Table of Contents
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Introduction to Participant Guide Creation ...
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Exercise 1
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Tables and Figures Tables and Figures Figure 1 Smart A
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Table of Contents
Table of Contents
QM Master Data Introduction ...4 QM Master Data Introduction ...4
Using this Guide
Using this Guide ...
... ...
... ...
... ... 4
... 4
Lesson 1: QM Overview ...5 Lesson 1: QM Overview ...5
Lesson 1 Objectives
Lesson 1 Objectives ...
... ...
... ...
... 5
5
QM
QM Process Process Overview Overview 55 QM Inspection Process 5 QM Inspection Process 5
Exercise 1
Exercise 1 – – Display Display an an Inspection Inspection Lot Lot (QA03) (QA03) 88
Exercise 2
Exercise 2 – – Display Display Material Material Master Master QM QM View View (MM03) (MM03) 99
Lesson 2: Material Master QM View ... 10 Lesson 2: Material Master QM View ... 10
Lesson 2 Objectives
Lesson 2 Objectives ...
... ...
... ...
... 10
10
Master
Master Data Data 1010 Material
Material Master Master Data Data 1010 The Importance
The Importance of Master of Master Data Data 1111 Catalog
Catalog Profile Profile 1212 QM proc. active 12 QM proc. active 12 QM Contr
QM Contr ol Keol Key y 1212
Quality Inspection Settings
Quality Inspection Settings – – Inspection Inspection Lots Lots 1313
Exercise
Exercise 1 1 Material Material Master Master Settings Settings (MM02) (MM02) 1616 Exercise
Exercise 2 2 Assign Assign Material Material to to Inspection Inspection Plan Plan (QP02) (QP02) 1818
Lesson 3: Sampling Procedures ... 19 Lesson 3: Sampling Procedures ... 19
Lesson 3 Objectives
Lesson 3 Objectives ...
... ...
... ...
... 19
19
Sampling
Sampling Overview Overview 1919
Exercise
Exercise 1 1 Display Display Sampling Sampling Procedure Procedure (QDV3) (QDV3) 2222 Exercise
Exercise 2 2 Create Create Sampling Sampling Procedure Procedure (QDV1) (QDV1) 2323 Exercise
Exercise 3 3 Change Change Sampling Sampling Procedure Procedure (QDV2) (QDV2) 2424
Dynamic
Dynamic Modification Modification Rule Rule (DMR) (DMR) 2525
Lesson 4: Master Inspection Characteristics ... 26 Lesson 4: Master Inspection Characteristics ... 26
Lesson 4 Objectives
Lesson 4 Objectives ...
... ...
... ...
... 26
26
Master
Master Inspection Inspection Characteristics Characteristics Overview Overview 2626 WCB
WCB Qualitative Qualitative Control Control Indicators Indicators 2727 WCB
Table of Contents
Table of Contents
QM Master Data Introduction ...4 QM Master Data Introduction ...4
Using this Guide
Using this Guide ...
... ...
... ...
... ... 4
... 4
Lesson 1: QM Overview ...5 Lesson 1: QM Overview ...5
Lesson 1 Objectives
Lesson 1 Objectives ...
... ...
... ...
... 5
5
QM
QM Process Process Overview Overview 55 QM Inspection Process 5 QM Inspection Process 5
Exercise 1
Exercise 1 – – Display Display an an Inspection Inspection Lot Lot (QA03) (QA03) 88
Exercise 2
Exercise 2 – – Display Display Material Material Master Master QM QM View View (MM03) (MM03) 99
Lesson 2: Material Master QM View ... 10 Lesson 2: Material Master QM View ... 10
Lesson 2 Objectives
Lesson 2 Objectives ...
... ...
... ...
... 10
10
Master
Master Data Data 1010 Material
Material Master Master Data Data 1010 The Importance
The Importance of Master of Master Data Data 1111 Catalog
Catalog Profile Profile 1212 QM proc. active 12 QM proc. active 12 QM Contr
QM Contr ol Keol Key y 1212
Quality Inspection Settings
Quality Inspection Settings – – Inspection Inspection Lots Lots 1313
Exercise
Exercise 1 1 Material Material Master Master Settings Settings (MM02) (MM02) 1616 Exercise
Exercise 2 2 Assign Assign Material Material to to Inspection Inspection Plan Plan (QP02) (QP02) 1818
Lesson 3: Sampling Procedures ... 19 Lesson 3: Sampling Procedures ... 19
Lesson 3 Objectives
Lesson 3 Objectives ...
... ...
... ...
... 19
19
Sampling
Sampling Overview Overview 1919
Exercise
Exercise 1 1 Display Display Sampling Sampling Procedure Procedure (QDV3) (QDV3) 2222 Exercise
Exercise 2 2 Create Create Sampling Sampling Procedure Procedure (QDV1) (QDV1) 2323 Exercise
Exercise 3 3 Change Change Sampling Sampling Procedure Procedure (QDV2) (QDV2) 2424
Dynamic
Inspection
Inspection Plan Plan Structure Structure 3232
Exercise
Exercise 1 1 Display Display Inspection Inspection Plan Plan (QP03) (QP03) 3434 Exercise
Exercise 2 2 Create Create Inspection Inspection Plan Plan (QP01) (QP01) 3535
Material
Material Assignment Assignment to to an an Inspection Inspection Plan Plan 3737
Exercise
Exercise 3 3 Display Display Material Material Assignment Assignment for for an an Inspection Inspection Plan Plan (QS62) (QS62) 3838 Exercise
Exercise 4 4 Create Create a a Material Material Assignment Assignment for for an an Inspection Inspection Plan Plan (QS61) (QS61) 3939
Inspection Plan Operation Level 40 Inspection Plan Operation Level 40 Inspection
Inspection Characteristics Characteristics 4040 Changes
Changes to to Inspection Inspection Plans Plans 4141
Exercise
Exercise 5 5 Change Change Inspection Inspection Plan Plan (QP02) (QP02) 4242
Engineering W
Engineering W orkbench orkbench 4343
Exercise
Exercise 6 6 Maintain Maintain Inspection Inspection Plan Plan (CWBQM) (CWBQM) 4444
Quality
Quality Info Info Records Records 4545 Vendor
Vendor Contact Contact Persons Persons 4545 Code
Code Groups Groups and and Codes Codes 4646 Selected
Selected Sets Sets 4747 Quality
Quality Notifications Notifications 4848
Lesson 6: Vendor Portal ... 50 Lesson 6: Vendor Portal ... 50
Lesson 6 Objectives
Lesson 6 Objectives ...
