Title: QM config ppt
1SAP Quality Management (QM) When to Leverage It,
How to Set It Up, and How to Integrate It with
Your Current Production Planning Processes
- Isaac Mazliach
- S.D.M. Israel
2What This Session Will Cover, and Why!
- Due to regulations put forth by the Food Drug
Administration (FDA), the Federal Aviation
Association (FAA), Sarbanes-Oxley (SOX), and
others, SAP customers are compelled to use the
Quality Management (QM) component more than ever
3What This Session Will Cover, and Why! (cont.)
- QM is increasingly viewed as a business advantage
(as with Motorola Six Sigma plan Statistical
Process Control SPC) - This session will introduce the Quality
Management component (QM), and describe its main
uses relevant to SAP Production Planning (PP)
processes
4What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
5A Definition of QM
- Quality Management (QM) is a component of mySAP
PLM used to plan, check, verify, and document the
quality of products and processes - Three main requirements for a QM system
- Total Quality Management (TQM)
- Industry-specific standards FDA and Good
Manufacturing Practice (GMP) - Standards for QM systems (ISO 9000)
6Evolution of QM
- Lets see a brief look at the history of software
development in the quality management area - SAP R/3 QM Planned and event-controlled
processes in quality management for purchasing
and production, with little functionality
(compared to todays) - mySAP PLM QM Functional area of mySAP PLM,
encompassing quality engineering, quality
improvement, and quality assurance and control - mySAP ERP QM All QM-relevant processes
(quality planning, quality inspection, quality
certificate, quality notification, quality
control, test equipment management, stability
study)
7What Does QM Include?
- Quality Management is integrated in the SAP
system and uses basic and cross-application
functions, such as - Document Management System (DMS)
- Engineering Change Management (ECM)
- Classification System
- Audit Management
- Workflow
- ArchiveLink
- SAPoffice
- Example QM documents may be managed with DMS
(txn CC04) and/or SAPoffice (txn SBWP)
8Functions of the Quality Management Area
- Quality planning create and manage the master
data that is required to plan and execute quality
inspections - Quality inspection identify whether the
inspected units fulfill the predefined quality
requirements - Quality certificate certify the quality of a
material (contains texts, specification values,
and inspection results) - Quality notification record and process
internal and external problems that are primarily
caused by poor-quality goods or services
9Functions of the Quality Management Area (cont.)
- Quality control implement various preventive,
monitoring, and corrective activities - Specifications from quality planning and
evaluations from quality inspections and quality
notifications, form the basis for quality control
- Test equipment management manage master data,
as well as plan and process calibration
inspections for test equipment - Stability study manage basic data, as well as
the planning and execution of stability studies
10Quality Management (QM) in Production Planning
(PP)
- QM in PP covers the following areas
- Integrating inspection planning/production
operations - Inspection operations can be directly included in
routines (discrete manufacturing and repetitive
manufacturing) or Master Recipes (process
industry) - Controlling inspections during production
- Inspection lot origin 03 (during production)
- Inspection lot origin 04 (Goods Receipt GR
from production) - Statistical Process Control (SPC)
- For example, control chart with mean value and
standard deviation for an inspection
characteristic - Processing internal problem notifications
notification type Q3
11What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
12Discrete Manufacturing
- As soon as a planned order is generated from
Materials Requirement Planning (MRP), shop floor
takes over the information available and adds the
order-relevant data to it to guarantee complete
order processing - Production orders are used to control production
within a company, and also to control cost
accounting
- These are the normal production orders
- Each material is produced individually (i.e., an
individual production order for each production
lot) - The work processes within a company are executed
using production orders - A production order defines which material is to
be processed, at which location, at which time,
and requiring how much work - It also defines which resources are to be used
and how the order costs are to be settled
13Repetitive Manufacturing
- A component in the SAP system for planning and
controlling repetitive manufacturing and flow
manufacturing - It enables the period-dependent and
quantity-dependent planning of production lines,
reduces the work involved in production control,
and simplifies backflushing (confirmation, Goods
Receipt posting)
- Implement repetitive manufacturing if the
following is true of your production process - You produce the same or similar products over a
lengthy period of time - You do not manufacture in individually defined
lots. Instead, a total quantity is produced over
a certain period at a certain rate per
part-period. - Your products always follow the same sequence
through the machines and work centers in
production - Routings tend to be simple and do not vary much
14Process Industry Manufacturing (PP-PI)
- With PP-PI, SAP provides an integrated planning
tool for batch-oriented process manufacturing - It is primarily designed for the chemical,
pharmaceutical, food, and beverage industries, as
well as the batch-oriented electronics industries
- PP-PI uses terms such as
- Master Recipes the processes to be used for
producing materials in your plant, as well as the
resources and ingredients required for production - Process Orders copy a process described in a
Master Recipe and adjust it to the actual
production run - Process Management coordinate the communication
between PP-PI and the process control during the
execution of a process order
15QM Changes According to Production Method
- QM uses different blocks (customizing, master
data, etc.) according to the production method
(discrete, process, and repetitive). Here are
some examples - When process order is used inspection planning
may reside in the Master Recipe - When production order is used inspection
planning may reside in the routine (txn CA03) - When PP-PI is used inspection results shall be
recorded in the PI sheet (txn CO60) - When discrete or repetitive is used inspection
results shall be recorded in the inspection lot
(txn QE51N)
16What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
17Production Chain
Production Planning
Order release
Inspection during production
Order confirmation
