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SAP QM Overview

Introduction to SAP QM

To understand the SAP terminologies & QM organization structure

Master date in Quality Management

QM business processes in SAP

Agenda

SAP QM module is one of the Logistics SAP Module where

QM stands for Quality Management, which includes

QM in Procurement

QM in Production

QM in Sales and Distribution

Quality Control

Introduction

SAP AG

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Functions in the QM Component

Test equipment mgmt.

Quality planning

Quality notifications

Quality certificates

Quality inspection

Quality control

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P l a n n e d p r o c e s s e sP l a n n e d p r o c e s s e s

Q M P r o c e s s e s i n t h e L o g i s t i c s S u p p l y C h a i n

E v e n t - c o n t r o l l e dE v e n t - c o n t r o l l e d p r o c e s s e sp r o c e s s e s

I n f o r m a t i o n m a n a g e m e n tI n f o r m a t i o n m a n a g e m e n t

xx

$

!

SAP AG

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DecisionInspectionRequest forinspection

Planned Processes

Goods movements

Orders

Deadline monitoring

What triggers an inspection?

Inspection lot

Inspectioninstruction

What and how muchmust be inspected?

What are the inspectionresults?

Usage decision

What should happento the goods?

Inspection stock

CauseCause

Logistics Supply ChainLogistics Supply Chain

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Event-Controlled Processes

Procurement Production Sales Service

Logistics Supply Chain

NotificationComplaint against

a vendor Customer complaint

Internal problem notification

DefectsDamage

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General Master Data: Overview

Batch Batch classificationclassification

Quality planningCustomer masterCustomer master

Customer info recordCustomer info record

MaterialMaterialmastermaster

Q-Q-Info recordInfo record

Vendor Vendor mastermaster

Material specificationMaterial specificationQuality documentsQuality documents

AA

SAP AG

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QM-Specific Master Data

MaterialMaterial

WhichWhich materialmaterial??

WhoWho supplies the supplies the materialmaterial ? ?

WhoWho receives the receives the materialmaterial//finished productfinished product??

General Master Data

LogisticsQM

Material master

Vendor master

MM

Customer master

SD

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QM Information Records in Logistics

MaterialMaterial

Which customerWhich customer receives the material?receives the material?

Information Records

QMQM

Q-Info record

Customer info record

QM

Which vendor Which vendor supplies the material?supplies the material?

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Inspection Planning

Inspection plan

Material 1236

Material 1235

Material 1234

Which material will beWhich material will be inspected?inspected?

What are the inspection What are the inspection steps? steps?

What will be inspected?What will be inspected?

How should you inspect?How should you inspect?

Which test equipment do Which test equipment do you need? you need?

Where will the inspectionWhere will the inspection take place? take place?

Criteria

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Basic Data for Inspection Planning

Inspection plan

Work centers

Referenceoperation sets

Test equipment

Catalogs

Sampledetermination/

Dyn. modification

Basic Data

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Sample Determination (Procedure)

Sampling procedure- Fixed- 100%- Based on sampling scheme

Quality level Dynamic modification rule

Inspection lot

Sample Sample

R

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Using Catalogs

Characteristic:Characteristic:Surface propertiesSurface properties

Defects:Defects:Code 105 - scratchedCode 105 - scratchedCode 110 - Code 110 - Code 115Code 115......

Defect consequences Defect consequences

CatalogsCatalogs

!!

ScratchedScratched DefectsDefects

CausesCauses

EventsEvents

Usage decisionUsage decision

TasksTasks

Characteristic attributesCharacteristic attributes

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Test Equipment

Inspection plan

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Quality inspectionQuality inspection

Material

Document Equipment

Production resources/

tools

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Work Centers

Costing

Capacity planning/schedulingInspection planning

Personnel and machine Personnel and machine capacitiescapacities

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Inspection Lot Creation

12

9

6

3

11 1

7 58 4

210

Goods movement

Order (production/maintenance)

