Applicable Process Steps
Quality Management In Discrete Manufacturing - Goods Receipt from Production
Process Step | Description |
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Make-to-Order Production - Semifinished Goods Planning and Assembly (1BM) | To execute this step, complete the following activities from the Make-to-Order Production - Semifinished Goods Planning and Assembly (1BM) scope item:
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Display Inspection Plan for Inspection Characteristics | In this step, you display the inspection plan that is related to the semifinished goods. The inspection plan defines all inspection characteristics used later in the quality inspection. |
Post Goods Receipt for Production Order | In this activity, you post the goods receipt from production after completing a production order. This is required to perform a quality inspection for the assembled material. |
Display Material Stock Before Quality Inspection | In this optional step, a review of the subassembly material stock is done. Due to quality inspection, the material is not available for other processing. |
Display Quality Technician Overview (optional) | In this optional step, you can display an overview of open inspection lots via the overview page for quality technicians. |
Display Inspection Methods | The inspection lot is used to record the results of the inspection operation. In this optional step, the references to the goods receipt and production order are verified as well as the sample size used for quality inspection reviewed. |
Display Open Inspection Lot | The assembly undergoes a quality inspection to ensure that it meets the predefined quality requirements. In this step, the quality technician records the inspection result for the required inspection characteristics. Afterwards, the quality engineer completes the inspection with a usage decision. |
Record Inspection Results | The quality technician executes the quality inspection and records inspection results for the inspection lot. |
Display Quality Engineer Overview (Optional) | The inspection is done and the inspection result is recorded. You must decide whether or not to accept the inspection lot depending on the inspection result. As an optional entry point for making this usage decision, you can use the Quality Engineer Overview (F2360) app. The app displays inspection lots without an inspection plan (for example if automatic assignment of an inspection plan is not set up in the material master or if automatic assignment failed), inspection lots without usage decision, inspection lots ready for usage decision. If negative inspection results are recorded, you can check the defect details in the cards Inspection Lots with Defects, Top Defective Materials, or Top Defective Codes in the Quality Engineer Overview (F2360) app. |
Make Usage Decision | The inspection is done and the inspection result is recorded. You must decide whether or not to accept the assembly depending on the inspection result. If you do not want to use the Quality Engineer Overview (F2360) app, you can open the Manage Usage Decisions (F2345) app directly. |
Display Material Stock after Quality Inspection | In this optional step, we now verify the material movement done based on the usage decision codes by looking again at the material stock. |
Display Inspection Results History (Optional) | In this optional step, an overview about the history of inspection result is shown. For each Inspection Characteristics are several statistical Values and the development for recorded results are illustrated. |
Quality Management in Discrete Manufacturing - Within Production Process
Process Step | Description |
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Make-to-Stock Production - Discrete Manufacturing (BJ5) | To execute this step, complete the following activities from the Make-to-Stock Production - Discrete Manufacturing (BJ5) scope item:
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Display Routing for Inspection Characteristics | An inspection during production is triggered by the release of a production order. When you save the production order, an inspection lot is generated for operation 0020. An inspection lot for an inspection during production is not stock relevant. In this step we review the automatically created inspection point for operation 0020 as well as the inspection characteristics which will have to be maintained in the Quality inspection step. |
Display Quality Technician Overview (Optional) | In this optional step, you can display an overview of open inspection lots via the overview page for quality technicians. |
Display Open Inspection Lot | The assembly undergoes a quality inspection to ensure that it meets the predefined quality requirements. In this step, the quality technician records the inspection result for the required inspection characteristics. Afterwards, the quality engineer completes the inspection with a usage decision. |
Display Inspection Methods | The inspection method is reviewed with attached document. |
Record Inspection Result Before Activation of the Control Chart | In this step, you perform the inspection and record the result to decide if you can go on with the next operation of the production order. The result is recorded in the inspection lot according to the defined inspection parameters in the routing. The master inspection characteristic diameter is valuated leveraging a SPC control chart. If the control chart has not been activated, yet, the user must valuate the characteristic manually. After activation of the control chart, the respective characteristic is automatically valuated by the system according to the control charts action limits. As it is currently not possible to specify the control charts limits manually, a minimal amount of data points must have been collected before the chart can be activated. |
Analyze and Activate Control Chart (Optional) | You can display the control chart in graphical and tabular form. If you have collected enough data that describes the statistical variation of your manufacturing process, you can execute this step to activate a control chart. After activating a control chart, the corresponding inspection characteristics will be valuated against this control chart. |
Record Inspection Result After Activation of the Control Chart | You perform the inspection and record the result to decide if you can go on with the next operation of the production order. The result is recorded in the inspection lot according to the defined inspection parameters in the routing. |
