LO-720 QM in Discrete and Repetitive Manufacturing

LO720 QM in Discrete and Repetitive Manufacturing
LO720
R/3 System Release 46D 11.05.2001
0
LO720 QM in Discrete and Repetitive
Manufacturing
LO720
LO
QM in Discrete and Repetitive

Manufacturing
SAP AG 1999
SAP AG
R/3 System
Release 4.6B
July 2000
50036192
Copyright
Copyright 2001 SAP AG. All rights reserved.

Neither this training manual nor any part thereof may
be copied or reproduced in any form or by any means,
or translated into another language, without the prior
consent of SAP AG. The information contained in this
document is subject to change and supplement without prior
notice.
All rights reserved.
SAP AG 1999
Trademarks:
Some software products marketed by SAP AG and its distributors contain proprietary software
components of other software vendors.
Microsoft, WINDOWS, NT, EXCEL, Word and SQL Server are registered trademarks of
Microsoft Corporation.
IBM, DB2, OS/2, DB2/6000, Parallel Sysplex, MVS/ESA, RS/6000, AIX, S/390,
AS/400, OS/390, and OS/400 are registered trademarks of IBM Corporation.
ORACLE is a registered trademark of ORACLE Corporation, California, USA.
INFORMIX-OnLine for SAP and Informix Dynamic ServerTM are registered trademarks of
Informix Software Incorporated.
UNIX, X/Open, OSF/1, and Motif are registered trademarks of The Open Group.
HTML, DHTML, XML, XHTML are trademarks or registered trademarks of W3C, World Wide
Web Consortium, Laboratory for Computer Science NE43-358, Massachusetts Institute of
Technology, 545 Technology Square, Cambridge, MA 02139.
JAVA is a registered trademark of Sun Microsystems, Inc. , 901 San Antonio Road, Palo Alto, CA
94303 USA.
JAVASCRIPT is a registered trademark of Sun Microsystems, Inc., used under license for
technology invented and implemented by Netscape.
SAP, SAP Logo, mySAP.com, mySAP.com Marketplace, mySAP.com Workplace, mySAP.com
Business Scenarios, mySAP.com Application Hosting, WebFlow, R/2, R/3, RIVA, ABAP, SAP
Business Workflow, SAP EarlyWatch, SAP ArchiveLink, BAPI, SAPPHIRE, Management Cockpit,
SEM, are trademarks or registered trademarks of SAP AG in Germany and in several other countries
all over the world. All other products mentioned are trademarks or registered trademarks of their
respective companies.
Design: SAP Communications Media
Quality Management (QM)
Level 2 Level 3
LO715 3 days
QM in
Procurement
LO170 3 days LO705 3 days LO720 2 days LO750 3 days

QM in Discrete and
Quality Inspections Repetitive QM Organization and
Quality Management Configuration
Manufacturing
LO710 3 days LO721 3 days
Quality Notifications QM in the Process

Industry
LO725 2 days
QM in Sales and
Distribution / Quality
Certificates
SAP AG 1999
Course Prerequisites
LO050 - Planning & Execution for Discrete and

Repetitive Manufacturing
LO705 - Quality Inspections
SAP AG 1999
Target Group
Audience:
Project leaders and members of the project team, who
have experience of quality management and production.
Duration: 2 days
SAP AG 1999
Notes to the user

The training materials are not teach-yourself programs. They complement the course instructor's
explanations. On the sheets, there is space for you to write down additional information.
Course Overview
Contents:
Course Goals
Course Objectives
Course Content
Course Overview Diagram
SAP AG 1999
SAP AG
Course Goals
This course deals with:
The integration of the Quality Management

component in PP processes
QM-specific features of a quality inspection for orders
(production orders, run schedule headers,
maintenance orders/calibration orders)
Uses for QM functions
The most important settings for orders in QM

processes
SAP AG 1999
SAP AG
Course Objectives
At the conclusion of this course, you will be

able to:
Describe the integration of the QM component in PP,
based on different manufacturing types
Plan and perform an inspection during production
and an inspection at the end of the production
process
Use control charts to monitor your processes
Plan and process inspections in repetitive

manufacturing
Plan and perform a calibration inspection
SAP AG 1999
Course Content
Preface
Unit 1 Course Overview Unit 5 Quality Inspection for

External Processing
Unit 2 Inspection During
Production Unit 6 Inspection at the End of
the Production Process
Unit 3 QM in Repetitive
Manufacturing Unit 7 Comparison of
Manufacturing Types
Unit 4 Test Equipment
Management
SAP AG 1999
Course Overview Diagram (1)
Course Overview START
Inspection During Production
QM in Repetitive Manufacturing
Test Equipment Management
Quality Inspection for External Processing
Inspection at the End of the Production Process
Comparison of Manufacturing Types
SAP AG 1999
Planning Control Charts
Inspection Characteristic in
Task List
Sampling procedure Control indicator
Control chart type Sampling procedure
Valuation mode SPC criterion
You use the SPC
criterion to plan the
number of control charts
for a characteristic
[Codes for automatic defects
recording]
SAP AG 1999
You make the preparations for a control chart in the sampling procedure and the task list or master
inspection characteristic.
You use control charts to control or monitor one or more processes. In the task list characteristic, you
use the SPC criterion to 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.
Contents:
Defects Recording for an Order

Results Recording by Characteristic for an
Order
Inspection Point Processing
SPC - Statistical Process Control
Integration of the QM and PP Components
SAP AG 1999
Inspection During Production: Unit Objectives
At the conclusion of this unit, you will be

able to:
Plan and implement an inspection during
production
Use different QM variants for an inspection
during production
Use SPC functions to control your
processes
Describe the integration of the QM and PP
components
SAP AG 1999
Introduction
SAP AG 1999
Results Recording by Characteristic for an Order
SAP AG 1999
Defects Recording for an Order: Objectives
At the conclusion of this topic, 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 an inspection during

production
SAP AG 1999
SAP AG
Defects Recording for an Order: Business Scenario
You manufacture shafts using PP orders. You

want to record any defects that are identified
during production, and to inform the vendor, if
necessary.
SAP AG 1999
Procurement Production Sales Service
Integrating insp. planning/production operations

Integrating order processing
QM tasks
Controlling inspections during production
Statistical process control (SPC)
Processing internal problem notifications
SAP AG 1999
In production, the QM component provides important information about the current production
quality and allows the production process to be corrected with the help of quality notifications.
Inspection Lot Origins in Production (1)
Inspection
Inspection lot
lot origin
origin 03
03
Discrete
DiscreteManufacturing
Manufacturing
Inspection
Inspection lot
lot origin
origin 13
13
Repetitive
RepetitiveManufacturing
Manufacturing
Inspection
Inspection lot
lot origin
origin 03
03
Process
ProcessManufacturing
Manufacturing
SAP AG 1999
Production orders are often used in discrete production (for example, in machine construction).
Run schedule headers are often used in repetitive manufacturing (for example, in automotive
construction).
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
PP order type in Customizing.
Inspection Lot Origins in Production (2)
Inspection lot origin 03 / 13
Kanban
Kanban
Inspection lot origin 04
GR
GRfor
forOrder
Order
Inspection lot origin 14
Plant
PlantMaintenance
Maintenance
SAP AG 1999
Run schedule headers and production orders are used for Kanban production.
Integration in the Production Process (1.1)
Order
Manufacture Manufacture Inspect Manufacture

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Inspection
Defect For inspection lot
lot
For operation
(For characteristic)
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Q-notification
Inspection
lot
For operation
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Integration in the Production Process (1)
Q-notification
Inspection
lot
For operation
Usage
Order decision

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
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.
Prerequisites for Inspection During Production
with Defects Recording
Inspection type for

origin 03 or 13 is active
Material
Catalogs
Other master data
Defect catalog
Usage decision catalog
SAP AG 1999
This slide shows how you can use SAP QM without having to make comprehensive settings (for
example, in the electronics industry).
A prerequisite for the creation of an inspection lot for an order is that an inspection type with 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.
Inspection Results
Inspection
lot
Recording inspection results
ta
fe c t da Defect data Characteristic results
De rd
o e
r ec f ect typ
.
De fect loc
D e
use Qualitative chars Quantitative chars
Ca
...
Activate
Quality notification
SAP AG 1999
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.
Automatic Usage Decision
General UD UD for Orders

Order completed
Selection options
Consider
skip lots
Consider completed Order technically
lots completed
Consider long-term Order

characteristics confirmed
No defects
Prerequisites
No rejection
Queue time
No characs outstanding
SAP AG 1999
The report program/job UD for orders takes into consideration inspection lots with the following
origins:
03 (production)
13 (repetitive manufacturing)
14 (Plant Maintenance)
The report program/job General UD 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.
SAP AG 1999
Results Recording by Characteristic for an Order:
Objectives

Add the QM data required for a quality inspection to a
routing
Record results for an inspection during production
SAP AG 1999
Results Recording by Characteristic for an Order:
Business Scenario
You manufacture shafts using PP orders.