Sales order

Delivery

Deadline monitoring

Manual

Quality inspection

Inspection lot

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Inspection Lot Processing

Basic data from quality planning Inspection specifications

Inspection results Usage decision Appraisal costs

Before inspection

After inspectionInspection

lot

Goods receipt

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Sequence of Inspection Lot Processing

Inspection lotInspection lotcompletioncompletionInspectionInspectionInspection lot Inspection lot

creationcreation

Usage decision

Inspection lot

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Inspection Results

Recording inspection results for operations in inspection lot

Unplanned

Characteristic results

Qualitative characteristics

Quality notification

ActivateActivate Quality control

Planned

Defect data

Inspection lot

Quantitative characteristics

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Quality Control FunctionsQuality Control

Statistical process control (SPC)

Quality scores

Quality costs

Evaluations

Dynamic modification of inspection scopeQM

Vendor evaluation

SAP AG

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Test Equipment Management Functions

Test equipment management

Master data

Calibration inspection(planning)

Calibration inspection(processing)

QM

SAP AG

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Aspects of PM/QM Integration

Test equipmentmanagement

(calibration inspection)

Maintenance inspection(extended recording of

measured values in PM)Plant Maintenance

Quality Management

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Vendor Evaluation

VendorsVendors

?Total score: 97 points

Quality

Price DeliveryPerformance

ServiceSAP R/3

Purchasing organization

R

Materials Management

VendorVendor

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Cost Processing with QM OrdersComplaint processing

Charging of costs

Cost center Order Warehouse Accounting

QM - Auftrag QM order

Inspection lot processing

Confirmation of appraisal costs in: Results recording Usage decision

QM order

Nonconformity costs

Inspection lot

SAP AG

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QM Information System (QMIS)

QM Information System

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Quality notificationsQuality notificationsInspection lotsInspection lots

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Standard Analyses in QMIS

Analyses with reference to inspection lots

Analyses with reference to quality notifications

PrüfloPrüfloInspection

lot

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Early Warning System

QM Information SystemQM Information System

Number of quality notifications

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Quality Certificates

Results from an inspection orvaluated results from a batch

MaterialMaterial

CertificateFulfillment of manufacturer‘s specifications or procedures of ordering party

Confirmation of requiredcondition

Manufacture usingappropriate methods

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Quality Certificate Functions

Quality certificates

Certificate planning

Certificateprocessing

QM

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Problem

Problem

Problem

Problem

Complaints Processing in the Company

!

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Quality Notifications in the Log. Supply Chain

SalesSalesProductionProductionProcurementProcurement

Q-notification

User-definednotificationtype(s)

Customer complaintComplaint againsta vendor

Internalproblem

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I n f o r m a t i o n M a n a g e m e n t

Q MI n f o r m a t i o n

S y s t e m

Q MI n f o r m a t i o n

S y s t e mE a r l y W a r n i n g S y s t e m

A n a l y s i s /E v a l u a t i o n s

P r o d u c t q u a l i t yx

x$

7 8 6 5D e f e c t

Q u a l i t y i n s p e c t i o nr e s u l t s

P r o b l e m n o t i f i c a t i o n s

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QM in the Procurement Process

Materials planning

Procurement

Storage Delivery Customerservice

Productionplanning

11

33

Influence of Quality Management

77 88

55

66

44Production

ServiceServiceShippingShippingMaterialsMaterialsManagementManagementProductionProductionSalesSales

Salesorder

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The Procurement Chain

Release

Technical delivery terms

QA agreement

Release

Vendor/Manufacturerrelease

Q-info record

Source inspection

Technical delivery terms

QA agreement

Certificate rqmt.

Certificate reqmt.

