Consulting

Transforming Enterprises

Title QM Business Process

1.0
Version

Author Pawan Dubey

Reviewed By Hirendra Kumar

Date 25.08.2017
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TABLE OF CONTENT

1. QUALITY CHECK................................................................................................................. 3
2. BLUEPRINT AGREEMENT.................................................................................................. 3
3. LEGEND................................................................................................................................ 4
4. OVERVIEW QUALITY MANAGEMENT................................................................................5
4.1. QUALITY PLANNING.................................................................................................... 6
4.1.1. Basic data for Quality Management.......................................................................6
4.1.2. Inspection planning................................................................................................6
4.2. QUALITY INSPECTION................................................................................................. 6
4.2.1. Inspection for goods receipt from suppiler.............................................................6
4.2.2. Inspection for in-process item..............................................................................10
4.2.3. Inspection for final product (Clinker + Cement)....................................................12
4.2.4. Other Inspection.................................................................................................. 14
4.3. QUALITY CONTROL................................................................................................... 16
4.4. QUALITY CERTIFICATES........................................................................................... 16
4.5. QUALITY NOTIFICATIONS......................................................................................... 18
4.5.1. Customer Complaints.......................................................................................... 19
4.5.2. Complaint against Vendor....................................................................................20
4.5.3. Internal Problem Report.......................................................................................20
4.6. TEST EQUIPMENT CALIBRATION............................................................................22
4.7. TRANSACTIONS......................................................................................................... 23
4.8. REPORTS.................................................................................................................... 25

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1. QUALITY CHECK

Version Date Validated by Date Signature

1.0
1.0
1.0

1. BLUEPRINT AGREEMENT
Signing this document records your agreement to the contents of the Blueprint, and confirms that
the remainder of the project can proceed.

Name Position Date Signature

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2. LEGEND

The following describes the symbols used in the process map:

High-level process
activity. A more
detailed process map Decision
is provided in the
document to describe
the activity

Activity step Document

Manual Operation Process Ends

Continuation of the
System process map to a
different page

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3. OVERVIEW QUALITY MANAGEMENT

The SAP System consists of a number of components that are completely integrated with one
another. This integration allows the various departments and units of an enterprise to share and
maintain the same information.

The Quality Management component (QM) is part of the integrated R/3 System. With the
functions of the Quality Management (QM) module, we can implement the most important
elements of a QM system, as specified in ISO 9000. The following features are supported in
Quality Management -

Quality planning

Basic data for Quality Management

Inspection planning

Quality assurance

Quality inspection
Quality certificates

Quality control

Quality notifications
QM information system

The QM component shares master data, in particular the material master, with other components.
It can be triggered from other components and can affect processes in other components.

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3.1. QUALITY PLANNING

Quality Planning involves creating and managing the Master data that is required to plan and
execute quality inspections. It has basic data for Quality Management. The term "Quality
Planning" covers inspection planning and its relevant basic data.

Process Flow

3.1.1. Basic data for Quality Management

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)

3.1.2. Inspection planning

Inspection planning enables to plan quality inspections with the help of inspection plans and
material specifications, a source inspection at the vendors premises and trigger this inspection
before the delivery date, inspections for goods receipt, stock transfers, for production orders, for
predefined inspection points, in shipping when deliveries are created and plan recurring
inspections, inspection operations in work processes.

3.2. QUALITY INSPECTION

Quality Inspection component is used to determine whether the companys product consistently
meets defined quality requirements. In a quality inspection, inspection is carried out for a material
or product, using inspection specifications that have been predefined in the Inspection planning
component. Although the inspection results only document the current quality of a material or
product, this information is also useful for quality control (for example, to optimize future
processes)

Quality inspection covers the following important functions:

Inspection lot creation

Results recording

Defects recording

Inspection lot completion

3.2.1. Inspection for goods receipt from suppiler

The business process of the Inspection of Raw / Packing material, component to determine
whether Raw / Packing materials consistently meets defined quality requirements. In a quality
inspection, inspect a Raw material or Packing Material, using inspection specifications that have
been predefined in the Quality planning component. Although the inspection results only
document the current quality of Raw material or Packing material, this information is also useful
for Quality Control.

