WELCOME TO QUALITY MANAGEMENT MODULE Sanjay Kumar

25th June 2008

QM Module

QM Module General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Business Scenario : Main Business Scenario
Industrial companies perform quality inspections on

products at various stages in the logistics supply chain.

They need to maintain inspection specifications,

record inspection results, and can perform evaluations using this data.

SAP AG 1999

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

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

PP

Production Production planning planning

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

QM

Inspection lot
Inspection lot Inspection lot

PM
Test equipment Test equipment management management Usage decision Usage decision

SD
Shipping Shipping Billing Billing

QM Overview

Planning

Inspection

Control
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QM Overview
Quality Planning: Activities
Quality planning Quality inspection Quality control Quality certificates Quality notifications Test equipment mgmt.

Creating and managing the master data that is required (among other items) to plan and execute quality inspections.

QM Overview
Quality Inspection: Activities
Quality Quality Quality Quality Quality Test

planning inspection control certificates notifications

Determining whether the units inspected fulfill the predefined quality requirements.

equipment mgmt.

QM Overview
Quality Control: Activities
Quality Quality Quality Quality Quality Test

planning inspection control certificates notifications

Implementing different preventive, monitoring and corrective activities. These activities are based on the specifications from quality planning and the evaluations of quality inspections and quality notifications.

equipment mgmt.

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np
np

QM Overview
Quality Certificates: Activities
Quality Quality Quality Quality Quality Test

planning inspection control certificates notifications

Certifying the quality of a material or product. Quality certificates contain specification values, and inspection results. texts,

equipment mgmt.

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QM Overview
Quality Notification : Activities
Recording the Non-Conformance
Quality Quality Quality Quality Quality Test

planning inspection control certificates notifications

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

equipment mgmt.

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QM Overview
Test Equipment Management: Activities
Quality planning Quality inspection Quality control Quality certificates Quality notifications Test equipment mgmt.

Managing master data as well as the planning and processing calibration inspections for test and measurement equipment.

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QM Module - General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Quality Planning: Activities
Quality planning Quality inspection Quality control Quality certificates Quality notifications Test equipment mgmt.

Creating and managing the master data that is required (among other items) to plan and execute quality inspections.

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Quality Planning

Inspection Planning

Inspection Plan Master Recipes Basic Data Catalog / Selected Sets Master Inspection Characteristics Class Characteristics Inspection Method Sampling Procedure / Sampling Scheme Work Center Logistic Master Data Material master QM-View Quality Info Record

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Quality Planning
QM Basic Data and Inspection Plan Structure

Inspection Plan Structure :

Material master record Vendor master record Customer master record

Insp. plan
Header

Inspection characteristic Work center

Operation

Production resources/tools
SAP AG 2001

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Quality Planning
Inspection Plan : Inspection plans is used to describe how a quality inspection should be performed for one or more materials. Define in the inspection plan in which order individual inspection operations should occur and which inspection characteristics should be inspected, using which inspection specifications. Inspection plans for different uses (for Example goods issue inspection, Inprocess Inspection, Inspection during Sales etc.).

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Quality Planning
Basic Data : Master Inspection Characteristics
Master Inspection Characteristic

Characteristic control

What is to be inspected?

General data

References to master records

Administrative data

SAP AG 1999

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Quality Planning
Master Inspection Characteristics : Inspection characteristic describes WHAT needs to be inspected.
MIC can be either Qualitative or Quantitative and intended for repetitive use. Catalogs & inspection Methods are assigned to MICs Defect Catalogs are assigned in case Defect Recording is required. Control Indicators defines the parameters for Result recording of the MIC & Result analysis.

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Quality Planning
Basic Data : Usage of Catalog Usage of Catalogs
Cracked Cracked

Damaged Damaged

Scratched Scratched

Warped Warped

CODING
1001 1002 1003 1004
SAP AG 2001

Warped Damaged Cracked Dented

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

9 6 5 4 3 2 1

Defects Defect consequences Causes Events Usage decisions Task Characteristic attributes
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Quality Planning
Catalog :
The catalog contains unique, non-numerical data in the system that is defined at client or plant level. Can define our own code groups and codes for each catalog type. Directly assign catalogs to master inspection characteristics Use the catalogs to make it easier to record inspection results, defects, and defect locations during inspection lot processing
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Quality Planning
Basic Data : Inspection Method
Inspection Method: General

Qualification

What kind of inspection is to be performed?