Inspection stock

GR inspection lots

Phys.sample drwg

Dyn. modification

Complaint

Payment block

Quality costs

Request(RFQ)

VendorSelection

Vendor evaluation

QM system

Purchase Order

GoodsReceipt

Vendor block

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QM in Procurement

Procurement Production Sales Service

QMactivities

Managing material/vendor information Evaluating, releasing, and selecteing vendors Managing quality documents Controlling source inspections Processing complaints against a vendor

SAP AG

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QM in Procurement

Production

Storage

ProcurementProcurement- - GoodsGoods receipt inspectionsreceipt inspections- Source inspections- Source inspections- Control of procurement - Control of procurement process process- Complaints processing- Complaints processing- Certificate and QM system- Certificate and QM system- Vendor evaluation- Vendor evaluation

ShippingShippingMaterials ManagementMaterials ManagementProductionProduction

55

Procure-ment

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Vendor - Request for Quotation (RFQ)

MaterialMaterial

VendorVendorPurchasing

TDT

DMS

R

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Quality Criteria for Vendor Selection

GR

Bates

Müller

ComplaintQty. AuditPrice

85 10 1,50 88

93

70

5

20

1,80

1,95

92

78

QM

Mat: 60 - 100F

Purchasing Purchasing

Martin

Baxter

SAP AG

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Purchase Order

Purchase order

1

2

Vendor

Quality info recordMaterialMaterial

R

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Inspection Processing at Goods Receipt

Vendor

Inspection lot

Goods receipt

OK

OK

Inspection

Unrestricted- use stock

AB B C

B

Q-notification!

Inspectionstock

R

SAP AG

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Source Inspection

Insp. start =Delivery date -Lead time Q-info record:

Source inspection in placeof goods receipt inspection

Insp. start=

Delivery date

Purchase order- Delivery date

Sourceinspection

Goods receipt- Delivery date

Purchase order- Delivery date

Goods receipt- Delivery date

Q-info record:- Inspection type- Lead time

Insp. lot

R

Inspectionlot

Inspectionlot

Controlling

EvaluationsQ-Costs

SDQM

SDQM

Quality Management in Production/Distribution

Production

Distribution

In process inspection

Result entry using

inspection lots/points

Certificate creation

Handling of customer returns

SDQM

SDCO

SAP AG

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QM in Production (Materials Planning)

Sales order

Procurement

Production

Productionplanning

Duration of GR inspection takenDuration of GR inspection takeninto considerationinto consideration

Release of production resources/toolsRelease of production resources/tools

Materialsplanning

22

MaterialsMaterialsManagementManagement

ProductionProductionSalesSales

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QM in Production

Production

Storage

Inspections during production Inspections during production Statistical process control (SPC)Statistical process control (SPC) Complaints processing (internalComplaints processing (internal

problem notifications)problem notifications) GR from production orderGR from production order Creation of partial lotsCreation of partial lots

33Production

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The Production Chain

ProductionPlanning

OrderRelease

Goods Movements

Inspection During Production

Order Confirmation

Operations +inspectioncharacteristics

Externallyprocessedoperations

Sample calculation

Measured valueand defectsrecordingSPC -control charts

Recording ofscrap

GR towarehouse

Batchproposal

Batch classification

Inspection lotcreation

Partial lotcreation

Valuation

Releasebatch record

Batch classification

Approval procedure

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Order Release

Sample calculationSample calculation

Order4711

Oper. 10Oper. 20

Oper. 40

RoutingRouting

Oper. 30R

Inspection lot 4711

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Inspection Lot Approval Procedure

Inspectionlot

Inspectionlot

Single approvalwith specialauthorization

Approval

Approval

Insp. plan

Notapproved

Automaticsingle approval

Material specificationMaterial specification

SAP AG

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Inspection During Production

AutomaticAutomaticdefects recordingdefects recording

Z

Inspection lot 4711

Insp. pt. 1 Charac. Target Actual

Length 50mm 49,8Width 30mm 31,2

NrNr.. TasksTasks

R

SAP AG

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Characteristic Specs from Variant Configuration

QM-relevant master inspection characteristic

Frame

Tire type

Tire pressure

Titanium

Low-profile

2 - 3 bar

:

:

:

Sales order

Customer

Material no.

