Non Conformance Report

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<p>SAP Manufacturing Execution 5.1.3Setting Up NonconformanceIncluding PCA Dashboard and DPMO</p> <p> Copyright 2008 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, Windows, Outlook, and PowerPoint are registered trademarks of Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400, iSeries, pSeries, xSeries, zSeries, z/OS, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, Informix, i5/OS, POWER, POWER5, OpenPower and PowerPC are trademarks or registered trademarks of IBM Corporation. Adobe, the Adobe logo, Acrobat, PostScript, and Reader are either trademarks or registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Oracle is a registered trademark of Oracle Corporation. UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group. Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or registered trademarks of Citrix Systems, Inc. HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C, World Wide Web Consortium, Massachusetts Institute of Technology. Java is a registered trademark of Sun Microsystems, Inc.</p> <p>JavaScript is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. MaxDB is a trademark of MySQL AB, Sweden. SAP, R/3, mySAP, mySAP.com, xApps, xApp, SAP NetWeaver, and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other product and service names mentioned are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary. These materials are subject to change without notice. These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty. Disclaimer Some components of this product are based on Java. Any code change in these components may cause unpredictable and severe malfunctions and is therefore expressively prohibited, as is any decompilation of these components. Any Java Source Code delivered with this product is only to be used by SAPs Support Services and may not be modified or altered in any way.</p> <p>Table of ContentsIntroduction ..........................................................................................................................................1 What Is Nonconformance? ................................................................................................................1 Decisions to Make..............................................................................................................................1 Branching and Dispositioning on Routers .......................................................................................3 Operator Determination .....................................................................................................................3 System Determination........................................................................................................................3 More Information About Routers........................................................................................................3 Collecting Information.........................................................................................................................5 What Is a Data Type? ........................................................................................................................5 Assigning NC Data Types..................................................................................................................5 Defining Nonconformance (NC) Codes .............................................................................................7 What Is an NC Code? ........................................................................................................................7 Categorizing NC Codes .....................................................................................................................7 Creating a Hierarchy ..........................................................................................................................8 Setting Up and Overriding Maximum NC Limit................................................................................10 Closing NC Codes ...........................................................................................................................10 Assigning Operations.......................................................................................................................11 Setting Up Activity Hooks ................................................................................................................11 Logging an NC Reject in the Rich POD...........................................................................................11 Working with Real-Time Warnings...................................................................................................13 Working with Standard Nonconformance Clients..........................................................................15 Standard Nonconformance Clients..................................................................................................15 Working with the Fast Barcode Interface.........................................................................................16 Allowing Operators to Auto Remove/Replace NCs Components...................................................17 Typical Scenarios for the Standard Nonconformance Clients .........................................................17 Verifying Defects..............................................................................................................................19 Setting Up Incident Numbers...........................................................................................................20 Working with Graphical (PCA) Nonconformance Clients..............................................................21 Typical Scenarios for the Graphical (PCA) Nonconformance Clients .............................................24 PCA Dashboard Buttons..................................................................................................................26 Using DPMO (Defects per Million Opportunities)...........................................................................29 What Is DPMO? ...............................................................................................................................29 What Comes with the System?........................................................................................................29 Setting Up Nonconformance ............................................................................................................31 Setting Up Nonconformance............................................................................................................31 Creating Primary and Secondary NC Codes...................................................................................31 Setting Up and Overriding Maximum NC Limit................................................................................32 Setting Up the POD for