Validity

Texts

Classification

SAP AG 2001

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Quality Planning
Inspection Method:
An inspection method describes how the inspection to be carried out for an inspection characteristic. Common family of components which are inspected under standard specifications, norms etc can be treated as inspection method which will be assigned to master inspection characteristic Up to ten inspection methods can be assigned to a master inspection characteristic, however only one inspection method can be assigned to the planned characteristic. Inspection method is maintained at plant level and validity from effective date. Inspection method identifier is optional Text, Long Text, Inspector Qualification to be entered on data screen for every inspection method

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Quality Planning
Quality Info Record :

When a quotation or purchase order is created, the system checks whether a Q-info record is required and available for the combination of material and vendor. A check is made to determine whether the purchase order can be released Specify a status profile for releasing the supply relationships as well as the QM system of the material-vendor combination in the Q-info record This facilitates the inspection or perform a goods receipt inspection and/or source inspections

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

planning inspection control certificates notifications

Determining whether the units inspected fulfill the predefined quality requirements.

equipment mgmt.

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Quality Inspection

Inspection Lot Creation

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

Defect Recording : For deviation

Usage Decision

Quality Inspection
Inspection Lot :
Inspection Lot: Business Scenario

Inspection lot

The inspection lot represents the request to a plant to perform a quality inspection on a certain quantity of a material.
SAP AG 1999

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Quality Inspection
Inspection Lot Lot: General Inspection : General
Maintenance order Goods movement Production order Customer order Delivery

Inspection lot

Quality inspection

Deadline monitoring Manual

SAP AG 2001

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8 7 6 5 4

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Quality Inspection
Inspection Process : Result Recording
QM Inspection Process: Results Recording

Event

Inspection lot

Sample determination Enter results

Results recording
Defects recording

Valuation Completion

Usage decision

Evaluation
SAP AG 1999

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

SAP AG 1999

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Quality Inspection
Usage DecisionDecision: Effects Effects : Usage

Vendor

Stock

A B C D

Purchasing

!
Units t

Production

Inspection stage

Statistics
SAP AG 1999

Quality level
Time

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

planning inspection control certificates notifications

Certifying the quality of a material or product. Quality certificates contain specification values, and inspection results. texts,

equipment mgmt.

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Quality Certificate

Incoming

Vendor certificate against Good receipt

Outgoing

Certificate Profile

- Certificate Planning - Certificate Processing

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Quality Certificate

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Quality Notification : Activities
Recording the Non-Conformance
Quality Quality Quality Quality Quality Test

planning inspection control certificates notifications

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

equipment mgmt.

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Quality Notification
Notification Type

Vendor problem Internal problem Customer complaint Automatic trigger from defect recording / Manual creation. Predefined codes as per catalog used in Item / Task / Activity Catalog maintained at client level. Task completion for notification closure Standard report for notification.
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Notification Process

Quality Notification
Elements:
Archive Link Description

Workflow

Defects analysis

Evaluations Controlling

Q Notification

Tasks

Nonconformity costs QM costs Actions

Status management

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

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

Task Completion and Notification closure Report

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment Management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Overview
Test Equipment Management: Activities
Quality planning Quality inspection Quality control Quality certificates Quality notifications Test equipment mgmt.

Managing master data as well as the planning and processing calibration inspections for test and measurement equipment.

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Test Equipment Management

Purpose : To ensure that the Test Equipment ( which is used for Inspection ) continues to meet the pre-defined specifications. Process: Creation of Equipment Maintenance task list Maintenance plan Scheduling the Plan Processing of Calibration order (Internal / External) Creation of the lot Result recording Defect recording Usage decision Notification processing for any deviation.

