QM Manual English

Automotive Systems

SAP R/3 DocumentationRelease 4.6C

Quality management

Automotive Systems

Contents

0 Change management...............................................................................0-1

0.1 Status and Release Information...............................................................................0-10.2 Changes to previous releases..................................................................................0-1

1 Introduction...............................................................................................1-1

1.1 About this manual.....................................................................................................1-11.2 Contact persons........................................................................................................1-21.3 Prerequisites..............................................................................................................1-21.4 Starting transactions in SAP....................................................................................1-2

1.4.1 SAP R/3 Menus................................................................................................................1-31.4.2 Using favorites.................................................................................................................1-41.4.3 Direct use of transaction codes.....................................................................................1-51.4.4 Creating a new session...................................................................................................1-6

2 Organizational structure and process description................................2-1

2.1 SAP Quality Management (QM)................................................................................2-12.1.1 Integration........................................................................................................................2-12.1.2 Functions..........................................................................................................................2-1

2.2 SAP Organizational levels........................................................................................2-22.2.1 Client, company code.....................................................................................................2-22.2.2 Purchasing organization.................................................................................................2-32.2.3 Plant..................................................................................................................................2-3

3 Master data................................................................................................3-1

3.1 Quality planning........................................................................................................3-13.1.1 Catalog..............................................................................................................................3-1

3.1.1.1 Characteristic attributes (1).....................................................................................3-33.1.1.2 Tasks (2)....................................................................................................................3-33.1.1.3 Usage decisions (3)..................................................................................................3-33.1.1.4 Causes (5).................................................................................................................3-33.1.1.5 Defect types (9).........................................................................................................3-33.1.1.6 Complaint (D)............................................................................................................3-33.1.1.7 Defect locations (E)..................................................................................................3-4

3.1.2 Maintaining catalogs.......................................................................................................3-43.1.2.1 Creating Code groups..............................................................................................3-43.1.2.2 Changing code groups............................................................................................3-63.1.2.3 Creating and changing codes.................................................................................3-63.1.2.4 Translating code groups and codes.......................................................................3-8

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3.1.2.5 Overview on catalog types......................................................................................3-93.1.2.6 Selected sets..........................................................................................................3-10

3.1.3 Sample management.....................................................................................................3-133.1.3.1 Sampling procedures.............................................................................................3-133.1.3.2 Sample size.............................................................................................................3-183.1.3.3 Dynamic modification rule....................................................................................3-18

3.1.4 QM work centers............................................................................................................3-283.1.5 Tools...............................................................................................................................3-31

3.1.5.1 Where-used lists.....................................................................................................3-333.1.5.2 Replacing tools / mass change.............................................................................3-35

3.1.6 Master inspection characteristics................................................................................3-403.1.6.1 Creating master inspection characteristics.........................................................3-403.1.6.2 Changing / displaying master inspection characteristics..................................3-613.1.6.3 Deleting a master inspection characteristic........................................................3-613.1.6.4 Where-used list of master inspection characteristics........................................3-623.1.6.5 Replacing master inspection characteristics......................................................3-63

3.1.7 QM view of the material master record.......................................................................3-643.1.7.1 Maintaining a QM view...........................................................................................3-643.1.7.2 Maintaining the QM view using workflows..........................................................3-743.1.7.3 Mass maintenance.................................................................................................3-76

3.1.8 Quality info record.........................................................................................................3-833.1.8.1 Maintaining a quality info record..........................................................................3-833.1.8.2 Mass maintenance.................................................................................................3-92

3.1.9 Quality level...................................................................................................................3-953.1.9.1 Maintaining the quality level.................................................................................3-953.1.9.2 Quality level history...............................................................................................3-993.1.9.3 Displaying all quality levels of a certain inspection stage...............................3-100

3.2 Inspection planning...............................................................................................3-1093.2.1 Task list types..............................................................................................................3-109

3.2.1.1 Reference operation set......................................................................................3-1093.2.1.2 Inspection plan.....................................................................................................3-109

3.2.2 Maintaining inspection plans.....................................................................................3-1103.2.2.1 Maintaining header data......................................................................................3-1153.2.2.2 Maintaining inspection operations.....................................................................3-1193.2.2.3 Allocating tools....................................................................................................3-1203.2.2.4 Creating new inspection characteristics from within the task list (no master inspection characteristic)..................................................................................................3-1223.2.2.5 Allocating tools to inspection characteristics...................................................3-1393.2.2.6 Referencing master inspection characteristics................................................3-1403.2.2.7 Unlocking a reference..........................................................................................3-1423.2.2.8 Defining dependent characteristic specifications............................................3-1433.2.2.9 Copying characteristics from other task lists...................................................3-1453.2.2.10 Using reference operation sets...........................................................................3-1463.2.2.11 Where-used list of master inspection characteristics......................................3-1483.2.2.12 Replacing master inspection characteristics....................................................3-1493.2.2.13 Where-used list of reference operation sets.....................................................3-1503.2.2.14 Replacing reference operation sets...................................................................3-151

3.2.3 Printing inspection plans............................................................................................3-1533.2.3.1 Printing lists of inspection plans (general) available in the system...............3-1533.2.3.2 Printing lists of inspection plans by material....................................................3-1543.2.3.3 Printing inspection plans....................................................................................3-156

3.2.4 Displaying a list of missing inspection plans...........................................................3-1573.2.5 Displaying a list of multiple material/inspection plan allocations..........................3-160

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3.2.6 Inspection planning using the Engineering Workbench (EWB).............................3-1623.2.6.1 EWB: Starting the Engineering Workbench......................................................3-1623.2.6.2 EWB: Selecting a working area...........................................................................3-1633.2.6.3 EWB: Entering selection criteria.........................................................................3-1633.2.6.4 EWB: Product Structure Browser.......................................................................3-1663.2.6.5 EWB: Creating inspection plans.........................................................................3-1673.2.6.6 EWB: Changing an inspection plan....................................................................3-172

4 Business transactions.............................................................................4-1

4.1 Quality inspection in procurement..........................................................................4-14.1.1 Inspection lot...................................................................................................................4-2

4.1.1.1 Automatic creation of an inspection lot.................................................................4-24.1.1.2 Manual creation of an inspection lot......................................................................4-24.1.1.3 Printing sample drawing instructions....................................................................4-6

4.1.2 Results recording............................................................................................................4-74.1.2.1 Worklist.....................................................................................................................4-74.1.2.2 Results recording worklist......................................................................................4-74.1.2.3 Worklist inspection lots.........................................................................................4-154.1.2.4 Recording results without worklists....................................................................4-214.1.2.5 Recording results...................................................................................................4-224.1.2.6 Adding characteristics...........................................................................................4-284.1.2.7 Skipping required characteristics........................................................................4-294.1.2.8 Valuating and closing characteristics..................................................................4-294.1.2.9 Defects recording...................................................................................................4-30

4.1.3 Making usage decisions...............................................................................................4-354.1.3.1 Worklist for inspection lots...................................................................................4-354.1.3.2 Recording results worklist....................................................................................4-374.1.3.3 UD without worklist................................................................................................4-39

4.1.4 Sampling.........................................................................................................................4-504.2 Quality notification..................................................................................................4-56

4.2.1 Structure of quality notifications.................................................................................4-564.2.2 Quality notification types..............................................................................................4-564.2.3 Creating a quality notification......................................................................................4-57

4.2.3.1 Tab: Subject............................................................................................................4-594.2.3.2 Tab Dates and quantities.......................................................................................4-644.2.3.3 Tab QM order..........................................................................................................4-664.2.3.4 Tab Item...................................................................................................................4-674.2.3.5 Tab: Tasks (immediate measures)........................................................................4-69

4.2.4 Action box......................................................................................................................4-724.2.5 Putting quality notifications in process......................................................................4-764.2.6 Completing quality notifications..................................................................................4-764.2.7 Putting a notification back in process.........................................................................4-774.2.8 Action log.......................................................................................................................4-784.2.9 Document flow...............................................................................................................4-804.2.10 Creating attachments................................................................................................4-814.2.11 Printing quality notifications (shop papers)............................................................4-844.2.12 Mailing quality notifications (shop papers).............................................................4-874.2.13 Worklists.....................................................................................................................4-88

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5 Evaluations................................................................................................5-1

5.1 Possibilities for evaluations in SAP........................................................................5-15.2 Vendor analysis (standard analysis).......................................................................5-25.3 Evaluations using flexible analyses......................................................................5-12

5.3.1 Characteristics of flexible analyses.............................................................................5-125.3.2 Calling up a flexible analyses.......................................................................................5-135.3.3 Selecting selection parameters....................................................................................5-145.3.4 Displaying a flexible analysis.......................................................................................5-155.3.5 Office integration...........................................................................................................5-185.3.6 Formatting for SRS........................................................................................................5-20

5.4 Conti-Teves reports.................................................................................................5-21

6 Overlapping functions..............................................................................6-1

6.1 Scrap recording.........................................................................................................6-16.1.1 Prerequisites to use transaction ZM42..........................................................................6-16.1.2 Processing transaction ZM42.........................................................................................6-36.1.3 Reversing scrap recordings...........................................................................................6-6

6.2 Scrap recording and updating in QMIS...................................................................6-76.2.1 Graphical diagram...........................................................................................................6-76.2.2 Explanation......................................................................................................................6-8

7 Documents and forms..............................................................................7-1

7.1 Sample drawing instruction (SDI)............................................................................7-17.1.1 Field description sample drawing instruction..............................................................7-27.1.2 Example for a sample drawing instruction...................................................................7-4

7.2 Inspection instruction...............................................................................................7-57.3 Inspection report.......................................................................................................7-6

7.3.1 Field description inspection report...............................................................................7-67.3.2 Example for an inspection report and information report.........................................7-12

7.4 Inspection plan printout..........................................................................................7-147.4.1 Field description inspection plan printout..................................................................7-147.4.2 Example for an inspection plan printout.....................................................................7-157.4.3 Printout inspection plan - header data........................................................................7-177.4.4 Printout inspection plan - operation / inspection characteristic..............................7-187.4.5 Printout inspection plan – inspection plan footer......................................................7-197.4.6 Inspection plan - Layout...............................................................................................7-20

8 Authorizations...........................................................................................8-1

9 Appendix...................................................................................................9-1

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10 Glossary..................................................................................................10-1

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Change management

0 Change management

0.1 Status and Release Information

Release 31.09.2003

0.2 Changes to previous releases

None.

SAP R/3, 4.6C Quality management Release 31.09.2003 Page 1

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Change management


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Introduction

1 Introduction

1.1 About this manualThe manual has 10 chapters. Those chapters dealing with master data, business transactions, evaluations and overlapping functions include also details on menu paths or transaction codes.

Example:

Logistics Quality management Quality planning Inspection planning

Inspection plan Create (QP01)

The document follows the sequence of the process. All functions referring to different processes or which are not a clear-cut part of the business process are mentioned in the chapter ’Overlapping Functions’.

In this manual the dealing with reports will be explained by a few representative examples.

Plant specific differences to the standard process are mentioned in the appendix and documented by additional descriptions.

Not every screen field will be addressed. Only those fields relevant for the process will be examined. The description of all other fields can be accessed by using the F1-help function.

Hints and menu paths will be marked particularly :

- Menu paths will be marked by the symbol .

- Examples will be marked by the symbol .

- Hints will be marked by the symbol .

- Warning notices will be marked by the symbol .


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Introduction

1.2 Contact personsMr. Lotze Tel. 069 7603 3719

1.3 PrerequisitesFor a better understanding of the functions described in this manual a basic knowledge of MS-Windows, MS-Office and a certain proficiency in dealing with the SAP R/3 Release 4.6 surface is necessary..

1.4 Starting transactions in SAP

There are different possibilities to start a program (transaction) in SAP R/3:

Using the SAP R/3- standard menu or SAP R/3-user specific menu. Using favorites Using transaction codes directly


Automotive Systems

Introduction

1.4.1 SAP R/3 Menus

Required programs (transactions) may be started in the SAP Easy Access screen by opening the menu paths of the programs step by step pressing .

Calling up the transaction to create an inspection plan: Logistics Quality management Quality planning Inspection planning



Automotive Systems

Introduction

The transaction codes can be displayed using the

menu settings.

Choose Extras Settings from the main menu, select Display technical names (transaction codes) from the settings.

This setting provides an additional display of transaction codes in the SAP menu, like e.g. transaction code QP01.

1.4.2 Using favorites

You can add the transaction to the personal favorites by clicking on the selected row in the SAP-menu or SAP-user menu using the right mouse button. So the most important transactions for an individual user can be collected among the favorites.

A direct transaction code can be added by clicking on the favorites row using the right mouse button (option “Insert Transaction”).


Automotive Systems

Introduction

In the same manner you may delete favorite entries (option “Delete Favorite”).

1.4.3 Direct use of transaction codes

Frequently used transactions can be entered directly in the command row. Afterwards press .

If you want to start a transaction from an active program you have to type in an /n and afterwards the transaction code.

The active program will close immediately without warning and without saving. The new

program will start at once.


Automotive Systems

Introduction

When starting the transaction code by an /o a new session will be opened automatically and the selected transaction will be started.

1.4.4 Creating a new session

In SAP you are able to work on several sessions. The number of sessions is limited by the system and should be kept low due to system performance. You can carry out several transactions in different parallel sessions.

If you work on the same master data or document during parallel sessions you may block

yourself.

To create a new session press the button , which can be found on every SAP screen.


Automotive Systems

Introduction

To end a session press one of the buttons until you get back to the main screen.

Closing the sessions with the windows functions, e. g. using , may cause a loss of data.


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Organizational structure and process description

2 Organizational structure and process description

2.1 SAP Quality Management (QM)

2.1.1 Integration

The QM application uses the integration of SAP to connect QM functions with other SAP components like material management, production, sales and controlling.

2.1.2 Functions

The QM application supports tasks in quality planning, quality inspection and quality control. Furthermore, it creates quality certificates and supports the problem management using quality notifications. The following components are part of QM:

Master data (e.g. material master, catalogs, inspection characteristics, inspection methods, dynamic modification rules, sample procedures)

Quality planning (inspection plans, reference operation sets, material specifications)

QM in procurement

QM in sales and distribution

Inspection lot processing (inspection lot creation and inspection lot completion)

Results recording

Defects recording

Sample management

Quality information system

Dynamic modification of the inspection scope

Quality certificates

Quality notifications

Test equipment management


Automotive Systems


2.2 SAP Organizational levels

Organizational levels are hierarchy levels for storing SAP data.

CAS (Continental Automotive Systems) distinguishes between central and local systems. Both systems use their own organizational levels.

2.2.1 Client, company code

The client is the highest hierarchy level. According to SAP a client is a self-contained unit in an R/3 System (e.g. a corporate group) regarding commercial, organizational, and technical terms. Every client has its own data such as master data and transaction data, user master data and chart of account.

The company code is the smallest organizational unit for which a complete self-contained set of accounts can be drawn up on purpose of external reporting. On company code level all supporting documents for financial statements such as balance sheets and profit and loss statements are created.

Company codes are implemented using the customizing of financial accounting. For Continental Teves Europe each country has its own company code.


Automotive Systems


2.2.2 Purchasing organization

A purchasing organisation is an organizational unit responsible for procuring materials or services for one or more plants and for negotiating general conditions of purchase with vendors.

A purchasing organization can be assigned to one or more plants and a plant can be procured by one or more purchasing organizations.

In the central system (CSE) the reference purchasing organizations are not assigned to plants. In the local systems the purchasing organizations are assigned to plants.

2.2.3 Plant

To control stock it is necessary to implement places in the system, where stock is kept. This is done by plants and storage locations.

A plant is an organizational unit within a company (company code), which produces materials or provides goods and services. It represents the organizational level for planning and inventory management and can consist of several storage locations. The plant is the main organizational level in material management.


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Master data

3 Master data

3.1 Quality planning

3.1.1 Catalog

A catalog allows an exact definition of inspection results, observations, tasks or decisions, since perceptions, not rated by numbers, are usually rated differently by different persons. In catalogs these information is standardized by unique keys and their description. For standardization within a client or plant you need codes for rating and evaluation. A catalog contains unique, non-numerical data on plant or client level.Catalogs used at Continental Teves are valid worldwide. The maintenance of these catalogs is done by the departments central quality and after-sales service.Missing or new entries have to be applied for via the central quality department.The corresponding form can be accessed in the system D10 client 450 via Office Workplace Shared folders RELEASE UPG MODULES QM-QUALITY 00 GENERAL Request for addition/change of SAP catalogs.

The hierarchy structure of a catalog may be as follows:


Catalog type

Code group(client level)

Code group

Selected set(plant level)

Set codesCombining codes from several code groups

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Master data

In catalogs code groups and selected sets are on the same level. The difference between them is that code groups are maintained on client level and selected sets are defined on plant level.

Code groups contain codes. Codes, that are assigned to a code group are also known as group codes.

Selected sets combine any codes, even from different code groups. In catalogs the lowest level of information are codes, which are included in code groups and

selected sets.

Code groups and selected sets of a catalog are used to create and collect codes, like e.g. the coded descriptions of usage decisions, causes or defect types.

SAP standard uses the following catalog types:

The catalog types used by Continental-TEVES in quality management are:

Characteristic attributes (1) Tasks (2) Usage decisions (3) Causes (5) Defect types (9) Complaint (D) Defect locations (E)


Automotive Systems

Master data

The catalog types used at Continental-TEVES are briefly explained below.

3.1.1.1 Characteristic attributes (1)

This catalog type is used for recording results and defining qualitative inspection characteristics. Visual checks okay / not okay damaged not according to instructions

3.1.1.2 Tasks (2)

This catalog contains tasks resulting from quality notifications. Typical code groups are e.g.: Tasks concerning product design Tasks in production Tasks in logistics Tasks of the vendor Tasks at customer

3.1.1.3 Usage decisions (3)

This special catalog type is used for inspection lot completion. E.g.: Acceptance with reservations Acceptance after rework Rejection, return delivery to vendor

3.1.1.4 Causes (5)

The catalog type “Causes” is used for quality notifications. Typical causes for defects are: Wrong work documents Defect test equipment Tool defects

3.1.1.5 Defect types (9)

The defect types of this catalog allow exact descriptions of defects: Wrong software version Wrong software parameters Wrong software configuration Control software failure Security concept software failure Diagnose software failure

3.1.1.6 Complaint (D)

Global description used as title or subject of notifications (defect notifications, problem notifications, complaints, etc.). These catalog entries are used only for customer complaints or vendor complaints based upon customer complaints.Complaints of code group “Software complaints”:

Not relevant software relais Software defective Software does not fit to ECU ESD / EMC disturbance Other software faults

3.1.1.7 Defect locations (E)

The main reference of an inspection or complaint is usually a single material or an assembly. If it is an assembly, the next level to locate the defect is the bill of material. Possible defect locations for the material E-Regulator are:

Guide bush Guide washer


Automotive Systems

Master data

Casing Thread protective cap

3.1.2 Maintaining catalogs

At Continental Teves catalogs are maintained centrally.They are build up hierarchically:

3.1.2.1 Creating Code groups

Logistics Quality management Quality planning Basic data Catalog

Code group Edit (QS41)

The initial screen for creating/changing/displaying a catalog is shown.


Catalog type

Code group

Code

Selected set

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Master data

To create a code group follow these steps:

1. Choose a catalog number (data field catalog).

2. Enter a key for the code group.To display existing code groups, search using the asterisk (*).

3. Choose .The code group overview will be shown.

4. Press The code group table is ready for input.

Enter the following values:- a key for the code group Pay attention to the name convention for code groups at Continental Teves: 1.-2. digit: QM 3. digit: - 4.-6. digit: 000 7.-8. digit: number (unrestricted, usually using steps of five or ten)- a short description for the codegroup- a status for the code group (for use the code group has to be released)- a long text for the code group (optional)

5. Save your entries.


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Master data

3.1.2.2 Changing code groups

Follow the steps as explained in chapter “Creating code groups” including steps 3 and 4. Choose the code group you want to change.

Then you are able to change short description, status and long text.

The key of the code group cannot be changed. If you want to change this key, you will have to

delete the code group and create a new one.

3.1.2.3 Creating and changing codes


Code group Edit (QS41)

The initial screen for maintaining catalogs will be shown again. Follow these steps:

1. Enter a catalog number and the code group key (or *) and press .

2.

Mark a code group and choose .


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Master data

3. On the following screen the codes will be displayed. You can change the short description and the long text.

The code itself cannot be changed. If you want to change the code, you will have to

create a new code and to delete the old one.

4. To create a new code press New codes may be entered in the table. Fill out key and short description of the code. Optionally you may enter a long text.


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Master data

3.1.2.4 Translating code groups and codes

To enter text for code groups and codes in different languages choose the path Utilities Choose language when changing code groups or codes.

A pop-up window will appear, where you can choose the desired language.

Use the menu path Edit Translation to maintain texts in the chosen language.


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Master data

3.1.2.5 Overview on catalog types

Logistics Quality management Quality planning Basic data Catalog Code

group Index (QS49)

An overview of all catalog types or of a single one can be displayed as follows:

Choose which of the catalog types and code groups you would like to see.

The chosen catalog types will be displayed. Press (Index) for display.


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Master data

3.1.2.6 Selected sets

A code group (client level) can have many different entries. A number of 100 codes may be possible. To reduce the number or to structure these codes, selected sets may be build from these code groups. The codes can be chosen from different code groups of a catalog. Selected sets are maintained on plant level.Especially for catalog types 1 (characteristic attributes) and 3 (usage decision) codes of code groups should be grouped using different aspects. Additionally the valuations “Accept” or “Reject” are allocated to every code of a selected set. Depending on the inspection (incoming inspection, production inspection) the selected sets possess only those codes, that fit the inspection type.The selected sets of catalog E (defect locations) are created by products.