... ...
... ...
... 50
50
Vendor Portal Overview 50 Vendor Portal Overview 50 Vendor Portal
Vendor Portal – – Pre-inspection Pre-inspection App App 5050 Vendor Portal
Vendor Portal – – Quality Quality Tasks Tasks App App 5050 Vendor Portal
Vendor Portal – – Deviation Deviation Management Management App App 5050 Vendor Portal
Vendor Portal – – Inspection Inspection Report Report Email Email Program Program 5050
Lesson 7: Batch Jobs ... 52 Lesson 7: Batch Jobs ... 52
Lesson 7 Objectives
Lesson 7 Objectives ...
... ...
... ...
... 52
52
Batch
Batch Jobs Jobs Overview Overview 5252 Inspection
Inspection Report Report 5252 Automatic Usage Decision
Related Transactions & Processes 53 Tips & Tricks 53
Activity 54
Lesson 2: Material Master Settings (MM02) ... 56
Material Master Processing 56
Related Transactions & Processes 56 Tips & Tricks 56
Activity 57
Lesson 2: Assign Material to Inspection Plan (QP02) ... 58
Lesson 3: Display Sampling Procedure (QDV3)... 58
Lesson 3: Create Sampling Procedure (QDV1) ... 59
Create Sampling Procedure 59 Related Transactions 59
Activity 59
Lesson 3: Change Sampling Procedure (QDV2) ... 61
Change Sample Procedures 61 Related Transactions 61
Activity 61
Lesson 4: Create Qualitative Master Inspection Characteristic (QS21) ... 62
Lesson 5: Display Inspection Plan (QP03) ... 62
Lesson 5: Create Inspection Plan (QP01) ... 62
Create Inspection Plan 62 Related Transactions 62 Tips and Tricks 63
QM M
ASTER
D
ATA
I
NTRODUCTION
This course will equip participants with the SAP skills necessary to create, change and manage master data records that impact the quality management process.
The following topics are covered in this guide :
The quality management process
Types of master data used in the quality management process Material master – QM view
Inspection characteristics Sampling procedures Inspection plans
After completing this course, you will be able to:
Explain the role of master data in the quality management process Describe the master data used in QM
Maintain the material master – QM view
Create and assign inspection characteristics to task list Create and maintain sampling procedures
Create and maintain inspection plans
Using this Guide
This guide is designed to provide you with:
Information regarding the listed topics Exercises to practice what you learn
Quick reference guides to assist you while doing your job in SAP
Use this guide in a classroom setting to follow along with the instructor and add notes wherever needed. You can also use this guide in a self-paced manner to review how to perform the listed tasks learned in class.
L
ESSON
1: QM O
VERVIEW
Lesson 1 Objectives
After completing this lesson, you will be able to:
Describe the three phases of QM Define an inspection lot
Describe the QM inspection process Recognize log triggers
QM Process Overview
Figure 1 QM Process
QM Inspection Process
The data important for the quality inspection is contained in the inspection lot data record that includes:
The lot quantity lot
Planning
•
Material Master, Inspection Characteristics, Inspection Plan
•Sample Procedures & Dynamic Modification (Skip)
Processing
•
Record Results (Accept / Reject)
•Usage Decision
Evaluation
•
Quality Notifications
•Quality Scores
The originating documents contain the inspection lot materials and may be any one of the following:
Purchasing document Material document
Order
An inspection lot is assigned to a mater ial.
Each inspection lot follows the same process regardless of the type of inspection (goods movements, returns, etc.).
Figure 2 QM Inspection Process
An inspection lot is a request t o perform a quality inspection for a quantity (sample) of a material. Inspecti no lots are data records and have statuses. Inspection lots are assigned to an inspection plan and may contain seeral opererations that define inspection activities.
Each operation on the inspection plan may contain one or many inspection characteristics that describe what needs to be inspected. Inspection lots can be triggered by the following events:
Business Process
Event
Goods movements
Good receipts – Goods receipt for purchase order into the warehouse. Transfer postings – Plant to plant moves.
Returns – Return from vendor or customer orders.
Complaints Customer – Each customer complaint will be inspected.
Vendor – Each vendor complaint will be inspected.
Internal problems Defects – All defects will be inspected.
Table 1 Master Data Terms
Create
Inspection Lot
Determine SampleInspect
Material
Record
Results /
Defects
Usage
Decision
EvaluationExercise 1
–
Display an Inspection Lot (QA03)
Scenario: An inspection lot is a request to inspect a quantity of material for pre- defined characteristics. Display an inspection lot and answer the questions below.
Support Document: QA03 Display Inspection Lot
Complete the following field(s): Required Data / Results
Transaction Code QA03
Complete the following field(s): Required Data
Inspection Lot
What is the Insp.lot origin? Who is the vendor?
What is the inspection lot quantity? What is the valuation code?
Has a usage decision been made on this lot?
Don’t have an eup
Exercise 2
–
Display Material Master QM View (MM03)
Scenario: The inspection set-up in the material master (QM view) activates and triggers the creation of
inspections lots, assigns an inspection plan and calculates the sample size. In addition to other settings on the inspection type, other actions are performed automatically. Display the QM view inspection set-up for goods receipt for PO – B and answer the following questions.
Support Document: MM03 Display Material Master Record
Transaction Code MM03
Complete the following field(s): Required Data
Material
Select views Quality Management
Plant Enter
Review inspection setup
What is the inspection type for Goods Receipt Inspection?
What is the description of the material?
Want is the material group number and name? Enter
What is the base unit of measure? What is the Catalog profile?
Don’t have an eup
L
ESSON
2: M
ATERIAL
M
ASTER
QM V
IEW
Lesson 2 Objectives
After completing this lesson, you will be able to:
Explain the master data used in QM processes Define inspection types
Maintain and activate inspection types Assign a material to an inspection plan Display material master – QM view Additional material master transactions
Master Data
Accurate master data is one of the key factors for a successful SAP im plementation. Master data is centr ally stored data that forms the base of all business transactions. The data is static in nature, meaning it does not change when it used in a transaction. While the transactions themselves are dynamic and changed based on the execution of the transaction, the master data itself used does not.