Display Quality Engineer Overview (Optional) | The inspection is done and the inspection result is recorded. You must decide whether or not to accept the inspection lot depending on the inspection result. As an optional entry point for making this usage decision, you can use the Quality Engineer Overview (F2360) application. The app displays inspection lots without an inspection plan (for example if automatic assignment of an inspection plan is not set up in the material master or if automatic assignment failed), inspection lots without usage decision, inspection lots ready for usage decision. If negative inspection results are recorded, you can check the defect details in the cards Inspection Lots with Defects, Top Defective Materials, or Top Defective Codes in the Quality Engineer Overview (F2360) app. |
Make Usage Decision | The inspection is done and the inspection result is recorded. You must decide whether or not to accept the assembly depending on the inspection result. If you do not want to use the Quality Engineer Overview (F2360) app, you can open the Manage Usage Decisions (F2345) app directly. |
Confirm Production Order Operation | In this step, you confirm the production order. |
Review Production Order | After the release or confirm of finished goods orders is performed, the production supervisor could display and check the order using the app Monitor Production Orders for the material. |
Make-to-Stock Production - Discrete Manufacturing (BJ5) | To execute this step, complete the following activities from the Make-to-Stock Production - Discrete Manufacturing (BJ5) scope item:
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Quality Management Within Production Process - Make-to-Stock Production of a Batch Managed Material | In this process, a batch-managed semi-finished product is produced. The routing contains a quality-inspection operation with inspection points in order to monitor the quality during the production process. |
Create Raw Material Stock | In a real business case, the materials are usually purchased from external suppliers. In that case, process is covered by the standard purchasing or subcontracting processes. For the purpose of this test, we post initial stock directly to the Issue Storage Location. |
Create and Release Production Order | For demo purposes, we directly create a production order without a planned production order. The comprehensive process is covered in the scope items Make-to-Stock Production - Discrete Manufacturing (BJ5) and Make-to-Stock - Process Manufacturing Based on Production Order (2UG). |
Goods Issue of Batch-Managed Components via Pick List | The withdrawal of the raw materials is used for the order. This withdrawal can be done by using the picking list or doing a manual goods issue. If the material is set for backflush (in material master or resource), the withdrawing is done automatically after you confirm the operation or the whole order. Backflushing should not be used for batch-managed components (to ensure that the physically picked and consumed batch is the same as the recorded batch). |
Confirm Production Operations | In the process industry, GR and GI postings are usually done immediately during the physical movements of the materials to ensure batch traceability and data consistency. Order confirmations with backflush are done at shift end or day end. The sum of the GI and GR quantity for the given order is then recorded within the confirmation and scrap quantities (optional). The time ticket confirmation allows recording either the default times for machine and labor usage, or record actual times for major deviations. After a production operation is completed, the production operator confirms the production operation in the system so that the next operation can be started. He reports quantities (for example, yield, scrap, rework) and times (for example, machine preparation time, labor time, and so on). |
Execute Quality Inspection With Inspection Points | In this step, the quality technician performs the quality inspection and records the inspection result(s) in order to decide whether the next operation of the production order can be executed. The result is recorded in the inspection lot according to the defined inspection parameters in the routing. Here, time-based inspection points are used for result recording. Leveraging inspection points, you can have several inspections and can record multiple sets of characteristic results for a single operation. Each inspection point is valuated separately with a coded valuation. |
Confirm Production Operations | In the process industry, GR and GI postings are usually done immediately during the physical movements of the materials to ensure batch traceability and data consistency. Order confirmations with backflush are done at shift end or day end. The sum of the GI and GR quantity for the given order is then recorded within the confirmation and scrap quantities (optional). The time ticket confirmation allows recording either the default times for machine and labor usage, or record actual times for major deviations. After a production operation is completed, the production operator confirms the production operation in the system so that the next operation can be started. He reports quantities (for example, yield, scrap, rework) and times (for example, machine preparation time, labor time, and so on). |
Post Goods Receipt for Order | The purpose of this activity is to post the goods receipt for the production order. You may post goods receipt for the total quantity or partial quantities if the production has not finished, yet. In the latter case, the partially completed production operations should be confirmed without the final completion status until production is completed. |
Make Usage Decision | In order to close the inspection lot, the quality engineer makes a usage decision. As the inspection lot of origin 03 is not stock-relevant, there is no follow-up action assigned to the usage decision code that triggers a goods movement. |
Review Batch Data (Optional) | A batch class is assigned to the batch-managed material. The batch class contains characteristics for information related to the usage decision (usage decision code and quality score) as well as inspection characteristics. In this step, the batch classification of the produced batch is displayed. By transferring inspection results to classification data, the data can be used for example in a batch-search strategy to find products with specified characteristics. |