The selected sets of a catalog type can be created or changed using the following menu path:


Selected set Edit (QS51)

The initial screen for maintaining selected sets will be shown.

Enter catalog, plant and the selected set you want to change. If you want to list all selected sets of a catalog and plant, enter an asterisk * as selected set.

Press .


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Master data

An overview on selected sets will be displayed.

Change short description, long text or status of the selected sets.

The key of the selected sets cannot be changed. If you want to change this key, you will have

to enter a new selected set and to delete the old one.

To create new selected sets press . Then the table can be changed. Enter key, description and status of the new selected set (for use it has to be released). You may enter a long text, too.Pay attention to the name convention for selected sets at Continental Teves:

1.-2. digit: QM 3. digit: = 4.-6. digit: 000 7.-8. digit: Number (unrestricted, usually using steps of five or ten)

Allocating codes to a selected set

To allocate codes to a selected set follow these steps:


Selected set Edit (QS51)

The initial screen for maintaining selected sets will be shown again.

1. Choose catalog number and plant and press .

2. Mark a selected set and select .

3. Choose .

4. Press F4 .


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Master data

5. The code groups of the chosen catalog will be listed. Open the folders to display the corresponding codes.

6. Mark the codes to be taken over into the selected set.

7. Press .

8. In catalog 3 (usage decision) allocate a valuation (accept / reject) to each code.

9. Save your entries.

Removing codes from selected sets

To remove codes from selected sets mark the code and press (delete).


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Master data

3.1.3 Sample management

If sampling procedures and optional dynamic modification rules are in use, the system is able to adjust the inspection scope to the quality level. This procedure is not used at Continental Teves.

3.1.3.1 Sampling procedures

Sampling procedures determine the inspection scope and valuation mode for recording results (qualitative characteristics, tolerances, characteristic attributes, etc.). A sampling procedure is allocated to an inspection characteristic of an inspection plan if this is set accordingly in the control indicator of the characteristic.

The advantage in using sampling procedures is that inspection characteristics are not valuated manually (accept/reject) but can be valuated automatically based upon the procedure.

The maintenance of sampling procedures is done on a comprehensive level in all plants.

Logistics Quality management Quality planning Basic data Sample

Sampling procedure Create / Change / Display (QDV1 / QDV2 / QDV3)

After entering the sampling procedure and confirming via you will be shown the next screen.


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Master data

Short text – description of the sampling procedure

sampling type Dependence100 – Fixed sample Enter a fixed sample quantity e.g. 10 (pce.)200 - 100 % inspection No further data necessary, because the complete inspection

lot quantity will be used as sample quantity.300 – Sampling scheme Enter a sampling scheme.

400 – Percentage sample Enter a percentage, e.g. 10 (%), i.e. 10% of the inspection lot quantity are sample quantity

Sampling type – determines type and scope of the sample

At Continental Teves “fixed sample” is usually used.

Depending on the selected sampling type additional data may be necessary:


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Master data

Valuation mode – The valuation mode defines rules for accepting or rejecting a sample. Sampling type and valuation mode are used to define the parameters for sample determination.

The following options can be chosen:

inspection point – By defining the inspection point type in the sampling procedure, you specify whether the system creates inspection points for an inspection lot, and if so, how many have to be created. It is used for inspection in production only.

usage indicator – If the blocking indicator is marked, this sampling procedure cannot be used anymore.

After confirming with the next screen will appear:


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Master data

No inspection stage change – By setting the indicator - No stage change - you can prevent an inspection stage change from taking place. This means that the sample size will not be dynamically modified.

Multiple samples – Definition of an additional valuation rule. If this option is set, further data has to be specified.

If you use sampling procedure 100 or 400 press the button to display another screen, where you have to enter sample quantity or percentage:

When using qualitative inspection characteristics enter in data field acceptance number the maximum number of defect units of a sample that still results in an acceptance.

Save your entries. The sampling procedure may be used in inspection plans after saving.

Translating description:To translate descriptions it is necessary, to log on to the SAP R/3 system using the desired language. Maintain texts in this language using transaction QDV2 (Change sampling procedure).


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Master data

3.1.3.2 Sample size

The sample size describes the inspection scope for incoming inspections. The system contains the following sampling procedures:

Sample size inspection50; 80; 125; 200 Visual inspection (qualitative inspection characteristics)

150 Cleanliness inspection20 Inspection characteristics (qualitative, quantitative)5 Rubber inspection

This inspection contains five different inspections for a single part4 Inspection using 3D measuring machines1 Chemical analysis

assumption: The material is part of a material batch100 % Pilot lot

3.1.3.3 Dynamic modification rule

Dynamic modification rules contain the definition of inspection stages and the conditions that lead to an inspection stage change.

The inspection scope may vary depending on inspection stages. For steady inspection scopes other conditions for inspection stage changes may occur.

Dynamic modification rules may be entered in an inspection plan (header, characteristics) or in the material master (inspection type).


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Master data

Dynamic modification rules are maintained cross-plant. They can be used for

Sampling procedures (sample size / inspection severity) Not used at Continental Teves!

Inspection lots

Inspection characteristics of inspection plans (inspection scope)

Logistics Quality management Quality planning Basic data Sample

Dynamic modification rule Create / Change / Display (QDR1 / QDR2 / QDR3)

The initial screen for maintaining dynamic modification rules will be displayed.

Enter the key for the dynamic modification rule. This key has a length of three digits. Use the button

to copy existing dynamic modification rules.

Confirm pressing to display the header data of the dynamic modification rule.


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Master data

Short text – description of the dynamic modification rule

Time of dynamic modification – Dynamic modification at usage decision – The dynamic modification is done after the usage decision has taken place.

Dynamic modification at lot creation – Immediate dynamic modification after lot creation. The system assumes, that the inspection lot / all inspection characteristics are accepted. This is default at Continental Teves.

Reset period – after this time period the inspection stage will start again with the first stage of the dynamic modification rule.

Usage indicator – blocking indicator – blocks the usage in inspection plans

Usage indicator – Usage in task list / plan – this dynamic modification rule is used in an inspection plan. If this flag is set, the rule cannot be deleted. The flag is set automatically by the system, if this rule is used in an inspection plan. It will be reset automatically, if the allocation to an inspection plan is cancelled.

Press (next screen) to define the inspection stages.


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Master data

Stage – Is defined by allocating an inspection severity (or the skip indicator) and by defining rules for the inspection stage change.

Inspection change stages have to be defined for each inspection stage.

Inspection severity – If using sampling schemes the inspection severity has to be identical to the ones used in the schemes. (Not used at Continental Teves)

Skip – Inspection stage is a skip, i.e. characteristics or inspection lots are not inspected.

Inspection severity should not be entered for skips.

ISt – initial inspection stage

Has to be assigned to an inspection stage.

Short text – description / text of max. 40 digits.

StC – Stage change for the inspection stage. This flag is set automatically, when the conditions for an inspection stage change are defined.


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Master data

For each stage the stage changes have to be maintained to define the procedure in cases of “acceptance (OK)” and “rejection (not OK)”.

Mark the stage you want to maintain. Press the button to create stage changes.

No skip Skip

No. of inspections – Number of inspections which are okay, that are necessary to reach the next inspection stage. Usually it is followed by a skip. Skip: Number of skips, usually followed by an inspection.

Maximum skip duration – maximum skip duration in days.. If this duration is exceeded (no goods receipt / inspection lot), the next inspection stage is reached.

Can only be entered for skips.

New inspection stage (OK) – The inspection stage to be used for the next inspection if the conditions for an acceptance are met.

Rejections – Number of rejections resulting in an inspection stage change. Usually it results in the initial inspection stage.

New inspection stage (not OK) – The inspection stage to be used for the next inspection if the conditions for a rejection are met.


Automotive Systems

Master data

Dynamic modification rules maintained at Continental Teves:

Dynamic modification rules define the inspection frequency for goods receipts (incoming inspections). The following rules are maintained in the SAP R/3 system:

Dynamic modification rule: Incoming inspection 001

stage activity number of OK inspection lots for a stage change1. stage 5 inspections 52. stage 3 skips 83. stage 1 inspection 94. stage 3 skips 125. stage 1 inspection 136. stage 3 skips 167. stage 1 inspection 178. stage 3 skips 209. stage 1 inspection 21

10. stage 6 skips 2711. stage 1 inspection 2812. stage 6 skips 3413. stage 1 inspection 3514. stage 6 skips 4115. stage 1 inspection 4216. stage 6 skips 4817. stage 1 inspection 4918. stage 6 skips 5519. stage 1 inspection 5620. stage 12 skips 6821. stage 1 inspection 69 with an inspection scope of 15 inspections22. stage Permanent skip 99. stage Permanent inspection

The R/3 quality level is used to control inspection requirements for material / vendor relationships depending on further inspections. It records the described stage changes.

If a lot is rejected, it is reset automatically to stage 1.


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A manual stage change without creating additional inspection lots is possible. It should be done only if the incoming quality allows it or makes it necessary.

The inspection history of material / vendor relationships is comprehensible.

If stage 22 is reached, further inspections can be carried out only if the quality level is changed manually.

If quality problems occur, the quality level can be changed manually to permanent inspection (stage 99).

Dynamic modification rule: Incoming inspections with intermediate inspections 002

stage Activity number of OK inspection lots for a stage change

1. stage 5 inspections 52. stage Up to 10 inspections at quality problems3. stage 3 skips 84. stage 1 inspection 95. stage Up to 10 inspections at quality problems6. stage 3 skips 127. stage 1 inspection 138. stage Up to 10 inspections at quality problems9. stage 3 skips 1610. stage 1 inspection 1711. stage Up to 10 inspections at quality problems12. stage 3 skips 2013. stage 1 inspection 2114. stage Up to 10 inspections at quality problems15. stage 6 skips 2716. stage 1 inspection 2817. stage Up to 10 inspections at quality problems18. stage 6 skips 3419. stage 1 inspection 3520. stage Up to 10 inspections at quality problems21. stage 6 skips 4122. stage 1 inspection 4223. stage Up to 10 inspections at quality problems24. stage 6 skips 4825. stage 1 inspection 4926. stage Up to 10 inspections at quality problems27. stage 6 skips 5528. stage 1 inspection 5629. stage Up to 10 inspections at quality problems30. stage 12 skips 6831. stage 1 inspection 69 with an inspection scope of 15

inspections32. stage Up to 10 inspections at quality problems33. stage Permanent skip Max. 180 days or 19 skips94. stage 1 inspection95. stage Up to 10 inspections at quality problems96. stage Permanent skip Max. 365 days


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Master data

97. stage Up to 10 inspections at quality problems98. stage Permanent skip 99. stage Permanent inspection

The dynamic modification rule “Incoming inspections with intermediate inspections” allows a certain number of intermediate inspections (1…10) without changing the quality level to permanent inspection. If the intermediate inspections are OK, the inspection level before these inspections does not have to be set manually again. The intermediate stage will be left and the dynamic modification rule will continue. Usually the intermediate inspections are skipped. They are activated manually when quality problems occur.The maximum skip duration (in days) or the maximum number of skips of stage 33 are used to inspect material/vendor relationships periodically.Stage 96 can be reached manually only. In this stage further inspections will be done every 365 days.Stage 98 can only be reached manually, too. Further inspections are only possible if the quality level is changed manually.The R/3 quality level can be changed to stage 99 manually, if permanent inspections are necessary due to serious quality problems.

Dynamic modification rule: Incoming inspection 003 (6 inspections in fixed intervals)

stage activity number of OK inspection lots for a stage change

1. stage 6 inspections 62. stage Skip Max. 90 days3. stage 1 inspection 74. stage Up to 10 inspections at quality problems94. stage 6 inspections 695. stage Skip Max. 30 days96. stage 1 inspection 797. stage Up to 10 inspections at quality problems98. stage Permanent skip 99. stage Permanent inspection

This dynamic modification rule with intermediate inspections allows a certain number of intermediate inspections (1…10) without changing the quality level to permanent inspection. If the intermediate inspections are OK, the inspection level prior to these inspections does not have to be set manually again. The intermediate stage will be left and the dynamic modification rule will continue. Usually the intermediate inspections are skipped. They are activated manually when quality problems occur.The maximum skip duration (in days) or the maximum number of skips are used to inspect material/vendor relationships periodically.Stage 94 can be reached manually only. Further inspections are carried out every 30 days.Stage 98 can only be reached manually, too. Further inspections are only possible if the quality level is changed manually.The R/3 quality level can be changed to stage 99 manually if permanent inspections are necessary due to serious quality problems.


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Master data

Dynamic modification rule: Incoming inspection with laboratory/functional inspection 005stage activity number of OK inspection lots

for a stage change1. stage 1 inspection 12. stage Up to 10 inspections at quality problems3. stage 19 skips (or. max. 365 days) 201. stage 1 inspection 21; 41; 61; ...2. stage Up to 10 inspections at quality problems3. stage 19 skips (or. max. 365 days) 40; 60; 80; ...97. stage Up to 10 inspections at quality problems98. stage Permanent skip 99. stage Permanent inspection

The dynamic modification rule for laboratory/functional inspections allows expensive inspections in laboratories or expensive functional inspections in certain intervals.

The dynamic modification rule is built for a never-ending inspection.

Every 20th inspection lot will be inspected.

The stages permanent skip and permanent inspection can be reached or left only manually.

Dynamic modification rule: Incoming inspection for identity inspection 007

stage activity number of OK inspection lots for a stage change

1. stage 4 inspections 42. stage Up to 10 inspections at quality inspections3. stage 1 inspection 54. stage Skips (max. 180 days) Max. 180 days

97. stage Up to 10 inspections at quality problems98. stage Permanent skip 99. stage Permanent inspection

To minimize efforts in goods receipt an identity inspection is carried out. An identity inspection contains additional characteristics apart from the ones of a normal dimension inspection. An identity inspection is an expanded dimension inspection.The dynamic modification rule is built for a never-ending inspection.

Every 180 days an inspection lot will be inspected.

The stages permanent skip and permanent inspection can be reached or left only manually.

Dynamic modification rule: Goods issue 011

stage activity number of OK inspection lots for a stage change1. stage 5 inspections 52. stage Permanent skip 99. stage Permanent inspection


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Master data

The R/3 quality level is used to control inspection requirements for material / vendor relationships depending on further inspections. It records the described stage changes.

If a lot is rejected, it is reset automatically to stage 1.

A manual stage change without creating additional inspection lots is possible. This should be done only if the incoming quality allows it or makes it necessary.

The inspection history of material / vendor relationships is comprehensible.

If level 2 is reached, further inspections can be started only by changing theR/3 quality level manually.

The R/3 quality level can be changed to stage 99 manually if permanent inspections are necessary due to serious quality problems.

Translating description:To translate descriptions it is necessary, to log on to the SAP R/3 system using the desired language. Maintain texts in this language using transaction QDR2 (Change dynamic modification rule).


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Master data

3.1.4 QM work centers

QM work centers as master data are used for production and control. QM work centers are used to structure worklists and have to be entered when creating inspection plans.

To create a QM work center follow these steps:

Logistics Quality management Quality planning Basic data Work center

QM Work center Work center Create / Change / Display (CRQ1 / CRQ2 / CRQ3)

plant – key identifying a unique plant

Work center – key identifying a work center.Number convention for QM work centers:1.-3. digit: 9734.-8. digit: any numbers (unrestricted)

Work center category – key distinguishing work center categories like e.g. PP work centers or QM work centers.

Copy from – existing work center used for copying. Data from this work centers can be taken over into the new work center.

Enter plant, work center number and work center category. Choose to maintain basic data.


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Master data

Short text – description of the work center. This data field contains a short description of the object (e.g. an organizational unit, qualification or event)

Person responsible – key identifying a person or group of persons responsible for maintaining this work center.

Location – key for the location, where the work center is.

Usage – key controlling in which task list types the object may be used (e.g. the work center or production resource/tool).


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Master data

Standard value key – key containing a maximum of six standard values with description and dimension (e.g. time or area). Standard values are used as parameters in formulas for calculating operation times, required capacity or costs. A parameter ID is allocated to these standard values. This parameter ID is used to identify the standard value in formulas. The parameter ID defines the key word of a standard value (e.g. setup, machine, labor).

Save your entries. The work center will be saved and you will return automatically to the initial screen.


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Master data

3.1.5 Miscellaneous production resource/tools

Production resource/tools are operational facilities, test equipments or documents used to carry out inspections in production or goods receipt.The following kinds of production resources/tools are distinguished:

material, taken into account in material management, e.g. inventory management, material requirement planning and procurement

equipments, e.g. test equipments or expensive tools, which have to be serviced. documents, e.g. drawings or programs, for which the document management system is used. Other tools (with tool master data), which maintenance is less time-consuming

For the inspection planning at Continental Teves three kinds of production resources/tools are used, material, documents and miscellaneous.

Tools can be assigned to the operations in inspection plans, where they are needed.

This is done when maintaining inspection plans. The procedure for maintaining inspection plans is described in chapter 3.2.2.

On the operation overview of an inspection plan mark the operation, to which a tool should be assigned.

If some tools already exist, press the button to display them.


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Use the menu path Edit New entries and choose the type of production resource/tool. Then you are able to enter the key of a new tool.

If no tool has been assigned, you get the pop-up window shown above.As a default tool category “material” is proposed. Use the buttons

to change the tool category.

Use control key 1000 or 1003 if you get the tool from a test equipment department.


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Master data

3.1.5.1 Where-used lists

Production resource/tools can be assigned to operations in inspection plans. Use the where-used list to get an overview on inspection lists, where a tool is used.

Logistics Quality management Quality planning Basic data Production

resources/Tools Where-used list (CA70)

On the initial screen enter the key for the tool plant task list type task list status

The where-used list is executed by pressing the button .


Automotive Systems

Master data


Automotive Systems

Master data

3.1.5.2 Replacing production resources/tools / mass change

Use this transaction to replace a certain production resource/tool in several or all inspection plans.

Logistics Quality management Quality planning Basic data Production

resources/Tools Replace (CA75)

On the initial screen enter the key for a tool (which should be replaced) plant task list type task list status.

Press the button to display a where-used list for the selected production resource/tool.


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Master data

Via the menu path Settings Replace with and by choosing a type of production resource/tool you will receive the following screen.


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Master data

Enter the key for the new production resource/tool and a plant.

Press the button to get back to the where-used list.

From the where-used list choose the operations where the production resource/tool should be replaced.


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Master data

Afterwards press the button to replace the production resource/tool in these operations.

If the tool should be replaced in all operations, use the menu path Edit Selections Select all PRTs to mark all operations.

Afterwards press the button .


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Master data

3.1.6 Master inspection characteristics

Inspection characteristics describe what should be checked. They define inspection requests for materials or products. To make inspection planning more comfortable, inspection characteristics can be created as master data called master inspection characteristics. As an advantage inspection characteristics do not have to be created for each inspection plan. Master inspection characteristics can be referenced or copied to inspection plans.

Another advantage for maintaining inspection characteristics is, that where-used lists are created and master inspection characteristics can be replaced using a mass change (if they have been referenced).

The following chapters describe, how master inspection characteristics are created, changed, displayed or deleted.

3.1.6.1 Creating master inspection characteristics

Use the transaction to create master inspection characteristics:

Logistics Quality management Quality planning Basic data Inspection

characteristic Create (QS21)

plant – plant valid for the master inspection characteristic. It has to be entered when creating one.


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Master data

Master inspection characteristic – Number of the master inspection characteristic. The number is allocated manually.1.-2. digit QM 3. digit -4.-8. digit sequential numbere.g. QM-000099

Valid from – date, from which the master inspection characteristic is valid

Class characteristic – If you want to link a class characteristic and a master inspection characteristic, enter the number of the class characteristic. This means, inspection results are handed over to batch classification. This data field is not used at Continental Teves.

Data to copy from, if needed

After entering data on the initial screen, press to reach the next screen.


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Master data

preset indicators – used as input help. It contains default parameters for control indicators.

Quantitative / Qualitative characteristic – If the preset indicator is not used, these flags indicate which kind of characteristic it is.

General information Status – Controls whether the master inspection characteristic may be used. Set to “2” if the

usage should be allowed.


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Master data

Language key – language used for texts

Short text – description of the master inspection characteristic

Search field – text; used for matchcode search

Internal characteristics description – may be used to enter an additional characteristic description

Additional information Authorization group – used to control authorization for this transaction

Inspector qualification – used to check the qualification of an inspector

Fraction calculation – distribution key

Weighting of characteristic – indicating the importance of a characteristic.

Info fields – data fields for additional information

Press .

Screens for control indicators are shown. They depend on the kind of characteristic if it is a qualitative or quantitative characteristic.

In the following sections the maintenance of quantitative and qualitative characteristics is described, as it is done when creating or changing master inspection characteristics. The maintenance is influenced by the kind of characteristic. Because of this the procedure for both kinds of characteristics is described separately.

Quantitative characteristics

Quantitative characteristics are variable characteristics, for which numerical measured values can be recorded.

Control indicatorsSucceeding the control indicators for quantitative characteristics.


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Control indicator screen 1

Lower specification limit:If this flag is set, a lower specification limit has to be entered in the inspection plan.

Upper specification limit:If this flag is set, an upper specification limit has to be entered in the inspection plan.

Check target value:If this flag is set, a target value has to be entered in the inspection plan. The system checks automatically if the target value lies within the tolerances.


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Sampling procedure:A sampling procedure have to be assigned to the characteristic in the inspection plan. The sampling procedure determine the inspection scope and valuation mode (attributive, variable, manual, …) for the result recording. If you don’t assign a sampling procedure a 100% inspection takes place.

