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You use this indicator to define that a batch record must be archived for all batches that have been produced with the selected order type. When the orders and their related inspection lots are created, they automatically receive the status Batch record required. The status is deleted when the batch record is archived. Only then can you archive and delete the orders and inspection lots.


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Feedback SAP AG has made every effort in the preparation of this course to ensure the accuracy and completeness of the materials. If you have any corrections or suggestions for improvement, please record them in the appropriate place in the course evaluation.

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