Goods movement
- Sample calculation
- Inspection lot creation
- Approval procedure
- Recording of scrap
- Partial lot creation
- Valuation
- Batch classification
- GR in warehouse
- Batch proposal
- Batch classification
- Release of batch record
- Operations inspection characteristics
- Inspection points
- Measured value and defects recording
- SPC control chart
- Externally processed operations
18QM During Production
- Inspection lot origin 03
- Inspection lot is created at the PP order release
- At Goods Receipt, material immediately entered
into unrestricted-use stock - Control is less strict
- Materials with bad inspection may enter the
good stock - If better control is required, production
reporting should be on the operation level - In this case, it should be forbidden to move to
the next operation if the previous one was not
accepted
19QM at the End of Production
- Inspection lot origin 04
- Inspection lot is created at Goods Receipt
- At Goods Received, the produced material is
received into QI-Stock - Only usage-decision may move it to
unrestricted-use stock - Control is more strict
- If material did not pass inspection, it cannot be
used - Production reporting may be on operation level or
on order level
20What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
21Customization Tasks to Integrate QM with PP
- Separate transaction for QM customization QCC0
- Quality planning
- Inspection characteristics, inspection methods
- Sample determination
- Define task list types, usage, and status
- Define control key for inspection operations
- The required Task List Usages can be created in
customizing - The Task List Usage is entered in the headers of
the task lists and in customizing of the
inspection types
22Assign Task List Type to Material Types
23Quality Inspection
- Inspection types
- Inspection for goods movements
- Assign inspection type for manufacturing order
(per production order type or process order
type) - Maintain usage decision for catalog type 3
- Define physical sample type, container, and
locations
- Important
- The meaning of the catalogs 0 to 9 Z and A to O
is defined by SAP - The other catalogs (P to Z) can be defined by
the customer
24Define Control Keys for Inspection Operations
25Quality Certificates
- Certificate profile
- Maintain form
- Output determination
26Quality Notifications
- Notification types and content
- Additional notification functions (action box and
follow-up actions)
Q What are Quality
Notifications? A Quality Notifications are the
central medium in QM for processing problems and
unplanned events
27Quality Control
- In Materials Management (MM) Vendor evaluation
- In Logistics Information System (LIS) Quality
Management Information System (QMIS) - In QM Definition and evaluation of original
documents
Control Chart Form for the graphical display of
characteristics values that occur during an
inspection. The control chart compares the
displayed values with the action limits and, in
this way, supports the quality-related control of
the process. The run-chart is a graphical display
of the single values of a quantitative
characteristic in a run time. You cannot valuate
inspection results using the run-chart.
28Stability Study
- Define physical sample types
- Define testing schedule category
- Notification types
- Catalogs
- Inspection types
Stability Studies are performed in the chemical,
pharmaceutical, and food industries to examine
how different conditions affect a product over a
specified period of time
29What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
30Quality Planning as a Foundation for Master Data
- In quality planning, you define information and
processes on a long-term basis as Master Records - Quality planning provides the basis for
inspection processing - To do that, quality planning uses
cross-application data, such as - Material Master
- Batch classification
- Quality documents
- Work center
- Serial numbers
31Master Data Material Master QM View
32Master Data Routine View
33Master Data Routine View (cont.)
34Quality Planning as Part of QM
- Quality planning uses QM-specific basic data such
as - Master inspection characteristics
- Inspection methods
- Sampling procedures
- QM work center (with its capacity)
- Catalog
35Quality Planning and Inspection Planning Data
- Quality planning uses inspection planning data
such as - Inspection plans
- PP-PI Master Recipe, Resource
- Routing
- Material specifications
36What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
37Process Order Without QM
- When production is complete, enter a Goods
Receipt of the material into stock - The Transaction is CO60 maintain PI sheet
38DEMO Process Order Without QM
No QM data!
39Process Order with QM
- When production is complete, enter the following
- Inspection results (through characteristics)
- Usage decision
- Only then, enter Goods Receipt of the material
into stock - The transactions
- CO60 maintain PI sheet
- QE51N find inspection lot per material
- QA11 enter usage decision
40DEMO Process Order with QM
Enter QM data here!
41DEMO Process Order with QM (cont.)
42DEMO Process Order with QM (cont.)
43DEMO Process Order with QM (cont.)
44What Well Cover
- What is QM?
- How different manufacturing strategies
discrete, repetitive, and Process Industry
(PP-PI) change the ways to integrate QM - What are the differences between QM during
production and QM at the end of production? - Main customizing tasks to integrate QM with PP
- Master data requirements to integrate QM with PP
- Demo Process order with and without QM
- Wrap-up
45Resources
- Product information
- www.sap.com/plm
- Product documentation
- http//help.sap.com
- For customers and partners
- http//service.sap.com/qm
- Information about courses
- www.sap.com/education
Requires login credentials to the SAP Service
Marketplace
467 Key Points to Take Home
- QM became crucial in recent years
- Now, more than ever, it is important to implement
it in PP - Before starting the QM project, make sure your
implementation complies to the rules and
regulations of your companys business (SOX,
FDA, etc.) - To allow the QM process to work, allocate the
necessary resources to ensure that master data is
correct - If a more strict control is required, you may
consider inspecting the material at the end of
production - If the production process is long or divided into
many processes, you may consider inspecting
during production, also
477 Key Points to Take Home (cont.)
- Focus on the main customizing and master data
tasks - Do not try to achieve everything right at the
beginning - Use notification wisely. It is very powerful.
- Make sure you allow production to continue
working after QM implementation - Do not sacrifice production on the altar of QM
48Your Turn!
How to contact me Isaac Mazliach ISAAC_at_SDM-C.COM