Additive sample:The sample size is increased by the quantity that is required for the inspection of this characteristic. It is set, e.g., if inspections are carried out on parallel.

SPC characteristic:Defines whether a control chart has to be run (the flag for sampling procedure is mandatory).

Destructive inspection:Indicates characteristics, which use a destructive inspection (destructed quantity will be posted ‘To sample usage in inventory management).

Summarized recording:The recording results of this characteristic are maintained as summary value.

Single result:The single recording results are maintained in the system (measured values, codes,...).


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No characteristics recording:No inspection results are entered.

Classed recording:The inspection results of a characteristic are entered as classed values.

Defects recording:If this flag is set, a defects recording is carried out when rejecting the characteristic. Prerequisite for an automatic defect recording is, that a defect code (from catalog 9 = defect types) is entered in the inspection plan. If no defect code is entered, a warning message will appear at saving the inspection plan.

Required characteristic:Results have to be recorded for this characteristic before a usage decision can be carried out.

Optional characteristic:Results do not have to be recorded for this characteristic before a usage decision can be carried out.

After acceptance:This flag is used for conditional characteristics. This characteristic will be inspected only if the previous required characteristic of the same operation has been valuated “A” (acceptance). The flag is used e.g. for expensive inspections, these are carried out only when the former characteristic has been accepted.

After rejection:This flag is used for conditional characteristics. This characteristic will be inspected only if the previous required characteristic of the same operation has been valuated “R” (rejection).

E.g.: If a visual inspection detects a burr, the characteristic has to be rejected. A conditional characteristic may be used for a detailed inspection of the burr and may result in an acceptance after all.

After filling out control indicator screen 1 press to display the second control indicator screen.


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Master data

Scope not fixed:The inspection scope is not checked at results recording. The number of parts to be inspected has to be determined by the inspector.

Fixed scope:The inspection scope has to be kept exactly at results recording. (If the inspection lot quantity is less than the inspection scope, then the inspection lot quantity is defined as the inspection scope.)

Smaller scope:Sample quantity may be smaller than the calculated inspection scope when recording results.

Larger scope:Sample quantity may be larger than the calculated inspection scope when recording results.


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No documentation:When recording the results no additional text has to be entered as documentation.

Documentation if rejected:When recording the results an additional text has to be entered as documentation if the characteristic has been rejected.

Documentation required:When recording the results an additional text has to be entered in any case as documentation.

Long-term inspection:It is allowed to make a usage decision even if the results have not been recorded yet (e.g. inspection takes place during a long period of time). For such characteristics it is possible to record results and defects even if the UD was already made.

Scrap share/Q-score:Defines whether the fraction of nonconforming units for this characteristic is taken into account when the scrap share for the inspection lot is calculated. It is used to calculate the Q-score (The Q-score is not used at Continental Teves).

RR change docs:When recording or changing the results change documents are created or updated.


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Master data

Test equipment assignment:Test equipments which have to be used for result recording can be assigned to this characteristic (e.g. caliper).

On operation level all required production resources/tools for all characteristics of the operation are assigned using the material number of the production resources/tools (test equipments).

On characteristics level the required production resources/tools (test equipments) for this characteristic are assigned .

Record measured values:Flag has to be set, if single measured values have to be recorded and confirmed for this characteristic.

If the flag is set, a certain number of single measured values has to be confirmed.

If the flag is not set, no single measured values can be confirmed. Only the mean value and the standard deviation can be confirmed.

Calculated characteristic:The results are not determined by inspecting the characteristic, but by calculation from results of characteristics of the same operation (flag Record measured values has to be set)Example:

A0 = parameter ( here: single measured value)0010 = characteristic, from which the value is taken (here: characteristic 0010).

Print:Inspection characteristic will be printed on the inspection instruction.

Do not print:Inspection characteristic will not be printed on the inspection instruction.

Do not print at skip:Inspection characteristic will be printed on the inspection instruction if there is no skip.


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Master data

Quantitative data and tolerance key

On the next step the quantitative data is maintained for the characteristic. Furthermore tolerance limits are set.

Choose the menu path Goto Quantitative Data or press the button .

The screen for quantitative data will be displayed. Which data fields are opened for input depends on control indicators set for this characteristic. If maintained e.g. control indicators for use of lower and upper limits, all data fields for maintaining these limits are displayed.

The most important data fields are described below.

Decimal places – precision used for values. If no value is entered, the system assumes 0 decimal places.

Measurement unit – measurement unit for values (e.g. target value, tolerances).

Target value – The measured value of a quantitative characteristic should not differ from this value.

Tolerance key – These key may contain target value, measurement unit, decimal places and tolerances. It is used to define tolerances for characteristics centrally.

Lower/Upper limit – Lower / upper limit for a measured value of this characteristic. Values off limits make the inspection refuse the valuation by ‘rejected’.


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Master data

As described a tolerance key can be used as an input help. If a tolerance key is used, its values are taken over into the screen. The values can be changed.

From the menu choose Goto Tolerance key

Choose a tolerance key from the list by double-clicking on it.


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Master data

Qualitative characteristic

Qualitative characteristics are attributive characteristics that cannot be measured by numerical values.

Control indicators

Control indicators for qualitative characteristics are shown below.

Control indicators screen 1

Characteristics attribute:The characteristic is attributive and refers to a catalog.


Automotive Systems

Master data

Sampling procedure:A sampling procedure have to be assigned to the characteristic in the inspection plan. The sampling procedure determine the inspection scope and valuation mode (attributive, variable, manual, …) for the result recording. If you don’t assign a sampling procedure a 100% inspection takes place.

Additive sampleThe sample size is increased by the quantity that is required for the inspection of this characteristic. It is set, e.g., if inspections are carried out parallel.

SPC characteristic:Defines whether a control chart is to be run (the flag for sampling procedure is mandatory).

Destructive inspection:Indicates characteristics, which use a destructive inspection (destructed quantity will be posted ‘To sample usage’ in inventory management).

Recording the number of defects:In the results recording, you can enter the number of nonconforming units and the number of defects.When using sampling procedures for incoming inspections maintained in the system, a confirmation of defect is not possible, because these sampling procedures contain an inspection based upon defective parts.


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Summarized recording:The recording results of this characteristic are maintained as a summary value.

Single result:The single recording results are maintained in the system (measured values, codes,...).

No characteristics recording:No inspection results are entered.

Classed recording:The inspection results of a characteristic are entered as classed values.

Defects recording:If this flag is set, a defects recording is carried out when rejecting the characteristic. Prerequisite for an automatic defect recording is, that a defect code (from catalog 9 = defect types) is entered in the inspection plan. If no defect code is entered, a warning message will appear at saving the inspection plan.

Required characteristic:Results have to be recorded for this characteristic before a usage decision can be carried out.

Optional characteristic:Results do not have to be recorded for this characteristic before a usage decision can be carried out.

After acceptance:This flag is used for conditional characteristics. This characteristic will be inspected only, if the previous required characteristic of the same operation has been valuated “A” (acceptance). The flag is used e.g. for expensive inspections, which are carried out only when the former characteristic has been accepted.

After rejection:This flag is used for conditional characteristics. This characteristic will be inspected only, if the previous required characteristic of the same operation has been valuated “R” (rejection).


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E.g.: If a visual inspection detects a burr, the characteristic has to be rejected. A conditional characteristic may be used for a detailed inspection of the burr and may result in an acceptance after all.

After filling out control indicator screen 1 press to display the second control indicator screen. This screen is similar to the screen of quantitative characteristics. The data fields Record measured values and Calculated characteristics are blanked out.

Scope not fixed:The inspection scope is not checked at results recording. The number of parts to be inspected has to be determined by the inspector.


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Master data

Fixed scope:The inspection scope has to be kept exactly at results recording. (If the inspection lot quantity is less than the inspection scope, then the inspection lot quantity is defined as the inspection scope.)

Smaller scope:The inspection scope may be smaller than the calculated inspection scope at results recording.

Larger scope:The inspection scope may be larger than the calculated inspection scope at results recording.

No documentation:When recording the results no additional text has to be entered as documentation.

Documentation if rejected:When recording the results an additional text has to be entered as documentation, if the characteristic has been rejected.

Documentation required:When recording the results an additional text has to be entered in any case as documentation.

Long-term inspection:

It is allowed to make a usage decision, even if the results have not been recorded yet (e.g. inspection takes place during a long period of time). For such characteristics it is possible to record results and defects even if the UD was already made.


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Master data

Scrap share/Q-score:Defines whether the fraction of nonconforming units for this characteristic is taken into account, when the scrap share for the inspection lot is calculated. It is used to calculate the Q-score (The Q-score is not used at Continental Teves).

RR change docs:When recording or changing results, change documents are created or updated.

Test equipment assignment:Test equipments which have to be used for results recording can be assigned to this characteristic (e.g. caliper).

On operation level all required production resources/tools for all characteristics of the operation are assigned using the material number of the production resources/tools (test equipments).

On characteristics level the required production resources/tools (test equipments) for this charateristic are assigned.

Print:Inspection characteristic will be printed on the inspection instruction.

Do not print:Inspection characteristic will not be printed on the inspection instruction.

Do not print at skip:Inspection characteristic will be printed on the inspection instruction if there is no skip.


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Master data

Catalog assignment

Code groups or selected sets and even single codes can be allocated to defect codes in case of rejection.

In this case choose from the menu Goto Catalogs for the characteristic or press the button when working on a characteristic.

Maintaining texts in other languages

Additionally short and long text may be maintained in different languages.

Choose from the menu Goto additional languages

or press the button of a characteristic.


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Master data

3.1.6.2 Changing / displaying master inspection characteristics

Use the following path to change or display a master inspection characteristic.

Logistics Quality management Quality planning Master data Inspection

characteristic Change / Display (QS23/QS24)

On the initial screen enter plant and master inspection characteristic. Confirm hitting to display the characteristics screen. There you are able to change the data.

Save your changes pressing the button (Save).

3.1.6.3 Deleting a master inspection characteristic

A master inspection characteristic may be deleted using the following path:


characteristic Delete (QS25)

On the initial screen enter plant and master inspection characteristic.

Afterwards press the button . The general data will be shown.

To delete it, press the button .

Confirm the pop-up:

A master inspection characteristic can only be deleted if the usage indicator is not set for any

version of the master inspection characteristic (i.e. it has never been used in a task list, material specification or certificate profile). If it has been used, all links to these objects have to be deleted and the status of the characteristic has to be changed to Deletion flag. The characteristic will be deleted by the next archiving session.


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Master data

3.1.6.4 Where-used list of master inspection characteristics

This where-used list can be used to display all inspection plans using a specific master inspection characteristic.


characteristic Where-used list (QS26)

After entering characteristics number and plant press the button to display a list of all inspection plans where the characteristic is used.

The list contains inspection plans and their operations using the characteristic.


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Master data

3.1.6.5 Replacing master inspection characteristics

Use this function to replace master inspection characteristics in some or all inspection plans.


characteristic Replace (QS27)

On the initial screen enter the characteristic you want to replace and the new characteristic. Press the

button to display a where-used list for the master inspection characteristic you want to replace.

Mark the operations in which the old characteristic should be replaced. If you want to replace it in all

operations, press the button (select all). Afterwards replace it in the selected operations by

pressing the button .


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Master data

3.1.7 QM view of the material master record

The material master record of SAP R/3 is splitted into different views. The QM view expands the general data and contains quality requirements like e.g. inspection types or certificate type. The QM view is plant-specific.

Prerequisite for maintaining a QM view is, that a material master record exists. I.e. material number and general data are maintained in SAP R/3.

Information about newly created material master records in the local system is given to the person responsible for maintaining master data by workflows. The QM view can be created from this workflow.

3.1.7.1 Maintaining a QM view

Logistics Quality management Quality planning Logistics Master Data

Material Create / Change (MM01 / MM02)

Material – Material number existing in SAP R/3. The material number is mandatory.

Industry sector – The industry sector is part of the general data and does not have to be entered.

Material type – The material type is taken from the general data, too.

Change number – Number identifying a unique change master record.

Copy from – Used to copy QM data from another material.

Enter the material number for which you would like to maintain the QM view.


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Master data

Press

and choose a plant.

The QM view will be shown.

You can save the view selection and organizational levels by pressing the button on the desired screen.

To blank these screens in the future, mark the options and .

Presetting the view selection and organizational levels

It is possible to preset the view selection and organizational levels.

Default Views... or Organizational levels...


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Master data


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Master data

Use the options and to use the presetting when creating or changing QM views in the future.

The presetting can be changed at any time if different values are entered.

For a single change correct the presetting using the buttons . When creating or changing data again, the system will use the saved presetting again.

General data (The data fields used at Continental Teves are highlighted)

Base unit of measure – unit of measure in which the stock of a material is managed. It will be filled from the general data view.

Unit of issue – unit of measure used for goods issues

Plant specific material status – plant-specific indicator restricting the use of a material.

GR processing time – Goods receipt processing time maintained by purchasing on the purchasing view; number of days needed for inspection; if a long inspection period is necessary, enter the estimated inspection duration. This time is taken into account in material requirement planning.

Catalog profile – profile used for PM and QM notifications.


Automotive Systems

Master data

QM material authorization – restricting access of material specific data to certain users

Post to inspection stock – Defines if the material is inspected (without inspection lot processing) and the goods receipt is posted to the inspection stock. This flag is taken over to purchase items and goods receipt items as a default. It is set automatically if inspection types are activated.

Documentation required – Changes to inspection lots and usage decisions are documented.

Inspection setup – If this flag is set, QM inspection data exists on the material in the maintained plant .

Inspection interval – Time interval for reinspection

Procurement data

QM procurement active – If this flag is set, QM procurement for all plants of a client is active. On plant level a control key has to be maintained. If QM procurement should not be used, inspection types have to be deactivated and the control key and the flag for “QM procurement active” has to be deleted. Inspection types should not be deactivated if open purchase orders exist. Because QM procurement was active when creating the purchase order, a quality inspection should be carried out even if the material master record does not require it. Therefore open purchase orders should be closed first before deactivating QM procurement. If a status profile is set in the quality info record, a warning message will appear when deactivating QM procurement.

QM control key – The QM control key defines quality requirements for a material. These can be requirements concerning the vendor, e.g. adding certificates when delivering, or concerning the purchaser (adding quality requirement documents). If a release is necessary, the combination of vendor and material has to be released (quality info record). If QM procurement is active, a control key has to be entered on plant level (you cannot save without the control key).


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Usage of control keys:

CtrlKey Short text Description0001 Vendor release Quality info record mandatory; this is the usual control key!0002 Vendor release, tech. delivery terms Quality info record and technical delivery terms necessary

If this control key is used, a document for technical delivery terms has to be maintained. The flag “Tech. delivery terms” will be set automatically.

0003 Vend.release,tech.del.terms,QA agreem. Quality info record, technical delivery terms and QA agreement necessaryIf this key is used, not only a document with technical delivery terms has to exist, but additionally a QA agreement with the vendor has to be maintained. It is maintained in the quality info record.

0004 Vend.rel,TechDelT.,QA agreement, certif. Quality info record, technical delivery terms, QA agreement and certificates are necessaryAdditionally a certificate type has to be maintained.

0005 Vendor release, certificate Usage possible.0006 Delivery release, documentation required This key should not be used, because it is not supported by the

system.0007 Delivery release, invoice block Not for use in QM.8888 Vendor block inactive Block set in the quality info record is deactivated. The block

function of the quality info record does not block a material-vendor-combination (Customizing).

9999 All functions active with error message Usage not possible

Certificate typeThe certificate type defines the certificate the vendor has to add to the delivery. If you enter a certificate, you should choose a control key using certificates, otherwise the entered data is of no use. The input field is activated by the control key. If a certificate is necessary, you will be asked for it when posting the goods receipt.


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Target QM system:This key and its description defines the requirements for the QM system of the vendor.When carrying out purchasing functions like inquiries or purchase orders the system checks if the QM system of the vendor meets the requirements entered in the material master record (customizing table). If it does not meet the requirements, a purchase order cannot be created (customizing).

Checked using:

Logistics Material management Purchasing Master data Vendor

Central Change(XK02)

Enter vendor and plant; mark all; choose second page; QM system

Technical delivery termsThis flag indicates that technical delivery terms are allocated.The flag is set automatically if the SAP document management system is active and an corresponding control key is set. Technical delivery terms can be printed when processing purchase orders.


Material Technical delivery terms Create (QV11)

Document types


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Master data

Inspection data

Press the button to display a window containing inspection types. Inspection types are used to control necessary inspections. Several different inspection types may be valid at a time.

To enter new inspection type activate the table pressing the button .

The following inspection types can be used:

Inspection types for incoming inspections:

01, 0101 und 0102

Inspection types used in production:

7, 9 und 15

Inspection types for goods issues:

10, 11 und 12

The default values shown as detailed information on the inspection types should not be

changed.


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Every inspection type contains detailed information. If you enter a new inspection type, press .

Post to inspection stock – causes postings of material to the inspection stock. A material transfer can only be done in QM by a usage decision.

Inspection for HU – Determines that the inspection lot is not created by the goods receipt posting but when a shipping notification is received.

Inspection with material specification – If this flag is set, the material inspection is based upon the material specification. The inspection by material specification can expand or even replace the inspection with task list.

Inspection with task list – Means that a task list is necessary for inspection.

Inspection by configuration – If this flag is set, configurations from the sales or production order may expand or change inspection characteristics from task lists or material specifications when creating an inspection lot.

Automatic assignment – the system tries to allocate a task list automatically. This flag can only be set if the flag “Inspection with task list“ is set.

Inspection by characteristics – A result recording based upon inspection characteristics is necessary for the inspection lot. Therefore an inspection with task list is mandatory. Inspection by characteristics is a prerequisite for dynamic modification based upon characteristics. I.e. if Dynamic modification at material or characteristic level is chosen, the decision on the next quality level depends upon the valuation of the inspection characteristic.

Sampling procedure – This data field is used only, if the inspection is not based upon a task list. If you enter a sampling procedure, the sample size is calculated from the inspection lot quantity.

100% inspection – The sample size is equal to the inspection lot quantity.

Inspection % – In this case the sample size is the entered percentage of the inspection lot quantity.

Manual sample calculation – If this flag is set, the calculation has to be started manually in the inspection lot.


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Manual sample entry – This flag determines, that you have to enter the sample size yourself (manually).

Dynamic modification rule – This data field is used only, if the inspection is not based upon a task list.- If a dynamic modification rule has been entered, the quality level will be determined by material, plant and inspection type. The dynamic modification criteria is determined using the inspection lot origin when maintaining the quality level (automatically).

Skips allowed – Skips are allowed when calculating the sample size. If all characteristics of an inspection lot are on status skip, a skip lot will be created.

Automatic usage decision – If this flag is set, the system will take usage decisions for inspection lots automatically. The inspection lot has to fulfil the following conditions: All characteristics are closed, no characteristic has been rejected, no defect and no quality notification exist, the lead time entered in customizing has to be reached.

Serial numbers possible – If this flag is set, the inspection lot contains individual pieces with serial numbers. For the material the serial number requirement has to be set in the material master required using a serial number profile. For the following inspection lot origins a list of serial numbers is taken over into the inspection lot: inspection based upon goods movements; inspection in production.

Average inspection duration – Average inspection duration for an inspection type in days. If the start date of an inspection is entered, the end date will be calculated using the average inspection duration. If the end date is entered, the start date will be calculated. Like the goods receipt processing time the average inspection duration influences the scheduling of sales orders.

Q-score procedure – Coded key of the procedure used to calculate the Q-score. This most simple procedure takes over the Q-score from the code of the usage decision. A different procedure calculates the Q-score based upon the scrap share of the inspected characteristics. Q-score procedures are not used at Continental Teves at the moment.

Allowed scrap share – Some Q-score procedures need a scrap share to calculate the Q-score.

Control inspection lot – This flag is used for incoming inspections. For a sequence of different goods receipts an existing inspection lot may be expanded under certain conditions and a new inspection lot will not be created.

It may be used for the inspection lot origins 01, 04, 05, 08. Following entries are possible: One inspection lot for each goods receipt item – For each goods receipt item an inspection lot

will be created. One inspection lot for each purchase order item or production order item and batch – An

inspection lot is created for the first goods receipt of a purchase order item or production order.

One inspection lot for each material document, material and batch – For each material document (for each goods receipt transaction) and each material/batch an inspection lot will be created. This may be the case if different purchase orders or different deliveries of the same material are processed with one goods receipt posting.

One inspection lot for each material and batch – For each material and batch an inspection lot will be created. This is useful if material has to be handled in batches.

Individual QM order – If this flag is set, an individual QM order for each material / inspection type combination is created.


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QM order – individual number of the QM order used for collecting costs.

Activating an inspection type

Parameters of an inspection type are activated when the corresponding flag is set .

3.1.7.2 Maintaining the QM view using workflows

As soon as a new production material has been created in a local system (usually by the plant change service department), the persons responsible for QM master data will be informed via an express mail. This means, the pop-up shown below will appear on screen immediately after creating the master record.

Additionally a work item is created in the inbox folder.Use the menu Office Workplace Inbox Workflow to display open work items.


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Master data

Mark the work item and press “Execute” or double-click on it to open the work item.The transaction to maintain the QM view will be shown. Necessary parameters will be set as a default and can be changed. Confirm the screen sequence with “Enter”.After creating/saving the QM view the pop-up shown below will be displayed.

If you want to close the creation of the QM view, press the button . The work item will be deleted from the inbox folder. The work item will be deleted for all users that have received the work item.

If the creation should not be closed, press the button . The work item will be displayed in the inbox folder of the user who processed the work item. This user can continue processing the work item. But it will be deleted from the inbox folder of all other users who have received it.