Master Data is the responsibility of a team dedicated to its creation maintenance to insure the data’s correctness. This important task also reduces redundancy of data records across the entire company.
The main Master Data types ae shown below. For this course, we will focus primarily on Material and Vendor Master Data.
Figure 3 Master Data Types
Material Master Data
Master data is created at different levels to accommodate its use by the various organization elements in the company. For example, members of the procurement team work with information different from the data used by the sales team. Master data is created at different organizational levels. Depending on the material type, different functional areas within the company maintain different data screens. This screen selection applying specifically to an application is called a "view".
Because of the large of amount of information contained in a single material master record, the viewing method for a material employs multiple data screens. Depending on the material type, different functional areas within the company maintain the different data screens. Basic data views are the same across all company locations. Other views are specific for each plant location. Each material is created for at least one plant, but can be “extended” to
Figure 4 Material Master Data
The Importance of Master Data
The accuracy of master data is essential to efficient performance of the inspection process. Characteristics of master data include:
Static
Centrally stored and shared across other modules and systems Is copied into transaction data
Examples of QM master data include:
Materials
Inspection plans
Master inspections characteristics
Material types in the SAP system can be, for example, finished goods, semi-finished goods, raw materials, or services. The material type represents certain features of materials in the system, and has important control functions: the material type is used, among other things, to group field selection functions for a material, or to define the screen sequence, the type of number assignment and number ranges during material master record maintenance.
The QM view of the material master activates quality inspection for a material within a plant and controls the inspection process.
The material master settings control how materials will be inspected during the procurement process. Catalog Profile
Each business unit has a catalog profile created. This profile is entered in the QM View and determines which code groups and codes appear in the quality notifications for that material.
ZCB – Char-Broil Codes ZLL – Lamplight Codes ZZB – Zebco Codes
The Catalog Profiles contain the name of the code groups and codes that should be displayed in quality notifications for a material.
QM proc. active
Every item should have this box checked. It designates that there are QM functions active in the procurement process. The specific QM functions that are active are determined by two subsequent items, the QM Control Key configuration and the Quality Info Record
QM Control Key
Every item should ‘0000’ in this box. This means that there are no controling functions active in configuration. This simply designates that a Quality Info Record should exist, and serves as a place holder for a different control key if other functions are even implemented.
a. 0000 – No active functions
The QM Control Key can activate various QM functions in the procurement process. Control Key 0000 indicates the requirement for a Quality Info Record.
Quality Inspection Settings – Inspection Lots
Inspection lots contain the inspection types, origins, number ranges, and usage decisions for inspection plans. Inspection Type Setup
Every item that is inspected will have certain inspection types activated to allow for the creation of inspection lots. A material can have several inspection t ypes maintained and activated based on the inspection process defi ned
for that material.
Inspection types define when an inspection is to be carried out (goods receipts or stock transfers) in addition to how the inspection is to be carried out based on the settings for each inspection type.
Type
Description
01 This inspection type is used to ensure that stock goes into Quality
Inspection when received from a PO/Inbound Delivery. It is used in conjuntion with inspection type 17 for receiving inspections.
ZLL01 This inspection type is a copy of 01 and is used to ensure that stock goes into Quality Inspection when received from a PO/Inbound Delivery for Lamplight specifically. It is used in conjuntion with inspection type 17 for receiving inspections.
17 This inspection type is used to create inspection lots based on goods
receipts in the EWM system.
ZPSI This inspection type is used to create inspection lots for internal pre-shipment inspections in SAP. These inspection lots are manually created by inspectors in QA01.
ZLLPSI This inspection type is used to create inspection lots for internal pre-shipment inspections in SAP specifically for Lamplight. These
inspection lots are created by a batch job running QI07 in the
background. This inspection type requires a Quality Ino Record to be set up as well.
Z7 This inspection type is used by external vendors via the Vendor Portal
Pre-inspection App. It is used by the vendors to submit their own inspection reports and should be active for any material that gets a vendor report submitted.
Other Settings
Setting
Description
UD Selected Set This is the name of the selected set of UD codes that is used when processing the usage decision for an inspection lot with this inspection type.
Selected Set in Same Plant
This check box requires that the selected set used for the UD must be set up in the same plant that the inspection lot exists in (a Char-Broil inspection lot cannot be evaluated with a UD from Zebco).
Notification type This field determines the type of notification that is created
automatically at the time of defects recording within results recording for the inspection lot.
Task list usage This setting determines what type of inspection plans will be called up when inspection lots are created with this inspection type. This field will match the task list usage field in the inspection plan.
Additional transactions for the m aterial master are described below:
Tcode
Description
Function
MM01 Create Material Master Use this transaction to create new materials for a plant or to extend current materials to other WCB plants
This is a highly authorized transaction
MM06 Flag Material for Deletion This transaction flags a material for deletion at different organizational levels
The material will still exist in the database and depending on the configuration – the system will issue either a
warning or error message when it is used in a transaction. It is physically removed from the database when the archive program is run
MM03 Display a material master – QM View
Use this transaction to display the QM view in a material / plant
This transaction displays the QM inspection type(s) that are activated for a material / plant and the associated settings for each type
Changes are not allowed with this transaction
MM19 Display material at Key Date Use this transaction to display a material for a particular point in time (date).
QA08 Mass Change of Inspection
Setup Data in Materials
This transaction is used to activate, deactivate, materials in a plants(s)
Exercise 1 Material Master Settings (MM02)
Scenario: Every material should have a plant-specific QM view in the material master. Activate the procurement data for a material in your plant.
Support Document: MM02 Create Duty of Inspection
Transaction Code MM02
Complete the following field(s): Required Data
Material
Select views Quality Management
Plant Enter
Select a catalog profile type Select procurement data
Make sure the QM procurement data selection box is selected.
Select one or more inspection types and select the Active checkbox
Save
Don’t have an eup
The material assignment to an inspection plan is performed at the Header level in the inspection plan. An inspection plan can have many materials assigned to it.
Once the inspection type is created and activated, the material must be assigned to an inspection plan. A material can be assigned to an inspection plan by using the change transaction (QP02) and adding the material to the existing assignments. If no inspection plan is available, a new plan for the material has to be created. We will discuss creating an inspection plan in another lesson.