Once the operations 'anneal' and 'lathe' have been
completed for the shafts, they are to be subject to a
quality inspection by the workmen. The inspection
results are to be confirmed for process control and
documentation purposes.
SAP AG 1999
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot Inspection
Inspection
Results
results
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
Inspection
lot Inspection
results
Usage
decision
Order

010 020 + 030 040
manufacture
Goods receipt
SAP AG 1999
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.
Since the quantity to be inspected is classed as 'goods in process', the inspection lot is NOT relevant
for stock.
On the slide, 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. There are several programs available in the
system that enable you to make an automatic usage decision.
The results for the inspection lot are updated in the Quality Management Information System
(QMIS).
Prerequisites for an Inspection During Production
with Results Recording
Inspection setup
Origin 03 or 13 is active
Inspect with task list
Material Inspect by characteristic
QM-
QM-relevant data in
routing/recipe
Other Inspection characteristics
master data Inspection method
Additional QM basic data
SAP AG 1999
To record results by characteristic 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 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 origin 04 (early inspection for a goods receipt), in addition to lots of origin 03
and 13.
Specifications from the Task List
A
Material Material
Header
Operation 20 Insp. characteristics
Operation 10
Prod. resources/tools
Work center
Material components
SAP AG 1999
In an inspection during production, the inspection operations are integrated in the routing, rate
routing or recipe.
Inspection Results
Inspection
lot
Recording inspection results

for insp. lot (based on operation)
ect Defect data Characteristic results

Def record
a e
dat ct typ
fe c.
De fect lo
De use
Qualitative chars Quantitative chars
Ca
...
Activate
Quality notification
SAP AG 1999
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).
Recording Steps
Operation 10
Record results
Insp. charac. 1
Valuate
characteristic
Complete
characteristic
Make usage decision

for inspection lot
SAP AG 1999
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).
Once all characteristics have been closed, the inspection lot is completed by the usage decision.
SAP AG 1999
Inspection Point Processing: Objectives

Plan and implement multiple inspections for an
operation using inspection point processing
SAP AG 1999
Inspection Point Processing: Business Scenario
You manufacture shafts using PP orders. The shafts are

manufactured in wire baskets of 50. Once the operations
'lathe' and 'anneal' have been completed, 5 shafts from
each wire basket are to be inspected for quality.
SAP AG 1999
Order
on
s pecti
In lts
resu
Inspection
lot 040
030
020 Quality inspection at

regular intervals during
each operation
010
SAP AG 1999
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...). You valuate each object (inspection point) after you have recorded results for
the characteristics.
Prerequisites for an Inspection During Production
with Inspection Points
Inspection setup
Origin 03 or 13 is active
Inspect with task list
Material Inspect by characteristic
QM-
QM-relevant data in
routing/recipe
Other (e.g. insp. point)
master data Inspection characteristics
Additional QM basic data
SAP AG 1999
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 identification for the inspection point (inspection point user field combination) must be defined
in the task list header.
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.
Time-Based Inspection
Inspection point
Char. Insp. freq.
10 1
S S S 20 2
S S S S 30 3
t
8.00 9.00 10.00 11.00 12.00 13.00 14.00
Operation: Default split 1 h S = SKIP
SAP AG 1999
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.
Quantity-Based Inspection
Inspection point
Char. Insp. freq.
10 1
S S S 20 2
S S S S 30 3
Cumulative quantity
50 100 150 200 250 300 350 manufactured
Operation: Default split 50 pcs S = SKIP
SAP AG 1999
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.
Inspection During Production - with Inspection
Points
Operation 30: Manuf. + inspect ... Operation 90: Inspect
Basket 001 Basket 002 Basket 003 Basket 001 Basket 002 Basket 003
Qty. 50 Qty. 55 Qty. 52 Qty. 50 Qty. 55 Qty. 49
Yield 47
Scrap 3
Rework 2
Inspect every 50 pcs
SAP AG 1999
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.
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.
Inspection Point Settings in the Task List
Task List
Header Operation Characteristic

Inspection point Default split Sampling procedure
user fields - Time reference with inspection
- Qty. reference points and
Partial lot
- Freely defined inspection frequency
assignment
Sample-drawing Variant for inspection
procedure completion
Last partial lot
assignment indicator
Partial lot quantity
indicator
SAP AG 1999
Variants for Inspection Completion
Quantity,
Quantity, valuation,
valuation, confirmation
confirmation
Quantity,
Quantity, valuation
valuation
Valuation
Valuation
Valuation
Valuation (automatic)
(automatic)
SAP AG 1999
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 PP 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.
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).
Settings for the Inspection Point (1)
Field combinat. Z10 Inspected object: Container Stored in the task list header
InspPt type Freely defined inspection point

Inspection point type
Fields Valuation Function modules dependent on the
application (e.g. freely
defined, for phys. sample,
Predefined field (dependent on insp. point type)
for equipment)
Field act. Keyword
You can freely

User fields define user fields to
identify the
Field act. Keyword
inspected object
Text length 18
Text length 10
Number length 10 1 Container
Restriction of number
Number length 3 2 Shift of sample results (for
Date example for performance
Time reasons)
No. insp. points for char. summmariz. For example, for "Phys.
Last inspected sample is valid -sample drawing until target
value reached"
SAP AG 1999
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).
Field combinat. Z10 Inspected object: Container

Fields Valuation Function modules
Default for valuating inspection point
Plant 0001 Selected set 03
Default when all chars are accepted

Code A Code group 03
Default when at least one char. is rejected

Code R Code group 03
SAP AG 1999
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.
Field combinat. Z10 Inspected object: Container

Fields Valuation Function modules Name of the function module
User-defined function modules for inspection point processing
QAPP_CUST_IP_CREATE Use func module

Automatic creation of inspection points and partial lots Activation of the function
module
QAPP_CUST_IP_PROPOSAL Use func module

Proposal of user fields in results recording
Function module
QAPP_CUST_IP_CHECK Use func module documentation
Verification of user fields in results recording
QAPP_CUST_IP_F4 Use func module

List of user fields in input help for results recording
SAP AG 1999
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.
Inspection During Production - with Batches
Operation 30: Manuf. + inspect ... Operation 90: Inspect
Basket 001 Basket 002 Basket 003 Basket 001 Basket 002 Basket 003
Qty. 50 Qty. 55 Qty. 52 Qty. 50 Qty. 55 Qty. 49
Ptl. lot 1 Ptl. lot 1 Ptl. lot 2 Ptl. lot 1 Ptl. lot 1 Ptl. lot 2
Ptl. lot 2
Batch 2
Ptl. lot 1 Ptl. lot 2

Batch 1 Batch 2
Inspect every 50 pcs

Ptl. lot = Partial lot
SAP AG 1999
You can assign the following:

Quantities to inspection points
Inspection points to partial lots
Partial lots to batches
When the goods receipt for the production order is posted, the inspection point quantity for the
operation is posted to inventory management, provided that the Last partial lot assignment indicator
is set for this operation.
The batches assigned to partial lots can be automatically classified using the QM inspection results.
SPC
SAP AG 1999
SPC: Objectives

Name the control charts in the SAP System
Plan an SPC characteristic
Display and process a control chart
Make settings for control charts in Customizing
SAP AG 1999
SPC: Business Scenario
You manufacture shafts using PP 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 are to be
displayed in a control chart.
SAP AG 1999
Statistical Process Control (SPC)
Control charts
Process capability
Results history
Histogram
Run-chart
SAP AG 1999
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)
Control Charts
Mean value
Time
SAP AG 1999
Control Charts
Specific influence
Mean value
General influence
Time
SAP AG 1999
Control Charts
Specific influence
Mean value
General influence
Time
SAP AG 1999
Control Charts
Specific influence
Mean value
General influence
Process change
Time
SAP AG 1999
Control Charts
The control chart is a graphical tool that helps you to differentiate

systematic changes in a quality characteristic from random
fluctuations.
Specific influence
Mean value
General influence
Process change
Time
SAP AG 1999
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 specific influence is
assumed and you can intervene in the process. You can also identify a permanent process change
from a control chart.
Control Chart Types
Quantitative characteristics
Mean value chart with consideration of tolerance (acceptance chart)
Mean value chart without consideration of tolerance (Shewhart chart)
Standard deviation chart (Shewhart chart)
Moving average chart
EWMA chart (for mean values with exponential weighting)
Original value and moving range chart for sample size n = 1
Qualitative characteristics
np-chart for the number of nonconforming units
p-chart for the fraction of nonconforming units
c-chart for the number of defects
u-chart for the number of defects in each sample unit
SAP AG 1999
This slide lists the control charts that are available in the R/3 System.
SPC Criteria
Task List Characteristic