It is possible to reset the work item via the button , so all (responsible) users will have access to it again.


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3.1.7.3 Mass maintenance

Mass change of inspection data for materialsThe function mass change of inspection data allows to change inspection data for several (all) plants or for a predefined section of master data.Use the mass change to activate/deactivate inspection data or to maintain it.

Logistics Quality management Inspection planning Logistics Master Data

Material Inspection setup (QA08)


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Activate/deactivate inspection types

- If this flag is not set, the inspection type will be activated for those materials to which already assigned it but deactivated yet.If this flag is set, the inspection type will be activated for all materials even if it was not assigned to them before.

- If this flag is not set, the material will be changed only if there will be no inconsistency after the processing between MM stocks and QM stocks (without creating inspection lots). If the flag is set, inspection lots will be created to avoid inconsistencies if necessary.

- If this flag is set, all selected materials will be processed immediately.If this flag is not set, a list of selected materials will be displayed. Materials going to be processed can be chosen manually from this list.

– If this flag is set, change documents will be created for all changes of materials.

Enter inspection types going to be activated/deactivated

Continue pressing (execute).


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If the flag is set, all selected materials will be processed immediately. If

the flag is not set, a list of selected materials will be displayed. Materials going to be processed can be chosen manually from this list.

Single processing

- If this flag is not set, then the material will be changed only if there will be no inconsistency after the processing between MM stocks and QM stocks (without creating inspection lots). If the flag is set, inspection lots will be created to avoid inconsistencies if necessary.


Continue pressing (execute).

Here those materials are selected for which inspection types should be changed.

Use the button to maintain detailed information on the inspection types.


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The inspection types going to be processed will be saved by the icon .

Mass processing

- If this flag is not set, then the material will be changed only if there will be no inconsistency after the processing between MM stocks and QM stocks (without creating inspection lots). If the flag is set, inspection lots will be created to avoid inconsistencies if necessary.

- If this flag is set, all selected materials will be processed immediately.If this flag is not set, a list of selected materials will be displayed. Materials going to be processed can be chosen manually from this list.


Enter inspection types going to be activated/deactivated.


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Continue pressing the button (execute).

A screen for maintaining inspection types will appear.

Change flags and data for inspection types.

Continue hitting .

If the flag is set, all selected materials will be processed immediately.

If the flag is not set, a list of selected materials will be displayed. Materials going to be processed can be chosen manually from this list.

To save the inspection data for selected materials press the button .


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Creating QM views


Material Extendable Materials (MM50)

Use maintenance status Q and additional selection criteria to get an overview on materials that do not contain a QM view.

Material that is not subject to quality inspection can be deleted from the list (mark and press

button ). These materials will not be displayed when starting the transaction (MM50) again.

To maintain a QM view for a material, mark it and press the button .


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Master data

Then you are able to maintain the QM data as mentioned before. Press the button (next screen) to go to the next material.


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3.1.8 Quality info record

If a material is subject to quality inspections (according to the control key entered on the QM view), the material/vendor combination has to be released. This is done by creating a quality info record. The quality info record is maintained on plant level. It contains

the inspection type for series-inspection at the vendor (acceptance inspection) and a lead time for inspections before the goods receipt. (not used at Continental Teves),

blocking options for purchase orders. Blocking options for inquiries, source determination and goods receipt should not be used (not used at Continental Teves),

a status profile for administration of vendor relationships (sequence of inspections), the possibility to enter a QA agreement.

Without creating a quality info record an inquiry still can be created, but a purchase order or scheduling agreement cannot be created.

Usually the quality info record is created after maintaining the QM view in the material master record.

3.1.8.1 Maintaining a quality info record


Quality info record procurement Create / Change / Display (QI01/QI02/QI03)

Via this path the initial screen for creating or changing (or displaying) a quality info record will be shown.


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Material, vendor and plant are mandatory. You can copy an existing quality info record. To do so enter the corresponding data you want to copy from.

On the initial screen press to display the quality info record.

Deletion flag – is set to mark a quality info record for deletion.

The programs ZQ36Q190 (deleting single quality info records) and ZQ36QDEL (deleting several quality info records) are available to delete quality info records.

deleting single quality info records: ZQ36QI90


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deleting several quality info records: ZQ36QDEL

Release date – Up to this date you are allowed to purchase material from the vendor in the defined plant. If there is no time restriction, enter 31.12.9999.If the release date has expired, purchase orders cannot be created anymore. Scheduling agreements can still be created! Only a warning message will appear. A manual delivery schedule cannot be created for the scheduling agreement! If the delivery schedule is created automatically by the MRP run, this date is not taken into account and the delivery schedule will be created.

Release quantity – For a purchase order the system checks if the purchase order quantity exceeds the released quantity (purchase order quantities from different purchase orders will be accumulated). A purchase order can be created only if the released quantity is not exceeded. If the released quantity is blank and the released quantity is activated, no purchase order can be processed. It is allowed to create scheduling agreements! A manual delivery schedule cannot be created for the scheduling agreement! If the delivery schedule is created automatically by the MRP run, this data field is not taken into account and the delivery schedule will be created.

Block – The vendor is blocked because of quality reasons. This block is valid for a certain plant. The quality level for this material/vendor combination is set to permanent inspection. Furthermore, the responsible MRP controller (MRP 1 view of the material master record) is informed via an express mail (see below). Permanent inspection is valid for the corresponding plant. Blocking function and blocking reason will be printed on the sample drawing instruction. Use blocking reasons starting with 9X only.If a vendor should be blocked completely, block him via the vendor master data.

The work item is sent to the inbox folder of the responsible MRP controller.Use the menu Office Workplace Inbox Workflow to display the open work items.


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Master data

Mark it and press the button “Execute” or double-click on the work item to open it.The transaction for maintaining the source list will be started.

If serious quality problems occur change the MRP indicator from 2 to 1. This means no automatic delivery schedule will be created anymore.

When leaving the transaction the following pop-up appears.


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If you want to close the process, press the button . The work item will be deleted from the inbox folder. The work item will be deleted for all users that received the work item.

If the process should not be closed, press the button . The work item will be displayed in the inbox folder of the user who processed the work item. This user can continue processing the work item. But it will be deleted from the inbox folder of all other users who received it.

It is possible to reset the work item via the button , so all (responsible) users have access to it again.


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Certification –The QM system used by the vendor can be entered here. When carrying out purchasing functions like e.g. creating an inquiry or purchase order the system checks if the QM system of the vendor meets the required QM system entered in the material master record. If the requirement is not met, the purchase order cannot be created (customizing). This data field is not used because the system uses the QM system of the material master record.

Inspection control – The inspection control decides whether an inspection lot is created or not. Following options are available: "Inspection active if vendor is not certified" - An inspection lot is created if the material master

record demands it and no other function forbids it. "No inspection" – No inspection lot is created even if the material master record demands

one. "Inspection active independent of vendor certification" – An inspection lot will be created even

if a skip should be used according to the QM system of the vendor. This is the usual entry at Continental-Teves.

Vendor source inspection – Defines the inspection type for the source inspection at the vendor. If the source inspection is done at the vendor, additionally, set the flag Source insp. – no GR. This avoids that an additional inspectional lot is created when posting the goods receipt. (Not used at Continental Teves because inspection lots are not created and therefore no SRS data exists.)

Certification control – Controlling the certificate receipt. It defines what kind of certificates are necessary.

The status profile is used to control the material/vendor relationship, i.e. it contains the valid status of the material/vendor relationship. An inspection type is allocated to each status.

When creating a quality info record enter the status profile QM000003 (this is the only valid

status profile for incoming inspections).


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When entering the status profile the initial status Delivery relation opened will be set. The status management contains the abbreviation and the status.The current status is highlighted in blue.This user status can be changed manually.

The status profile will be changed from “neu” to “voab” when posting a goods receipt. This way it is possible to accept series deliveries despite of open samples. Furthermore, the inspection type 0102 (Series GR despite open sample) will be active for the next incoming inspection and the task list for series will be allocated. According to the inspection type 0102 a skip is not possible and the usage decision has to be made manually (no auto. UD).

If the usage decision for the inspection lot of the samples has been made and the result is OK (samples are accepted), the status profile will change from “voab” to “seri”. The next incoming inspection will use inspection type 01 (incoming inspection) and the task list for series will still be used. If inspection lots with inspection type 0102 still exist, the usage decision has to be made manually, because an automatic usage decision with the according job is not possible.

All status changes are documented. Use the menu Extras Statusänderungen to display them.


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Master data

Press the button to display date and time of status changes or deletions.

Use the button to get a list indicating when each status has been active.


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Quality agreement – For handling of QA documents the SAP function quality agreements is used. If the QM control key of the QM view demands a QA document, it has to be entered here using the document management system. Otherwise no purchase order can be processed.


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3.1.8.2 Mass maintenance

Use the mass maintenance for quality info records to process several records at once.


Quality info record procurement Collective processing (QI06)

Use the selection to define which quality info records should be processed. You can enter single values or intervals for material, plant or vendor. Furthermore, via the multiple

selection (button ) you are able to enter additional single values or intervals or you can even exclude them.


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Use the button to import ASCII text files if necessary.

Enter path and name of the file. Press the button to import the file into the multiple selection.

The mass maintenance can be used to display, change or create quality info records. It is controlled

by the tabs .


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After executing the selection you will get a list of all selected records.

Mark the data records you want to process. Us the button (save) to create or change the marked records.

At the end you will get a message containing the number of processed quality info records.


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3.1.9 Quality level

The quality level is created automatically when the first series GR is posted. The creation of the quality level can be done manually when using dynamic modification at lot level, in case you do not want to start with the first inspection stage or if an incoming inspection is not necessary for the material.

If you use dynamic modification at characteristic level, you cannot create the quality level manually. If you do not want to start with the first inspection stage of the dynamic modification rule, execute the report ZMQDQL10 and afterwards change the created quality level manually.

3.1.9.1 Maintaining the quality level

Logistics Quality management Quality inspection Quality level Create /

Change / Display (QDL1/QDL2/QDL3)

Enter plant, material and vendor or customer. Press the button or to display another selection screen if more than one series task list exists. If this is not the case, the quality level will be displayed immediately.


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If more than one task list exists, select the correct quality level and its task list. (This should not be the case in the live system, because then an automatic allocation of task lists would not be possible.)

Double-click on a row to go to the next screen shown below.The display is different for dynamic modification at lot level or at characteristic level.


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This screen displays the inspection stage and the number of inspections since the inspection stage change for the inspection lot.The quality level will be updated when posting a goods receipt.

If a usage decision taken before is changed later on, the quality level will not be corrected. The quality level has to be changed manually. If you change it manually, you have to enter a reason for changing. The “old” and “new” quality level is documented using the company-specific table ZQQLHIST.

The same applies if the usage decision has to be changed because of an incorrect long term characteristic.

The number of “OK” or “not OK” inspections of the inspection stage can be displayed by pressing the

button .

Influence of the inspection type on the quality level:

Inspection lots of inspection type 01 go through all inspection and skip stages of the dynamic modification rule.

Inspection lots of inspection type 0102 go through all inspection and skip stages of the dynamic modification rule, too. But all inspection lots have to be inspected because of the inspection type 0102 (no skips allowed).

Inspection lots of inspection type 0101 (sample) have no influence on the quality level.


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3.1.9.2 Quality level history

When changing the quality level manually, you always have to enter a reason for changing before saving the changes.

Dynamic modification at lot level:

Dynamic modification at characteristic level:

The reason as well as old and new data of the quality level are documented in a table. This table can be accessed using transaction SE16 (data browser). Enter table name ZQQLHIST (ZQQLHIST_V) and confirm hitting .

The selection screen has to be filled out accordingly. Afterwards press button Execute (F8).

client plant material number vendor date of change time of change user

changed. changed new quality level. No. of OK / not OK inspections since inspection stage changeoperation characteristic

old inspection stage No of inspections / not OK inspections change reason of the old inspection stage

The columns “changed operation” and “changed characteristic” are blank or filled with “0000” when using dynamic modification at lot level.


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Mark a row and press the button Display or Change to display all data fields of this table for the selected row.

3.1.9.3 Displaying all quality levels of a certain inspection stage

Call up transaction SE16.

Select table QDQL.

Press the button to maintain user settings.

E.g. settings for the display (List width, max. number of hits, layout) or field descriptions of the selection menu.


Automotive Systems

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Enter plant and next inspection stage on the selection screen.

Use the function Execute (F8) to display all quality levels of a plant (here: plant 0010) with a certain inspection stage (here: inspection stage 99 permanent inspection).


Automotive Systems

Master data

Changing the list layout

Use the button (change layout) to change the list layout user-specifically according to your needs.

After pressing this button a pop-up will appear which includes the functions for changing the layout.

The left section on the tab Columns shows the current list layout. The columns are displayed from top to bottom in the sequence on the screen from the left to the right.

Columns not necessary can be blanked out. Mark the column and press the button to move the data fields to the columns set.Additional data fields of the columns set can be displayed in the list. Mark these data fields and press

the button to move them to the columns.


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Use the button (search) to search for columns.

The sequence of the columns displayed in the list can be changed using the buttons . First mark the column you would like to move. You can also move several columns at once (press the shift-key when marking columns).

If contents of a column can be summed up a checkbox will be shown in the corresponding column. If this box is checked, the system will calculate the total automatically and display it beneath the corresponding column in the list.

Use the tab Sort to enter criteria for sorting the list and to mark columns for which a subtotal should be calculated.

The tab Filter contains criteria to set a filter for the list. Only those data records will be shown, that match the filter criteria.


Automotive Systems

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Use the tab View to influence the list type.

The tab Display contains display options like e.g. grid lines or column headings.

Use the button (save layout) to save the layout user-specifically. You may have a look at the

layout first by pressing the button and afterwards saving it using the button (save layout).In both cases the following screen will appear.


Automotive Systems

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Enter a name and a description for your layout. Pay attention that a user-specific layout always has to start with a letter.

If you mark the option default, this layout will be saved as the standard layout in your user profile.

The user-specific layouts can only be accessed by the user, who created them.

If you want a different layout, press the button (select layout) and choose one from the list. This layout will be used for the list.


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Master data

Exporting list contents to an excel table

Use the button to export the list contents to Microsoft Excel.

First a message will appear containing the information, that filters, sorting, totals and subtotals will not be taken over.

in the next window choose the kind of table.

Microsoft Excel will be started and the content of the list will be displayed as an Excel-sheet.

Save the table in Excel if necessary.


Automotive Systems

Master data

3.2 Inspection planning

The inspection plan defines the inspection operations and the inspection characteristics going to be inspected. The inspection plan that is included in the QM module is related to routings and rate routings of Production Planning (PP) and to master recipes of Process Industry (PP-PI). These task list types differ only slightly. For inspections in production additional inspection plans do not have to be maintained. Inspection characteristics can be defined in routings, rate routings or master recipes. At Continental Teves separate routings or “inspection routings” are used with a group counter 50.

You can create inspection plans for different usages, e.g. inspection plans for incoming inspections or inspections in production. The correct selection will be done via the inspection plan usage.

An inspection plan can be created: copying a reference operation set copying an existing inspection plan referencing to a reference operation set manually

3.2.1 Task list types

3.2.1.1 Reference operation set

Reference operation sets are task list types that cannot be used directly for inspection planning or production planning. Usually they are not related to a material (even if it is possible) and carry an independent identification number and description. The reference operation set contains operation and characteristic sequences often used. The reference operation plan can be referenced to inspection plans on operation level, i.e. the inspection plan and reference operation set are linked. Every change of the reference operation set results in a change of the linked inspection plans. All inspection plans containing such a reference can be listed using a system report. The report includes next to the list itself several maintenance functions. Reference operation set can be used for copying instead of referencing, too.

The number allocation is done manually.

1. digit Q2.-8. digit continuous numberExample: Q0000099Additional notes: task list type: S, transactions QP.., ....

3.2.1.2 Inspection plan

The task list type “inspection plan” is used in the QM module to process quality inspections in procurement and production. Typical inspection types are the inspection of goods receipts or goods issues. Inspection plans contain all functions of reference operation sets. Because of this the manual deals only with the inspection plan itself.


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3.2.2 Maintaining inspection plans

To create (change or display) an inspection plan, choose:



Initial screen to create an inspection plan:

The unique identification of an inspection plan is done via material and plant or via group and group counter.

Material – key to identify a material.

Plant – key to identify a material.

Group – Several inspection plans for a material with different usages may be grouped. In a group the different inspection plans are distinguished by the group counter.

Change number – Number identifying a unique change master record

Key date – Date used for creating or changing the inspection plan

Revision level – Indicating the change status of a material or document


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Copying an inspection plan

If an existing inspection plan should be copied, press the button .

If no group is entered on the initial screen before you press the button, a new group will be created automatically for the inspection plan by the system. If a group is entered, this group will be kept and the group counter will be increased by one.

After pressing the buttons a pop-up will appear, where you should select the task list type.

On the next screen enter material number and plant or group. If you enter a group, all material/task list relations will be copied, too. Use further criteria for the task list selection to restrict the task list selection. A certain inspection plan of a group can be selected by entering the group counter.

If more than one inspection plan exists for a material or group, they will be displayed for selection.


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After selecting the desired inspection plan it will be used for copying. The new inspection plan will be displayed. Enter the status of the new inspection plan in the corresponding data field. Then the inspection plan is completely maintained and can be changed or saved.


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Master data

Creating a new inspection plan without reference

To create a new inspection plan press the button or .

If one or more inspection plans exist for the material, a plan overview will be shown. Otherwise this screen will not be displayed.

The existing plan can be changed here even if you are in creation mode.

To create a new inspection plan choose the button from the standard toolbar.


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3.2.2.1 Maintaining header data

The first step to create an inspection plan is to enter the header data.


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Task list Group –key of the chosen group

Group counter – consecutive number within a group. When creating a new task list the group counter will be increased by one.

Plant – key identifying a unique plant

Long text exists – Indicating if additional texts have been entered via

General data Deletion flag – If this flag is set the inspection plan will be deleted on the next archiving session.

Until that session the flag can be reset at any time.

Usage – Determines the functions that may use this task list.

Status – Indicates the processing status of a task list, e.g. if the inspection plan is still being created or released.

Status 1 and 3 are used for routings only.

Planner group – Key determining the person or group of persons responsible for maintaining the task list.

Planning work center – Key determining the work center used as critical work center for capacity evaluations of planned orders.

From lot size – Lower lot size limit for this task list.

To lot size – Upper lot size limit for this task list.


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Unit of measure – The unit of measure is taken from the material master record when the task list is created. Only those materials can be allocated to this task list, that use the same base unit of measure. If you want to use different units of measure, you have to create different inspection plans.

Old task list number – Can be used to enter the (old) inspection plan number from other systems.

If dynamic modification should be used, this has to be maintained in the header data.

Parameters for dynamic modification/inspection points Inspection points – To identify inspection points a combination of data fields can be entered in

the customizing. These combinations may contain user-specific data fields and fixed data fields and their keys and sequence according the inspection point type. (Only used for inspections in production / repetitive manufacturing)

Sample-drawing procedure – Master data object with instructions for sample-drawing (Not used at Continental Teves.)

Dynamic modification level – Without an entry no dynamic modification will take place. This means that every inspection lot will be inspected. If dynamic modification should be used, a dynamic modification level and a dynamic modification rule are necessary.

If you use dynamic modification at lot level, additional data fields will be displayed.

Modification rule – This modification rule is valid for all inspection characteristics.


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Administrative data If the task list has been maintained completely, administrative data will be shown in the

header. It contains the validity period, the person who created it and when it was created. It also contains the number of inspections this task list has been used for and the date of the last inspection according to this task list.

Use the long text function of the header to maintain text for printouts of the inspection plan.Pay attention to keeping the correct sequence of data shown below.

The abbreviation LL is used to print life cycle documents.


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3.2.2.2 Maintaining inspection operations

After entering the header data, define inspection operations.

Press the button .

Operation overview Operation – key for the operation

Work center – Work center used for inspection(s). The work center can be used as selection criteria for selecting inspection lots.

Plant – unique key for a plant

Control key – key defining which economic operations can be carried out for this object of the task list

Standard text key – key containing often used operation descriptions

Description – short description for the operation

Long text exists – If this flag is set, additional text has been entered. Press the button to display or maintain it. The flag is set automatically by the system.

Reference task list group and reference group counter – identifying a reference operation set allocated to this operation

Administrative data – Lists information on creation and changes of the operation


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3.2.2.3 Allocating tools

On the operation overview of the task list mark the operation to which a tool should be allocated and

press the button (Tool).

If tools already exist, an overview for the allocated tools to this operation will appear.

Use the path Edit New entries and choose the tool type or press one of the buttons

to enter the key of a new tool.


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If no tool has been allocated yet, this window will appear immediately. As a default the tool type “Material” will be proposed.

Press one of the buttons to change the tool type.


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3.2.2.4 Creating new inspection characteristics from within the task list (no master inspection characteristic)

Inspection characteristics are subordinate to inspection operations. The inspection characteristic is used to describe the characteristic and to control the result recording. You can refer to an inspection method, sampling procedure and dynamic modification rule. Depending on the type of characteristic qualitative or quantitative requirements for checks and result recording can be determined. When allocating the task list to material (mandatory), vendor (optional) or customer (optional) additional default values can be maintained. This means that there is no need for you as an inspection planner to create redundant inspection plans, if you only have to modify vendor-specific or customer-specific target values.

To allocate an inspection characteristic to an operation, choose an operation from the operation

overview (mark) and press from the toolbar. The characteristic overview will be shown.

On the characteristic overview enter a proposal for the characteristic control indicator or mark the corresponding data field QN or QL. Confirm pressing to display necessary screens automatically.

