qm overview
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Quality Management
© SAP 2008 / Page 2
Contents
Section 1 : General Overview
Section 2 : QM Integration
Section 3 : QM Process overview
© SAP 2008 / Page 3
ERP stands for Enterprise Resource Planning
Enterprise Resource Planning systems integrate all data and processes of an
organization into unified system.
The key feature of an ERP system is it uses a single or unified database to store
data for the various system modules.
Various Modules which comes under ERP are listed below:
Material Management
Production Planning
Quality Management
Finance
Costing
Sales and Distribution
Enterprise Resource planning
© SAP 2008 / Page 4
Quality Management
QM IntegrationPPPPMMMM
Purchasing Requisition
Inventory mgmt
Goods receiptStock transferGoods issue
ShippingBilling
SDSD
Invoiceverification
Warehousemanagement
Inspection lot
QMQM Inspection lotInspection lot
Print insp. instruction
Results recording
Usage decision
Basic dataBasic data
Test equipmentmanagement
PMPM
Productionplanning
Reqt planningR-cut capacity
planning
PlannedOrders
Openingperiod
Order:- Creation- Release- Confirmation
Shop floorcontrolCapacityleveling
MaterialsMaterials
VendorsVendors
RoutingsRoutings
DocumentsDocuments
Inspection plan
Characteristics
Insp. methods
Insp. catalogs
Test equipment
© SAP 2008 / Page 5
BENEFITS
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Comprehensive master data maintenance by system.
Stocks in Quality till inspection is completed.
Inspection Results are available on line, hence retrieval will be easy and trends/SPC of characteristics can be viewed on line
Quality Score for vendor is based on Usage Decision (Passed/Rejected).
Standardized methodology for complaint reporting and analysis.
Calibration frequency scheduled by system for instruments.
Standard reports for analysis and review.
© SAP 2008 / Page 6
Quality Management – FACT Processes
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List of QM ProcessesSl.No Process
TriggerStock Control
1.0 QM Master Data NA NA
2.0 Source Inspection Manual Inspection Non Stock
3.0 Incoming Inspection Automatic from GR posting. Stock
4.0 In-Process Inspection Automatic from Prod. Order Non Stock
5.0 Final Inspection Automatic from Prod. Confirmation
Stock
6.0 Stock transfer Inspection Automatic for Stock transfer Stock
7.0 Audit Management Manual NA
8.0 Calibration Inspection Automatic by Scheduling NA9.0 Notification Process NA NA
© SAP 2008 / Page 7
Quality Management
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SAP Terminologies
SAP TERMINOLOGY DESCRIPTION
Result Recording Recording of actual dimensions (Dimension, Visual check, …)
Defect recording Recording of defect codes (eg., Dimensional deviation, damage (visual check..)
Usage Decision After result recording, to give final disposition viz., (Passed,Rejected…)
© SAP 2008 / Page 8
Quality Management
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Master Data –What it containsContents in Master Data Examples
Material Master Contains material number, description, type of inspection (incoming/in process/final…)
Sampling Procedure Sampling plan
Master Inspection characteristics Eg, Dimension, Visual Observing, Performance test
Inspection method Method of checking: Dimension, Visual observation
Catalogs / Selected Sets Used in Qualitative characteristics,UD code, Defect code.
Inspection Plan / Routing / Maintenance Task List
List of specification to be checked
Equipment Master Equipment number, description…
© SAP 2008 / Page 9
Catalog
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Master Data – What it containsCatalogs - Maintained at Client level – is a kind of library wherein all qualitative characteristics are
defined and stored.
Selected sets : These qualitative characteristics can be fetched from Catalog and used at plant level – 1002,1003 and 1005
Catalog Selected setsCommon to ALL 1002 1003 1005
Visual OK
Visual Not OK
Visual OK
Visual Not OK
Visual OK
Visual Not OK
Visual OK
Visual Not OK
Dimensional check OK
Dimensional check Not OK
Dimensional check OK
Dimensional check Not OK
- -
Ex.,
© SAP 2008 / Page 10
Source Inspection
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Raw Material (Benzene, Sulphur,
….)
Bought outs (Cables,Generator
…
Components from
Sub-contractors (regular process)
SOURCE INSPECTION
© SAP 2008 / Page 11
Source Inspection
Source Inspection
Source inspections are performed upon request and with the participation of the plant persons and /or customer
A source inspection is performed by the receiver of the service, the vendor in the presence of the receiver or third party appointed by him
After creation of Purchase order, information is made available to quality function at vendor site based on the readiness of the goods for inspection
© SAP 2008 / Page 12
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Raw Material (Benzene, Sulphur,
….)
Bought outs (Cables,Generator
& Equip...Components from
Sub-contractors (regular process)
Goods Receipt Inspection
Goods Receipt Inspection
© SAP 2008 / Page 13
Goods Receipt Inspection
Goods Receipt Inspection - Features
Lot cannot be issued without quality inspection
Finance can make payment only after Quality Usage Decision (for limited vendor this facility would be waived)
Specification available on line material number wise – actual values only to be entered
Corrective action thro’ notification process
Concession/Deviation record details through notification process
Sampling Plan
© SAP 2008 / Page 14
In process Inspection
Operation wise inspection
INPROCESS INSPECTION
© SAP 2008 / Page 15
In process Inspection
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In process Inspection -Features
Inspection characteristics trend can be made
Corrective action thro’ notification process
Concession/Deviation process through notification process
Adherence to raising of first off /last off reports can be monitored
Inspection details can be sent to manufacturing thro notification in case of nonconformance
© SAP 2008 / Page 16
Final Inspection - Production
Final Inspection for Anon,Hyam etc.,
FINAL INSPECTION
© SAP 2008 / Page 17
Final Inspection
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Final Inspection - Features
Stock control i.e. QC can hold stock here
Specification available on line - material number wise – actual
values only to be entered
Corrective action thro’ notification process
Concession/Deviation record details through notification process
Assign the inspection characteristics against SPC requirement
© SAP 2008 / Page 18
Calibration
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External Calibration
CALIBRATION
Internal Calibration
© SAP 2008 / Page 19
Calibration
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Calibration - Features
Timely information of due calibration
Advance intimation facility available for due date calibration
Can de-activate the equipment which is out of calibration
User locations can be seen
Notification can be sent for out of calibration
Other Plants can view their calibration results for the equipments calibrated here.
© SAP 2008 / Page 20
Notification
Incoming Inspection
In-process Inspection
Final Inspection Calibration
NOTIFICATION
Plant to Plant/Suspect Materials
CustomerComplaints
Stock transfer – within Plant
© SAP 2008 / Page 21
Notification
Notification - Features
Partners and coordinators can be assigned
Common approach for initiating corrective actions thro specific report
Status of notification – Closed/Open can be listed out
Notification can be sent to inter plants
Linking of concession/deviation flow for closing notification as applicable
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Thank you
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