Task list characteristic
Task list characteristic/material
Task list characteristic/inspection lot
Task list characteristic/material/work center
...
Task list characteristic/equipment, functional location
Master Inspection Characteristic

Master inspection characteristic
Master inspection characteristic/material
Master inspection characteristic/equipment, functional location
SAP AG 1999
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).
Using Control Charts
Transactions
Results recording
Control charts for inspection lots
Control charts for task list characteristic
Control charts for master inspection characteristic
Functions
Calculating action limits
Defining action limits
Valuating samples
Closing control charts
Setting color/legend options for OCX graphics
SAP AG 1999
Customizing for Control Charts
Control Charts
You can define your own control chart types
Simulation of control charts
Definition of reference axis (time/object)
Definition of number of samples for each dialog box (in
modal display only)
Control Chart Tracks

You can add new tracks
Formulas and parameters for calculating the action limits can
be changed using function modules
Hide or show tolerance limits
Make settings to manually change control limits
SAP AG 1999
You can set new control chart types in Customizing. In addition, you can influence the calculation of
the action limits, by changing or substituting function modules.
The OCX graphic functions provide improved display options for the control charts:
Integrated display (similar to "Windows")
Automatic update of the graphic data in results recording
Flexible structuring options
Insp. lot
2306
SAP AG 1999
Insp. lot
2306
SAP AG 1999
Insp. lot
2306
SAP AG 1999
Insp. lot Insp. lot Insp. lot

2306 2501 2583
SAP AG 1999
Insp. lot Insp. lot Insp. lot Insp. lot

2306 2501 2583 2644
SAP AG 1999
Insp. lot Insp. lot Insp. lot Insp. lot

2306 2501 2583 2644
Quality notification Defects recording
SAP AG 1999
The life cycle of a control chart:

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
Process Capability
Cpk = 0.87
SAP AG 1999
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).
Results History
Results Results history
5001
4651
Process capability
4610 indices
Single value list Cpk = 1.23
... ... ... ...
QM-
QM-STI statistical
MS Excel evaluations
Run-
Run-chart
Histogram
18
16
14
12 t
22:15 23:00 23:35 00:05
SAP AG 1999
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.
SAP AG 1999
Integration of the QM and PP Components:
Objectives

Describe the integration of the QM and PP components
Send confirmations to the PP component directly from

the results recording function and forward inspected
quantities to goods receipt
Control the release of follow-up operations from QM
Trigger rework for an operation from QM and plan a

quality inspection for this rework
SAP AG 1999
Integration of the QM and PP Components:
Business Scenario
You manufacture shafts using PP orders. The costs

incurred in production and in the quality inspection are
to be recorded and valuated.
The 'spray paint' operation is only to be released for
processing, once the previous operation has been
inspected.
If rework is required, this is to be planned as an
additional operation.
SAP AG 1999
Features of the Integration
Quality Management
Planning QM
Task list types, authorization
Processing PP
Order types
Quality inspections during production
Quality inspections for external processing Production Planning
Quality inspections for the withdrawal of components

Confirmation of activities, times ...
Trigger points
Co-products
Quantity proposal at goods receipt for the order
Quality inspections at goods receipt
Other
Material requirements planning
SAP AG 1999
Confirmations
QM
Time ticket confirmations for the operation
Confirmation* from within PP
Results recording
Quantities, activities, dates ...
Inspection point processing
Quantities, target costs (in background)
Quantities, activities, dates ...
Check whether characteristic results exist, when

confirmations are made in PP
* Incl. retrograde withdrawals and automatic GR
SAP AG 1999
Trigger Points
QM
Are assigned to the operation in the routing
or in the production order PP
Functions
Adding a reference operation set
Creating an order
Triggering a Workflow
Releasing operations
Controlled by status changes
SAP AG 1999
Co-Products
QM
Co-products are basic materials that are
created together with other basic materials in PP
a joint process.
Their material number differs from that of the
production material.
Inspection points/partial lot processing allow
you to represent co-products in the QM
component.
These materials are taken into consideration at
automatic batch classification from QM and at
certificate creation.
SAP AG 1999
Inspection During Production:
Summary
You can now describe the various types of

inspections during production.
You can use control charts to monitor your
processes.
You can describe the integration of the QM
and PP components
SAP AG 1999
Data for the Exercises
Explanation of Symbols in the Exercises and Solutions
Exercises
Solutions
Objectives
Business Scenario
Tips & Tricks
Warning or Caution
Data Used in the Exercises

Data Data in Training System
Plant 1000
1200 (repetitive
manufacturing)
Material masters T-BQ6##
T-F7## (repetitive
manufacturing)
Vendors for external T-Q720-##
processing
Routings for an Task list group with group
inspection during counter 1 (lot size 1 100
production PC) and group counter 2
(lot size 101- 99,999 PC)
for materials
T-BQ6##
Rate routing for Task list group with group
repetitive counter 1
manufacturing
Inspection plans for Task list group with group
external processing counter 1 (task list usage 5)
and goods receipt and group counter 2 (task
inspection for an list usage 53)
order
Equipment to be TC1## and TC2##
calibrated
General task list for T-CAL##
calibration
Work center for T-CAL##
calibration
Inspection During Production: Exercises
Unit: Inspection During Production

Topic: Defects Recording for an Order
At the conclusion of these exercises, 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
You manufacture shafts using PP orders. You want to record any defects
that are identified during production, and to inform the vendor, if
necessary.
1-1 Activate the inspection during production for your material T-BQ6##.
1-1-1 What options are there for maintaining the inspection setup for materials?
______________________________________________________
______________________________________________________
______________________________________________________
1-1-2 Which inspection type must you activate for an inspection during
production?
______________________________________________________
1-1-3 Do you need to make special settings in the material master to record
defects for an inspection lot?
______________________________________________________
1-2 Create a production order for your material, 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).
1-2-1 Make a note of the path you use to create the order.
______________________________________________________
______________________________________________________
1-2-2 What is the number of the order you created?
______________________________________________________
1-2-3 What is the inspection lot number?
______________________________________________________
1-3 Record defects for the order.

1-3-1 What options are there for recording defects for an inspection lot?
______________________________________________________
______________________________________________________
______________________________________________________
Use the report type 00000002 Individual defect report.
1-3-2 Record several defects.

1-3-3 Defects are stored in a quality notification. How is this notification activated
and what are the consequences?
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
1-3-4 Which setting do you need to make, to allow defects recording for an
operation or characteristic?
______________________________________________________
______________________________________________________
1-4 Enter the usage decision for the inspection lot. What options do you have for
making the usage decision?
_________________________________________________________
_________________________________________________________
_________________________________________________________
_________________________________________________________
Exercises

Topic: Results Recording by Characteristic for an Order
At the conclusion of this exercise, you will be able to:

Maintain inspection characteristics in the routing
Record inspection results for an inspection lot
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.
2-1 Activate the function for recording results by characteristic for your material T-
BQ6##.
Which settings do you have to make?
____________________________________________________________
2-2 In the routing for your material T-BQ6## (task list with group counter 1),
inspection characteristics are already assigned to the operations anneal and check
measurements. In addition, the diameter should be inspected after the operation
'Lathe shaft'.
2-2-1 Assign a control key to operation 20, which allows you to assign inspection
characteristics. Which control key do you use?
______________________________________________________
2-2-2 Assign the master inspection characteristic 9-101 to the operation. The
sample is to be determined according to the procedure FIX5-0.
Save the routing.
2-3 Create and release a production order for your material T-BQ6##. Use the order
type PP01 in plant 1000. The order quantity is 100 pieces (PC). Use the scheduling
type Current date (4).
2-3-1 What order number was given?
______________________________________________________
2-3-2 What inspection lot number was given?
______________________________________________________
2-4 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.
Exercises

Topic: Inspection Point Processing

Plan inspection point processing in the routing
Record results for the inspection point
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.
3-1 Check the routing for your material T-BQ6##. (Use the task list with group counter
2.)
3-1-1 For which identification are inspection results to be recorded? What is the
user field combination?
______________________________________________________
3-1-2 What is the interval for quality inspections for operation 30?
______________________________________________________
3-1-3 From now on, operation 30 is to be confirmed using the appropriate PP
function. In addition, the system should valuate the inspection point
automatically. Set the operation accordingly.
Make a note of the parameter and its setting.
______________________________________________________
type PP01 in plant 1000. The order quantity is 1000 pieces (PC). Use the
scheduling type Current date (4).
______________________________________________________

______________________________________________________
3-3 Record several inspection results for your inspection lot. To do this, use the
worklist.
The inspection results are required for the SPC inspection.