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Business Process Details

Inspection lot Creation

Inspection processing begins with the creation of inspection lot, which can be created manually or
automatically. There are several functions to be carried out that will create and prepare an
inspection lot for processing. Inspection lot gets created as a result of goods movement like
goods receipt from Vendor, Goods receipt from Production, Goods issue to Customer.

Selection of Inspection Specs

As the inspection lot is created an inspection specification gets assigned to it. An inspection
specification should be assigned to inspection lot if you want to enter results and take Usage
Decision. Inspection specification can be assigned manually by user or automatically by system.
There are different criteria considered during inspection specification assignment like the
inspection type, inspection lot origin, and Material-Vendor-Plant combination.

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Sample Drawing

Relevant sampling procedures are selected, Once the inspection specification is assigned to the
inspection lot the sample size is to be calculated for the inspection lot. Calculation of sample size
can be done manually or automatically. The system can only calculate the sample size
automatically if you use an inspection specification to inspect the goods in the inspection lot.

Actual Inspection

Inspection method and equipments are selected.

Results Recording

Results of Characteristics are recorded. Recording and processing of results for inspection
characteristics are carried out. Results recording will be based on Characteristics. The recorded
results data will be used for all documentation and evaluation for Quality Control Purposes.

Defects Recording

Defects found during inspection are recorded. A defect is any property or attribute of a material,
product or process that does not meet the inspection characteristic specifications. You record the
defects with the help of predefined defect codes maintained in the inspection catalogs. Once a
defect record has been created, it is saved in the system as a quality notification. A quality
notification is a system-supported problem message that you can use to process different types of
problems relating to poor-quality goods or services.

Usage Decision

Decision on Accept/ Reject is recorded. With the Usage Decision we decide if the material is OK/
not OK.

Stock Posting

At the time of usage decision, we can transfer the Quality stock in to relevant stock categories like
as given below

Unrestricted
Blocked
Scrap
Return to vendor

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Process Flow Chart

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3.2.2. Inspection for in-process item

The business process of the Inspection of Process Material, component to determine, whether
process materials consistently meet defined quality requirements. In a quality inspection, inspect
a process material, using Recipe that has been predefined in the Quality planning component,
although the inspection results only document the current quality of Process material.

In JKT quality inspections is processed on the basis of inspection lots. To inspect a specified
quantity of a material, an inspection lot is created manually in the system. The system uses the
inspection lot to record, process, and manages information for a quality inspection. This
information includes Inspection processing data such as:

Inspection lot origin ( in-process inspection)

Inspection date
Processing status of inspection lot

Inspection specifications (for example, the task list or material specification according to which
operation/phase in the inspection lot will be inspected)

Inspection results
Recorded characteristic values

Usage decision (a decision that specifies whether the goods in the inspection have been
accepted, rejected, partially accepted, accepted with certain conditions, etc)

Business Process Details

Creation of Inspection Lot

In JKT in process inspection lots are created automatically by the system. Inspection lots are
created automatically at the time of against process order. The data is copied from process order
into inspection lot.

Recording Results

In JKT in process Results Recording component recorded based on time intervals, results for
inspection characteristics are recorded and processed. The inspection lot is the reference object
in results recording. The recorded inspection results documents the quality of the inspected
product. The recorded result data can be used to make evaluations for quality control purposes.

Usage Decision

After recording the results for an inspection lot and completing the inspection, a decision about
the usage of the inspected material is taken. The following activities are carried out.

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Process Flow Chart

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3.2.3. Inspection for final product (Clinker + Cement)

The business process of the Quality Inspection of before & after packing material , component to
determine whether material consistently meet defined quality requirements. In a quality
inspection, inspect a before and after packing material, using recipe and inspection plan that has
been predefined in the Quality planning component. Although the inspection results only
document the current quality of before and after packing Material, this information is also useful
for Quality Control.

Business Process Details

The business process of the Quality Inspection of before & after packing material , component to
determine whether material consistently meet defined quality requirements. In a quality
inspection, inspect a before and after packing material, using recipe and inspection plan that has
been predefined in the Quality planning component. Although the inspection results only
document the current quality of before and after packing Material, this information is also useful
for Quality Control.