Quantitative characteristic

A quantitative characteristic is a characteristic, for which numerical values can be recorded.

Control indicatorControl indicators for quantitative characteristics are shown below.


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Control view 1

Lower specification limit:If this flag is set, a lower specification limit has to be entered in the inspection plan.

Upper specification limit:If this flag is set, an upper specification limit has to be entered in the inspection plan.

Check target value:If this flag is set, a target value has to be entered in the inspection plan. The system checks automatically, if the target value lies within the tolerances.


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Sampling procedure:A sampling procedure is allocated to the material in the inspection plan. Sampling procedures determine the inspection scope and valuation mode for recording results (qualitative characteristics, tolerances, characteristic attributes, etc.).

Additive sampleThe size of the partial sample is increased by the quantity that is required for the inspection of this characteristic. It is set, e.g., if inspections are carried out parallel.

SPC characteristic:Defines whether a control chart is going to be run (the flag for sampling procedure is mandatory).

Destructive inspection:Indicates characteristics, which use a destructive inspection (destructed quantity will be posted to inspection sample in inventory management).

Summarized recording:

The recording results of this characteristic are maintained as a summarized value.

Single result:

The single recording results are maintained in the system (measured values, codes,...).


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No characteristics recording:

No recording results are maintained.

Classed recording:

The recording results of a characteristic are maintained as classed recordings.

Defects recording:

If this flag is set, a defects recording is carried out when rejecting the characteristic. Prerequisite for an automatic defect recording is, that a defect code (from catalog 9 = defect types) is entered in the inspection plan. If no defect code is entered, a warning message will appear for each result recording.

Required characteristic:

Results have to be recorded for this characteristic before a usage decision can be carried out.

Optional characteristic:

Results do not have to be recorded for this characteristic before a usage decision can be carried out.

After acceptance:

This flag is used for conditional characteristics. This characteristic will be inspected only if the previous required characteristic of the same operation has been valuated “A” (acceptance). The flag is used e.g. for expensive inspections which are carried out only when the former characteristic has been accepted.

After rejection:

This flag is used for conditional characteristics. This characteristic will be inspected only, if the previous required characteristic of the same operation has been valuated “R” (rejection).

E.g.: If a visual inspection detects a burr, the characteristic has to be rejected. A conditional characteristic may be used to check the burr and may result in an acceptance after all.

After filling out control indicator screen 1 press to display the second control indicator screen.


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Scope not fixed:

The inspection scope is not determined automatically. The number of parts going to be inspected has to be determined by the inspector.

Fixed scope:

The inspection scope has to be kept exactly when recording the results. (If the sample quantity is less than the inspection scope, then the sample quantity is defined as the inspection scope.)

Smaller scope:

Sample quantity may be smaller than the calculated inspection scope when recording the results.

Larger scope:

Sample quantity may be larger than the calculated inspection scope when recording the results.


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No documentation:

When recording the results, no additional text has to be entered as documentation.

Documentation if rejected:

When recording the results an additional text has to be entered as documentation if the characteristic has been rejected.

Documentation required:

When recording the results additional text has to be entered in any case as documentation


It is allowed to make a usage decision even if the results have not been recorded yet (e.g. inspection takes place over a long period of time).

Scrap share/Q-score:

Defines whether the fraction of nonconforming units for this characteristic is taken into account, when the scrap share for the inspection lot is calculated. It is used to calculate the Q-score (The Q-score is not used at Continental Teves).

RR change docs:

When recording or changing the results, change documents are created or updated.

Test equipment assignment:

Test equipment used to record results is allocated to this characteristic (e.g. sliding calliper).

On operation level tools for all characteristics of the operation are allocated using the material number of the tool (test equipment).


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On characteristics level a tool (test equipment) is allocated to a characteristic using the material number.

Confirm values:

Flag has to be set if single measured values have to be determined and confirmed for this characteristic.

If the flag is set, a certain number of single measured values has to be confirmed.

If the flag is not set, no single measured values can be confirmed.

Calculated characteristic:

The results are not determined by inspecting the characteristic but by calculation from results of characteristics of the same operation (flag Confirm values has to be set)Example:

A0 = parameter ( here: single measured value)0010 = characteristic, from which the value is taken (here: characteristic 0010).

Print:

Inspection characteristic will be printed on the inspection instruction.

Do not print:

Inspection characteristic will not be printed on the inspection instruction.

Do not print at skip:

Inspection characteristic will be printed on the inspection instruction, if there is no skip.


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Qualitative characteristic

Qualitative characteristics are attributive characteristics for which no numeric values can be recorded.

Control indicator

Control indicators for qualitative characteristics are shown below.

Control view 1

Characteristics attribute:

The characteristic is attributive and refers to a catalog.


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Sampling procedure:A sampling procedure is allocated to the material in the inspection plan. Sampling procedures determine the inspection scope and valuation mode for recording results (qualitative characteristics, tolerances, characteristic attributes, etc.).

Additive sampleThe size of the partial sample is increased by the quantity that is required for the inspection of this characteristic. It is set, e.g., if inspections are carried out parallel.

SPC characteristic:Defines whether a control chart is going to be run (the flag for sampling procedure is mandatory).

Destructive inspection:Indicates characteristics, which use a destructive inspection (destructed quantity will be posted to inspection sample in inventory management).

Defects confirmation:

In results recording you are able to confirm the number of defects instead of the number of defective parts. When using sampling procedures for incoming inspections maintained in the system, a confirmation of defect is not possible, because these sampling procedures contain an inspection based upon defective parts.

Summarized recording:

The recording results of this characteristic are maintained as a summarized value.


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Single result:

The single recording results are maintained in the system (measured values, codes,...).

No characteristics recording:

No recording results are maintained.

Classed recording:

The recording results of a characteristic are maintained as classed recordings.

Defects recording:

If this flag is set, a defects recording is carried out when rejecting the characteristic. Prerequisite for an automatic defect recording is, that a defect code (from catalog 9 = defect types) is entered in the inspection plan. If no defect code is entered, a warning message will appear for each result recording.

Required characteristic:

Results have to be recorded for this characteristic before a usage decision can be carried out.

Optional characteristic:

Results do not have to be recorded for this characteristic before a usage decision can be carried out.

After acceptance:

This flag is used for conditional characteristics. This characteristic will be inspected only, if the previous required characteristic of the same operation has been valuated “A” (acceptance). The flag is used e.g. for expensive inspections, which are carried out only when the former characteristic has been accepted.

After rejection:

This flag is used for conditional characteristics. This characteristic will be inspected only if the previous required characteristic of the same operation has been valuated “R” (rejection).

E.g.: If a visual inspection detects a burr, the characteristic has to be rejected. A conditional characteristic may be used to check the burr and may result in an acceptance after all.


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After filling out control indicator screen 1 press to display the second control indicator screen. This screen is similar to the screen of quantitative characteristics. The data fields Confirm values and Calculated characteristics are blanked out.

Scope not fixed:

The inspection scope is not determined automatically. The number of parts to be inspected has to be determined by the inspector.


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Fixed scope:

The inspection scope has to be kept exactly when recording results. (If the sample quantity is less than the inspection scope, then the sample quantity is defined as the inspection scope.)

Smaller scope:

Sample quantity may be smaller than the calculated inspection scope when recording results.

Larger scope:

Sample quantity may be larger than the calculated inspection scope when recording results

No documentation:

When recording results no additional text has to be entered as documentation.

Documentation if rejected:

When recording results an additional text has to be entered as documentation, if the characteristic has been rejected.

Documentation required:

When recording results additional text has to be entered in any case as documentation.


It is allowed to make a usage decision even if the results have not been recorded yet (e.g. inspection takes place over a long period of time).

Scrap share/Q-score:


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Defines whether the fraction of nonconforming units for this characteristic is taken into account, when the scrap share for the inspection lot is calculated. It is used to calculate the Q-score (The Q-score is not used at Continental Teves).

RR change docs:

When recording or changing results, change documents are created or updated.

Test equipment assignment:

Test equipment used to record results is allocated to this characteristic (e.g. sliding calliper).

On operation level tools for all characteristics of the operation are allocated using the material number of the tool (test equipment).

On characteristics level a tool (test equipment) is allocated to a characteristic using the material number.

Print:

Inspection characteristic will be printed on the inspection instruction.

Do not print:

Inspection characteristic will not be printed on the inspection instruction.

Do not print at skip:

Inspection characteristic will be printed on the inspection instruction if there is no skip.


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Details for general data, quantitative data, catalogs, samples, control indicator

Details General data

Partial sample - Number of the partial sample allocated to the inspection characteristic of the task list.

Inspector qualification – Information on the qualification of the inspector necessary to carry out the inspection.Fraction calculation – distribution key

Weighting of characteristic – indicating the importance of a characteristic (used for the inspection plan printout)

Characteristic-ID – key for identifying a characteristic

Data origin – specifies from which data source the results data should be copied.

Inspection method – key of an inspection method (The inspection method describes the processing of an inspection)

Test equipment – describing the test equipment(s) allocated to this characteristic (max. 5)

Info fields – fields for additional information


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Details for quantitative data

Which data fields are displayed depends on the control keys chosen for this characteristic.

The most important data fields are explained below.

Decimal places – precision used for values. If no value is entered, the system assumes 0 decimal places.

Measurement unit – measurement unit for values (e.g. target value, tolerances).

Tolerance key – These key may contain target value, measurement unit, decimal places and tolerances. It is used to centrally define tolerances for characteristics.

Target value – The measured value of a quantitative characteristic should not differ from this value.

Lower/Upper limit – Lower upper limit for a measured value of this characteristic. Values off limits cause the inspection to refuse the valuation by ‘ not accepted’.

As described a tolerance key can be used as an input facility. If a tolerance key is used, its values are taken over into the screen. The values can be changed.


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Master data

Details catalog

By entering a code group or selected set only the allocated codes will be displayed for the automatic defect recording (control indicator for the inspection characteristic). This means the selection of codes for the inspector is restricted.

If a defect code is entered, this code will be used automatically for rejection. No manual selection is necessary.

If no entry is made, the complete defect catalog will be displayed for the activated automatic defect recording.


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Details sample

Here the sampling procedure, which has to be used for this characteristic, has to be entered.

If the inspection plan is using dynamic modification at characteristic level, additional data will be displayed. There you have to enter a dynamic modification rule for the inspection characteristic or an inspection characteristic of the same operation containing a dynamic modification rule.

Details control indicator

Displaying and maintaining control indicators.


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3.2.2.5 Allocating tools to inspection characteristics

If the inspection characteristic has to be inspected using a certain test equipment, this test equipment has to be allocated to the characteristic as a tool.On operation level the tool has to be implemented. The allocation is done via the general data of the inspection characteristic.This data will only be displayed or can only be changed, if the option Test equipment assignment has been activated within the control indicators.

Use the button to allocate up to five tools to a characteristic.


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3.2.2.6 Referencing master inspection characteristics

Inspection characteristics are subordinate to inspection operations. The inspection characteristic is used to describe the characteristic and to control the result recording. You can refer to an inspection method, sampling procedure and dynamic modification rule. Depending on the type of characteristic qualitative or quantitative requirements for checks and result recording can be determined. When allocating the task list to material (mandatory), vendor (optional) or customer (optional) additional default values can be maintained. This means that there is no need for you as an inspection planner to create redundant inspection plans if you have to modify vendor-specific or customer-specific target values.

To allocate an inspection characteristic to an operation, choose an operation from the operation

overview (mark) and press from the toolbar. The characteristic overview will be shown.

To reference a defined master inspection characteristic enter the number of this characteristic in the

data field Master inspection characteristic or search for it using the matchcode search . Master inspection characteristics of any plant can be used, as far as you have the authorization.

After confirming with a sampling procedure has to be allocated to the characteristic, if this has been maintained within the control indicators of the master inspection characteristic. If dynamic modification has been maintained in the header of the task list, a dynamic modification rule can be entered.


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After confirmation via the master inspection characteristic is referenced.

Referenced means, that all changes that apply to the master inspection characteristic also apply to the inspection plans it is referenced to.

The symbols in column ’Reference to master inspection characteristic’ indicates that a reference exists.


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3.2.2.7 Unlocking a reference

If data of the master inspection characteristic should be changed (e.g. control indicators or quantitative data), the master inspection characteristic has to be unlocked. If you unlock it, the reference will be lost.

To unlock a characteristic, mark the corresponding row. Use the menu path Edit Unlock master

charac or the button to unlock it.

After the characteristic has been unlocked all values can be changed (e.g. control indicators, quantitative data).


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3.2.2.8 Defining dependent characteristic specifications

If inspection plans for e.g. certain materials only differ by some characteristics, e.g. tolerances, it is not necessary to create new inspection plans. It is possible to define dependent characteristic specifications. To define these, the master inspection characteristic has to be unlocked.

To define dependent characteristic specifications mark a characteristics row and press the button

an.

Use the button or to get a selection list of materials allocated to this inspection plan.

From this selection list choose the material you want to change.


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Use the button or the button New entries to display a screen where you can enter the new characteristic values for the chosen material.

This screen has to be filled out as shown above. Entering a target value is not necessary (not a required data field). Press to confirm the entered values.

Afterwards save the new characteristic allocation.


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The limits are only valid for this allocation, all other materials still use the “usual” values of the normal characteristic or master inspection characteristic.

3.2.2.9 Copying characteristics from other task lists

It is possible to copy characteristics from other inspection plans.

To copy a characteristic from another task list, place the cursor in a characteristics row, where the characteristic going to be copied should be entered.

If there are more characteristics following this one, they will be moved downwards. Use the menu path Copy .Characteristics. or the button

and select the inspection plan and characteristics going to be copied.

To copy characteristics of the same operation, mark the characteristics going to be copied, and place the cursor on the row, after which the characteristics should be entered. If there are further characteristics following the marked one, these will be moved downwards.

Use the menu path Edit Copy into operation to copy them.


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3.2.2.10 Using reference operation sets

Reference operation sets are implemented on operation level. To implement them an existing operation has to be marked or the cursor has to placed on an existing operation. Use Extras

Reference Create or the button to display the screen shown below.

Enter the operation, which should contain the reference operation set. The reference operation set has to be entered in the data field “Group referred to“ or use the matchcode search to select task lists of type “S“.


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If you execute the search, a list of reference operation sets will be displayed. Choose the correct one from the list. Press or save it to implement the reference operation set.

As long as the reference is active, the corresponding operation is highlighted in grey and cannot be changed.

Use Extras Reference Unlock to unlock this reference and change the operation if necessary.


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3.2.2.11 Where-used list of master inspection characteristics

Use the where-used list to display those inspection plans containing a certain master inspection characteristic.


characteristic Where-used list (QS26)

After entering the number of the master inspection characteristic and a plant press the button

to get the where-used list for the selected master inspection characteristic.

This list contains the inspection plan and the corresponding operations using the characteristic.


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3.2.2.12 Replacing master inspection characteristics

Use this function to replace master inspection characteristics in several or all inspection plans immediately.


characteristic Replace (QS27)

On the initial screen enter the master inspection characteristic to be replaced and the new

characteristic. Press the button to get a where-used list for the master inspection characteristic, that should be replaced.


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From the where-used list choose those operations, where the characteristic should be replaced.

If it should be replaced in all operations, press the button (mark all).

Afterwards replace the characteristics of the selected operations by pressing the button .

3.2.2.13 Where-used list of reference operation sets


Reference Operation Set Where-used list (CA90)

After entering group and task list status press the button (execute) to display the where–used list for the selected reference operation set.This list contains the inspection plans and corresponding operations using the reference operation set.


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3.2.2.14 Replacing reference operation sets


Reference operation set Replace (CA95)


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On the initial screen enter the reference operation set going to be replaced and the new one. Enter

further selection criteria (optional except task list status) for inspection plans and press the button (execute) to get a where-used list for the reference operation set, that should be replaced.

From the where-used list choose the operations in which the old reference operation set should be replaced.

Afterwards press the button to complete the replacement.


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3.2.3 Printing inspection plans

3.2.3.1 Printing lists of inspection plans (general) available in the system

Inspection plans can be selected and printed using different criteria. This report prints already existing inspection plans. Without entering a group counter all inspection plans of a group including their inspection characteristics specification will be printed.


Inspection plan Print (general) (CP05)


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3.2.3.2 Printing lists of inspection plans by material

Inspection plans for a special material can be printed as well. This report prints inspection characteristics specifications valid for a selected material or for a specific material/vendor/customer combination. The same inspection plan version will be selected, that is used to create an inspection lot for the material.


Inspection plan Print (selective) (CP08)


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Depending on the selected function and chosen selection criteria the system creates a list of existing inspection plans.


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3.2.3.3 Printing inspection plans

To print an inspection plan use transaction ZQ36PD10.

Fill out the selection screen. Press the button (execute) to start the selection.

If you marked the data field Print preview with an “X”, the selected inspection plan will be displayed on screen first. To print it use the menu path Text Print.

If you want to select reference operation sets (task list type ’S’) do not enter a plant or material number on the selection screen.


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Master data

The long text displayed in the header has been maintained in the header of the inspection plan using the long text function (see 3.2.2.1 Maintaining header data).

3.2.4 Displaying a list of missing inspection plans

Use this function to determine, which materials are not linked to a valid inspection plan.


Inspection plan Missing or unusable inspection plans (QP06)


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Master data

To search for a material use any combination of the selection criteria (material, plant, inspection type, key date).

Press the button to receive a list of materials with missing or invalid inspection plans.

From within this list use the button to display the material master record or the button

to go to the inspection plan.

Use the following function to create a list of materials in purchase but for which no valid inspection plan exists.


Inspection plan Missing or unusable inspection plans in procurement (QP07)


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Master data

To search for a material use any combination of the selection criteria (material, plant, inspection type, key date).

After hitting you will get a list of materials with missing or invalid inspection plans.

From within this list use the button to display the material master record or the button

to switch to the inspection plan.


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3.2.5 Displaying a list of multiple material/inspection plan allocations

Start transaction ZQ36PL80 to generate the list.

After entering selection criteria (plant, task list type and usage) start the list by pressing the button (execute).


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Master data


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Master data

3.2.6 Inspection planning using the Engineering Workbench (EWB)

Use the Engineering Workbench for a better overview on inspection plans and its faster maintenance.

First choose working area “PRUEFPLAN” (German for: inspection plan). This way you get the information you need to create or process an inspection plan.

Enter selection criteria to define, which inspection plans should be displayed or processed in the Engineering Workbench.

The system copies the selected inspection plans from the database to your worklist.

Then you can process the inspection plans of your worklist. If you create new plans, these plans will be transferred to your worklist.

Afterwards you save your worklist.

The system writes new and changed inspection plans to the database.

Using the Engineering Workbench you are able to create new inspection plans, to copy existing plans and to reference or to copy reference operation sets. Furthermore, you are able to process inspection plans.

3.2.6.1 EWB: Starting the Engineering Workbench


Inspection plan Workbench (CWBQM)


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3.2.6.2 EWB: Selecting a working area

Enter the needed working area and press (Continue).

By choosing a working area the Engineering Workbench will be set up for a certain task. In this case the working area is inspection plans.

Working areas can focus on the following object types:

Header (task list)Defines that the selection criteria have focus on task list headers. The system loads all operations of a task list to your worklist.

OperationDefines that the selection criteria have focus on operations. The system loads only certain (selected) operations of a task list to the worklist. Because less objects are shown, this display is more efficient for use.

BOM headerDefines that the selection criteria have focus on BOM headers. The system loads all items of a BOM to your worklist.

ItemDefines that the selection criteria have focus on items of a BOM. The system loads only certain (selected) items of a BOM to your worklist.

At the moment the focus on task list headers should be used only.

Use the button (save as default) to save the selected working area as a default. Then the Pop-Up for entering a working area will not be displayed anymore.

3.2.6.3 EWB: Entering selection criteria

Depending on the chosen working area, a screen for entering selection criteria for an inspection plan will be displayed.


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If you press the button you are able to choose from even more selection criteria.


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After entering selection criteria you have the following display possibilities:

According to the focus of your working area the screen headers overview or Operation overview will be displayed. If there are several task lists that match the selection criteria, a table for selection will be displayed.

(Headers)

The Headers overview will be shown.

(Operations)

The Operations overview will be shown.


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(Inspection characteristics)

The Inspection characteristics overview will be shown.

3.2.6.4 EWB: Product Structure Browser

For a more comfortable processing of inspection plans activate the Product Structure Browser using

the button . The Product Structure Browser is a navigation tool, which displays inspection plans, operations and inspection characteristics hierarchically in an object tree.

Then you are able to maintain inspection plans by selecting them directly from this tree.


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3.2.6.5 EWB: Creating inspection plans

Copying an inspection plan

Enter material number and task list type of the copy template in section Context.

Mark the desired copy template.

Press the button (Copy).

A selection screen for the target data will be displayed.

In the Context section of the target data enter material number and task list type for the new inspection plan.

To copy all subordinate objects and to create new references for them, mark the option

.

Which objects are copied, can be set in the options of the copy area .


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Use the button to create a new inspection plan based upon the copy template.

The new inspection plan will be indicated as blocked. Values will be taken from the copy template.

Maintaining task list header data

Use the tabs to work on the proposed data for the task list header.

Maintaining operations

To maintain default values for the operations, mark the task list you want to process. Afterwards go to the operations overview of the task list via the menu path Task list Operations.


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Use the tabs to check and change (if necessary) the default values of the operations.

Inspection characteristics

To create new inspection characteristics or to alter existing characteristics mark an operation and choose the menu path Task list Inspection characteristics.

Use the tabs to maintain the single inspection characteristics.


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Production resources and tools

To allocate a tool to an inspection characteristic, choose the menu path Task lists Production resources and tools from the inspection characteristic overview.