Inspection Plan
Header
Material 1
Material 2
Exercise 2 Assign Material to Inspection Plan (QP02)
Scenario: The inspection types have been created and activated in the material master. Based on the settings for the inspection type, the material must be assigned to an inspection. Assign the material to an existing inspection plan.
Support Document: QP02 Assign Material to Inspection Plan
Transaction Code QP02
Complete the following field(s): Required Data
Plant Group
Click task lists overview Click material assignment Group counter Material Plant Enter Save Don’t have an eup
L
ESSON
3: S
AMPLING
P
ROCEDURES
Lesson 3 Objectives
After completing this lesson, you will be able to:
Display a sampling procedure Create a sampling procedure Change a sampling procedure
Sampling Overview
Sampling procedures are used to determine the scope of samples for measuring an inspection characteristic. Sampling procedures are necessary to define the quantity of a sample and the valuation (accept / reject) for an inspection characteristic during results recording.
An example of a sampling procedure is descr ibed in the following table.
Sampling Procedure
Transaction Code: QDV1
Name 8 Characters (alpha / numeric)
Description 40 Characters (alpha / numeric)
Sampling Type Fixed Sample
Valuation mode Attributive inspection non-conforming units
Inspection Points Without inspection points
Sample Size 5
Sampling Schemes
Sampling schemes are used to determine the sample size for each characteristic that is evaluated during results recording for an inspection lot. It determines a sample size based on the receipt quantity and determines
accept/reject numbers. These accept/reject numbers can be determined by AQL and inspection severity.
Sampling
Scheme
Description
Lot size This corresponds to the inspection lot size and determines the sample size and accept/reject numbers for the sample size.
Sample size Sample size for an inspection characteristic at the given lot size.
Accept Number This number (blank for zero) determ ies the acceptance number for the sam ple size at the given AWL and inspection severity.
Reject Number Determines the rejection number for the sample size at the given AQL and inspection severity (blank for zero).
Sampling Procedure
A sampling procedure defines the ru les that specify how the system calculates the sample size and it contains information about the valuation of an inspection characteristic during results recording. Sampling procedures are usually used at characteristic level of an inspection plan.
Sampling
Procedure
Description
Sampling Type Designates how the sample size is determined.
Value Mode Designates how to determine if an inspection characteristic has passed or failed. Sampling Scheme This field references which sampling scheme this procedure is based on.
Additional data Specific inspection Severity and AQL from the sampling scheme are assigned to the sampling procedure.
Additional transactions used for sam pling procedures include:
Tcode
Description
Function
QDV3 Change Sampling Procedure This transaction is used to display a sampling
procedure
Changes cannot be made using this transaction
QDV6 Sampling Procedure Where-Used
List
This transaction displays all the inspection plans and material masters where the sampling procedure is assigned
QDV7 Replace Sampling Procedure Use this transaction to replace an obsolete sampling
procedure with a new or changes sampling procedure in inspections plans
Exercise 1 Display Sampling Procedure (QDV3)
Scenario: Display a sampling procedure.
Support Document: QDV3 Display Sampling Procedure
Transaction Code QDV3
Complete the following field(s): Required Data
Sampling Procedure Enter
What settings display for the sampling procedure?
Which sampling types are available? Which evaluation modes are available?
Don’t have an eup
Exercise 2 Create Sampling Procedure (QDV1)
Scenario: Sampling procedures are used to calculate the sample size of an inspection lot and also to how characteristics are valuated during results recording. Create a sampling procedure.
Support Document: QDV1 Create Sampling Procedures
Transaction Code QDV1
Complete the following field(s): Required Data
Sampling Procedure (enter a name) Click Short Text Sampling Type Valuation Mode Inspection Points Enter
Which multiple samples display? Select a multiple samples option Click
Exercise 3 Change Sampling Procedure (QDV2)
Scenario: Change the sample size of the sampling procedure created in the previous exercise. Support Document: QDV2 Change Sampling Procedure
Transaction Code QDV2
Complete the following field(s): Required Data
Sampling Procedure Click
Change the sample size 5
Change the acceptance number 0
Dynamic Modification Rule (DMR)
The DMR defines the change of the inspection stages, the dynamic modification time (at lot creation or after the usage decision has been made), and the conditions for the inspection stage change. Inspection stage changes occur on the basis of the inspection results that are recorded for inspection lots and inspection characteristics (that is, on the basis of their acceptance or rejection). Collectively these rules make up the conditions for creating SKIP LOTS in SAP.
The rules in the inspection stages are set with rules for advancing and reverting the inspection stage.
If you want to use a DMR and Sampling Procedures in the same inspection plan, their relationship has to be explicitly allowed using SAP transaction QDB1.
L
ESSON
4: M
ASTER
I
NSPECTION
C
HARACTERISTICS
Lesson 4 Objectives
After completing this lesson, you will be able to:
Define the different types of master inspection characteristics Explain the function of control indicators
Define the hierarchy of catalogs and when they are required for an MIC Create and display an MIC
Master Inspection Characteristics Overview
Master Inspection Characteristics (MICs) are assigned to inspection plans at the operation level. MICs
standardize the inspection process and make it more efficient – one MIC can be assigned to many inspection plants. It is QM master data that is created once and used long term.
A master inspection characteristic is an inspection characteristic, which has been def ined for frequent use in t ask lists or should be evaluated for all inspection plans. For example, if particular specifications are required in many inspection plans, a suitable MIC is created and assigned to many inspections plans
MICs help to improve and standardize inspection planning.
When a master inspection characteristic is created, the characteristic type has to be defined. There are
two options:
Quantitative characteristic: Numeric values are expected as inspection results (e.g. thickness in meter) Qualitative characteristic: Attribute values are expected as inspection results (e.g. color by color palette)
MIC Control Indicators What is to be Inspected? Admin. Data General Data
WCB will create master inspection characteristics as complete copy models. Complete copy models allow changes to the MIC when it is assigned to an inspection plan operation (for example, tolerances or color).
WCB Qualitative Control Indicators
Qualitative Characteristic Control Indicators
Characteristic attribute (required) Sampling procedure (required) Required characteristic (required) Fixed scope (required)
No documentation Print
WCB Quantitative Control Indicators
Quantitative Characteristic Control Indicators
Lower value (required, if the characteristic has a lower value) Upper value (required, if the characteristic has an upper value)
The following quantitative data of the characteristic should be maintained: • Decimal places
• Unit of measure
• Lower value (must, if selected in control key) • Upper value (must, if selected in control key) • Target value (must, if selected in control key)
For Qualitative characteristics, the selected set of the characteristic must be maintained for the catalog type ‘characteristic attributes’ (catalog type identifier ‘1’). The catalog and the plant specific selected set must be defined before by customizing settings.