Set the indicator No confirmation on the inspection point screen.
Do not record a usage decision for this inspection lot.
3-3-1 How does the rejection of a characteristic affect the valuation of an

inspection point?
______________________________________________________
______________________________________________________
3-4 The inspection point field combination is stored in the header of the routing. Check
the settings for the inspection point field combination in Customizing.
3-4-1 Which user fields are active?
______________________________________________________
3-4-2 Which code is proposed when all inspection characteristics are accepted,
and which is proposed when at least one inspection characteristic is
rejected?
______________________________________________________
3-4-3 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?
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Exercises

Topic: Statistical Process Control SPC

Plan an SPC characteristic
Call up and process a control chart
You manufacture shafts using PP 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 are to
be displayed in a control chart.
4-1 Initializing the control chart

4-1-1 Create a new inspection point for the length inspection and record the
inspection results. Use the inspection lot from the previous exercise.
To help you record the results, use a conversion with offset 149 and
factor 0.001.
4-1-2 Call up the control chart for this inspection characteristic.

4-1-3 Activate the control chart and calculate the action limits.
4-1-4 Make a note of the calculated action limit values for the mean value track (4
decimal places).
_____________________________________________________________
_______________________________________________
4-1-5 Save the changes you made to the control chart.

4-1-6 Save the inspection results.
4-2 SPC inspection

4-2-1 Create additional inspection points for the length inspection of the shafts
and record the inspection results.
4-2-2 Pay attention to the mean value for the sample and the standard deviation,
when you record the results. The sample is valuated based on the action
limits in the control chart.
4-2-4 Check the changes to the control chart using the control chart worklist.
Which menu path do you choose?
______________________________________________________
4-3 Planning control charts

4-3-1 How do you plan the automatic triggering of a quality notification, when the
action limits in a control chart have been exceeded?
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
4-3-2 Why is an x-bar/s-chart not advisable for a sample size of n=1?
______________________________________________________
______________________________________________________
4-4 Customizing for control charts

4-4-1 Check which reference axis has been set in Customizing for the control
chart used above and the characteristic category, for which the control chart
is set.
______________________________________________________
______________________________________________________
4-4-2 Display another control chart, using the simulation function.
Exercises

Topic: Integration of the QM and PP Components -
Confirmations

Create a confirmation for the order operation from the results
recording function in Quality Management.
The activities that were performed for the quality inspection of operation
60 are to be recorded based on cost.
5-1 Check the default values in the routing for your material T-BQ6## (group counter
2).
5-1-1 Which setting requires operation 60 to be confirmed?
______________________________________________________
______________________________________________________
5-1-2 What are the default value, the unit and the activity type for the labor?
______________________________________________________
______________________________________________________
5-2 Enter another inspection point for operation 60 in the order from the previous
exercise. 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.
____________________________________________________________
____________________________________________________________
Exercises

Topic: Integration of the QM and PP Components
Trigger Points

Use trigger points to control your production processes
Operation 65 spray paint is only to be started, if the quality inspection

that took place after the operation anneal has been completed.
6-1 Assign the standard trigger point created by the instructor to operation 60 in the
routing (group counter 2) for your material T-BQ6##.
6-2 Create a production order for your material T-BQ6##. Use the order type PP01 in
plant 1000. The order quantity is 1000 pieces (PC). Use the scheduling type
Current date (4).
Release operations 10 through 60 only. (To do this, switch to the operation
overview screen. Select operations 10 through 60. Execute the function Operation
Release.)
______________________________________________________
______________________________________________________
6-2-3 Which system status was set for operation 60 and which status was set for
operation 65?
______________________________________________________
______________________________________________________
6-3 Record results for operation 60.
Enter a yield of 1000 PC on the inspection point screen. Set the indicator for final
confirmation. What message appears when you save the results?
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
6-3-1 Check the release of the follow-up operation. What status is set for
operation 65?
______________________________________________________
Inspection During Production: Solutions

Topic: Defects Recording for an Order
1-1 Activate the inspection during production for your material T-BQ6##.
1-1-1 Individual maintenance:
Logistics Materials Management Material Master Material
Change Immediately
Mass maintenance:
Logistics Quality Management Quality Planning Logistics
Master Data Material Inspection Setup
1-1-2 An inspection type for inspection lot origin 03. In the SAP standard system,
this is inspection type 03.
1-1-3 No, you can record defects at any time (even in an inspection based on
characteristics).
1-2 Create a production order for your material, 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).
1-2-1 Logistics Production Production Control Order Create
With Material
1-2-2 Order number
1-2-3 Inspection lot number
1-3 Record defects for the order.

1-3-1 Single recording:
Logistics Quality Management Quality Inspection Defects
Record for Inspection Lot
Worklist:
Logistics Quality Management Quality Inspection Worklist
Inspection Change Data.
Use the report type 00000002 Individual defect report.
1-3-2 Record several defects.

1-3-3 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 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 cancelled when the usage decision is made).
1-3-4 Set the indicator Inspect with task list in the Inspection setup for the
material.
1-4 Manually
Individually
Worklists (for example, inspections, collective UD etc.)
Automatically
Automatic UD (orders)
Solutions

Topic: Results Recording by Characteristic for an
Order
2-1 Inspect with task list (or Inspect with spec.), Automatic assignment, Inspect by
characteristic.
2-2 Inspection characteristics are already assigned to the operations anneal and check
measurements in the routing for your material T-BQ6##. In addition, the diameter
should be inspected after the operation Lathe shaft.
2-2-1 PP06, for example, (the indicator Insp. char. required must be set in the
control key).
2-2-2 Assign the master inspection characteristic 9-101 to the operation. The
sample is to be determined according to the procedure FIX5-0.
Save the routing.
2-3-1 Order number
2-4 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.
Solutions

Topic: Inspection Point Processing
3-1 Check the routing for your material T-BQ6##.

3-1-1 Inspection point 990 for container, date
3-1-2 An inspection is to take place after every 25 annealed shafts.
3-1-3 Inspection point completion 3 Automatic valuation according to inspection
point definition
type PP01 in plant 1000. The order quantity is 1000 pieces (PC). Use the
scheduling type Current date (4).
3-2-1 Order number
3-3 Record several inspection results for your inspection lot.
The inspection results are required for the SPC inspection.

Set the indicator No confirmation on the inspection point screen
for operation 60.
Do not record a usage decision for this inspection lot.
3-3-1 When the inspection point is valuated, a code is proposed for the rejection.
This code comes from table TQ79 (Customizing: Definition of inspection
points).
3-4 Customizing settings for inspection point field combination.

3-4-1 Active user fields: 2 x Text, 2 x Number, Date, Time
3-4-2 Accepted: Code A, code group A1000000;
Rejected: Code R10, code group R1000000
3-4-3 Function modules:
Automatic creation of inspection points: QAPP_CUST_IP_CREATE
Proposal of default user fields: QAPP_CUST_IP_PROPOSAL
Verification of user fields: QAPP_CUST_IP_CHECK
F4 (input) help: QAPP_CUST_IP_F4
Solutions

Topic: Statistical Process Control SPC
4-1 Initializing the control chart

4-1-1 Create a new inspection point for the length inspection and record the
inspection results. Use the inspection lot from the previous exercise.
To help you record the results, use a conversion with offset 149 and
factor 0.001.
4-1-2 Call up the control chart for this inspection characteristic.

4-1-3 Activate the control chart and calculate the action limits.
4-1-4 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.
4-1-5 Save the inspection results. The changes in the control chart are
automatically saved.
4-2 SPC inspection

4-2-1 Create additional inspection points for the length inspection of the shafts
and record the inspection results.
4-2-2 Pay attention to the mean value for the sample and the standard deviation,
when you record the results. The sample is valuated based on the action
limits in the control chart.
4-2-4 Logistics Quality Management Quality Inspection Worklist
Quality Control Chart For Inspection Lot
4-3 Planning control charts
4-3-1 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 at rejection (general, based on upper or lower tolerance) must
be maintained on the catalog screen 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).
4-3-2 The standard deviation (s-chart) for a sample size of n=1 is always zero.
4-4 Customizing for control charts

4-4-1 SAP Standard Menu Tools AcceleratedSAP Customizing
Project Management
Choose Display SAP Reference IMG and then
Quality Management Quality Planning Basic Data Sample, SPC
Statistical Process Control Define Control Chart Type
Solutions

Topic: Integration of the QM and PP Components -
Confirmations
5-1 Check the default values in the routing for your material T-BQ6## (group counter
2).
5-1-1 The Confirmation parameter in the control key for the operation must plan a
confirmation.
5-1-2 The default value for the labor is 30 minutes. The activity type is 1421
(labor hours).
5-2 Logistics Production Production Control Confirmation Display