Before packing steps to be involved:

Creation of Inspection Lot

In JKT in process inspection lots are created automatically by the system. Inspection lots are
created automatically at the time of against process order. The data is copied from process order
into inspection lot.

Recording Results

In JKT in process Results Recording component recorded based on time intervals, results for
inspection characteristics are recorded and processed. The inspection lot is the reference object
in results recording. The recorded inspection results documents the quality of the inspected
material. The recorded result data can be used to make evaluations for quality control purposes.

Usage Decision

After recording the results for an inspection lot and completing the inspection, a decision about
the usage of the inspected material is taken. The following activities are carried out.

Complete an inspection (inspection completion)

Make the usage decision for an inspection lot

After packing steps to be involved:

Creation of Inspection Lot

In JKT after packing inspection lots are created automatically by the system. Inspection lots are
created automatically at the time of against Goods receipt from process order and delivery order
and return delivery order, the data is copied from process order into inspection lot.

Recording Results

In JKT after packing bags Results Recording component recorded based on inspection plan,
results for inspection characteristics are recorded and processed. The inspection lot is the

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reference object in results recording. The recorded inspection results documents the quality of the
inspected product. The recorded result data can be used to make evaluations for quality control
purposes.

Usage Decision

After recording the results for an inspection lot and completing the inspection, a decision about
the usage of the inspected material is taken.
After completion of production activity; Production Department transfer the finished goods to Store
department with Goods Transfer Note (GT Note) and it is received as Under Quality Inspection
Stock. The post production inspection lot for the batch or Inspection Lot of Finished product is
checked for characteristics and decision is taken to bring the stock of manufactured goods from
Quality stock to finished goods unrestricted stock.

Process Flow Chart

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3.2.4. Other Inspection

The business process of the Quality Inspection of the materials, component to determine whether
materials consistently meet defined quality requirements. Inspection specifications that have been
predefined in the Quality planning component. Although the inspection results only document the
current quality of other materials, this information is also useful for Quality Control.

Business Process Details

This Process details the steps to be performed in the SAP System for creation of Quality

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Inspection for the materials, Create Inspection Lot Manually, Assign the inspection plan or
specification in inspection Lot, Result recording, Inspection Lot Completion.

Creation of Inspection Lot

In JKT other materials (borehole/face cutting sample, water samples) inspection lots are created
manually by the user. Manually Inspection lots are created at the time of sample receipt from
Mines or power plant. The data is copied from against inspection lot.

Recording Results

Results recording component, results for inspection characteristics are recorded and processed.
The inspection lot is the reference object in results recording. The recorded inspection results
documents the quality of the inspected borehole/face samples and water samples. The recorded
result data can be used to make evaluations for quality control purposes.

Usage Decision

After recording the results for an inspection lot and completing the inspection, a decision about
the usage of the inspected material is taken. The following activities are carried out.

Complete an inspection (inspection completion)

Make the usage decision for an inspection lot

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Process Flow Chart

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3.3. QUALITY CONTROL

Quality Control involves implementing different preventive, monitoring and corrective activities.
These activities will be based on the specifications from quality planning and the evaluations of
quality inspections and quality notifications.
Dynamic modification of the inspection scope
Statistical process control (SPC; control charts, results history)
Quality scores (cp value, cpk value)
Vendor evaluation
Quality-related costs
Evaluations

3.4. QUALITY CERTIFICATES

Quality Certificates certifies the quality of the material or Product. Quality Certificates contain
texts, specifications, values and inspection results. The chemical or Physical properties of goods
can be recorded as, inspection result, characteristics for the inspection lot or Batch. A customer
may have specific demands for quality, which may take the form of customer-specifications
(specification limits) or lead to additional quality inspections.

To certify a process, operation or an inspection, a certificate is issued.

Business Process Details

For the certificate issuing to the customer, results of batch data after the production is taken as
the reference for material analysis and issued to the customer. The chemical or physical
properties of goods can be recorded as

Inspection results
Characteristics for the batch

Certificates can be created for each of the Inspection Lot, Batch and Delivery to the customer
based on the requirement. So whenever required test certificate for the lot and batch are to be
printed.

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Process Flow Chart

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3.5. QUALITY NOTIFICATIONS

This business process of Quality Notification contains functions for recording and processing
different types of problems (for example, problems resulting from poor-quality goods or service).
Use the notifications to analyze the recorded defects and monitor the Correction of these
problems.