Indicator
Description
Sampling Procedure Indicator
Designates that a sample size must be determined for the inspection lot and will cause a sampling procedure to be required for inspection plans that use this characteristic.
Record Number of Defects Indicator
Designates that the data recorded during results recording should be for the number of defects found when evaluating the material for critical, major, and minor defects.
Defects Recording Indicator Designates that defect codes should be recorded when the number of defects entered during results recording is greater than the reject number. This indicator causes the defect screen to pop up
Additional transactions used for m aster inspection characteristics include:
Tcode
Description
QS25 Delete a MIC. This transaction deletes a MIC. Once deleted, the MIC can no longer be used for new assignments in an inspection plan.
QS26 Where-Used List for MICs. This list displays all the inspection plans the MIC is assigned to. The selection criteria are based on the MIC and plant and version. QS27 Replace one MIC with another MIC in a plant.
Exercise 1 Create Qualitative Master Inspection Characteristic (QS21)
Scenario: Create a qualitative master inspection characteristic.
Support Document: QS21 Create Qualitative Master Inspection Characteristic
Transaction Code QS21
Complete the following field(s): Required Data
Plant
Master insp.charac. Enter
Short text Search field
Which qualitative characteristics are available? Select appropriate characteristic control
indicators Enter Save
Don’t have an eup
L
ESSON
5: I
NSPECTION
P
LAN
Lesson 5 Objectives
After completing this lesson, you will be able to:
Define inspection plan
Explain the structure of an inspection plan Create an inspection plan
Assign master data to an inspection plan
Inspection Plan Overview
Inspection plans describe how a quality inspection of one or several materials is to take place. The inspection plan designates the sequence of inspection operations and the range of specifications available for inspecting inspection characteristics. Inspection plans are defined at the plant-specific level.
Inspection plans are created to assign a material for quality inspection. • An inspection lot must have a status of “REL” for it to be processed • To display the status of an inspection lot: use transaction code QA03
• The inspection lot number can be found on the material document from the good receipt or by using other transactions.
• WCB will use inspection plans for the quality check of raw material and are assigned to the material when the inspection lot is created at goods receipt
• If a new material is created, generally only an assignment of the material to an existing plan is necessary
• The assignment of an inspection plan to a material is important because it defines which characteristics of a material has to be inspected
Inspection Plan Structure
The inspection plan group represents the material group in SAP and plan group counters are used if materials have different units of measure. This is necessary because the unit of measure in the plan header must match the unit of measure of the material assigned.
Inspection Plan Header
The inspection plan usage ties this inspection plan to a specific inspection type(s). The task list usage
defined for an inspection type will cause an inspection lot to call an inspection plan with the same usage.
Inspection Plan Unit of Measure – The inspection plan unit of measure designates what the unit of
measure can be for any material on the inspection plan. In order to use an inspection plan, a material must have that unit of measure as its base unit of measure, or there must be a conversion from the material’s base unit of measure to the inspection plan usage maintained in the alternate unit of measure are of the material master.
DMR level – The dynamic modification level determines whether inspection stage changes (and skip lots)
are determined by acceptable results at the inspection lot level, the inspection characteristic level, or the inspection type level. Char-Broil and Zebco will use the inspection lot level.
Exercise 1 Display Inspection Plan (QP03)
Scenario: Display an inspection plan.
Support Document: QP03 Display Inspection Plan
Transaction Code QP03
Complete the following field(s): Required Data
Material Plant Enter
Which operations are identified in the plan? Review header information.
What is the modification rule? Look at details for an operation.
What is the control key for the operation? Review the inspection characteristics.
What are the master inspection characteristics for the plan?
Don’t have an eup
Exercise 2 Create Inspection Plan (QP01)
Scenario: Create an inspection plan that will be used for quality inspections. Support Document: QP01 Create Inspection Plan
Transaction Code QP01
Complete the following field(s): Required Data
Key date
Click Header icon
Create new entries for the inspection plan Group counter Short text Plant Usage Status Lot size Assign operations Control key Description
Exercise 2 Create Inspection Plan (QP01)
SPC criterion Save
Material Assignment to an Inspection Plan
Materials are assigned at the header le vel in the inspection plan. An inspection plan can be assigned to many materials and group counters.
Materials are assigned at the plant-specific level. A material must exist in a plant to be assigned to an inspection plan there.
Exercise 3 Display Material Assignment for an Inspection Plan (QS62)
Scenario: You want to display the material assignment for an inspection plan. Support Document: QS62 Display Material Specification
Transaction Code QS62
Complete the following field(s): Required Data
Material Enter
Which master inspection characteristics are assigned to the material?
Review master inspection characteristics. What is the status?
Look at the control indicators.
Are sampling procedures scheduled for the material?
Review the inspection characteristics. Enter
Don’t have an eup
Exercise 4 Create a Material Assignment for an Inspection Plan (QS61)
Scenario: You want to create a new material assignment for an inspection plan and set the master isnpection characteristics.
Support Document: QS61 Create Material Specification
Transaction Code QS61
Complete the following field(s): Required Data
Material Enter Plant
Assign master inspection characteristic(s) . Which characteristics did you assign? Save
Don’t have an eup
Inspection Plan Operation Level
Inspection plan operations allow for the sequencing of inspection activities, similar to a routing. Inspection characteristics are assigned to an inspection plan operation.
Inspection Characteristics
Within each operation in an inpection plan there are inspection characteristics. These can be direct references to master inspection characteristics, or these can be set up uniquely in the inspection plan. All settings that are available in a master inspection characteristic are available and editable for an individual inspection plan.
Characteristic
Description
Master inspection characteristic
This column is where the reference to a master inspection characteristic is entered for an inspection plan.
Sampling Procedure This column is where the reference to a sampling procedure is entered for an inspection characteristic.
Changes to Inspection Plans
Changes can be made to inspection plans using transaction code QP02.
