Quality Management Overview - Objectives

At the end of this session You will understand:

Elements of SAP Quality Management

QM Integration with other SAP Modules

QM Processes in Logistics Supply Chain

Procurement, Production & SD

Functions In Quality Management Module
Elements of Quality Management Modules
Quality Planning
Quality Planning

Quality Planning covers the following functions:

General master data (for example, material master, batch
data, vendor master records)
QM specific master data (for example, master inspection
characteristics, inspection methods, sampling procedures)
Inspection planning functions (for example, inspection
plan, material specification)

Quality Planning will be covered in Detail In QM

Master Data....
Quality Inspection
Quality Inspection- Lot Creation
QM Inspection Processing- Work Flow

With Inspection Plan Without Inspection Plan

Create Inspection lot

Select inspection plan
Specify Sample size
Calculate samples
Print Shop Papers

Record characteristic results

Record defect data

Make Usage decision

Calculate Quality Score Specify Quality Score
Update Quality Level
Carry out follow-up action
Quality Inspection- Recording Inspection results

The inspector can :

Record the Results for
Planned or Unplanned
Inspection
Characteristics
Record the Confirmed
Defects
Valuate the
characteristics
Quality Inspection- Recording Inspection results-QA32
Quality Inspection- Recording Inspection results-QA32
Quality Inspection- Recording Inspection results-QA32
Quality Inspection- Defects Recording
Quality Inspection - Usage Decision
Quality Inspection - Usage Decision-QA32
Quality Control
Quality Control – SPC Quality Control Charts
Quality Notification
Quality Notification

Quality Notifications are used to for recording, correcting

& preventing Nonconformities during

Procurement (Q1)

Production (Q2)

Customer complaints(Q3)
Problem Management via Notifications

Tasks
Problem
Execution
Inspection
description

Process improvement

Analysis
Solutions Defects
Causes
Quality Certificate
Quality Certificates
QMIS
Quality Management Information System

STANDARD ANALYSES FLEXIBLE ANALYSES

Information Structures

material lots
defects
vendor
customer notifications
QMIS – Info Structures & Standard Analysis
QM Integration within Logistics Chain

MM PP
Basic
Basic data
data
Requisition Production
Production
Purchasing
Purchasing Requisition planning
planning
Materials
Inventory
Inventorymgmt
mgmt Reqt
Reqt planning
planning
Invoice
Invoice R-cut
Vendors verification R-cut capacity
capacity
verification planning
planning
Goods
Goodsreceipt
receipt
Routings Stock transfer
Stock transfer Warehouse Planned
Warehouse Planned
Goods
Goodsissue
issue management Orders
Orders
management
Documents Opening
Opening
period
period
Order:
Order:
Inspection plan QM Inspection lot -C
-Creation
reation
-- Release
Release
Characteristics Inspection
Inspection lot
lot -C
-Confirmation
onfirmation
Insp. methods Shop
Shopfloor
floor
control
control
Insp. catalogs Print
Print insp.
insp.instruction
instruction Capacity
Capacity
leveling
leveling
Test equipment CAM
Results
Resultsrecordi
recordinngg
PM SD
Test
Testequipment
equipment Shipping
Shipping
management
management Usage
Usagedecision
decision Billing
Billing
•
QM Processes in Logistics Supply Chain

Procurement Production Sales Servic

•Release Vendor
•Manages the release •Integrates Triggers
status of supply inspection planning inspection lots at
relationship & work scheduling delivery.
•Triggers goods receipt in •Triggers inspection •Quality
inspections. during production certificates.
•Quality Score •Supports •Customer
•Vendor integrated complaints
Evaluation confirmation of
•Quality quality/operating
certificates/Notifica tions data
•Manages problems in •Inspection points
procurement •Partial lots
•Manages vendor related •Control charts
technical delivery terms & •Problem
quality assurance plan notification
•Quality Audit
QM – Procurements

The procurement chain

Quotation Vendor selection Purchase order Goods receipt

Technical Vendor QA agreements GR inspection

delivery evaluation: Certificates Dynamic
terms quality score modification
Vendor release
audits (Q-Info) Inspection stock
complaints Inspection at the Defects,
vendor’s Nonconformities
premises Q-Notifications
QM in Procurements – Business Process View

MIC I. Methods

Inspection
Inspection
Plan
Plan

Inspection
Inspection Inspection Results
Results Usage
Usage Follow
Followup
up
GR
GR Lot Inspection Recording Decision Action
Lot Recording Decision Action