In difference to the “classic” transactions for maintaining inspection plans, which allow the

allocation of up to five tools, the Engineering Workbench only allows to allocate one tool.

For a faster access to certain objects use the tree.

Double-click on an object to divert to the corresponding overview and details screens.

If all data of the new inspection plan has been maintained, save it using the button (save).The system writes your worklist, including he new inspection plans, to the database.

You receive the system message .


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Creating an inspection plan without copying

Enter the material number and task list type of a template in section Context.

Choose the button (Create ) or press (Continue).

In the header overview new rows will be displayed for entering new inspection plans.

Use the tabs of the different levels to maintain data for the new inspection plan.

If you want to copy existing objects, it is recommended to use the drag&drop function in the overview tree.

E.g., if you want to copy an operation, click on this operation using the left mouse button, hold the mouse button and drag the operation to your new inspection plan.

Afterwards define the sequence in which the operations should be carried out.

To define which objects should be copied with the operation use the copy options which can be

accessed via (settings).

E.g., if you want to copy an operation including its subordinate tools but without the subordinate inspection characteristics, use the following setting for the copy area.


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Master data

If all values of the new inspection plan have been maintained, save the inspection plan using the

button (save).

The system writes your worklist, including the new inspection plan, to the database.

You will receive the system message .

3.2.6.6 EWB: Changing an inspection plan

To change an inspection plan choose the same data as for creation of a new plan.

First load the task list you would like to change to your worklist.

In your worklist mark one or more inspection plans you would like to process.

To change them press the button (Change/Lock).

First the system locks these inspection plans, i.e. they cannot be processed by another user.

The inspection plans will be marked by the symbol (object locked).

Now you can change those data fields which are ready for entry.


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Master data

If you maintained all changes, save the inspection plan using the button (save).

The system writes your worklist, including the new inspection plan, to the database.

You will receive the system message .

Afterwards unlock the inspection plan using the menu path Header Display/Unlock. The inspection plan can now be processed again by other users.

If you make a change on operation level, only this operation will be locked. Other operations of

the same task list can be maintained by other users at this time.

If you want to change an object locked by another user, you will receive the following message:


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Business transactions

4 Business transactions

4.1 Quality inspection in procurementThis chapter outlines how a quality inspection is documented and completed in SAP. Usually a quality inspection is processed after the automatic creation of an inspection lot after a goods receipt. Furthermore, it will explain how an inspection lot can be created manually. The processing will be the same.

This chapter is not about maintaining the master data, which is described in chapter 3.

Regular processing of a goods receipt using the QM module

GR posting

Inspection lot

Result recording

Qnotification

Usage decision

Inventory posting


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4.1.1 Inspection lot

The inspection lot is the instrument for the inspector, i.e. it carries all information necessary to process the inspection.

Depending on the inspection type and on the parameters of the material master record the material will be posted to the quality inspection stock when creating the inspection lot.

To create an inspection stock the corresponding inspection type has to be activated.

4.1.1.1 Automatic creation of an inspection lot

If the corresponding inspection type of the material master record is activated, the inspection lot will be created automatically when posting the goods receipt. It includes all information of the GR posting and you can go to the corresponding documents from within the inspection lot.

Exception:If a source inspection is done at the vendor and maintained in the quality info record, the incoming inspection can be deactivated. (This function is not used at Continental Teves.)

4.1.1.2 Manual creation of an inspection lot

Similar to the automatic creation the corresponding inspection type has to be activated in the material master record.

Logistics Quality management Quality inspection Inspection lot Processing

Create / Change / Display (QA01/QA02/QA03)

Material – Material number

Plant – key for a unique plant

Inspection lot origin – This origin names the origin of the inspection lot and (usually) combines several inspection types.


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On the initial screen enter material, plant and origin (01 = goods receipt). Press to display another selection screen.

If several inspection types are activated for the chosen origin, choose one of those from the next window.When posting a goods receipt, the valid inspection type will be determined automatically using the status of the quality info record or the document type of the purchasing order (for samples).

Choose the correct inspection type and confirm hitting . If inspection type 01 or 0102 is chosen, the inspection lot will be processed and completed similar to a series goods receipt. If you use inspection type 0101, no inspection plan will be allocated. This means, there will be no result recording, just a usage decision.


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Inspection lot quantity – quantity of the inspection lot

Number containers – number of trading units contained within the inspection lot

Start date – Start date for inspection. Default will be current date , which can be changed.

Insp. end date – End date of inspection. If no date is entered, the system calculates it using the start date and adding the average inspection duration entered in the material master record for the inspection type. If the average inspection duration is blank, the current date will be taken.

Manufacturer – If you receive the material from distributors, use this data field to enter the manufacturer of the material.

Vendor – unique vendor number. Used to take over information from the vendor master record.

Purchasing organization – key of a purchasing organisation. The purchasing organisation is an organizational unit dividing a company due to purchasing requirements.

Short text – Short description of the inspection lot (40 digits; use the button (long text) to add additional texts.


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If you press , the system tries to allocate an inspection plan to the inspection lot. An information message will appear in the status bar, telling you that the quality inspection will be prepared.

The system status should change to REL (released) and CALC (Sample calculated).

To display the status details in a separate window, press the button .

Apart from the status it includes the actual possible economic operations.

At the end save the inspection lot pressing .

If more than one inspection plan or if no inspection plan exists and is activated, the system cannot determine the inspection plan automatically. In this case a pop-up window will appear. Use this pop-up to allocate an inspection plan. Afterwards save the inspection lot. The status bar will display an information message telling you the number of plant and the one of the new inspection lot created.

After saving the inspection lot can be processed.

4.1.1.3 Printing sample drawing instructions

By pressing the buttons you are able to print an inspection instruction or sample drawing instruction at any time from within the inspection lot. Depending on customizing parameters the sample drawing instruction may be printed automatically when creating the inspection lot (default at Continental-Teves).

4.1.2 Results recording


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If an inspection plan carrying inspection characteristics is used, the results of the inspection have to be recorded.

4.1.2.1 Worklist

To record results of an inspection, two different kinds of worklists are available, which will be explained in this chapter. In general, results can be recorded directly without using worklists. Both procedures will use the same screen for result recording.

4.1.2.2 Results recording worklist

Logistics Quality management Quality inspection Worklist Results

recording (QE51N)

Initial screen:

This selection screen does not contain required data fields. Restrict as many parameters as possible, to get short lists and improve the system performance.


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Use the button (user settings) to define individual settings for the result recording and to influence the processing according to your needs.

Use the tab Recording configuration to define e.g. the navigation control for results recording.

Close on continue

If the following requirements are met, the inspection characteristic or partial sample will be closed when recording or changing results.

For the inspection characteristic the control indicators Fixed scope or Smaller scope are set. The target sample scope is reached. You have the authorization to valuate and close the characteristic. After recording the result for the inspection characteristic you chose Continue.

Automatic close when navigating


For the inspection characteristic the control indicators Fixed scope or Smaller scope are set. The target sample scope is reached. You have the authorization to valuate and close the characteristic After recording the result for the inspection characteristic you have used the navigation

function to go to the next inspection lot, next operation, next characteristic or you pressed the button Back or Characteristics overview.


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Automatic close when saving


For the inspection characteristic the control indicators Fixed scope or Smaller scope are set. The target sample scope is reached. You have the authorization to valuate and close the characteristic. After recording the result for the inspection characteristic you have saved.

Automatic close on confirmation of last value

If the following requirements are met, the operation will be saved.

Results have been recorded or changed. The cursor is placed on the last characteristic of the operation. The target sample scope of the last characteristic is reached. After recording the result for the inspection characteristic you have chosen Continue.

Go to next char., partial sample, insp. unit

If the following requirements are met, the next characteristic, next partial sample or next inspection unit will be displayed automatically when recording results.

The target sample scope of the last characteristic is reached. After a complete result recording you have chosen Continue, Valuate or Close.

Go to the next operation going to be inspected

If the following requirements are met, the next inspection operation will be displayed automatically.

Results have been recorded or changed. The cursor is placed on the last characteristic of the operation. The target sample scope of the last characteristic is reached. After recording the result for the inspection characteristic you have chosen Continue.


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Skip the characteristic overview screen

If the operation contains characteristics with status 1 or 2, the characteristics overview will be skipped and the result will be recorded on the main screen of the inspection characteristic.

Single values are not automatically expanded

After entering results the characteristics overview will not display rows for single results.

Use the tab Inspection point identification to define e.g. the field combination for inspection points.


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Define particular entries for recording on the Default values tab.

Define the report type on the Defects recording tab and offer a multiple selection of defect codes.

On the tab View define, if graphics should be started immediately after executing the transaction or if the graphic should be started on request.


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Press the button (execute) to display the worklist according to the entered selection criteria.

Double-click on the different levels to get access to the corresponding result recording automatically:

• Inspection lot level (10000333666) -> Usage decision• Operation level (0010) -> Recording results for all characteristics of an

operation • Characteristics level (0010) -> Result recording for a single characteristic

The worklist shows only inspection lots to which an inspection plan is allocated. This is the reason why inspection lots for samples will not be displayed. The colour of inspection lots indicates if it has to be inspected or skipped. If it has to be inspected it will be highlighted in blue. Skips or already completed inspection lots are highlighted in black.The coloured indicator in front of the characteristic shows if the characteristic has been accepted (green) or rejected (red).


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The listed data of the worklist (here: inspection lot number, material number with short text, vendor and creation date of the inspection lot) can be changed user-specific.

Change layout


Redundant columns can be blanked out. Mark the column and press the button to move the data fields to the columns set. Additional data fields of the columns set can be displayed in the list. Mark

these data fields and press the button to move them to the columns.

The sequence of columns can be changed using the column POS.


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The displayed columns and the sequence of the columns in the worklist itself can be set by the user, too. Place the mouse pointer on the column header, press the left mouse button and move the

column to the new position. Press the button on the top right corner of the table to save the new layout.

You can even define your new layout as a default.


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4.1.2.3 Worklist inspection lots

Logistics Quality management Quality inspection Worklist Inspection Change data /Display data (QA32/QA33)

This worklist is used to display inspection lots that have not been fully processed depending on the setting of the radio button. (result recording, UD, inventory posting).

On this screen enter selection criteria for inspection lots and values for list parameters.


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Do not enter data in the data field . If you enter a number, the list will not display the first X hits. Instead, only the first X entries of the database will be read.

Use the button to save the selection criteria and to list parameters as a user-specific variant.

If data fields cannot be changed (e.g. the lot creation date), use the button Variant attributes to check for a selection variable. Delete it to change the data field contents.

After maintaining selection parameters and values for list settings press the button to save them. When the transaction is started again, these values will be entered as a default. You can use or change them.

The transaction will be started by hitting (execute).


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Use the button (change layout) to change the list layout user-specifically according to your needs.

After pressing the button a window will appear which offers the functions for layout changes.


Redundant columns can be blanked out. Mark the column and press the button to move the data fields to the columns set. Additional data fields of the columns set can be displayed in the list. Mark

these data fields and press the button to move them to the columns.

The sequence of the columns displayed in the list can be changed using the buttons . First mark the column you would like to move. You can also move several columns at once (press the Shift-key when marking columns).

Use the button (save layout) to save the layout user-specific. You may have a look at the layout

first by pressing the button and afterwards saving it using the button (save layout).In both cases the following screen will appear.


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Enter a name and a description for your layout. Pay attention that a user-specific layout always has to start with a letter.

If you mark the option default, this layout will be saved as the standard layout to your user profile.

The user-specific layouts can only be accessed by the user who created them.

If you want a different layout, press the button (select layout) and choose one from the list. The list will be displayed using the chosen layout.


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The following functions can be accessed from the worklist:

Maintaining / changing usage decisions

Recording / changing defects

For more details on processing defects see chapter 4.1.2.7 (Recording defects).

Recording / changing result


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Changing inspection lots

Further functions are:

Printing a SAP inspection report

Printing a SAP quality certificate

Recording a defect This is the same function as described above.


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4.1.2.4 Recording results without worklists

If inspection lot numbers and inspection operation numbers are known or can be selected using the matchcode search functions on the initial screen, results can be recorded without using worklists.

Logistics Quality management Quality inspection Inspection result For

operation Record (QE01)


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4.1.2.5 Recording results

In general, results can be recorded on operation / characteristic level, i.e. results can be recorded separately for each work center.

The result recording can be accessed as described before either by using worklists or in a direct way. Both processes will guide you to the same screen for recording results.

Logistics Quality management Quality inspection Inspection result For

operation Record (QE01)

or


recording (QE51N)

Recording results using worklists:


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The left part of the screen contains a hierarchical display of inspection lots.

inspection lot or partial lot

Operation

Characteristic

If open characteristics exist, these will be highlighted by colours in the hierarchical tree.

The current valuation status is indicated by traffic lights:

Valuation of the characteristic

(grey) without valuation

(green) accepted

(red) rejected

valuation missed

Inspection lots that have to be inspected are highlighted in blue.Skips or processed inspection lots are highlighted in black.

You can use the worklist to navigate comfortably between the different levels.

On operation level the characteristics overview for this operation will be displayed.

You get an overview on the characteristics of the operation. On this overview the results can be recorded.


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The characteristics overview is divided into the following views with different focus:

General – Overview and recording possibility for summarized values and single values

Summarized - Overview and recording possibility for summarized values

Unit to be inspected – Overview and recording possibility for single values with reference to a sample device

Indicators - Overview and recording possibility for summarized values and single values displaying the control indicators (e.g. summarized recording, partial samples, measured values, controlling characteristic, automatic defect recording)

The different views can be selected via the different tabs.

The characteristics overview allows to navigate between characteristics and operations.

If you want to select a specified characteristic, double-click on the characteristic within the overview or double-click on the characteristic within the worklist. Another possibility is, marking the line within the

characteristic overview and to press the button .

Screen: Single values for characteristics

This screen is used to record results for a single characteristic depending on the way of recording.

There are different ways for recording results depending on if e.g. for each sample device the results have to be recorded or if summarized values are entered like mean value and standard deviation.

It depends on this recording type which data has to be entered on the characteristics screen when recording results. In general the following recording types are supported:

Summarized recording Single value recording Classed recording

You can also record results for a characteristic in several partial samples. If characteristics are recorded quantitative (measured values), qualitative (attribute codes for characteristics with selected sets) or attributive, depends on the settings of the control indicator of the task list.


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Summarized recording

When recording summarized statistics, the following types of results are supported:

Number of defectsEnter the number of inspected units in the data field Inspected. When closing the characteristic this number will be compared to the predefined sample scope and checked for compliance with predefined tolerances.The number of defect sample units is entered in the data field No. of defects. This number may not be greater than the number of inspected parts.


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Coded characteristic attributes for the inspection characteristic

You can confirm coded characteristic attributes for an inspection characteristic if you have assigned a selected set to the characteristic in the inspection plan.

Quantitative confirmation

Enter the number of inspected parts in the data field Inspected.The number of inspected parts below or above the tolerance limits are entered in the data fields No. above or No. below.

For quantitative inspection characteristics without tolerance limits, enter the number of nonconforming units in the Nonconforming field. The fields No. above and No. below are not displayed.

Coded characteristic attributes for single units

You can confirm coded characteristic attributes for an inspection characteristic, if you have assigned a selected set to the characteristic in the inspection plan.


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Single value recording

When recording single values, the following types of results are supported:

Number of defects

For an attributive single value recording based on the number of defects, enter in the column valuation of the Single Values screen area the valuation (accepted/rejected). If it is rejected you may be asked for a defect class. The system updates the values in the fields Inspected, No. of defects and Nonconforming.

Measured values

Enter the measured values for the unit to be inspected. The system valuates the measured values. Those that lie within the tolerance range defined by the upper/lower limit (section: specs) are valued “A” (accepted) in the Val column. Measured values that lie outside the tolerance range are rejected. If a measured value is rejected (R), the system enters the defect class of the code predefined in the task list in the Defects Class column.

After a measured value is entered, the system updates the data in the fields Inspected, Nonconforming, No.above, No.below and x-bar.

If no confirmation of measured values has been planned for an inspection characteristic with a single-sided or double-sided tolerance range, you only confirm the valuation (OK / not OK) for each single unit. After the valuation is entered, the system updates the values in the fields Inspected and Nonconforming.


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4.1.2.6 Adding characteristics

If it is necessary to add inspection characteristics to the predefined inspection scope, use the menu path Edit

Create additional characteristic or the button of the characteristics overview.

Enter a master inspection characteristics. Only those master inspection characteristics can be used, that have been entered before as master data.

Default values of the master inspection characteristics are taken over to the new characteristic.

To change these values you must have the authorization to change master inspection characteristics.

The following values can be changed:Quantitative characteristic: short text, upper specs limit, lower specs limit, target value, decimal

placesQualitative characteristic: short text

Enter a sampling procedure for the characteristic. If the flag for the sampling procedure is not set in the master inspection characteristic, the sampling procedure entered on plant-level in customizing will be used. If this is not set, either, the characteristic will be inspected with 100%.

The newly assigned characteristic can be processed like a planned characteristic. Every new

characteristic gets the number 9000


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4.1.2.7 Skipping required characteristics

If a required characteristic should not be inspected, this characteristic should be closed while recording results and provided with an corresponding inspection description.The characteristic can be closed without entering a value using the menu path Edit Characteristic

Force completion or by pressing the button .

Afterwards a window will be displayed asking you for acceptance or rejection of the characteristic.

The advantage of this procedure is that after closing all characteristics the inspection lot is respectively marked on the worklist and therefore turned valid for taking a usage decision.

4.1.2.8 Valuating and closing characteristics

The valuation determines if the quality requirements are met. The result of the valuation is the basis for the usage decision. The valuation function will be called up automatically if you try to close a characteristic.

If you want to valuate manually, press the button (valuate) on the characteristics overview or single characteristic screen. If you use the function on the overview screen, this function will be carried out for all marked characteristics or, if no characteristic is marked, for the characteristic where the cursor is placed onto.

After recording results the characteristics have to be closed to carry out the valuation. This can be carried out on the characteristics overview or single characteristics screen. To close it press the

button . If you have to correct it afterwards, you have to unlock it first. To do so press the button

, correct the value and close the characteristic again. If you use a sampling procedure that does not valuate a characteristic automatically when closing or you do not use any sampling procedure, the characteristic has to be valuated manually. The system will ask for the valuation by displaying the corresponding screen to accept or reject the characteristic.


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After all required characteristics have been valuated the usage decision can be made. The colour of characteristics changes in the worklist according to their valuation. The colour of the letters changes from blue to black.If the characteristic is accepted this will be indicated by a green traffic light, if it is rejected by a red one.

Automatic valuation of characteristics

Status of a characteristicThe processing status indicates the actual processing state of a characteristic.

4.1.2.9 Defects recording

Defects can not only be recorded when recording results, but also using the worklist for inspection lots and even before making the usage decision on the corresponding screen.

When recording result defects can be recorded on three levels:

Inspection lot Operation Characteristic

When recording defects you have to enter a report type on the first screen. It can be preselected via user parameters or user settings. The screen shown below already displays the following screen containing the defect overview.


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Several defects can be recorded using the catalog. This is done by selecting a code of the corresponding column. Furthermore, the number of defects can be entered. If no number is entered, the system sets the number to “1”.

The defect record should be activated. This is done by pressing the button . This will display the next screen:


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You can enter a description for the complete quality notification. It will be displayed in the quality notification in the short text data field under description. The responsible department defines the department for further processing and the responsible person defines who is responsible for it. This person will see the created quality notification in his worklist.

The data field for the responsible department can be preallocated via user parameters.

The department can be selected manually. To do so press the button Structure search twice.


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Choose the responsible department from the list, e.g. quality assurance department of plant 01.

The responsible person can be determined by entering the name in the right data field or by searching for the user using address data on the corresponding tab.

All reference data, like e.g. purchase order, material, vendor and inspection lot, will be taken over into the newly created quality notification.


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4.1.3 Making usage decisions

The usage decision, short form UD, is the final step within an inspection using inspection lots. Depending on the inspection type and the settings of the material master record an inventory posting from quality stock may be necessary.

Generally the following procedures can be distinguished when making a usage decision by a necessary inventory posting:

Entering the UD and transferring the quality stock (detailed description in chapter 4.1.3.2)

Transfer from quality stock onlyThis may be necessary if the material is needed before a UD is made, e.g. because of a production shortage.

If the UD is taken, no results can be changed or recorded anymore for the inspection lot, except for long term characteristics. Furthermore, defect recordings or changes of defect recordings are not possible. Only the defective quantity can be changed.

To mark an inspection lot respectively, which means that the UD can be made, all required characteristics of the inspection lot have to be closed.

Usually it is possible to make a UD without closing all required characteristics (see Skipping required characteristics 4.1.2.5).

4.1.3.1 Worklist for inspection lots

Logistics Quality management Quality inspection Worklist Inspection

Change data (QA32)

First you will get the initial screen:


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Enter selection criteria and execute the transaction pressing the button .

The worklist for inspection lots will be displayed according to the entered selection criteria.

Mark the inspection lot and press the button (usage decision).

You will be guided to transaction QA11 and the following screen will be displayed:

On this screen the UD can be made as described in chapter 4.1.3.3 and the inventory posting can be carried out.


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4.1.3.2 Recording results worklist


recording (QE51N)

First you get the initial screen already described:

This screen does not contain required fields. In general you should enter as many parameters as possible to get a short list and to improve the system performance.

Afterwards execute the transaction by pressing the button (execute).

On the left side of the screen the worklist will be shown according to the entered selection criteria.

Double-click on inspection lot level to get to transaction QA11 and the following screen will be displayed:


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On this screen the UD can be made as described in chapter 4.1.3.3 and the inventory posting can be carried out.


