QM Overview

Quality Management

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Contents

Section 1 : General Overview

Section 2 : QM Integration

Section 3 : QM Process overview

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ERP stands for Enterprise Resource Planning                        

Enterprise Resource Planning systems integrate all data and processes of an

organization into unified system.

The key feature of an ERP system is it uses a single or unified database to store

data for the various system modules.

Various Modules which comes under ERP are listed below:

Material Management

Production Planning

Quality Management

Finance

Costing

Sales and Distribution

Enterprise Resource planning

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Quality Management

QM IntegrationPPPPMMMM

Purchasing Requisition

Inventory mgmt

Goods receiptStock transferGoods issue

ShippingBilling

SDSD

Invoiceverification

Warehousemanagement

Inspection lot

QMQM Inspection lotInspection lot

Print insp. instruction

Results recording

Usage decision

Basic dataBasic data

Test equipmentmanagement

PMPM

Productionplanning

Reqt planningR-cut capacity

planning

PlannedOrders

Openingperiod

Order:- Creation- Release- Confirmation

Shop floorcontrolCapacityleveling

MaterialsMaterials

VendorsVendors

RoutingsRoutings

DocumentsDocuments

Inspection plan

Characteristics

Insp. methods

Insp. catalogs

Test equipment

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BENEFITS

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Comprehensive master data maintenance by system.

Stocks in Quality till inspection is completed.

Inspection Results are available on line, hence retrieval will be easy and trends/SPC of characteristics can be viewed on line

Quality Score for vendor is based on Usage Decision (Passed/Rejected).

Standardized methodology for complaint reporting and analysis.

Calibration frequency scheduled by system for instruments.

Standard reports for analysis and review.

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Quality Management – FACT Processes

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List of QM ProcessesSl.No Process

TriggerStock Control

1.0 QM Master Data NA NA

2.0 Source Inspection Manual Inspection Non Stock

3.0 Incoming Inspection Automatic from GR posting. Stock

4.0 In-Process Inspection Automatic from Prod. Order Non Stock

5.0 Final Inspection Automatic from Prod. Confirmation

Stock

6.0 Stock transfer Inspection Automatic for Stock transfer Stock

7.0 Audit Management Manual NA

8.0 Calibration Inspection Automatic by Scheduling NA9.0 Notification Process NA NA

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Quality Management

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SAP Terminologies

SAP TERMINOLOGY DESCRIPTION

Result Recording Recording of actual dimensions (Dimension, Visual check, …)

Defect recording Recording of defect codes (eg., Dimensional deviation, damage (visual check..)

Usage Decision After result recording, to give final disposition viz., (Passed,Rejected…)

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Quality Management

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Master Data –What it containsContents in Master Data Examples

Material Master Contains material number, description, type of inspection (incoming/in process/final…)

Sampling Procedure Sampling plan

Master Inspection characteristics Eg, Dimension, Visual Observing, Performance test

Inspection method Method of checking: Dimension, Visual observation

Catalogs / Selected Sets Used in Qualitative characteristics,UD code, Defect code.

Inspection Plan / Routing / Maintenance Task List

List of specification to be checked

Equipment Master Equipment number, description…

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Catalog

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Master Data – What it containsCatalogs - Maintained at Client level – is a kind of library wherein all qualitative characteristics are

defined and stored.

Selected sets : These qualitative characteristics can be fetched from Catalog and used at plant level – 1002,1003 and 1005

Catalog Selected setsCommon to ALL 1002 1003 1005

Visual OK

Visual Not OK

Visual OK

Visual Not OK

Visual OK

Visual Not OK

Visual OK

Visual Not OK

Dimensional check OK

Dimensional check Not OK

Dimensional check OK

Dimensional check Not OK

- -

Ex.,

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Source Inspection

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Raw Material (Benzene, Sulphur,

….)

Bought outs (Cables,Generator

…

Components from

Sub-contractors (regular process)

SOURCE INSPECTION

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Source Inspection

Source Inspection

Source inspections are performed upon request and with the participation of the plant persons and /or customer

A source inspection is performed by the receiver of the service, the vendor in the presence of the receiver or third party appointed by him

After creation of Purchase order, information is made available to quality function at vendor site based on the readiness of the goods for inspection

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Raw Material (Benzene, Sulphur,

….)

Bought outs (Cables,Generator

& Equip...Components from

Sub-contractors (regular process)

Goods Receipt Inspection

Goods Receipt Inspection

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Goods Receipt Inspection

Goods Receipt Inspection - Features

Lot cannot be issued without quality inspection

Finance can make payment only after Quality Usage Decision (for limited vendor this facility would be waived)

Specification available on line material number wise – actual values only to be entered

Corrective action thro’ notification process

Concession/Deviation record details through notification process

Sampling Plan

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In process Inspection

Operation wise inspection

INPROCESS INSPECTION

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In process Inspection

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In process Inspection -Features

Inspection characteristics trend can be made

Corrective action thro’ notification process

Concession/Deviation process through notification process

Adherence to raising of first off /last off reports can be monitored

Inspection details can be sent to manufacturing thro notification in case of nonconformance

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Final Inspection - Production

Final Inspection for Anon,Hyam etc.,

FINAL INSPECTION

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Final Inspection

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Final Inspection - Features

Stock control i.e. QC can hold stock here

Specification available on line - material number wise – actual

values only to be entered

Corrective action thro’ notification process

Concession/Deviation record details through notification process

Assign the inspection characteristics against SPC requirement

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Calibration

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External Calibration

CALIBRATION

Internal Calibration

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Calibration

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Calibration - Features

Timely information of due calibration

Advance intimation facility available for due date calibration

Can de-activate the equipment which is out of calibration

User locations can be seen

Notification can be sent for out of calibration

Other Plants can view their calibration results for the equipments calibrated here.

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Notification

Incoming Inspection

In-process Inspection

Final Inspection Calibration

NOTIFICATION

Plant to Plant/Suspect Materials

CustomerComplaints

Stock transfer – within Plant

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Notification

Notification - Features

Partners and coordinators can be assigned

Common approach for initiating corrective actions thro specific report

Status of notification – Closed/Open can be listed out

Notification can be sent to inter plants

Linking of concession/deviation flow for closing notification as applicable

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Thank you