Typical changes can include:
Adding material assignment Creating a new group counter
Any changes to master data (master inspection characteristic, sample procedures)
O l d D a t a N e w D a t a
Inspection
Plan
Exercise 5 Change Inspection Plan (QP02)
Scenario: You need to make changes to an inspection plan. For this exercise, add a work center. Support Document: QP02 Change Inspection Plan
Transaction Code QP02
Complete the following field(s): Required Data
Material Plant Enter
Which operations are identified in the plan? Add or change the work center.
Save
Don’t have an eup
Engineering Workbench
The engineering workbench is a mass maintenance tool for inspection plans. The engineering workbench uses the object-oriented approach and includes all of the object types that belong to an inspection plan. Object types can be combined to form complex search criteria resulting in a very specific work list. The work list allows
changes to be made at one time and will lock the inspection plan until the changes are saved.
You use the inspection planning functions to define inspection criteria (for example, material to be inspected, how the inspection is to take place, characteristics to be inspected, required test equipment, work center and
inspection specifications). The system contains the following inspection planning options:
You can use task lists (inspection plans, routings, rate routings, and maintenance task lists) to define inspection characteristics, their assignment to inspection operations and the test equipment to be used. This enables you to inspect materials at a quality inspection.
Additional transactions used for inspection plans include:
Tcode
Description
Function
QP03 Display inspection plan. Use this transaction to display all
inspection plans for a plant / material.
QP60 Task list changes. This transaction displays all changes to an
inspection plan based on selection criteria. QP61 Display change documents for inspection plan Use this transaction to display change
Exercise 6 Maintain Inspection Plan (CWBQM)
Scenario: You want to create a task for an inspection plan using the engineering workbench function. Support Document: CWBQM Workbench
Transaction Code CWBQM
Complete the following field(s): Required Data
Current Working Area Enter
Enter
What is the heading for the initial screen?
Date Defaults to today’s date
Material Plant
Task List Type Group
Group Counter
Load the details you added Did you get a system message? Save
Don’t have an eup
Quality Info Records
Quality info records are used to document the quality relationship between a vendor and the material they supply. These records are maintained at the plant level and have various functions in QM in procurement. Zebco will use quality info records to document the supply relationship with vendors and have them in place for future
considerations. Use transaction QI02 to make changes to the quality info records for procurement.
The Release tab displays details about quantities and blocks.
The Insp. control tab displays vendor details and lead time information.
Field
Description
Release Until Used to release the vendor relationship until the specified date. If the vendor control function is active, purchase orders to this vendor are prevented if the
The Function field is used to indicate that this contact is the one that should be used to supply the email address for the inspection report.
Code Groups and Codes
The SAP QM application utlizes codes in various areas for documentation and reporting purposes. The codes were loaded as part of the data migration based on legacy data provided by the businesses. The codes visible to each business are determined by their inclusion in a catalog profile assigned in the QM View of each material. Use QS41 to make changes to code groups and codes.
2 – Task Codes
Task codes are used in quality notifications to document the specific tasks that are required and tracked in the completion of an issue related to a vendor, product, or customer. Tasks are assigned at the header (general) level or at the defect (item) level. Tasks can be assigned to vendors and accessed through the vendor portal, or assign to users and accessed in SAP GUI.
3 – Usage Decision Codes
Usage decision codes are used to evaluate and close an inspection lot. Genreally they reflect an acceptance or rejection of the inspection lot. For Char-Broil, Lamplight, and Zebco, the usage decision will drive the stock type (unrestricted or blocked) in the warehouse, and will also designate inspection lots that should generate an email report to vendors. Any code that ends in the letter S will cause SAP to automatically send a report to the related vendor when it is applied as the usage decision for an inspection lot.
Defect codes are used in notifications to document the specific defects that are found in a material. These are a very important piece of information as these codes are used in reporting to determins specific and recurring problems with products, vendors, or customers. Defects can be tied to location codes, cause codes, and task codes.
D – Coding Codes
Coding codes are assigned at the header level of a notification to provide an additional level of classification about the issue.
E – Defect Location Codes
Defect location codes are used to document where on the product a defect was found. This codes are available to all businesses but are most extensively used by Char-Broil.
Selected Sets
Selected sets are created to combine code groups and codes into a single group for use within a specific area. For Char-Broil, Lamplight, and Zebco, selected sets will be used to determine which usage decisions codes are available for a given inspection type. Selected sets are set up at the plant-specific level. SAP transaction QS51 is used to make changes to selected sets.
Quality Notifications
Quality notifications are used to document quality issues with a product, a vendor, a customer, or a combination of the three. Notifications capture data like issue descriptions, long text, material number, plant number, defects, tasks, causes, etc. Notifications can be created directly from results recording for an inspection lot.
The following notification types are available for Char-Broil, Lamplight, and Zebco:
Notification Type
Description
F1 – Customer related defects There are no current processes utilizing this notification type, but it is available for future considerations.
F2 – Vendor related defects This notification type is tied to inspection types 01, ZLL01, 17, ZPSI, and ZLLPSI and documents quality issues experienced in vendor related inspections.
F3 – Material related defects This notification type is tied to inspection type ZRW and documents quality issues related to post-rework inspections.
Q1 – Customer Complaints There are no current processes utilizing this notification type, but it is available for future considerations.
Q2 – Vendor Complaints This notification type is created manually to document issues related to vendors that are not discovered as part of an inspection lot processing.
Q3 – Internal problem This notification type documents issues encountered internally outside of an inspection process.
ZC – Char-Broil Deviation Request
This notification type is created via the vendor portal for vendors to submit deviation requests.
ZL – Lamplight Deviation Request This notification type is created via the vendor portal for vendors to submit deviation requests.
ZZ – Zebco Deviation Request This notification type is created via the vendor portal for vendors to submit deviation requests.
Notification statuses and selection profiles are maintained by configuration specialists and display the information about how notifications will display during the QM processes.
Work with your configuration specialist to determine which SAP transaction should be used to maintain settings for notifications.
L
ESSON
6: V
ENDOR
P
ORTAL
Lesson 6 Objectives
After completing this lesson, you will be able to:
Define the vendor portal master data Describe the pre-inspection app
Explain how tasks are assigned and maintained Report on the vendor portal
Vendor Portal Overview
The vendor portal is an application that can be used by vendors to log quality complaints and is made up of the following components for QM:
Pre-inspection App Quality Tasks App
Deviation Management App Inspection Report Email Program
These components will help WCB and vendors identify and resolve issues quickly and effectively. Vendor Portal – Pre-inspection App
The pre-inspection application in the vendor portal is designed to allow vendors to submit inspection reports directly into the WC Bradley SAP system. The vendors will access PO line items via the application and create inspection lots within the SAP system. These inspection lots will have inspection type Z7 and do not require results recording. They will stay in released status (REL) for 24 hours, after which time SAP will make an automatic usage decision for them via a batch job.