Sampling
Sampling
Scheme
Scheme
QM in Production

Production Planning and Control

Production
Production order Order confirmation Goods receipt
planning

Routings Inspection lots

with
insp. Points
Sample
calculation
Process
control
Result
recording
Usage Decision
Stock
movements
QM in Production – Business Process View
QM – Sales and Distribution / Service

Sales and Distribution

Sales order Delivery Service

Quality
information
Inspection
lots
Certificates

Customer
Complaints
Service
Quality Inspection in SD
Summary

We have understood the following :

Elements of SAP Quality Management
QM Integration with other SAP Modules
QM Processes in Logistics Supply Chain
Procurement, Production & SD
QM Master Data
Objectives

At the end of this session You will understand the

details on QM Master Data:
Material Master - QM View
Basic Data -
Catalogs, Inspection Methods, Master Inspection
Characteristics
Inspection Plan
Master Data in QM
Views of a Material Master Record
Quality Management View
Quality Management View – General Data
Quality Management View – Procurement View
Material Master - Summary

QM specific data is maintained at the plant level

For every inspection type appropriate indicators
are selected. Default settings for each inspection
type are set. Inspection type specifies how an
inspection to be carried out.
The inspection type is assigned to inspection lot
origin For the inspection lot origin, goods receipt
for PO, you can find the following inspection
types.
-Model series
-Preliminary series
-Production series
CATALOGS

Inspection catalogs are created in QM module

Components of catalogs are
- Codes, Code groups, Selected sets & Codes
Unstructured Description of inspection results, observations, or
decisions made during inspection are coded to evaluate similar
information. Easy to evaluate such non numeric data in codes.
Evaluate descriptions such as cracked, dented, damaged,
defectives in terms of codes.These coded descriptions are
managed in catalogs.
Assign these codes to master inspection characteristic &
characteristics in the inspecti on plan.eg. Using code groups &
selected set codes.
Codes are used to record inspection results/defects/defect
location.
Codes are used to make usage decision and carry out
evaluation.
Codes for Task,Events,Causes, etc are used in notifications.
Hierarchy of Catalog

Characteristic
Catalog Type 1
attribute

Code group 1 Code group 2 Code group 3

Surface attribute Color Packaging Material

Gr. Code 1 Gr. Code 1 Gr. Code 1

Clear White Foam

Gr. Code 2 Gr. Code 2 Gr. Code 2

Frosted Red Wood-wool
Code Groups and Codes
Selected Sets

Catalog type 1

Characteristic attributes

Code group Code group Code group

Surface Valuation Structure

even all OK solid

dirty OK - other damaged
sticky not OK - other crushed
smooth has holes

Selected set

dirty all OK soaked

sticky OK - other dented
not OK - other undamaged
Set codes for the selected set torn
"Condition of pencil packaging"
Selected Sets and Set Code
Inspection Method
Validity of an Inspection Method

Time axis

Version 1 Version 2

Valid from Today Valid from

01-01-02 20-02-02
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.
Master Inspection Characteristics
Create Master Inspection Characteristics
Control Indicators for the Inspection
Characteristic
Assign. the insp. cat. to master insp. char.
Validity of an MIC Version Management

Time axis

Version 1 Version 2

Valid from Today Valid from

01-01-02 20-02-02
Master Inspection Characteristics - Summary

An inspection characteristic describes the inspection

requirements for materials,parts and products.

To standardize inspection planning, master inspection

characteristic can be defined.These can be used in
different inspection plans.
Where used lists and replacement functions support the
inspection planner in the maintenance of master data.

Changes are documented using version management.

Sampling Procedure

A sampling procedure is a procedure by which the

sample size is determined for an inspection

Sampling procedures are defined at characteristic

level

Sampling procedures are maintained at client level.

Creating a Sampling Procedure

Initial screen
•Description/Identifier

Assignments
•Texts
•Sample Type
•Valuation mode
•With inspection points
•Block indicator
Special conditions
•Sampling scheme
•Control chart
•No stage change
•Independent multiple samples (no.of samples)
.
Correlation sampling Type - Valuation Mode

Sampling Type Valuation Mode

...defines how the sample …defines rules for accepting

is determined and rejecting
•Fixed sample •Attributive inspection based on
•100% Inspection no.of nonconforming units/defects
•Sampling scheme •Variable inspection (s- method)
• % based sample •Attributive code
•Manual valuation
•Mean value within the tolerance
•SPC inspection

Sampling Plan
•Sample size n
•Acceptance no. c
Independent of
lot size
Sampling Scheme

A sampling scheme is an arrangement of sampling plans (in

sampling tables) for accepting the characteristics of an
inspection. A sampling plan defines the sample scope and the
acceptance criteria

