Inspection lot creation : sample size calculation

Purpose
Explains how sample size (field QALS-GESSTICHPR) is calculated during inspection lot creation.

Overview
This document introduces what settings influence sample size calculation and the logic about how the sample size is
determined during lot creation.

<Settings>
1. Plant level:
In the customizing t-code QCC0 -> Quality Management -> Basic Settings -> Maintain Settings at Plant Level, tab Insp. lot
creation, there are some fields called presettings for sampling procedures. These settings are used automatically if no
sampling procedures are defined in the characteristics.

2. Material level:
In the QM view of material master (t-code MM01/MM02/MM03), for each inspection type, there are several fields and
 indicators which control sample size calculation. The logic will be explained later.

3. Characteristic level:
If you set the control indicator sampling procedure for the characteristic, a sampling procedure has to be assigned to an
inspection characteristic in a task list or material specification..
If you do not enter a sampling procedure for an inspection characteristic, the system chooses a sampling procedure
proposed in the settings at plant level. If no sampling procedure was entered in these settings, the system takes the lot size
as the sample size.

<Sampling procedure>
A sampling procedure can be created in t-code QDV1.

Four sampling types can be used:

1. Sampling type 100 Fixed sample
You need to enter a fixed number as sample size.

2. Sampling type 200 100% inspection

As described it uses lot size as sample size.

3. Sampling type 300 Use sampling scheme

A sampling scheme and its severity need to be entered to calculate sample size.
4. Sampling type 400 Percentage sample
Enter a percentage to calculate sample size.

The sampling types are defined in the customizing t-code QCC0 -> Quality Management -> Basic Data -> Define Sample
Determination. You can read the documentation here to know more.

<Calculation logic>
There are two possibilities for determining the sample size:

The sample size is entered by the user

If the sample size is to be entered manually during the inspection, you must set the indicators Manual sample entry and
 Manual sample calc. in the material master. Please note the indicator Manual sample entry is only taken into account for
an inspection that is carried out without a task list or material specification.

The sample size is calculated automatically by the system

If the sample size is to be calculated automatically, a distinction must be made between the following two cases:

1. Inspection without an inspection plan or material specification

To calculate the sample size, you can set the fields sampling procedure or inspection percentage in the material master.
They are only relevant, when you carry out an inspection without reference to a task list or material specification.
The indicator 100% inspection can also be set in the material master. See the F1 help of this field to know more about this
indicator. The note 213505 explains why sample size is 1 although this indicator is set.

2. Inspection with an inspection plan or material specification

The sample size is calculated on the basis of the sampling procedure defined at the characteristic level of the inspection
plan or material specification.
If a sampling procedure was not defined in the inspection plan or material specification, the system uses the predefined
sampling procedure stored in customizing at plant level to determine the sample size.
If a sampling procedure is not specified in Customizing, the lot size is used as the sample size for the characteristic.

Attention:

If you set the indicator for a 100% inspection in the material master record, this has priority over all other
procedures defined to calculate the inspection size.

If several characteristics use different sampling procedures, the highest sample size of the characteristics is used
as the inspection lot sample size.

The following document introduces how sample drawing procedure influences the lot sample size in physical
sample management.
Physical Samples Management in SAP QM

Physical Samples Management in SAP QM

Physical Samples management is the functionality normally used in Process industries like
Pharma/Food/Chemical etc.

Following three types of physical samples are available:

Primary samples are taken directly from the population or inspection lot.
Pooled samples are created by pooling primary samples.
Reserve samples are primary samples that are reserved as specimen samples.

Number of samples to be taken for above three types samples is calculated by sample drawing Procedure.

Scenario : Lets say I received a material from a vendor 100 L material supplied in two containers
each 50 L.Now I have to check this material . so I need to take samples from each container lets say
I take 1 L from each container. so my primary samples will become two (each 1 L) as I take sample
from each container. Primary samples are the ones directly taken from inspection lot qty. Now the
above two primary samples are mixed to make a pooled sample. In my example it will become 1+1 =
2 L. Pooled samples are created by mixing primary samples. these pooled sample is used for
analysis. Reserve samples are taken from lot directly and not used for immediate analysis. they are
stored for future reference as per regulatory norms. Normally they are destroyed once the expiry of
the material is reached. in our case let say 0.25 L taken separately and stored.
Process Flow :

1. Create Sample Drawing Procedure QPV2

2. Assign the Sample Drawing Procedure in the Inspection Plan QP01

3. Create Manual Inspection Lot QA01

4. Check for the Physical Samples created -QA02

5. Results recording of the Inspection lot QA32/QA02/

6. Usage Decision QA32

Create Sample Drawing Procedure QPV2

click on new entries

Click on sample-drawing item folder

Click on New entries button.

Define primary samples, pooled samples and Reserve samples as shown below in the three
different tab
Finally save the sample drawing Procedure.

Assign the inspection points (200) & Sample Drawing Procedure in the Inspection Plan header
QP02
During creation of Inspection plan assign the inspection points (200) & Sample Drawing Procedure in the
header as shown below

Complete the creation of inspection plan.

Creation of inspection lot

here inspection lot is created manually for 100 L qty
assign the inspection plan

calculate the sample size.

Now save the inspection lot.

During saving of the inspection lot physical samples will get created as per the Sample drawing
procedure assigned in the inspection plan. Check for the same in QA02/QA03.

Check for the Physical Samples created -QA02

Go to Change mode QA02.

Now go to Sample tab

Now click on button. Now we will be able to see the three types of physical
samples created and each sample identified with unique number.
Results recording of the Inspection lot QA32/QA02
During result recording system will ask the physical sample number for identification as shown
below. to distinguish for which physical sample RR is done ..

Once RR done complete Usage decision as per the regular process

Thanks