Vendors are assigned to a quality engineer and will report purchase orders to that quality engineer using the vendor portal.
Vendor Portal – Quality Tasks App
The quality tasks application in the vendor portal is designed to allow vendors to see and process tasks that are assigned to them in quality notifications within the SAP system. Vendors can submit text notes, attach documents, and set tasks to complete status (TSCO).
In order to see quality tasks, the task in the notification must be assigned to the correct vendor number in the notification.
Vendors will see quality tasks that need to be addressed in the vendor portal. Vendor Portal – Deviation Management App
The deviation management application in the vendor portal is designed to allow vendors to submit deviation
requests directly in to the SAP system. The deviation request is submitted via a notification type (ZC – Char-Broil, ZL – Lamplight, ZZ – Zebco).
inspection lots with a usage decision date of the current date and a usage decision time within the last 30 minutes. The batch job will run every 30 minutes. The email will have the following attachments:
the standard SAP inspection report
Any files attached to the inspection lot via the generic object services function.
In order to function properly, the reference vendor must have a contact person created in transaction MAP1 with a function of ZQ to designate that contact as the recipient of the email report. The contact person must have a valid email address.
L
ESSON
7: B
ATCH
J
OBS
Lesson 7 Objectives
After completing this lesson, you will be able to:
Define the batch jobs used for quality management Maintain the inspection report
Maintain automatic usage decisions
Batch Jobs Overview
Batch jobs are utilized to tell the system how often to report certain quality management reports.
Inspection report
Automatic usage decision
Inspection Report
A batch job runs the inspection report email program. There is one batch j ob for each plant that does inspecti ons and sends reports to vendors. The interval for this batch job is every 30 minutes, and the pulls in all inspection lot numbers for a specific plant with a UD (usage decision) date equal to the current date. The program populates the time fields to select inspection lots from the last 30 minutes.
Automatic Usage Decision
A batch job makes usage decisions for inspection lots with inspection type Z7 because these lots are su bmitted by the vendors and WCB users will not be directly processing them. The transaction to set up the automatic usage decision job is QA17. One batch job is set up for each plant that has vendors submitting inspection reports using Z7 inspection lots.
A
A
PPENDIX
PPENDIX
–
–
E
E
ND
ND
U
U
SER
SER
P
P
ROCEDURES
ROCEDURES
Lesson 1: Display Inspection Lot (QA03)
Lesson 1: Display Inspection Lot (QA03)
No EUP No EUP
Lesson 1: Display Material Master QM View (MM03)
Lesson 1: Display Material Master QM View (MM03)
Material Master Processing Material Master Processing Use this transaction to display a
Use this transaction to display a material master record. material master record. The material master contains information for all theThe material master contains information for all the materials that a company procures or
materials that a company procures or produces, stores, and sells. produces, stores, and sells. The material master is used by all The material master is used by all componentscomponents in the SAP logistics system:
in the SAP logistics system:
In In Purchasing Purchasing for for orderingordering
In In Inventory Inventory management management for for goods goods movement movement postings postings and and physical physical inventoryinventory
In In Invoice Invoice verification verification for for posting posting invoicesinvoices
In In sales sales and and distribution distribution for for sales sales order order processingprocessing
In In production production planning planning and and control control for for material material requirements requirements planningplanning
The data in a material master record can be divided into two categories: The data in a material master record can be divided into two categories:
Data Data of of a a purely purely descriptive ndescriptive nature, such ature, such as as name, sizname, size, oe, or r dimensiondimension
Data Data that system that system uses uses to to perform control perform control function, such function, such as as MRP type MRP type control, and control, and price cprice controlontrol
The Material Master is maintained at different organization levels such as client, plant, and storage location. The Material Master is maintained at different organization levels such as client, plant, and storage location. A Material Master record
A Material Master record is created in following cases:is created in following cases:
If no If no material master material master record exists record exists for a for a particular material. particular material. In In this case, this case, you you must create must create the material the material mastermaster
record. record.
If a If a material master material master record exists record exists for a for a particular material, particular material, but the but the master for master for your your department is department is missing. missing. InIn
this case, you must extend the material master record. this case, you must extend the material master record.
If a If a material master record material master record exists for exists for a paa particular material and rticular material and the master the master data for data for your user your user department isdepartment is
entered, but not for the appropriate o
entered, but not for the appropriate organizational level. rganizational level. In this case, you In this case, you must extend the material mastermust extend the material master record.
record.
Related Transactions & Processes Related Transactions & Processes
MM01
MM01 Material Material Master Master - - CreateCreate MM02
MM02 Material Material Master Master - - ChangeChange MM03
MM03 Material Material Master Master - - DisplayDisplay MM04
MM04 List List of of QuotationsQuotations MM06
MM06 Flag Flag for for deletiondeletion MMSC
MMSC Enter Enter storage storage locationslocations MM60
MM60 Material Material Master Master - - ListList MM50
MM50 Extend Extend material material listlist Tips & Tricks
Tips & Tricks
If the If the same values same values are used are used frequently, it will frequently, it will be faster be faster to access to access the material master the material master data by data by setting upsetting up
defaults.
defaults. Default values can Default values can be set ube set up for Industry Sp for Industry Sector, Views and ector, Views and Organizational levels. Organizational levels. These defaultsThese defaults are set from the MM03 initial screen, f
Activity Activity
1.
1. Follow the Follow the SAP menu SAP menu as shownas shown, or , or type the type the transaction codetransaction code MM03MM03 in the command field. in the command field.
Result: The Display Material (Initial Screen) displays. Result: The Display Material (Initial Screen) displays.
2.
2. Enter Enter the the Material Material number.number. 3.
3. Click Click .. Result:
4.
4. Select the Select the appropriate screens appropriate screens to vto view, for iew, for example, MRP1 example, MRP1 view.view. 5.
5. Click Click .. Result:
Result: The Organizational LevThe Organizational Levels dialog els dialog box displays:box displays:
6.
6. Enter Enter the the Plant Plant code.code. 7.
7. Click Click ..
Result: The Purchase view screen displays: Result: The Purchase view screen displays:
8.