Acceptance Number and Rejection Number serve as criteria

You assign a sampling scheme to a sampling procedure

Creating a Sampling Scheme
Example : Determining the Sample Size
Dynamic Modification Rule

In order to adapt the inspection to the expected

quality level, the inspection scope can be modified
dynamically. The inspection scope is adapted to the
current quality level with the help of sampling
procedures and dynamic modification rules

SAP’s Quality Management (QM) module supports the

inspection planner in setting up and maintaining the
data needed for monitoring of quality levels. The QM
module also takes over the function of maintaining the
inspection history
Dynamic Modification
Create Dynamic Modification Rule
Dynamic Modification at Lot Creation
Dynamic Modification in the Inspection Plan

Sampling procedure Dynamic modification rule

•Assignment only to the •Assignment

characteristics
•At header level
•At characteristic level

Inspection Plan
Header
Operation
•Characteristic 1
•Characteristic 2
Quality Information 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

Decision on whether to deactivate the goods receipt

inspection or perform a goods receipt inspection and/or
source inspections
Q - Information Record

Q Info record is maintained at material,plant,vendor

combination level.
Prerequisites:
1)Material for the plant is defined
2)QM in procurement with appropriate control key must be
assigned.
3)Vendor must exist in the system.
If a quality assurance agreement or a vendor release is
required,you must create a Quality Information record.The Q-
info record controls further processing of the material.
Prior to quotation/P.O creati on ,system checks availability of
Q-info record.System also checks if vendor, material
combination is blocked or released for quotation/P.O/G.R
The Q-info record is created only after you maintain the QM
data in the material master.The master record for the vendor
must also be available.
Inspection Plan – QM Basic Data & Inspection Plan Structure
Creating Inspection Plan-QP01
Creating Inspection Plan-QP01
Inspection Plan Structure

A
Header
Material

Operation
Kopf 20
Operation
Kopf 10

Work Center

Insp. character istic

Insp. characteristic 20
Inspection Plan Header
Material

1
Material

2
Plan group counter

Plan Header

3
Usage

6 4
Lot Size Planner Group

5
Plan Status
Inspection Plan – Inspection Operation
Preparation of Inspection Plan

Following data screens to be filled to create a Inspection plan

-Create Inspection Plan-Initial screen (T.Code QP01)
-Create Inspection Plan-Header Details
-Create Inspection Plan-Operation Overview
-Create Inspection Plan-Characteristic Overview
-Assign PRT to characteristic ifrequired
-Assigning Inspection Planto Material & Plant
-Assigning materials vendors/customers at the plant level
Assigning an Inspection Plan to the Inspection Lot

Inspection Plan may not get assigned to the lot

-When more than one plan is available
-When there is no plan for the material
Go to the QP03 (display Inspection plan) & verify above.
If Inspection Plan is to be made
-Check whether available generic plan can be assigned,if yes,go
to QP02(change Inspection plan) of generic check list &assign
the same to the required item.
Assignment of the plan to the inspection lot
-Go to Inspection lot change
-Assign the appropriate inspection plan to the lot(by clicking
the next screen.Message indicating inspection plan is
revised.Sample calculated should appear).
Inspection Plan- Work Center

An operation is carried out at a work center (a work operation or

inspection operation)
The work center is assigned to a cost center in the master record.
The output of a work center is valuated by cost rates.Cost ratesare
determined by the assigned cost center and the activity types.
 Inspection Plan - PRTs/Test Eq

PRTs/Test equipments are assigned to Inspection operation and then to

inspection characteristic. The PRTS/test equipment can be printed on
the inspection instructions of the corresponding characteristic of a
Inspection Plan.

The PRTs/test equipment can be displayed in results recording.

The PRTs master data is maintained as material master data

Production Resource Tool

Inspection Plan – Assigning PRTs/ Test Equipment

Task
Tasklist
list

Operation
Operation10
10 PRTs/Equipment
PRTs/Equipment11

Operation
Operation20
20 PRTs/Equipment
PRTs/Equipment22

Operation
Operation30
30
Inspection Plan - Summary

The Inspection Plan and Routing have identical structure.

The inspection plan is selected by the system based on
material, plant, vendor,customer,group,group
counter,Task list usage &status .
The inspection plan is used to specify the inspection
operation,the characteristics to be inspected for each
operation and the test equipment to be used.
The Inspection Plan is assigned to inspection lot for every
Inspection Type The Inspection lot is created under each
Inspection Type for which Inspection Plan is assigned by
the system automatically or manually.
Summary

We Have Understood the following :

Material Master - QM View

Basic Data -
Catalogs, Inspection Methods, Master Inspection
Characteristics
Inspection Plan