Nonconformance........................................................................................32 Setting Up the Fast Barcode Interface for Operators ......................................................................33 Allowing Operators to Auto Remove/Replace NCd Components...................................................33 Allowing Operators to Close Multiple Primary NCs with One Secondary NC .................................34 Setting Up Standalone Failure Tracking ..........................................................................................34 Setting Up DPMO ............................................................................................................................34 Appendix: Installing PCA Server......................................................................................................37 Index....................................................................................................................................................41</p> <p>SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance</p> <p>iii</p> <p>IntroductionThe Nonconformance feature helps you improve product quality and customer responsiveness by allowing you to: Track failure, defect, and repair information about SFCs. Control the routing of nonconforming products. With Nonconformance, you can also: Collect test and inspection data for analysis, integrity checking, and other uses. Assign incident numbers to logged nonconformances. Calculate defects with the standardized DPMO (defects per million opportunities) methodology as defined in the IPC-9261 standard for printed board assembly manufacturing. Display up-to-date engineering schematics graphically in the PCA Dashboard, allowing you to display engineering changes in real time.</p> <p>What Is Nonconformance?At various steps on your routers, you can include operations where product is tested for defects. When a product fails a test, the operator or machine at that step nonconforms, or logs a nonconformance (NC) against that particular SFC. Note: You can indicate not only test failures, but also nonconformance to any standard, such as a scratch on a chassis. When an operator logs an NC, the system can automatically send the nonconformed SFC to: The first step on a disposition router. A disposition function. Another step on the current router for analysis or repair. Operators at these steps can log additional NCs against the SFC to detail its current condition. You can also have operators or machines log NCs to pull products randomly for sampling.</p> <p>Decisions to MakeWhen you set up Nonconformance, you must decide: How you want router branching and dispositioning to behave in the system. What information you want to collect for analysis, integrity checking, and other uses when operators log nonconformances. Which nonconformance (NC) codes you want operators to use when they log NCs, and how you want to organize them. How you will use Real-Time Warnings.</p> <p>SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance</p> <p>1</p> <p>Introduction How you want the POD to behave and appear for operators who log nonconformances. How you want the PCA Dashboard in the POD to behave and appear for operators who work with nonconformances against PCA boards. How you will use DPMO.</p> <p>SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance</p> <p>2</p> <p>Branching and Dispositioning on RoutersWhen you set up Nonconformance, you must decide how you want router branching and dispositioning to behave. When an operator logs an NC against an SFC at a router step, you can: Allow the operator to determine where the system should send the SFC. Allow the system to automatically determine where to send the SFC. For more information about branching and dispositioning, see the Setting Up Production Lines guide.</p> <p>Operator DeterminationIf you allow the operator to determine where the system should send the SFC, the system displays a list of choices the operator can select from. These choices can include: A next step on the same router. The first step on a separate router. A SCRAP step. A Return step. Keeping the SFC at the current step.</p> <p>System DeterminationIf you allow the system to automatically determine where to send the SFC, you can: Use scripting to send the SFC to a SCRAP step, a Return step, a next step on the same router, or other location, based on criteria, such as how many times the SFC has failed the test. Set up a disposition router to automatically send the SFC there when it is nonconformed. Set up disposition functions to either send the SFC automatically to a specific destination when it is nonconformed, or allow the operator to choose from a menu of several destinations.</p> <p>More Information About RoutersFor more information about setting up routers and scripting, see the Setting Up Production Lines guide and the online help for Router Maintenance.</p> <p>SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance</p> <p>3</p> <p>Collecting InformationThe NC category in Data Type Maintenance allows you to collect information for analysis, integrity checking, and other uses when operators log nonconformances.</p> <p>What Is a Data Type?A data type is a set of fields you can display to users to collect information about individual components or higher-level assemblies during a process, such as assembly, disassembly, inventory receipt, nonconformance, packing, or working with RMAs. You define data types in Data Type Maintenance.</p> <p>Assigning NC Data TypesWhen you create NC codes, you must assign an NC data type to each code. The system comes with several NC data types to which fields have already been allocated. You can add or delete fields to the existing NC data type. Note: If you do not want to collect data at nonconformance operations, leave the default value, SIMPLE, in the NC Data Type field in NC Code Maintenance. The SIMPLE data type displays no fields to the operator by default. The following list is a sampling of fields you can have the system display in the POD for each type. For a complete list, in Data Type Maintenance, select NC in the Category field, browse on the Data Type field, and retrieve the record. Click Edit &gt; Insert New, and browse in the Data Field column of the new row. Defect Count Ref Des Failure ID Location Comments Component Component SFC Component SFC Item Root Cause Operation Pin Note: You can also create custom fields in Data Type Maintenance to collect data that is not listed in Data Type Maintenance. When the operator logs a nonconformance, the system displays the field(s) you specified based on the data type of the NC code. The operator enters the information you want to collect in each field. You can make each field required or optional for the operator.</p> <p>SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance</p> <p>5</p> <p>Collecting Information Note: Use the Root Cause Operation fiel...</p>

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