The notifications can help complaints against vendors, customers and production.

The following quality notification types are predefined in the system:

Customer complaint

Complaint against a vendor

Internal problem report

Quality notifications can also be used to record the following information:

Problem description

Affected reference objects (for example, material, purchase order or delivery)

Partner information (for example, customer, vendor, or coordinator)

Defect items

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Response monitoring for tasks

Status management

Follow-up actions for tasks

Action box

Action log

Causes of defect items

A quality notification supports in processing activities with the following functions

3.5.1. Customer Complaints

A customer complaint is a quality notification type (Q1) that deals with a problem involving poor-
quality goods or services delivered to a customer.

A customer complaint can be recorded with following information

Customer
Material / batch
Sales order
Sales organization
Division
Distribution channel
Delivery
Inspection lot

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3.5.2. Complaint against Vendor

A complaint against a vendor is a quality notification type (Q2) that deals with a problem involving
poor-quality goods or services delivered by a vendor or manufacturer.
Following information will be included for a complaint against a vendor:
Vendor
Material / batch
Material document (goods receipt)
Purchase order
Purchase organization
Purchasing document
Inspection lot

3.5.3. Internal Problem Report

An internal problem report is a quality notification type (Q3) that deals with quality-related
problems that originate within ones own organization. To use a notification for an internal problem
report to record and process company-internal problems (for example, defects confirmed for a
material or product in a production process).

An internal problem report can contain following information:

Material / batch
Production order
Work center

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Inspection lot

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Process Flow Chart

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3.6. TEST EQUIPMENT CALIBRATION

The business process Test Equipment Calibration involves Managing Master data as well as the
planning and processing calibration inspections for test and measurement equipment. The quality
tests are conducted with the help of test equipment and measuring devices which needs to be
calibrated periodically to ensure its proper working. This section explains how calibration
inspection is scheduled for the inspection.

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Process Flow Chart

3.7. TRANSACTIONS

Code Description
MM03 Display Material Master
QA01 Create Manual Inspection Lot
QA02 Change Inspection Lot
QA03 Display Inspection Lot
QVM3 Pending Inspection Lot without Usage Decision
QE01 Results Recording
QE02 Change the Results (before closing)
QE51N Results Recording Worklist
QE53 Result Recording Worklist for Equipment
QA11 Manual Usage Decision
QA13 Display Usage Decision
MMBE Stock Overview
QP01 Create Inspection Plan
QP02 Change Inspection Plan
QP03 Display Inspection Plan
QS21 Create Master Inspection Characteristics
QS22 Create Master Inspection Characteristics: Version
Code Description
QS23 Change Master Inspection Characteristics
QS24 Display Master Inspection Characteristics
QDV1 Create Sampling procedure
QDV2 Change Sampling procedure
QDV3 Display Sampling procedure
QI01 Create Q Info Record: Procurement
QI02 Change Q Info Record: Procurement
QI03 Display Q Info Record: Procurement
CRQ1 Create QM Work Center
CRQ2 Change QM Work Center
CRQ3 Display QM Work Center
QC01 Create Certificate Profile
QC15 Create Certificate Assignment
Copyright QC21
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QM01 Create quality notification
QM02 Change quality notification
QM03 Display quality notification
QM10 Change list of quality notifications
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3.8. REPORTS

Following are the reports available for QM -

Sr. No. Report Name T code

1 Master Inspection Characteristics Where Used List QS26

2 Sampling Procedure Where Used List QDV6
3 QC Chart for Inspection Lot QGC1
4 QC Chart for Master Inspection Characteristics QGC3
5 Inspection Lots without Inspection Completion QVM1
6 Inspection Lots with Stock QVM2
7 Inspection Lots without Usage Decision QVM3
8 Quality Score for Material MCXE
9 Quality Score for Vendor MCVE
10 Overview of Inspection Lots MCXA
11 Overview of Inspection Lots by Vendor MCVA
12 Archive Display of Certificate for Inspection Lot QC32
13 History of Calibration Results QGP2
14 Stock Overview MMBE
15 Display List of Qual. Notifications QM11

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