Solutions

Topic: Integration of the QM and PP Components
Trigger Points
6-1 Assign the standard trigger point created by the instructor to operation 60 in the
routing (group counter 2) for your material T-BQ6##.
6-2 Create a production order for your material T-BQ6##. Use the order type PP01 in
plant 1000. The order quantity is 1000 pieces (PC). Use the scheduling type
Current date (4).
Release operations 10 through 60 only. (To do this, switch to the operation
overview screen. Select operations 10 through 60. Execute the function Operation
Release).
6-2-1 Order number
6-2-3 Operation 60: REL (released) ICHA (planned insp. characs allocated)
Operation 65: CRTD (created)
6-3 Trigger point function: Direct release of the follow-up operations, caused by trigger
point Order ... Sequence ... Operation ...
6-3-1 REL (released)
Contents:
Processing and Features of Quality Management Tasks
in Repetitive Manufacturing
SAP AG 1999
QM in Repetitive Manufacturing: Unit Objectives
At the conclusion of this unit, you will be able to:
Create inspection lots for production versions

Explain features of quality management used in
repetitive manufacturing
SAP AG 1999
Introduction
External Processing of Operations
SAP AG 1999
QM in Repetitive Manufacturing: Business
Scenario
You manufacture personal computers using

repetitive manufacturing.
Inspections during production are performed at
regular intervals.
SAP AG 1999
Inspection Lot Monitor (1)
Create
New
production version
for material 4713
SAP AG 1999
Inspection Lot Monitor (2)
Create
New
production
version
for material 4713
Monitor
Create insp. lot
Material Plant Material description QM active Insp. lots

Production version Valid from Valid to Insp. lot no. UD
4711 0001 Can type A
1 09.24.1999 12.31.2001 12000013
4712 0001 Can type B
4713 0001 Can type C
1
4714 0001 Can type D
1 03.19.1999 12.31.2000 12000014
2 04.06.1999 12.31.2004 12000015
SAP AG 1999
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).
QM in Repetitive Manufacturing: Process
New Tolerance
Insp. lot operation Insp. lot change Insp. lot
4711 4712 4713
Production version
Current inspection lot 4713
Inspection Lot Overview
No. Material
4711 Shaft
4712 ...
4713 ...
... ...
SAP AG 1999
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 data in the task list has
changed, without a new production version having to be created.
QM in Repetitive Manufacturing: Unit Summary
In repetitive manufacturing, an inspection lot is

created for a production version.
A monitor is available (transaction MFPR) to
monitor and create inspection lots for a
production version.
If the usage decision has been made for an
inspection lot for a production version, a new
inspection lot can be created for the same
production version. This allows changes to task
list data to be included in an inspection that is in
progress.
SAP AG 1999
QM in Repetitive Manufacturing: Exercises
Unit: QM in Repetitive Manufacturing

Topic: Processing Inspections in Repetitive
Manufacturing
Create inspection lots for production versions of a material in
repetitive manufacturing
Use the monitor for inspection lots for production versions
You manufacture personal computers using repetitive

manufacturing. Inspections during production are performed at
regular intervals.
1-1 Activate the required inspection lot for inspection of the material T-F7## in
repetitive manufacturing in plant 1200.
1-1-1 Which inspection type do you use?
______________________________________________________
1-2 Use the inspection lot monitor to create an inspection lot for the production version.
Use the menu path Logistics Production Repetitive Manufacturing
Backflush Inspection Lots for Prod. Versions
1-2-1 Make a note of the inspection lot number.
______________________________________________________
1-2-2 Record results for the inspection lot and make the usage decision.
1-3 Change the inspection characteristic short text in the relevant rate routing for the
material T-F7##.
1-3-1 Create a new inspection lot for the material with the current task list. How
do you proceed?
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
__________________________
QM in Repetitive Manufacturing: Solutions
Unit: QM in Repetitive Manufacturing

Topic: Processing Inspections in Repetitive
Manufacturing
1-1 Inspection type for inspection in repetitive manufacturing

1-1-1 Inspection type 13
1-2 Inspection lot for production version

1-3 Change the inspection characteristic short text in the relevant rate routing for the
material
1-3-1 Choose
Logistics Production Repetitive Manufacturing Backflush Insp. lots
for prod. versions
It is important that the previous inspection lot for the characteristic has been
completed
Contents:
Master Data
Calibration Planning
Calibration Processing
SAP AG 1999
Test Equipment Management: Unit Objectives

Manage test equipment as master data
Maintain the master data required for calibration
Schedule the calibration
Perform a calibration inspection and analyze
results of previous inspections, if test
equipment is rejected
SAP AG 1999
Course Overview
SAP AG 1999
Test Equipment Management: Business Scenario
You use test equipment in your quality inspection.

This test equipment is managed as a master data
record and calibrated at regular intervals (annually).
SAP AG 1999
PM/QM Integration
Test equipment
Quality Management management
(calibration inspection)
Equipment
QM
PM Funct. Locs
Maintenance inspection
Plant Maintenance (extended recording of
measurement readings
in PM)
SAP AG 1999
The integration with the Plant Maintenance (PM) component allows you to process and manage test
equipment.
These functions provide extended recording options for measurement readings in classic plant
maintenance.
Test Equipment Types in R/3
Material Document
Material
Production
resources/tools
Equipment PRT master
Inclusion in
task list
SAP AG 1999
Test equipment is included in the inspection plan or maintenance task list using the functions for
production resources/tools (PRT).
You can manage test equipment as:
Material master
Document master record
Separate production resources/tools master record
Equipment
Calibration takes place at single unit level (equipment).
Test Equipment Management Functions
QM
Master data
Calibration inspection
(planning)
Calibration inspection
(processing)
SAP AG 1999
You use the Test Equipment Management component to monitor the test equipment you use in
inspections.
Calibration Inspection Planning (1)
Planning
Planning
Create
Create
equipment
equipment master
master record
record
4.502 4.502 4.502
A/101 A/102 A/103
SAP AG 1999
Calibration Inspection Planning (2)
Planning
Planning
Define maintenance
Create
Create strategy
equipment
equipment master
master record
record
4.502 4.502 4.502
Define
Define maintenance
maintenance task
task list
list
A/101 A/102 A/103
OP.10 Calibrate
Create
Create (master)
(master) Zero-point deviation
inspection
inspection characteristics
characteristics General appearance
Zero-point deviation
General appearance
SAP AG 1999
Calibration Inspection Planning
Planning
Planning
Define maintenance
Create
Create strategy
equipment
equipment master
master record
record
4.502 4.502 4.502
Define
Define maintenance
maintenance task
task list
list
A/101 A/102 A/103
OP.10 Calibrate
Create
Create (master)
(master) Zero-point deviation
inspection
inspection characteristics
characteristics General appearance
General appearance
Create
Create maintenance
maintenance plan
plan
Scheduling Test equipment list
4.5 02 4.5 02 4.502
30
101 102 103
SAP AG 1999
Test equipment is managed as an equipment master record.

Inspection characteristics can be included in the maintenance task list for the equipment or in the
general task list, 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.
Alternatively, you can determine the calibration intervals using maintenance strategies or a
maintenance cycle.
Calibration Inspection Processing
Inspection
Inspection lot
lot
creation
creation
Schedule
Schedule maintenance
maintenance plan
plan
By automatic batch program
Manually
SAP AG 1999
Inspection
Inspection lot
lot
creation
creation
Schedule
maintenance plan
plan
By automatic batch program
Manually
Maintenance
Maintenance order
order is
is created
created
and
and released
released
SAP AG 1999
Inspection
Inspection lot
lot
creation
creation
Schedule
maintenance plan
plan
By automatic batch program Inspection
Inspection lot
lot is
is created
created
Manually
Test
Test equipment
equipment list
list
Maintenance
Maintenance order
order is
is created
created Insp. lot 35 Balance A
and
and released
released
4.502 4.502 4.502
A/101 A/102 A/103
SAP AG 1999
The maintenance plan is usually scheduled using a batch program.