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

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

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

PP

Production Production planning planning

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

QM

Inspection lot
Inspection lot Inspection lot

PM
Test equipment Test equipment management management Usage decision Usage decision

SD
Shipping Shipping Billing Billing

QM integration
Position of QM

Quality Management:
Integration in logistical processes

MM
Quality Management

PP

PM

SD

SAP AG 1999

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QM integration
Material Management Manages quality information for materials, vendors Releases vendors; Monitors their QM systems Manages the release status of delivery relationships, for example Vendor approval, Sample Approval etc Evaluates vendors on the basis of quality using quality scores from audits, goods receipt inspections, and problem notifications. Requests quality certificates and monitors their receipt. Tracking of vendor certificates. Triggers source inspections to be carried out at the vendors premises before the vendor is due to make a delivery - Source inspection. Triggers inspections for goods movements, for example, goods receipt Blocks payments until Inspection Lots are accepted
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QM integration
Production Planning Batch management Handles inspection characteristics and setup characteristics for operations Manages quality inspections for manufacturing orders Handles in-process inspections during production at freely defined inspection Points- In-process Inspection (Qty/time based) Scrapping procedures Triggers final inspection upon goods receipt from production Confirms quality and quantity information for manufacturing orders Monitors production quality with the help of control charts and determines process capability. Manages problems in production using quality notifications and by processing corrective tasks

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QM integration
Sales and Distribution

Batch allocation during delivery of finished goods Customer Complaints Handling Manages customer-related quality information Triggers an inspection at shipping when the delivery is createdLot Creation thro PGI for Sales Inspection Lot Creation thro PGR for Customer Returns Creates quality certificates with the delivery

Plant Maintenance

Equipment related data maintenance Calibration

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

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Reports

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Reports

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Reports

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Reports

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

Comprehensive master data maintenance by system. Stocks in Quality till inspection is completed. Inspection Results are available on line, hence retrieval is will be easy and trends/SPC of characteristics can be viewed on line Quality Score for vendor is based on U D. Standardized methodology for complaint reporting and analysis. Calibration frequency scheduled by system for instruments. Standard reports for analysis and review.

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QM Module : General
QM Overview Quality Planning Quality Inspection Quality Certificate Quality Notification Test Equipment management QM Integration with Other Modules Standard Reports Benefits Processes
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QM Processes
1. 2. 3. 4. 5. 6. 7. 8.

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

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1. QM Master Data

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QM Master Data
Create
(One time only)

Change
(many times)

Display
(any time)

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

: : : : : : : : : :

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

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2. Incoming Inspection

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Incoming Inspection
Incoming Insp
GR-MIGO Posting by MM Inspection Lot : Type 01 created and viewed thro QA32 Result Recording (QE51n) for inspection characteristics Not Ok

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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3. In-Process Inspection

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In-process Inspection
In-process Materials

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

Defect Recording in RR

Resul t
OK

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Valuation is required on each recording

Lot Usage Decision

Notification Closure
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4. Final Packing Inspection

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

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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5. Stock Transfer Inspection

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Stock Transfer Inspection

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

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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6. Customer complaint and Returns

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Customer Rejection
Create Return Sale Order by SD thro VA01 Post Goods Receipt to storage loc using VL01n for Inspection lot creation.

Classification of customer complaint

Inspection Lot : Type 05 created and viewed thro QA32

Result Recording for investigation finding Defect Recording Create Notification Task Completion and Notification closure

Usage Decision for the Lot

Notifications Process contains : Customer Details / Sale order Complaint type and rejection details Partners and Coordinator Internal and External failures Causes (Root Cause) Tasks (Corrective Action ) Activities (Preventive Action)

Generate Report

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Customer complaint

Notification Raised by SD
Notifications Process contains : Customer Details / Sale order Complaint type and rejection details Partners and Coordinator Internal and External failures Causes (Root Cause) Tasks (Corrective Action ) Activities (Preventive Action)

Send to Concerned Personnel for actions

Task Completion and Notification closure

Generate Report

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7. Miscellaneous Inspection

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

Defect Recording in RR

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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8. Calibration Inspection

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

Calibration Order Searching thro IW39 Inspection Lot list :Type 14 created and viewed thro QA32

Defect Recording in RR Not Ok

Result Recording (QE51n) for inspection characteristics

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

Notification Closure
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External Calibration
Lab Equipment to be calibrated by external
Calibration Order Searching thro IW39 Calibration Order Processing thro IW32
Master Data : Equipment Master : IE01,IE02,IE03 Maintenance Task list : IA01,IA02,IA03 Maintenance Plan : IP41 Scheduling : IP10

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

Defect Recording in RR Not Ok

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

Notification Creation (QM01) Background Notification processing (QM02)

Quality Notification

If Inspection Lot not required

Service Entry Sheet completion / MIRO Processing by QM

Notification Closure
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Thank you

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