4713

Meyers

BIKE 12

CH10 Frame size: 58 cm + 0,5

Op. 10

Insp. lot 4718

Op. 20

CH20 Tire pressure: 2 - 3 bar

Inspection lot

R

Routing

CH10 Frame size: 58cm

Material no.; BIKE 12Op. 10Op. 20

CH20 Tire pressure: 1 - 5 bar

Production order 4715

Tire pressure: 2 - 3 bar

Frame : Titanium

Tire type: Low-profile

BIKE 12

SAP AG

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Insp. stockInsp. stock

Goods Movements

Warehouse Warehouse

DeliveryDelivery

Order 4711

SAP AG

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QM in the Storage Process (1)

Procure-ment

Production

StorageStorage- Transfer of stock between plants- Transfer of stock between plants- GR inspection from production- GR inspection from production

44

ShippingShippingMaterials ManagementMaterials ManagementProductionProduction

Storage

SAP AG

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QM in the Storage Process (2)

Procure-ment

Production

StorageStorage-- RecurringRecurring inspectionsinspections of batches of batches-- Inspections for goods Inspections for goods movementsmovements

ShippingShippingMaterials ManagementMaterials ManagementProductionProduction

66

Storage

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QM in Sales/Service

Procurement Production Sales Service

Managing material/customer information Controlling goods issue inspections Creating quality certificates Processing customer complaints

QMActivities

SAP AG

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Sales & Distribution Chain

ServiceServiceDeliveryDelivery

Controlling data

Inspection lot

Batch determination

Quality certificate

Sales OrderSales Order

Customer-specific inspection specifications

Customer/materialinformation

Customer complaint

Inspection for areturn delivery

Sales

SAP AG

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Sales Order

MaterialMaterial

Customer-specificCustomer-specificspecificationsspecifications

Customer/Customer/MaterialMaterial

At the customer’spremises

On delivery

R

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Sales Order

Inspection lot Certificate Delivery

Warehouse

Production

AABatchBatch

Insp. lot: 4711Batch: C1

R

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Update of statistics

Service

RepairRepair

Subsequent deliverySubsequent delivery

Credit MemoCredit Memo

CompanyCredit Memo

CompanyCredit Memo

Q notificationQ notification

Return delivery

Fax

R

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QM in Shipping

Customer service

77

Inspection of the delivery Inspection of the delivery Goods issue inspectionsGoods issue inspections Quality certificatesQuality certificates Customer complaintsCustomer complaints

ServiceShippingShippingMaterialsMaterialsManagementManagement

Delivery

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QM in Service

Delivery

Complaints processingComplaints processing Inspections of customer returnsInspections of customer returns

ServiceServiceShippingShipping

88

Customer service

Active Problem Management

Qualitymessage

Diagnostics

Failure analysis

Cause determination

Corrective measures

Immediate measures

Initiation

external internal

Customer Complaints Complaint against Vendor Internal Problems

Structured Problem report for enabling Continuous improvementAllows - collect, manage and evaluate data

Quality Notification

Quality Inspection

Inspection lot

Print insp. instruction

Result recording

Usage decision

SDQM Q/Inspection

Generate order

Order accounting

Inspectionplan

Goods receiptblocking codecertificate

Transfer postingsfreeblockedbackscrapsort

Stock in qualityor inspection

damaged

defective

deformed

crushed

?Evaluation

Evaluate unstructured descriptions using Codes

Coded descriptions are maintained in “Catalogs”

Use of Inspection Catalogs

Method to classify unstructured descriptions of Insp. tasks, activities defects, decisions etc.

Catalog

Measured Value recording

Single Values

Characteristics

Quantitative Qualitative

Long Term Inspection

Tolerance Limits

Sampling Procedures

Documentation of Exceptions

Confirmation in Classes

Req. Char. Optional. Char.

Inspection Scope

Master Inspection Characteristics

Sample size n Acceptance no. c Independent of lot size

Sampling plan

.... defines how the sample is determined

100% inspection Fixed Sample % Sample Sampling Scheme

.. defines rules for acceptance & rejection

Variable inspection method Manual Valuation Attributive insp. by

nonconforming units

Sampling Type Independent of lot size

Calculation of sample size and type of valuation for result recording

Sampling Procedure

Sampling planSample scope Acceptance Criteria Lot size, Sample size Acceptance no. / Rejection no.

Arrangement of sampling plans for acceptance of char. for various lot sizes

Sampling Scheme

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