Scheduling produces a maintenance order. When this order is released, an inspection lot is created.
This can take place in a single step.
The test equipment in the maintenance plan is copied to the inspection lot.
Processing
Processing
Results
Results recording
recording
Insp. lot 35 Balance A

Op.10 Calibrate
Balance A/101
Gen. appearance
Balance A/102
Op. 20 Calibrate
SAP AG 1999
Processing
Processing Process maintenance order
Time recording
Costs recording
Required materials
Results
Results recording
recording

Op.10 Calibrate
Balance A/101
Gen. appearance
Balance A/102
Op. 20 Calibrate
SAP AG 1999
Processing
Processing Process maintenance order
Time recording
Costs recording
Required materials
Results
Results recording
recording

Op.10 Calibrate
Balance A/101 Make
Make usage
usage decision
decision
Gen. appearance
Balance A/102
Follow-up actions
Op. 20 Calibrate
are implemented
Change equip. status
Order technically completed
automat.
Change cycleBatchprogramm
modification factor
Manuell
(Update measurement docs)
Customer def. follow-up actions
SAP AG 1999
You display items of equipment to be inspected in a special worklist for results recording.
You can record results for each item of test equipment (by unit to be inspected).
You can record costs and track capacity load utilization in the order.
You use a relevant follow-up action to change the equipment status.
Results History for Equipment/Functional Location
Past
Past Future
Future
Results history Trend

Charac. 10/Equipment 4711 Charac. 10/Equipment 4711
Inspection lots Result
Result
Time
SAP AG 1999
The results history allows you to analyze past calibration results and to predict future trends.
You can call up the results history from results recording, the usage decision and as a separate
transaction.
You can also run control charts for equipment or functional locations.
Test Equipment Tracking (1)
In which inspections
was balance 4711-1 used?
Material 4711 'Balance'
Balance 4711-1 Balance 4711-2
SAP AG 1999
In which inspections
Material 4711 'Balance'
Balance 4711-1 Balance 4711-2
Usage list Usage list

4711-1 4711-2
Period Usage site Period Usage site

01.01.-03.17. Center A 01.01.-03.28. Center C
04.01.-07.31. Center B 04.03.-07.31. Center D

Calibration Calibration
08.01.-08.18. 08.02.-08.14.
station station
08.19.-12.31. Center A 08.17.-12.31. Center D
SAP AG 1999
In which inspections Inspection Plan/Routing

1 Zero-point
2
Zero-point
deviation B
deviation A
Material 4711 'Balance' Characteristic 30,
Characteristic 10,
test equipment
test equipment
(PRT) 4711
Balance 4711-1 Balance 4711-2 (PRT) 4711

4711-1 4711-2

01.01.-03.17. Center A 01.01.-03.28. Center C
04.01.-07.31. Center B 04.03.-07.31. Center D

08.01.-08.18. 08.02.-08.14.
station station
08.19.-12.31. Center A 08.17.-12.31. Center D
SAP AG 1999

1 Zero-point
2
Zero-point
deviation B
deviation A
Characteristic 10,
test equipment
test equipment
(PRT) 4711

4711-1 4711-2

01.01.-03.17. Center A 01.01.-03.28. Center C
Insp. lot
04.01.-07.31. Center B 04.03.-07.31. Center D

08.01.-08.18.
station
08.02.-08.14.
station
Where-Used List 4711
08.19.-12.31. Center A 08.17.-12.31. Center D Period Insp. lot Work center
01.01.-01.05. 100001 A
01.10.-01.13. 100010 F
01.15.-01.20. 100015 D
....
03.31.-04.10. 120011 B
04.04.-04.10. 120020 B
SAP AG 1999
Test Equipment Tracking

1 Zero-point
2
Zero-point
deviation B
deviation A
Characteristic 10,
test equipment
test equipment
(PRT) 4711

4711-1 4711-2

01.01.-03.17. Center A 01.01.-03.28. Center C
Inspection
lot
04.01.-07.31. Center B 04.03.-07.31. Center D
08.01.-08.18.
station
08.02.-08.14.
station
Where-Used List 4711
08.19.-12.31. Center A 08.17.-12.31. Center D Period Insp. lot Work center
01.01.-01.05. 100001 A
Test Equip. Tracking: Balance 4711-1 01.10.-01.13. 100010 F
Insp. lot Period Characteristic 01.15.-01.20. 100015 D
10001 Zero-point deviation A ....
12011 Zero-point deviation B 03.31.-04.10. 120011 B
.... 04.04.-04.10. 120020 B
SAP AG 1999
If the calibration leads to the equipment being rejected, you must determine which inspection results
were recorded using this equipment.
A prerequisite for this is that the usage site for the test equipment has been stored in the test
equipment master, and the test equipment to be used has been defined in the inspection plan or
routing. You can define the test equipment, based on the material or as an item of equipment.
The following separate evaluation functions are then available:
Results history
Usage list
Where-used list
Test equipment tracking
Equipment Master Record
Location A
Location B
Equipment usage
List
Classification X
X
X
X
X
X
Equipment Master Record

Documents/
Documents/
General data technical drawings
Location data
Multilingual texts
Maintenance Partner/address
data
Measuring points 0471
Serialization data 0123
Configuration Approvals
Internal note
SAP AG 1999
The equipment master record contains the following data groups:

General data
(For example, reference data, manufacturer data etc.)
Location data
(For example, plant, company code, cost center etc.)
Classification
(For example, class, characteristics)
Documents
Partners
In addition, you can set the following additional views by choosing Edit -> View Selection from the
menu:
Serialization data
Configuration
PRT data
Sales data
Structure of Preventive Maintenance
Maintenance plan Preview of due dates
Scheduling
Scheduling
parameters
parameters Maintenance 03.08.97
strategy/cycle 03.10.97 30
03.12.97
Maintenance orders
Maintenance items
Equipment no.
12345
Maintenance
task list
SAP AG 1999
Maintenance planning links the required data for calibration and allows the scheduling of the
calibration inspection.
Maintenance Strategies
Strategy A Strategy B
P1 Monthly P1 1000 readings
P2 Semiannually P2 2000 readings
P3 Every 2 years P3 3000 readings
SAP AG 1999
The maintenance strategy can either be time-based or performance-based.

Measuring points form the basis for performance-based maintenance. You enter counter readings for
these measuring points.
Maintenance Plan
WITH Maintenance Strategy W/OUT Maintenance Strategy
MO TU WE TH FR SA SU Time-based
Time-based 1
8
2
9
3
10
4
11
5
12
6
13
7
14 single cycle
15 16 17 18 19 20 21
21 22 23 24 25 26 27
Multiple counter plans

28 29 30 31
Performance-based Performance-based
single cycle
Counter reading: 5000
Measuring points
(counters)
SAP AG 1999
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.
Several time-based and performance-based maintenance cycles are combined in a multiple counter
plan.
Inspection Characteristics in the Maintenance Task
List
Structure of
Maintenance Task List
Task list header
Status REL
Inspection points 510 Char. 0020
Operation 0010 Calibration insp. Text: Zero-point deviation
Work center PMC05 Target value: 0
Upper tolerance: 0.01
Inspection characteristics Lower tolerance: - 0.01
0010 Surface
0020 Zero-point deviation
Suboperation No inspection
characteristics
SAP AG 1999
You define inspection characteristics in the maintenance task list, in the same way as you define
characteristics in the routing or inspection plan.
You can only create inspection characteristics for operations, not for suboperations.
Inspection Lots for Origin 14
Default values
for Number ranges for
Assignment inspection type inspection lot origin 14
Insp. type - order type
Insp. type
identification
Order of type 1 or 2
release System
prerequisite Assignment of
maintenance task
UD code with list to order
follow-up action
Insp. point identification
in task list header
Worklist user
variants
Default for insp.
point valuation
Sampling
Maint. order type:
procedure
Release immediately
for PM
SAP AG 1999
In the standard system, inspection type "14" is reserved for the calibration inspection.
If an inspection lot is to be created for a maintenance order, an inspection type must be assigned to
an appropriate order type.
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.
Test Equipment Management: Unit Summary
You know how the inclusion of inspection processing

in PM procedures forms the basis for test equipment
management.
You are familiar with the inspection processing
functions for equipment and functional locations.
You can use the maintenance task list and
maintenance plan for processing calibration
inspections.
You are familiar with time-based or performance-based
planning of the maintenance cycles.
You can describe the evaluations and system settings
for a calibration inspection.
SAP AG 1999
Test Equipment Management: Exercises
Unit: Test Equipment Management

Name the master data for calibration processing
Maintain and schedule a maintenance plan for a calibration
inspection
Record inspection results for the calibration inspection
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.
1-1 Maintain the maintenance plan for the equipment T-C1## and T-C2##.
1-1-1 As the first step, enter the following:
Maintenance plan category: Plant Maintenance

Description: TEM group ##
Equipment: T-C1##
1-1-2 Assign the maintenance task list.
Task list cat.: A (General task list)

Task list group: T-CAL##
Group counter: 1
1-2 Calibration is to take place every 12 months.
1-3 Assign the second item of test equipment T-C2## using the object list and save the
maintenance plan.
1-4 What number is given to the maintenance plan?