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4.1.3.3 UD without worklist

If the inspection lot numbers are known or can be selected using the matchcode search function, the usage decision can be made without using worklists.

Logistics Quality management Quality inspection Inspection lot Usage

decision Record (QA11)

Initial screen:

Enter the inspection lot number and press or hit .


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The screen of making the usage decision will appear:

Confirm certification receipt

If the following error message appears when making a usage decision, the receipt of a quality certificate has to be confirmed.

To do so choose the menu path Edit Confirm receipt of certificate.


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Defect recording

To record defects press the button and enter a report type.

The data field report type can be preset using the corresponding user parameters.

Another possibility for a preset of the report type is to use the button for user settings in the result recording worklist.The tab defect recording can be used to preset the report type.


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Now you can record defects in a catalogue. To record defects select the code of the corresponding column. Furthermore, enter the number of defects. If no number is entered, the system sets it to “1”.


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The defect record should be activated. This is done by pressing the button . This will display the next screen:

You can enter a description for the complete quality notification. It will be displayed in the quality notification in the short text data field under description. The responsible department defines the department for further processing and the responsible person defines who is responsible for it. This person will see the created quality notification in his worklist.

The data field for the responsible department can be preallocated via user parameters.


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If the responsible department is not preset, select it using the matchcode search and press the button Structure search.

The responsible person can be determined by entering the name in the right data field or by searching for the user using address data on the corresponding tab.

Forced closure

As described before it may be necessary to use a forced closure. This may be necessary, if not all required characteristics have been closed.

In this case press the button . Confirm the following security interrogation. If you enter and save a UD code the pop-up will appear, too, if open required characteristics exist.


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Recording a defective quantity

Defective quantities are recorded using the button .

Entered defective quantities are used in SRS to calculate ppm key numbers.

Now enter a usage decision code.

If necessary expand needed code groups.Double-click on a code to copy it to the field for the UD code.The information will be copied to the UD code field, too. Apart from the code group and code the system copies the valuation code, quality score and follow-up action.


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Follow-up action of a usage decision

Activity, that is executed after making a usage decision.In the selected set of catalog 3 (usage decision) the key of a follow-up action is allocated to a usage decision. If this code is entered when a usage decision is made, the system carries out the follow-up action allocated to this code.

The catalog Usage decisions contains two selected sets (=) for making usage decisions.

The selected set QM=00001 (UD sampling goods receipt) contains codes and follow-up actions for usage decisions of samples.

The selected set QM=00001 (UD serial delivery receiving) contains codes and follow-up actions for usage decisions of regular deliveries.


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UD code QM=00001 (sample) follow-up action2101 Acceptance sample free release date is set to infinite

status of quality info record is set to “seri” update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail

2102 Accepance sample free with control insp. release date is set to 2 years status of quality info record is set to “seri” update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail

2103 Accept sample with restriction sup. fault status of quality info record is set to “seri” update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail calling up transaction Change quality info record

2105 Accept sample with restriction (CT fault) status of quality info record is set to “seri” update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail calling up transaction Change quality info record

2199 Acceptance for test lot cancelling calling up transaction Change quality info record

2201 Rej. samples, one time rel., fail. supplier update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail calling up transaction Change quality info record

2202 Rejection sample update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail calling up transaction Change quality info record

2204 Accept samples, no series rel. (CT fault) update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail calling up transaction Change quality info record

2205 Reject samples (CT fault) update of table ZQBE printing the inspection report sending the inspection report via SAP-Mail calling up transaction Change quality info record


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UD code QM=00002 (series) follow-up action1101 Acceptance automatic inventory posting (to unrestricted use)1102 Acceptance with info to the supplier printing the inspection report

sending the inspection report via SAP-Mail1103 Acceptance with reservations diverting to transaction Change quality level1104 Acceptance with deviation diverting to transaction Change quality level1105 Acceptance after sorting diverting to transaction Change quality level1106 Acceptance after rework diverting to transaction Change quality level1199 Acceptance for test lot cancelling diverting to transaction Change quality level

automatic inventory posting (to unrestricted use)

1201 Rejection, backshipment to the supplier automatic inventory posting (to blocked stock)1202 Rejection, scrapping to our own account automatic inventory posting (to blocked stock)1203 Rejection, rework to our own account automatic inventory posting (to blocked stock)

Inventory posting

The inventory posting has to be carried out when material has been transferred to quality stock due to the inspection lot creation, e.g. for a goods receipt. Inventory postings are not necessary for manually created inspection lots.In general, the transfer from quality stock can be carried out without making a usage decision. This would be a special release.

Choose the tab to display the data fields for the inventory posting.

The button is displayed only if a UD code has been entered that is related to an inventory posting. By clicking this button the system copies the quantity to be posted in the corresponding data field based upon the UD code.


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The following inventory postings are possible.

To unrestricted-use material will be posted to the unrestricted-use stockTo scrap material is defect and will be scrapped to the expense of Continental Teves.

The material will be posted using a designated account.To sample usage The material, inspected in a destructive inspection, will be posted using a

designated account.To blocked stock Using this function the material will be stored with blocking reason “return to

vendor”. The shipping department initiates the return to the vendor.Other inventory postings not mentioned here are not allowed.

Saving the usage decision

Press the button to save the usage decision including the inventory posting.


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Creating a purchase order with order type M5 or M7Samples are deliveredGoods receipt posting

Inspection lot creation

If nec. change status in quality info rec.Execute samplingusage decision

Creating inspection lot manuallyIf nec. change status in quality info rec.

Execute samplingUsage decisionSamples are delivered


4.1.4 Sampling

Process of sampling

A)

B)

To inspect the first regular delivery or deliveries for sampling when a material is changed, use

the status “voab“ to make sure that all deliveries use inspection type 0102 and no skips are allowed.

Step 1 (A): Creating a purchase order with order type M5 for first sample or M7 for change sample

Step 3: (A) Posting the goods receipt.

Transaction MB01 = GR posting


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Enter document date, delivery note, movement type (101), purchase order number and plant and

press the button .

If necessary correct the quantity, press the button Copy and save.

Step 2: (B) Creating an inspection lot manually

Logistics Quality management Quality inspection Inspection lot Processing

Create (QA01)

Enter material, plant and inspection lot origin (01). After pressing , select the inspection type on the following screen.


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Enter inspection lot quantity, vendor and purchasing organization.

Confirm with and save pressing the button .

Step 5 (A) or 3 (B): if necessary, check and change the status of the quality info record.


Quality info record procurement Change (QI02)

Enter material, vendor and plant and hit .

Use the button to change the status manually.


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Change status if necessary and save afterwards hitting the button (save).

Step 7(A) or 5(B): Usage decision

Double-click on inspection lot level.

Select UD code and press button (save).

If you save the usage decision for a sample, the pop-up window shown below will appear.In this pop-up enter or select using the matchcode function:

Document version Change index of the material Sampling type,


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Change number A text row

When saving, document version and change index of the material are compared to the present document version and change index (view: basic data 1 drawing (table MARA)) in the central system (CSE). If the entered document version or change index is greater than the one of the central system, an error message will appear. By pressing the Copy button the sampling data, including document version, change index material, sampling type, change number and text, will be updating the sampling history (table ZQBE).This table can be accessed via transaction SE16 (data browser).

Use the button to maintain user settings, e.g. list settings (list width, maximum number of hits, format of the list display) or field description of the selection menu.


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In the data browser enter table name ZQBE

and press .

On the following selection screen (here just a cut-out) enter necessary data.

You will receive a result list according to the entered selection criteria.


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4.2 Quality notification

Complaints are processed in SAP using quality notifications. The different kinds of quality notifications have basically the same structure and provide the same functions. Some of the data on the different screens may differ according to the different quality notification types.

4.2.1 Structure of quality notifications

The SAP quality notification is includes the header and item data (defect items).To each notification a material number is allocated. Defect items are used to control several defects of a material. The defect itself is described by defect type, defect location and a cause (customer complaint only). Apart from defect descriptions also control measures can be governed by the quality notification. Responsible persons and planned dates can be allocated to these measures to supervise them. Measures can be allocated to the header of the notification (usually immediate measures) or to defect items (corrective or preventive measures).

4.2.2 Quality notification types

Quality-related problems can occur in different business, organization or production areas and can be of different kinds. To detect the different causes of these problems, the system distinguishes between different quality notification types. This chapter deals with vendor-related notifications only.

Depending on the application area (goods receipt, production, customer complaints) different notification types are used:

Q2 for notification of vendor-related problems ('notification of defects') in the goods receipt

Q3 for notification of problems in production ('Internal problem notification’)

Q4 for notification of vendor-related problems ('notification of defects') in production

Q5 for notification of vendor-related problems ('notification of defects‘) based upon customer complaints


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4.2.3 Creating a quality notification

Logistics Quality management Quality notification Create (QM01)

Initial screen:

Notification type – This key is used to distinguish notifications based upon type, origin and other criteria. The characteristics of each notification type is defined in customizing.

Notification – Unique identification of a notification in the system. The number assignment is done internally by the system, when a notification is saved.

Reference Notification – Number of a notification used as a template. If you reference to a notification when creating a new one, data of the notification header including long text and partner, items and tasks including their long texts will be taken over into the new notification.


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Key data of a notification

Notification – notification number assigned by the SAP system (see before). The number assignment is carried out when the notification is saved.

Notification type – see above

Status – current processing status of the quality notification

Description – Short description of the notification


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4.2.3.1 Tab: Subject

Reference object

Item (required data) – key, determining a unique material.

Plant for mat. (required date ) – Key, defining a unique plant.

VendorBatch (blanked out, if it is not used) – Number, that allocates a material, manufactured in batches or lots, to a unique batch.


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Reference documents

Reference notif – Number of the reference notification (when created using a template)

Purchasing doc. – Number of the purchasing document (Purchase order or scheduling agreement) / item number within the purchasing documentThe purchasing document can be entered manually or assigned using the activity ’Assign purchasing document’.

Material doc. – Year / Number / Item of the material document (GR posting document)The material document can be assigned manually or via the action ’assign material document’.

Reference No. – External reference number, that is not checked by the system (e.g. complaint number of the vendor)

Partner

Partner data includes all persons who have something to do with the notification. These are the persons who initiate the notification, and the ones who have to process the notification. You are able to enter partner data for the notification header and for tasks. Partner data, that can be entered in the header, is predefined depending on the notification type.

Function (required data) – Description of the function of the partner Supplier: - supplier of the defect materialDept. resp. (header): Department responsible for processing this notification User resp. (header): User responsible for processing this notification

Partner – key identifying a unique partner (e.g. vendor number, user)

Name, Address – taken from the master data of the partner

You can use the matchcode search function to select a partner. The button for the matchcode will be displayed on the right side of the data field if you place the cursor on it.

To search for a vendor number enter all information you have on the vendor. You can also use wildcards (* replaces a alphanumeric sequence of variable length; + replaces a single alphanumeric digit).


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Use the structure search to search for the responsible department.

To search for a user use the tab Users by address data and enter the name of the user.


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Subject

Description – Short text, displayed in the worklists of quality notifications. Should always be entered.

Long text – can be used for defect description and comments on defects. Data on entering or changing texts is recorded. Changes are logged.

Use the button to access the long text editor.Comments, that should not be printed in the inspection report, have to be indicated in the format column as “/* “.

Item Defect type – catalogued defect description using codegroup and code

Text – Short description of the defect item

Use the button (Item) to enter further items.

The button (Item detail) can be used to display details of an item.

Press the button (Next) to go to the next item.


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4.2.3.2 Tab Dates and quantities

Execution Priority – key determining the importance of execution.

Required start and desired end are calculated based upon customizing parameters (intervals).

1 very high Processing of this notification should be completed after one day. 2 normal Processing of this notification should be completed after five days.3 low Processing of this notification should be completed after 98 days.

The calculation is based upon the factory calendar.

Breakdown – this flag should be used if a machine has broken down. (Not relevant)

Req. start – Required start for processing of the notification (Date/Time).

Desired end – Desired end for completing the notification (Date/Time).Should be maintained, otherwise monitor functions in worklists cannot be carried out.

Malfunct. Start – Start of the malfunction (Date/Time). (Not relevant)

Malfunct. End – End of the malfunction (Date/Time). (Not relevant)

Dept. Resp. (header) - Responsible department (header); entry will be taken over from tab ’Subject’.

User Resp. (header) – Responsible user (header); entry will be taken over from tab ’Subject’.


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Quantities Complaint qty. – contains the complaint quantity

Ref. Quantity – reference quantity; used as reference for the notification, e.g. inspection lot quantity. On internal defects the production quantity can be entered here.

ReturnDelivQty – contains the return delivery quantity

Returned on – day of return

Def qty (int.) – part of complaint quantity, that has been caused internally. Do not enter for notification types Q2; Q4 and Q5.

Def qty (exter.) – part of complaint quantity, that has been caused externally (i.e. by the vendor). The total of internal and external defect quantity should not exceed the complaint quantity. The entered quantity is used for ppm calculation in Q4 and Q5 notifications.

Quality of response Quality of response is used in SRS. I.e., if you are not satisfied with the reaction time or response

of a vendor, switch the radio button to ‘nok‘. The vendor will be down rated in SRS.


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4.2.3.3 Tab QM order

Costs QM order – Cost collector to record defect costs of a quality notification. Possible costs: hours,

material and fixed costs

Business area – Key identifying a unique business area

Order type – Order type of the QM order

Account assignment used as cost object for the settlement of costs Order – Key identifying a unique internal order.

Cost center – Key identifying a unique cost center.

Sales order – Key identifying a unique sales order.

CO area – Key identifying a unique controlling area.

Spec. SR – this flag is set if you want to maintain settlement rules for a QM order in detail.


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4.2.3.4 Tab Item

Subordinate tab: Item overview Use the different columns or a row to record defects.

Subordinate tab: Causes

Before entering causes, mark one or more items and then choose the tab . In case of a vendor-related quality notification the cause told by the vendor can be entered here.


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Subordinate tab: Tasks (corrective measures)

This tab is used to record tasks concerning an item. These tasks are called corrective measures. They should list tasks that will solve the problems completely.In case of a vendor-related quality notification the tasks carried out by the vendor can be entered here.

The maintenance and status management of tasks on header and item level is identical. These topics will be described in chapter 4.2.3.5.


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4.2.3.5 Tab: Tasks (immediate measures)

On this tab enter tasks that refer to the complete quality notification.

For each task the following data can be defined: catalogue description of the task a person (partner) responsible for executing the task. If necessary, the partner can be changed

later on. a time interval in which the task has to be executed.

Task data can be displayed on different detail levels. Instead of the task overview, task details can be displayed.

Mark a task and press the button (detail view)


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You can use the matchcode search function to select a responsible person. The button for the matchcode will be displayed on the right side of the data field if you place the cursor on it.The matchcode search, shown, below, will be displayed. Enter a name or the asterisk’*’.

Furthermore, the planned finish of the task and the status should be maintained.

If the task is completed, the status has to be changed to complete and it has to be entered when the task has been finished and who executed it.


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Status management tasks

To process a task, the status management has to be used.

For the status management use the buttons .

First the task is released by pressing the button . Then the task can be carried out.

After the execution of the task complete it using .

If the task has been carried out successfully, use the button to indicate it.

User status can be set via the button .

Status details can be displayed using the button .


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4.2.4 Action box

When you process quality notifications, you can use the action box to execute follow-up functions.Follow-up functions make the processing of notifications easier. They are documented as an action or task in the notification header after being executed.

The action box is displayed as an overview tree. In this mode the follow-up functions are displayed in a list using different colours. The colours have the following meaning:

blue: The follow-up function is active and can be executed.

black:The follow-up function is inactive and cannot be executed (yet).

grey: The follow-up function has been executed and cannot be executed again.

You can use this function to search the solution database for symptoms and solutions that may be similar to the problem you are currently processing.If you find a symptom/solution in the database that applies to the problem in your current notification, you can:

Document your database search as an activity in the notification

Copy the tasks associated with the solution into your notification

Not used at Continental Teves.

You can display a list of vendors for your complaint material. From this list you can select and assign a vendor to the notification you are processing. If you want to create a return delivery with reference to an original purchasing document, you must first assign this document to the notification. This function can be used to assign the purchasing


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document to a notification.Use this function to assign e.g. a goods receipt to a notification.

Display the stock overview for the complaint material.

Use this function to transfer the material from storage location to another, e.g. from the production storage location to the storage location for blocked stock.

Use this function to transfer material to the blocked stock (stock type S). As long as a material is in the blocked stock, you can decide whether to scrap the material or return it to the vendor.The usual movement types for this inventory posting are "344" in MM and "309" in WM.The system prints a goods receipt/issue slip carrying the relevant data, which can be placed on the material.It is used to print an internal goods issue slip for returning the material to the vendor.

If you determine, that the material has to be inspected, you can transfer it to the quality inspection stock (stock type Q).The usual movement types for this inventory posting are "322" in MM and "321" in WM.If inspection type 08 (inspection when transferring) for this movement has been activated in the quality data of the material master record, an inspection lot will be created automatically when posting to the quality inspection stock.The system prints a goods receipt/issue slip containing the relevant data which can be placed on the material.Not used at Continental Teves.

If e.g. the material in the blocked stock has been sorted or reworked, the “OK” quantity can be transferred back to the unrestricted-use stock.The usual movement types for this inventory posting are "343" in MM and "309" in WM.The system prints a goods receipt/issue slip containing the relevant data which can be placed on the material.

If the component Warehouse management (LE-WM) is active in your company, use this function to create a transfer order to transfer the material from a storage location to another one.Not used at Continental Teves.

If you determine that the material cannot be used anymore, you can scrap it.Not used at Continental Teves.


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To be able to create a return delivery, make sure the notification contains the following information: material, plant, vendor, complaint quantity, and if applicable, the batch.You have the following options to create a return delivery:

Creating a return delivery with reference to an original purchasing documentWhen you choose this function, the system displays a dialog box in which you enter various information for the return delivery. Make sure you set the indicator Return delivery with reference to original purchase order in the dialog box. If several goods receipts exist for the purchasing document, you must select the goods receipt in another dialog box, for which you want to process the return delivery.

Creating a returns to vendor without referencing an original purchasing documentThe system creates a purchase order with a returns item and a return delivery in the background. The system displays a dialog box in which you can enter various information for the return delivery.Make sure you do not set the indicator Return delivery with reference to original purchase order.The system displays a second dialog box in which you can enter additional information for the delivery.If a purchasing info record exists, the system proposes the settlement data contained in the info record. This information is then copied into the purchase order with the returns item.After creating the delivery, the system displays the log for the delivery run. When you exit the log, the system records the document flow between the notification, purchase order, and delivery. The system then exits the notification.

Not used at Continental Teves.

The system saves the notification and branches to the delivery in the change mode. This allows you to add or change information in the delivery, pick the order, and post the goods issue.

If you posted the material to the quality stock and the system created an inspection lot, you can use this function to branch to the transaction for making a usage decision.

Documents indicating that you request a statement from the vendor.In the task details a date and a responsible person for this task can be added.


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An 8D report is a standard form that is used in the automobile industry to document the correction of defects. For example, as an automobile manufacturer, you can use this follow-up function to request an 8D report from a vendor to receive a statement about the confirmed defects and how the vendor intends to correct the defects.You can use this function to create an 8D report for a defect while processing a quality notification. When you save the notification, the system prints the 8D report by means of a corresponding follow-up action.

With this function internal notes or remarks can be recorded. The system documents the memo as a notification.

Use this function to change the quality level of the corresponding material-vendor combination. If e.g. the defects have been detected in production, a possible skip level can be changed into an inspection level.

You can use this function to record a telephone call that you initiated while processing a notification. The system logs the details of your telephone call as a notification activity.

You can use this function to read and format selected data in a notification, which the system can then print, fax, or send as an e-mail to an internal or external (Internet) address.You can view the document in a print preview before you save the notification. When you save the notification, the system sends the notice by executing a corresponding follow-up action.


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4.2.5 Putting quality notifications in process

A quality notification can be put in process if all relevant information to describe the problem has been entered. Then the notification is released for further processing. If a QM order exists for the notification, this notification is released automatically by the system.

To release it manually choose the menu path Notification Functions Put in process or press the

button .

The system status of the notification will change from "outstanding" (OSNO) to "notification in process" (NOPR).

4.2.6 Completing quality notifications

To complete a quality notification call up the change function

Logistics Quality management Quality notification Change (QM02).

The screen to change a notification will be displayed. Enter the number of the notification, which you want to change, and press .

In change mode select: Notification Function Complete or hit the button .

The dialogue window to change the completion data will be displayed.

Specify the completion date/time and mark the correct flag for the cause of the problem (internal or external).

Press the button (continue). The notification will be completed. The notification will receive the status “notification completed” (NOCO).


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The notification can only be completed, if all tasks have at least the status completed.

4.2.7 Putting a notification back in process

A completed notification can be put back in process, if further processing is necessary.To do that, select in change mode the menu path Notification Function Back in process.The status of the notification will change from NOCO to NOPR.First you will be asked if the old completion date should be taken over into the notification.


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4.2.8 Action log

The system records changes to notification in the action log. It documents:

which data were changed for the selected fields status changes who made the changes when the changes were made changes made to tasks, items, activities and partners

Select the menu path Extras Notification documents Action log or press the button

. On the initial screen of the action log all changes of the notification header are recorded.


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Use the button to display an overview on existing items and tasks.

Detailed information on items and tasks can be displayed by hitting the button .


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4.2.9 Document flow

With this function the document flow for a quality notification can be displayed as a list or network graphic.