8. Click Click .. Result:
Lesson 2: Material Master Settings (MM02)
Material Master Processing
Use this transaction to change a material master record. The material master contains information for all the materials that a company procures or produces, stores, and sells. The material master is used by all components in the SAP logistics system:
In Purchasing for ordering
In Inventory management for goods movement postings and physical inventory In Invoice verification for posting invoices
In sales and distribution for sales order processing
In production planning and control for material requirements planning
The data in a material master record can be divided into two categories:
Data of a purely descriptive nature, such as name, size, or dimension
Data that system uses to perform control function, such as MRP type control, and price control
The Material Master is maintained at different organization levels such as client, plant, and storage location. A Material Master record is created in following cases:
If no material master record exists for a particular material. In this case, you must create the material
master record.
If a material master record exists for a particular material, but the master for your department is missing.
In this case, you must extend the material master record.
If a material master record exists for a particular material and the master data for your user department is
entered, but not for the appropriate organizational level. In this case, you must extend the material master record.
Fields within the material master can be added and maintained after the initial creation process. Some fields cannot be changed after transactions have been processed against the material (i.e., base unit of measure), and some should not be changed without proper precautions.
Related Transactions & Processes
MM01 Material Master - Create
MM02 Material Master - Change
MM03 Material Master - Display
MM04 List of Quotations
MM06 Flag for deletion
MMSC Enter storage locations
MM60 Material Master - List
MM50 Extend the material views
Tips & Tricks
To select the view to change, it is faster to click the Select All button rather than clicking on each view
button.
Click to move between the displayed views. You can also click the view tabs individually to control the
progression through the views.
The Views that you select will determine the Organizational level dialog box and its fields. To set user defaults for views and organizational levels for a new material, follow these steps:
o Views:
Use the menu path Defaults Views
Select those views for which you want to establish defaults. You can also select
Activity
1. Follow the SAP menu as shown, or type the transaction code MM02 in the command field.
Result: The Change Material (Initial Screen) displays.
2. Enter the Material number.
3. Click .
Result: The Organizational Levels dialog box displays:
6. Enter the Plant code. 7. Click .
Result: The Purchasing view screen displays:
8. Change the field information as needed. For example, change the GR processing time from 3 days to 4 9. days. Click .
Result: The Last data screen reached screen displays.
10. Click .
Result: SAP displays a message at the bottom of screen like the one shown below.
Lesson 2: Assign Material to Inspection Plan (QP02)
No EUP
Lesson 3: Create Sampling Procedure (QDV1)
Create Sampling Procedure
A sampling procedure defines the ru les that specify how the system calculates the sample size and it contains information about the valuation of an inspection characteristic during results recording (attributive, variable, manual, etc.). This document describes the process of creating a new sampling procedure.
Related Transactions
QDV2 Change Sampling Procedure
QDV3 Display Sampling Procedure
Activity
1. Follow the SAP menu as shown, or type the transaction code QDV1 in the command field.
Result: The Create Sampling Procedure: Initial screen displays.
2. Enter the name of the sampling procedure and click on
Field Name Description R/O/C User Action and Values
Short Text Short Text for sampling procedure R Enter the short text or short description for the Sampling Procedure
Sampling Type
Specifies how the sample is determined e.g., 100% sample, sample with a fixed size.
R Enter the alphanumeric that uniquely identifies the sampling type. (use the down arrow to search and pick the required one) Valuation
Mode
Defines the rules for accepting or rejecting a characteristic or sample
R Enter the alphanumeric that uniquely identifies the valuation mode (use the down arrow to search and pick the required one). Inspection
Points
Choose one of the following inspection points indicator
Without insp. points Plant maintenance Sample Management Free inspection pts
R Click on one of the 4 radio buttons
4. Hit Enter
Result: The Create Sampling Procedure: Special Conditions screen displays
5. Choose one of the 3 options present under the Multiple Samples group. (No multiple samples, Indep. Multiple samples, Sep. multiple samples).
6. Click on
Result: The Fixed Sample pop-up box displays.
Note:
The fields in this screen will be different based on the inspection Type and Valuation mode selected. The following are the ones for “Fixed Sample” inspection type and “Attributive inspectionLesson 3: Change Sampling Procedure (QDV2)
Change Sample Procedures
A sampling procedure defines the ru les that specify how the system calculates the sample size and it contains information about the valuation of an inspection characteristic during results recording (attributive, variable, manual, etc.). This document describes the process of changing a sampling procedure.
Related Transactions
QDV1 Create Sample Procedure
QDV2 Display Sample Procedure
Activity
1. Follow the SAP menu as shown, or type the transaction code QDV2 in the command field.
Result: The Change Sample Procedure: Initial screen displays.
4. Make changes to each tab as required.
Note:
Click on the “Administrative Data” icon in order to view the person created or changed the dynamic modification and the data it was done5. Click on
Result: Confirmatory message appears at the bottom of the SAP screen. 6. To return to the SAP menu, click on .
Lesson 4: Create Qualitative Master Inspection Characteristic (QS21)
No EUP
Lesson 5: Display Inspection Plan (QP03)
No EUP
Lesson 5: Create Inspection Plan (QP01)
Create Inspection Plan
The inspection plan is the task list used by the Quality Management (QM) component to process quality
inspections. Inspection plans are used to carry out such production-related tasks (for example, inspecting goods upon goods receipt or goods issue). Quality inspections during production are carried out on the basis of the routing. This end user procedure covers the use of inspection plans for quality management applications. The inspection plan structure mirrors the structure of the routing in the Production Planning (PP) component. The plan consists of the following elements:
General information (header)
One or more operations; operations within the QM component are created and maintained exactly as those within the Production Planning (PP) component. For information about operations, see the online documentation for PP Production Planning.
For each operation you can define
Test equipment used for the inspection (as production resources)
Location where the inspection takes place (as work centers) Related Transactions
QP02 Change Inspection Plan
Tips and Tricks
You can assign one or more materials to an inspection plan.
Providing you do not use master inspection characteristics in the plan, you can assign different characteristic
values for each material for an inspection characteristic. These are known as allocation values for an inspection characteristic.
Inspection characteristics (inspection characteristics cannot be assigned to a sub-operation).
Activity
1. Follow the SAP menu as shown, or type the transaction code QP01 in the command field.