____________________________________________________________
1-5 Schedule your maintenance plan manually. Choose Logistics Quality
Management Test Equipment Management Calibration Planning Maintenance
Planning Scheduling
Start the scheduling and enter the current date as the start of the cycle. Save the
scheduling information.
1-6 Then record the inspection results for the calibration inspection. Use the worklist.
Test Equipment Management: Solutions
Unit: Test Equipment Management
1-1 Maintain the maintenance plan for the equipment T-C1## and T-C2##.
1-1-1 As the first step, enter the following:
Maintenance plan category: PM

Description: TEM group ##
Equipment: T-C1##
1-1-2 Assign the maintenance task list.
Task list cat.: A (General task list)

Task list group: T-CAL##
Group counter : 1
1-2 Calibration is to take place every 12 months.
1-3 Assign the second item of test equipment T-C2## using the object list and save the
maintenance plan.
1-4 Maintenance plan number
1-5 Schedule your maintenance plan manually. Use the path:

Logistics Quality Management Test Equipment Management
Calibration Planning Maintenance Planning Scheduling
Start the scheduling and enter the current date as the start of the cycle. Save the
scheduling information.
1-6 Then record the inspection results for the calibration inspection. Use the worklist.
Select the inspection lots using the inspection lot origin 14 and your work center T-
CAL##.
Contents:
Planning and Processing a Quality Inspection
for Externally Processed Operations in an Order
SAP AG 1999
Quality Inspection for External Processing: Unit
Objectives

Plan externally processed operations for quality
inspection
Implement quality inspections for external
processing
SAP AG 1999
Introduction
SAP AG 1999
Quality Inspection for External Processing:
Business Scenario
You manufacture shafts using PP orders.

The shafts have to be sprayed. Since your company
does not have its own paint shop, you commission
a vendor to perform the 'spray paint' operation.
When the goods are received, the shade of the paint
is to be inspected.
SAP AG 1999
Materials Management
Production
: order 4713
Material : Shaft Purchase requisition
Quantity : 1000
Op. Short text Control key Purchase order

10 Lathe PP01
20 Inspect PP04
30 Spray (external) PP02 Goods receipt
40 Assemble PP01
... ...
Insp. lot : 4712

Material : Shaft
Quantity : 500
SAP AG 1999
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 released.
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.
Prerequisites and Features
Prerequisites
An inspection type is defined on the external processing screen for
the operation.
The inspection type is active for the finished product in the order.
Features
The inspection type can be defined on the external data screen in the
routing, and can then be copied automatically into the order.
The inspection type belongs to origin 01 (goods receipt).
Inspection plan selection takes place using the inspection type.
Evaluations can be made at inspection type level.
SAP AG 1999
Quality Inspection for External Processing: Unit
Summary
Operations in an order can be externally processed

by vendors. Processing (purchase requisition,
purchase order, goods receipt) takes place in MM
with the material number '0'.
If you want to inspect externally-processed goods,
you can enter an inspection type for origin 01 in the
operation of the task list or order. In the inspection
lot, the material number '0' is then replaced by the
material number for the finished product (from the
order).
The inspection lot that is created is not relevant for
stock.
SAP AG 1999
Quality Inspection for External Processing: Exercises
Unit: Quality Inspection for External Processing

Plan a quality inspection for externally processed operations
Externally processed operations can be represented in the
system by a quality inspection, from the order to the making of
the usage decision.
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.
1-1 Activate the quality inspection for external processing for your material T-BQ6##
in the material master. Which inspection type do you have to activate?
____________________________________________________________
1-2 Change the routing for material T-BQ6## (group counter 1). From now on,
operation 65 'Spray paint' is to be externally processed. Make the following
changes:
Control key: PP02

Assignment of work center: Delete
Inspection type (external processing data): 0130
What order number was given?
____________________________________________________________
1-4 Check the purchase requisition on the external processing screen in the order
operation. What purchase requisition number was given?
____________________________________________________________
1-5 The purchase requisition is to be converted into a purchase order. Choose menu
path
Logistics Materials Management Purchasing Purchase Requisition Follow-On

Functions Create Purchase Order Via Assignment List
Use vendor T-Q720-## as the selection criterion. Position the cursor on the
continuation line for your vendor. Start the function Process assignment (F2) to
convert the purchase requisition into a purchase order. Enter the purchase order
type NB.
Select the line containing your purchase requisition number and start the function
Copy (Shift +F5).
Save the purchase order. What is the purchase order number?
____________________________________________________________
1-6 Post the goods receipt for your purchase order. Choose menu path Logistics
Materials Management Inventory Management Goods Movement Goods Receipt
For Purchase Order PO Number Known
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?
____________________________________________________________
1-7 Switch to the display transaction for the inspection lot that was created.
Which reference documents are displayed on the tab page for Data for lot origin?
____________________________________________________________
____________________________________________________________
1-8 Record inspection results for the created inspection lot. To do this, use the worklist.
1-9 Make the usage decision for the inspection lot.

Quality Inspection for External Processing: Solutions
Unit: Quality Inspection for External Processing
1-1 0130 - Goods receipt inspection from external processing
1-2 Change the routing for material T-BQ6## (group counter 1): From now on,
operation 65 'Spray paint' is to be externally processed. Make the following
changes:
Control key: PP02

Assignment of work center: Delete
Inspection type (external processing data): 0130
1-3 Order number
1-4 Purchase requisition number
1-5 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 Via Assignment List
Use vendor T-Q720-## as the selection criterion. Position the cursor on the
continuation line for your vendor. Start the function Process assignment (F2) to
convert the purchase requisition into a purchase order. Enter the purchase order
type NB.
Select the line containing your purchase requisition number and start the function
Copy (Shift +F5).
Save the purchase order. What is the purchase order number?
Purchase order number

1-6 Post the goods receipt for your purchase order. Use the following menu path:
Logistics Materials Management Inventory Management Goods
Movement Goods Receipt For purchase order PO Number Known
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?
Goods receipt document number
1-7 There is a reference to the purchasing and material documents, as well as to the
order.
1-8 Record inspection results for the created inspection lot. To do this, use the worklist.
1-9 Make the usage decision for the inspection lot.
Contents:
Planning and Implementing a Quality Inspection
at Goods Receipt for an Order.
Postings to Inspection Stock
SAP AG 1999
Inspection at the End of the Production Process:
Unit Objectives

Activate material for a quality inspection, when
goods produced for an order are received
Process inspection lots from this goods receipt
Control stock using these inspection lots
SAP AG 1999
Introduction
SAP AG 1999
Business Scenario
You manufacture shafts using PP orders. You want

the goods produced for these orders to be posted to
inspection stock and to be inspected. After the
quality inspection, the stock is to be released,
posted to scrap, or submitted for rework.
SAP AG 1999
Quality Inspection Options for Orders
Quality Inspection at Goods Receipt for an Order
Early Goods Receipt Inspection
SAP AG 1999
Types of Inspection at the End of the Production
Process
Quality inspection as final operation of an order

(Origin 03)
Quality inspection, when goods produced for an order are

received
(Origin 04)
Early goods receipt lots

(Origin 04)
SAP AG 1999
You can plan a final inspection using the last operation (inspection operation) of an order (origin 03),
or using a quality inspection for produced goods received for an order (origin 04).
As of Release 4.5, goods receipt lots can be created at an early stage, when an order is released
(origin 04).
QM can take control of stock for inspection lots of origin 04.
Quality Inspection at Goods Receipt for Order
Insp.
Insp. QM data Unrestr. use
plan
plan stock?
Material
Insp. type 04 active 1234
Production
Usage decision
Results recording
Insp. stock? 1234

Warehouse
receipt X 96
Insp. lot
Y 1750
1234
4711
SAP AG 1999
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
merely record defects. In this case, an inspection plan is not required.
You can have the warehouse receipt posted to inspection stock for the duration of the quality
inspection.
Posting to Inspection Stock
Setting
Settingthe
thecontrol
controlindicators
indicators
A Insp. type 04
In or
Inmaterial
materialmaster
master A
B E.g. op. view
Order
A Insp. type 04
In
Inorder
order or
B Proposal
At
Atwarehouse
warehousereceipt
receipt A Insp. type 04
or
Warehouse B Proposal
receipt
SAP AG 1999
If the quality control indicator is set, the inspection lot is posted automatically to inspection stock for
the duration of the quality inspection. You can set the indicator at various levels.
If the indicator is set in the inspection setup for the material master (inspection type), you cannot
change the setting 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.
Quality Inspection Options for Orders
Quality Inspection at Goods Receipt for an Order
SAP AG 1999
Order Release
Order
release GR posting
creation
Routing Stock in
quality inspection
Insp. lot Results Usage decision

Origin 04 recording
Insp. lot Unrestricted-use

stock
SAP AG 1999
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 early 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 lot provides a type of inspection lot summary.
Once the goods have been received, the inspection lot becomes relevant for inventory purposes 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.
Comparison: Origin 03 - Origin 04
Origin 04
Feature/Function Origin 03
(early inspection lot)
Separate planning
Dynamic modification
Stock-relevant
Inspection points
Partial lots
Batch
classification
Direct link
inspection lot - order
SAP AG 1999
If you use early GR lots (origin 04), work scheduling (task list type N / 2) and inspection planning
(task list type Q) take place separately.
You can only control stock using the early inspection lot with origin 04.
Unit Summary
Inspections at the end of the production process can

take place using:
An operation in the order (origin 03)
An inspection lot (origin 04) that is created by the goods

receipt posting for the order
Inspection lots with origin 04 can be relevant for
stock. This allows you to control goods receipt stock
with the QM component.
Early GR lots (origin 04) can be created when the
order is released, and can run in parallel to
inspection lots during production (origin 03).
SAP AG 1999
Inspection at the End of the Production Process: Exercises
Unit: Inspection at the End of the Production

Process
Topic: Goods Receipt Inspection for an Order

Activate an inspection at the goods receipt for an order
Inspect the goods receipt and make a transfer posting for the
goods receipt quantity, based on the inspection results
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.
1-1 Enter the inspection type for a goods receipt for an order in the material master (T-
BQ6##).
______________________________________________________
1-1-2 Which indicator ensures that the GR quantity cannot be withdrawn before
the usage decision has been made?
______________________________________________________
Make sure that you set the indicator for the goods receipt inspection,
and cancel the indicator for an inspection during production.
1-2 Post the goods receipt for the order from the previous exercise.
Reduce the goods receipt quantity. What document number is given?

____________________________________________________________
1-3 Check the stock for your material. What quantity is in unrestricted use stock, what
quantity is in inspection stock? You can display the stock overview by choosing
Environment from the Inventory Management menu.
____________________________________________________________
____________________________________________________________
1-4 Then record the inspection results for the goods receipt inspection lot. Use the
worklist. Select your inspection lot using the material number and the inspection lot
origin 04. Reject at least one characteristic.
1-5 Make the usage decision for your inspection lot. Post part of the inspection lot
quantity to unrestricted-use stock and the other part to the order. What additional
entry do you have to make?
____________________________________________________________
1-6 Check the stock again. What quantity is now in unrestricted use stock and what
quantity in inspection stock?
____________________________________________________________
____________________________________________________________
Exercises

Process
Topic: Early Goods Receipt Inspection

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
As an alternative to an inspection during production, an early

inspection at goods receipt is to be performed. QM is to take over
control of the stock.
1-1 Set an inspection type for the early goods receipt inspection for an order in the
material master (T-BQ6##).
______________________________________________________
1-1-2 Which indicator controls that the inspection lot is created when the
production order is released?
______________________________________________________
1-2 The inspection plan that has previously been used to inspect the goods receipt is
used for the inspection. Include an additional operation that contains the inspection
characteristics for the inspection during production.
1-3 Create a new production order for the material.

1-3-1 What document number was given?
______________________________________________________
1-4 Then record the inspection results for the early goods receipt inspection lot. Use the
worklist.
1-5 Post a goods receipt for your order.

Use the following menu path:
Movement Goods Receipt For Order
1-5-1 What document number was given?
______________________________________________________
1-5-2 Was a new inspection lot created?
______________________________________________________
1-6 Check the stock for your material. What quantity is in unrestricted use stock, what
quantity is in inspection stock?
You can display the stock overview by choosing Environment from the Inventory
Management menu. Then check the quantity in the inspection lot to be posted
(transaction: Record usage decision).
1-7 Make the usage decision for your inspection lot. Post part of the inspection lot
quantity to unrestricted-use stock and the other part to the order. Then check the
stock again. What quantity is now in unrestricted use stock and what quantity in
inspection stock?
___________________________________________________________________
_____________________________________________________
Inspection at the End of the Production Process: Solutions

Process
Topic: Goods Receipt Inspection for an Order
1-1 Enter the inspection type for a goods receipt for an order in the material master.
1-1-1 Inspection type 04, Final inspection at goods receipt from production
1-1-2 Post to inspection stock
Make sure that you set the indicator for the goods receipt inspection,
and cancel the indicator for an inspection during production.
1-2 Post the goods receipt for the order from the previous exercise. Use the following
menu path:
Reduce the goods receipt quantity.

What document number is given?
Goods receipt document number
1-3 Quantity in unrestricted use and inspection stock in plant 1000.
1-4 Then record the inspection results for the goods receipt inspection lot. Use the
worklist. Select your inspection lot using the material number and the inspection lot
origin 04. Reject at least one characteristic.
1-5 Reason for the goods movement for the return delivery for an order and an
explanatory text (optional)
1-6 Quantity in unrestricted use and quantity in inspection stock in plant 1000.
Process
Topic: Early Goods Receipt Inspection
1-1 Inspection type for early goods receipt inspection for an order
1-1-1 An inspection type assigned to inspection lot origin 04
1-1-2 Ctrl indicator. Lot creation with the setting Early lot creation for order
item.
1-3 New production order for material

1-3-1 Document number for production order
1-5 Post goods receipt for order

1-5-1 Document number for goods receipt
1-5-2 No. The quantity in the existing inspection lot is increased by the GR stock.
Contents:
Description of QM-Specific Features, Dependent on

Manufacturing Type or Inspection Lot Origin
SAP AG 1999
Comparison of Manufacturing Types: Unit
Objectives
At the conclusion of this unit, you will be able to

describe the effect on the QM component when
you choose a certain order category in PP.
SAP AG 1999
Introduction
SAP AG 1999
Quality Inspection in an Order Environment (1)
Discrete Manufact.
Manufact. Repetitive Manufact.
Manufact. Process Manufact.
Manufact.
Inspection lot origin 03 / 04* 13 03 / 04*
Task list types N / Q* R 2 / Q*
No. of insp. lots 1 N** 1
Stock No/Yes* No No/Yes*
Approval No/Yes* No Yes/Yes*
Insp. point/Ptl. lots Yes-Yes/Yes-No* Yes-Yes Yes-Yes/Yes-No*
Insp. pt. completion 0,1,2,3 / 2*,3* 0,1,2,3 0,1,2,3 / 2*,3*
Worklist QE51n QE51n QE51n
PI sheet No No Yes/No*
Time ticket/ Time ticket/
Confirmation QM order* Reporting point QM order*
*Early GR 04 lots; ** Only one inspection lot may be in process at any one time.
SAP AG 1999
The task list types are as follows:

N = Routing
Q = Inspection plan
R = Rate routing
2 = Master recipe
Variants for inspection completion are as follows:
0 = 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
Quality Inspection in an Order Environment (2)
GR for Order Plant Maintenance
Task list types Q E, T, A
Inspection lot origin 04 14
No. of insp. lots 1 or n 1
Stock Yes No
Approval Yes No
Insp. point/Ptl. lots Yes/No (Equip., funct. location)/No
Insp. pt. completion 2, 3 2, 3
Worklist QE51n/QE52* QE51n/QE53/QE54
PI sheet No No
Confirmation QM order Time ticket

*Sample management
SAP AG 1999
Comparison of Manufacturing Types: Unit Summary
The selection of an order category in PP affects the

way it is processed in QM.
SAP AG 1999

LO-720 QM in Discrete and Repetitive Manufacturing

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

LO-720 QM in Discrete and Repetitive Manufacturing

Caricato da

Copyright:

Formati disponibili

LO720 QM in Discrete and Repetitive Manufacturing

R/3 System Release 46D 11.05.2001

QM in Discrete and Repetitive

Copyright 2001 SAP AG. All rights reserved.

All rights reserved.

LO170 3 days LO705 3 days LO720 2 days LO750 3 days

LO710 3 days LO721 3 days

Quality Notifications QM in the Process

LO050 - Planning & Execution for Discrete and

Notes to the user

This course deals with:

The integration of the Quality Management

The most important settings for orders in QM

At the conclusion of this course, you will be

Plan and process inspections in repetitive

Unit 1 Course Overview Unit 5 Quality Inspection for

Course Overview START

Inspection During Production

Test Equipment Management

Quality Inspection for External Processing

Inspection at the End of the Production Process

Comparison of Manufacturing Types

Defects Recording for an Order

At the conclusion of this unit, you will be

Inspection During Production

Test Equipment Management

Quality Inspection for External Processing

Inspection at the End of the Production Process

Comparison of Manufacturing Types

Defects Recording for an Order

Results Recording by Characteristic for an Order

Inspection Point Processing

SPC - Statistical Process Control

Integration of the QM and PP Components

At the conclusion of this topic, you will be able to:

Make a usage decision for an inspection during

You manufacture shafts using PP orders. You

Procurement Production Sales Service

Integrating insp. planning/production operations

Inspection lot origin 03 / 13

Inspection lot origin 04

Inspection lot origin 14

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Inspection type for

Recording inspection results

General UD UD for Orders

Consider long-term Order

Defects Recording for an Order

Results Recording by Characteristic for an Order

Inspection Point Processing

SPC - Statistical Process Control

Integration of the QM and PP Components

At the conclusion of this topic, you will be able to:

You manufacture shafts using PP orders.

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture

Manufacture Manufacture Inspect Manufacture