You can see preceding documents (documents from which the current notification originated, like e.g. the number of a goods receipt document or the inspection lot number), subsequent documents (documents originating from the current notification, e.g. the number of a transfer document) and "To-and-from" references between documents.

To display the document flow, use the following functions:

Document flow (list form): Choose the path Extras Notification documents Document flow List

Document flow (network graphic): Choose the path Extras Notification documents Document flow Graphic

or press the button .

The document flow shows all documents (inspection lot, GR document, transfer document, ...) for the

notification in graphical form. Double-click or press the button to display the single document or the inspection lot.


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4.2.10 Creating attachments

Use the services for objects to add attachments like e.g. inspection reports or pictures to the quality notification. These attachments will be displayed in the document flow, too.

First choose an object you want to attach.


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The desired attachment has to be selected and will be assigned to the quality notification after

pressing the buttons .


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4.2.11 Printing quality notifications (shop papers)

Printed quality notification data is called shop papers. To print a quality notification call up the quality notification in change mode. Then select the path Notification Print Notification or press the

button (print).

The dialogue screen for selecting the shop papers will be shown. This dialogue screen lists all papers, that can be printed for the notification type.

Select and print the inspection report from the shop papers.

Use the data field Output language to select the language for the output. Usually the language entered in the vendor master data is used.


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The inspection report can be saved as a pdf-file on your local computer.

If the flag in column D ‘Delete after output’ is not set, the spool request will be preserved and can be saved as a pdf-file using the transaction ZQPDF.Use the path System Own spool requests to determine the number of the spool request.

Start the transaction ZQPDF


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Enter spool request number, destination and filename.

Execute the transaction by pressing (execute).

Hit the button to save the file on your computer.

The pdf-file will be saved to the entered destination folder.


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4.2.12 Mailing quality notifications (shop papers)

A prerequisite to send a quality notification via e-mail is that the internet e-mail address has been maintained in the user profile.

To send shop papers via e-mail, press the button (print) within the quality notification. The dialogue screen shown below will appear. Choose the shop paper, you want to send, enter the e-mail

address of the recipient and press the button (print preview).

Check in the status bar, if the e-mail has been sent successfully or not.

After a maximum of 10 minutes (job period of the job that transfers the data to the mail server) the shop paper (here: inspection report) will be attached to an e-mail and sent.Mail and inspection report will be sent using the language entered in the vendor master data. Use the data field Output language in the dialogue screen to choose a different language.


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The documents sent are recorded in Office Workplace Outbox Documents and can be accessed there.

4.2.13 Worklists

In SAP the worklists of quality notifications, defect items, tasks and actions can be displayed and processed.

Logistics Quality management Quality notification Worklist Notification Change data (QM10) or Display data (QM11)

The processing of tasks and defect items is similar to quality notifications.

... Notification/Item Change data (QM10/QM14/) or Display data (QM11/QM15/)


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In the data field Partner User Resp. (Head) enter the user name of the person whose worklist you like to display or process.


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Use the selection screen and its selection criteria to filter and display certain notifications from the mass of quality notification.

The button or the menu Edit Dynamic selections give access to additional selection criteria.

Use a user variant to preset the selection criteria. It will be used automatically when the user logs on.

Press the button to save the selection parameters and values for list settings as a user variant.


Use the button (change layout) to change the list layout user-specific according to your needs.

After pressing this button a pop-up will appear listing the functions to change the layout.


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The left section on the tab Columns contains the present list layout. The columns are displayed from top to bottom in the sequence on the screen from the left to the right.

Redundant columns can be blanked out. Mark the column and press the button to move the data fields to the columns set.Additional data fields of the columns set can be displayed in the list. Mark these data fields and press

the button to move them to the columns.

Use the button (search) to search for columns.

The sequence of the columns displayed in the list can be changed using the buttons . First mark the column you would like to move. You can also move several columns at once (press the Shift-key when marking columns).


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If contents of a column can be summed up, a checkbox will be shown in the corresponding column.

If this box is checked, the system will calculate the total automatically and display it beneath the corresponding column in the list.

Use the tab Sort to enter criteria for sorting the list and to mark columns for which a subtotal should be calculated.

The tab Filter contains criteria to set a filter for the list. Only those data records will be shown, that match the filter criteria.

Use the tab View to influence the list format.


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The tab Display contains display options like e.g. grid lines or column headings.

Use the button (save layout) to save the layout user-specific. You may have a look at the layout

first by pressing the button and afterwards saving it using the button (save layout).In both cases the following screen will appear.


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Enter a name and a description for your layout. Remember that a user-specific layout always has to start with a letter.

If you mark the option default, this layout will be saved as the standard layout in your user profile.

The user-specific layouts can only be accessed by the user who created them.

If you want a different layout, press the button (select layout) and choose one from the list. This layout will be used for the list.

Reference field monitor

In the selection screen the field monitor function can be activated.


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The quality notification list shows a traffic light, which changes colours depending on the status of the notification.

• Green: Processing start in the future• Yellow: Processing started and in time• Red: Closing overdue• none no dates maintained


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Evaluations

5 Evaluations

An evaluation is the result of executing a report. The evaluation can be displayed on screen or sent to a printer.

In many evaluations you can go to detailed data or documents by double-clicking or by using the corresponding buttons on screen.

Standard evaluations can be accessed via the SAP Easy Access menu.

Use the SAP Easy Access menu to navigate to the folder Information systems of the corresponding directory.

5.1 Possibilities for evaluations in SAP

The SAP system distinguishes between the following analysis procedures:

Standard analysis of pre-aggregated data in LIS (logistics information system as a general data base for all logistic modules). They are stored in folders of the information system. Standard analyses are evaluations, that are predefined by SAP or can be defined by the user.

Flexible analysis of pre-aggregated data in LIS. Flexible analyses can be used to compile data individually, to aggregate it and to build reports comfortably.

Reports using uncompressed SAP online data. These reports have to be written by the user himself as ABAP reports.

annotation:LIS = Logistics information system (shared data base for all logistic modules)ABAP/4 = Programming language of SAP


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Evaluations

5.2 Vendor analysis (standard analysis)

Logistics Quality management Quality control Key figures Vendor

Inspection lots Overview (MCVA)

When starting this program the selection screen for the analysis will be displayed.This screen is used to determine the data which should be read by the evaluation program.

Without entering any selection criteria all data, saved in the system for this evaluation, will be displayed. By entering selection criteria the evaluation will be restricted to certain values, e.g. data of


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Evaluations

plant 0001 or data of a certain vendor-material combination. For the restriction two data fields are available for each selection criteria, where single values or ranges can be entered. Additional values

can be entered via the button (multiple selection).

There additional single values or ranges can be included or

excluded .

Press the button (user settings) to maintain user-specific characteristics, key figures and parameters.

First confirm the user whose settings should be maintained. The system proposes the own user name, so you should not change anything here.


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Evaluations

Press the button to open a selection screen for characteristics. It can be used to determine the drill-down sequence.


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Evaluations

The left column displays the present selection of characteristics. The right column shows the pool of

not-used characteristics. Mark a characteristic and press the corresponding

arrow to select characteristics.

If you want to change the sequence, mark first the characteristic which should be moved.

Afterwards click on the data field above which the characteristic should be entered.

In this example the characteristic material should be moved above the characteristic vendor.

To move it, press the button ( move).

Confirm the sequence hitting .

Press the button to select key figures.


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Evaluations

Use the button to display the correspondent screen. The proceeding of selecting and sorting key figures is the same as the processing of characteristics.

Press the button to maintain values for the layout or to enter the evaluated time period as a default.


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Evaluations

If the option “key and description” has been selected for the characteristics layout, the column width of the characteristics column should be changed respectively.

The settings are saved by hitting the button .

Use the button (execute) to start the evaluation.

The basic list shows the total quantity divided by plant. According to the sequence defined for the characteristics, the list can be drilled-down to the next level by double-clicking on a row. Only the materials of the chosen plant will then be displayed.


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Evaluations

The button provides different functions. It corresponds to the double-clicking on a data field.

The column width can be changed if you use it on a column header. This change is only valid for the current session.

If you use it on a characteristic, the next level will be displayed. Used on a indicator, it displays all key figures for the characteristic.

Press the button to save the evaluation on your local computer.

If you want to send the evaluation to another SAP user, press the button .


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Evaluations

Use the button to display a SAP graphic.

The button complies to double-clicking on a characteristic. Within the characteristic the single values of the next drill-down level will be shown.

If you want to change the drill-down, press the button . In that case all materials are shown, e.g. not only materials for a single plant.


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Evaluations

A chronological display of key figures can be displayed by hitting the button . First the corresponding indicator column has to be marked.

Use the buttons to sort the list in ascending or descending order. First mark the column used for the sorting of the list. To mark a column click on its header.

A ranking list can be displayed by pressing the button . Again mark the corresponding column first.

Afterwards determine the maximum number of ranks, which should be displayed.

As a result you get a ranking for the selected indicator. Other characteristic items will be displayed as a remainder in total.

Additional key figures can be maintained using the button .These are valid for the actual session only. The user settings remain unchanged.

The present selection version can be saved pressing the button .


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Evaluations

Enter name and description of the selection version and save it by pressing .

When accessing the next evaluation you can call up this version hitting the button .

Double-click to display the selected selection version.

Use the menu Extras Inspection lots to branch to the original document, i.e. the inspection lot, from e.g. the drill-down by material. A list of selected inspection lots will be displayed. Double-click on an inspection lot to display it.


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Evaluations

5.3 Evaluations using flexible analyses

Use flexible analyses to compile data individually, to aggregate it and to build reports comfortably. In doing so the functionality of the report writer is used, a tool to create reports for different applications.

5.3.1 Characteristics of flexible analyses

• possibility to calculate key figures from other key figures (e.g. ppm)

• predefined, not changeable data grouping (drill-downs structure) within a single evaluation (other data groupings are possible by additional evaluations)

• subsequent change of summarization levels possible

• Complete display of all information of all hierarchy levels

• Display of data in MS Excel, if the MS Office integration is activated


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Evaluations

5.3.2 Calling up a flexible analyses

Logistics Quality management Quality control Key figures Tools Flexible

analyses Evaluation Execute (MCX4)


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Evaluations

To display a flexible analysis enter evaluation structure and evaluation.

Different evaluations may exist for a single evaluation structure, which contain different

characteristics/key figure combinations of the evaluation structure.

Evaluation structure and evaluation can be preset using user parameters.

5.3.3 Selecting selection parameters

Press the button (execute) to get a selection screen for entering selection parameters.

By entering corresponding selection criteria, the selection can be restricted to certain characteristics (e.g. plants, months, vendors , etc.).


Automotive Systems

Evaluations

Often used combinations of selection parameters can be saved as a variant.

After maintaining the selection criteria use the button ( save as variant) to save them.

Press the button to access saved variants. The saved characteristics are a default and can be changed or completed before executing.

Data fields named “Set” should not be used for selection.

5.3.4 Displaying a flexible analysis

Press the button (execute) to display a flexible analysis according to the entered selection parameters.

Column 1 and 2 contain the key figures ppm number (SRS) and total quantity (= inspection lot / delivered quantity)


Automotive Systems

Evaluations

Row 1 (*** = highest summarization level) contains:The summarized ppm number / total quantity for all vendors of plant 0001 in time period 01.2003 until 03.2003

Row 2 (**)The summarized ppm number / total quantity of vendor Huettenberger Produktionstechnik for all material numbers delivered by him from month 01.2003 until 02.2003

Row 3 (*)The summarized ppm number / total quantity of vendor Huettenberger Produktionstechnik for all material numbers delivered by him in month 01.2003

Row 4 (last level, no further summarization)The summarized ppm number / total quantity for material number 10-0810-0136-2-00 in month 01.2003

If the analysis display a ´*´ as unit of measure, different units of measure have been

summarized.

Use the icons on the left margin to expand or collapse rows.

If certain summarization levels should be displayed in the list, choose the menu path Settings Summation levels… .If e.g. single vendors with their monthly figures should be displayed, choose summarization levels 1 and 2.


Automotive Systems

Evaluations


Automotive Systems

Evaluations

5.3.5 Office integration

The Office Integration can be used as an alternative to the list display. It allows to display the selected data using other applications.

The Office Integration is executed with the button (Options Office Integration).


Automotive Systems

Evaluations

The Office application (Microsoft Excel or Lotus 123) is started within the SAP R/3 window. Thus the functions of office applications are available for processing.

The hierarchy levels of SAP indicated by the different number of asterisks (*) are transferred into structuring levels of MS Excel. The highest hierarchy level '' complies to structuring level '1' in MS Excel.

Use Settings Options or the button (Options Office Integration) to switch between the list display (inactive) and the Office integration.

If the defined Office application is not installed on your PC, the list will be displayed in the

conventional list format.


Automotive Systems

Evaluations

5.3.6 Formatting for SRS

Execute Extras SAP-Flexible Analyses 4.6 from the Excel menu.

This add-in executes the following tasks: Summarization of defective quantity and defective quantity (external) Adjustment of column width and frames Deleting unnecessary notes (reduces the file size by 50%)

Prerequisite for formatting is the installation of the Excel add-in on the local PC using the

EXCEL Add-In Manager.

The document for the Supplier Rating Systems (SRS) used at Continental Teves can be found

in the CAS Intranet following Quality management Supplier development Documentation.


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Evaluations

5.4 Conti-Teves reports

The following reports can be called up as a transaction, via the QM menu or transaction ZQ01.Program Title

ZQ28AB10 ZQ28AB10 - Inspection certificate printingZQ28AB20 ZQ28AB20 - Blank inspection certificate printing ZQ36BE10 ZQ36BE10 - Repetitive-/ control sampling overview ZQ36BE20 ZQ36BE20 - Vendor-material data overview ZQ36D308 ZQ36D308 - BOM break down - overview for Q-planning of componentsZQ36FA10 ZQ36FA10 - Inspection Lots - Overview of defects ZQ36PB90 ZQ36PB90 - Quality report printingZQ36PD10 ZQ36PD10 - Inspection plan printing ZQ36PD20 ZQ36PD20 - Blank inspection plan form printing ZQ36PL80 ZQ36PL80 - List of multiple material-plan assignments ZQ36QP10 ZQ36QP10 - BOM break down-overview f. Q-planning of components ZQ36VE10 ZQ36VE10 - Collective Usage Decision for Skip-Lots with defects

Call-up via ZQ01


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Overlapping functions

6 Overlapping functions

6.1 Scrap recording

6.1.1 Prerequisites to use transaction ZM42

The repetitive manufacturing profile (material master record) has to allow optional reporting point backflush

The relevant operations have to be maintained in the routing as reporting points. (control key)

A new standard costing has to be carried out.

Table ZM370 has to be filled with desired parameters.

Table ZM370

This table ZM370 has to be maintained on client/plant level. Area item

Parameter maintained in ZM42 for the selection assembly/production. It controls the follow-up selection of parameters in this table.

Movement typeContains the movement type for scrap postings, which should be used by the system.

Movement type excess consumptionContains the movement type, which should be used by the system for later postings.

Activity posting Contains the type of activity posting used for postings.


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Overview/BOM explosion not used anymore.

Production versionentry is proposed on the initial screen of transaction ZM42.


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6.1.2 Processing transaction ZM42

Transaction ZM42 is used to simplify the use of transaction MFBF.

On the initial screen enter plant, material, production version, backflush quantity and select production or assembly.

After pressing the following error message will appear:

This error message cannot be avoided, because the system offers a selection of possible

scrap reasons only if it has read the entered plant.


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After selecting a reason press button (execute).Without any interference of the user the transaction MFBF will be executed.

First the entered data in ZM42 is checked. If this program check has been successful, control data for MFBF is created and transferred along with the entered data to the processing transaction MFBF. MFBF is executed in the background because of the entered parameters until a final screen is displayed.

Then the user takes over further processing.Before the final posting changes to the displayed BOM are possible. This way additional parts can be maintained or not-used parts can be deleted.

At this time the user processes transaction MFBF.

If all necessary data has been maintained, press the button (post) for the data backup.


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After posting the system will return to the initial screen of transaction ZM42.A posting document is created.

The posting log can be displayed using transaction MF12.

Of course transaction MFBF can be accessed directly.

If the data checks of pre-transaction ZM42 detect an inconsistency, an error screen with an

error message will be displayed by transaction MFBF. The user has to correct the data manually or – if this is to complex – to cancel the transaction.

To cancel the transaction press the function key F12 (Cancel) or button several times. The initial screen of transaction ZM42 will be shown. It may be necessary to press F12 several times because the active control of the pre-transaction has to be rewritten.


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6.1.3 Reversing scrap recordings

To reverse a scrap recording, transaction ZM42 has to be executed, too.

Enter plant and document number of the document going to be reversed.

To reverse the document press button .

Afterwards the following message will be displayed:


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6.2 Scrap recording and updating in QMIS6.2.1 Graphical diagram


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6.2.2 Explanation

The reports evaluate the following data:

CO report/MM (ZC281060):o –scrapping of stock using movement type 551

CO report/PP (ZC281051):o –maintained scrap of production

Data of both reports is written to table ZQAUS.

The report ZQ32SC10 reads the table ZQAUS and creates quality notifications of type Q3. These notifications are opened and completed immediately.(If further processing is necessary, you can put it back in process)

The automatic saving of the notification results in an updating of quality notification data in QMIS.


Automotive Systems

Documents and forms

7 Documents and forms

7.1 Sample drawing instruction (SDI)

The sample drawing instruction gives information on the necessary sample size that has to be taken from the inspection lot/goods receipt and, if necessary, information on the distribution of the sample to different work centers.Furthermore, the sample drawing instruction contains several material and vendor specific data.

The sample drawing instruction will be printed when the goods receipt is posted or the inspection lot is created, depending on settings in customizing.

Company specific table ZQPARA indicates which printer is used and the number of printed SDIs.

If the inspection lot is skipped (and a printout is necessary anyway), the printout will include a text telling that a sample should not be drawn because of skip.

If sample drawing instruction should be printed again after the original printout, you have to initiate the

printout manually via “Change inspection lot” and button . The following

warning has to be confirmed with .

Even for a manually created inspection lot the sample drawing instruction will be printed automatically when saving.


Automotive Systems

Documents and forms

7.1.1 Field description sample drawing instruction

Field Explanation Possible entriesSample Drawing Instruction

Print date / Print time

Print date of the SDIPrint time of the SDI

27.02.2003 / 17 :39 :46

Page Automatic page number Page: 001

Plant actual plant from inspection lot 0001Material Material number and description from material

master data10-0460-5003-1-00 high pressure membrane

DV / MI: Document version of the drawing (from field MARC-ZZAEIP) and change index of the material (from field MARC-ZZAEIM) taken from the view plant change service/work scheduling of the material master record

03 / 01

EAN-no./Un

Short number

European Article Number (EAN) with alternative base unit of measure from material master record. Used for aftermarket only.In aftermarket a short number (= order/ catalog number) is used for the material.

4006633009287 / AEK

010503Supplier Number and description from inspection lot 700908 Freudenberg

S.A.Release Release level and release number from basic

data 1 of material master record (MARA)08 / 01111161

Change Change type and change number of plant change service / work scheduling view of material master record (MARC)

21 / 01110786

Instruction Instruction of plant change service / work scheduling view of material master record (MARC)

05

First: Initial sampleDV = Document version, MI = change index material, Sampl.-Date = sampling date, Val = Evaluation (A = accept, R = reject)Data is taken from the sampling history (ZQBE) of material and vendor (most actual entry).

06 02 10.06.2002 A

Control: Control sample, w.o. w.o.Change: Change sample, w.o. w.o.Insp. Lot Internally assigned continous number 010000359397Insp. Plan Task group and group counter of the inspection

plan480 / 1

Change Date Date of the last change of the inspection plan 05.11.2000Goods rec. no Number of the GR document (material

document) Empty in case of a manually created inspection lot

50019190

Delivery date GR date from GR documentEmpty in case of a manually created inspection

27.02.2003


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Documents and forms

lotDel. Quantity GR quantity

Empty in case of a manually created inspection lot

110

Del. Note no. Number of delivery note (of the vendor)Required for posting the GREntered in field Reference of material document header (table MKPF)

653201

Unloading point Text field for GR postings Mr. LotzeStorage location Number of the storage location used for posting

the material.0030

Batch Plant specific field (activated via table ZQPARA) to hand over a vendor batch number. The content of field Item text of the GR posting will be printed on the SDI.Only used for plant Palmela

24280 / 24279

SeriesSeries prev.Sample

Information from the status of the quality info record.In case of a sample inspection lot the sample type is printed according to the document type of the purchase order.

Series

Initial sample

BlockIf an entry exists in field Blocking function of the quality info record, the two digit code along

with the description and text from field Blocking reason will be entered.

Reprint SDI

If a reprint is done (using button ), a note will appear.

No sample to be drawn, skip!!!if the inspection lot is skipped

Sample no. always 00000 000000Qantity. In sampling unit

According unit of measure of inspection plan, according sample size

40,000 ST

Quantity in base 40 STSample distribution to the laboratories

Sample no. Always 00000 000000IO Operation according inspection plan 0010Work center Work center of operation 97320301Plant Plant of work center 0001Name of work center

Work center description Incoming inspection

No. Sample size for each work center 20 ST


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Documents and forms

7.1.2 Example for a sample drawing instruction


Automotive Systems

Documents and forms

7.2 Inspection instruction

The inspection instruction can be printed automatically by the system when posting a goods receipt / creating an

inspection lot. Can be printed manually by the user, too. contains inspection specifications of the inspection plan. The header of the inspection

instruction is identical to the header of a sample drawing instruction. contains tools necessary for inspection. describes contents and procedures of an inspection for a certain work center.


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Documents and forms

7.3 Inspection report

In general the inspection report is printed from within a quality notification.

The information report is printed for sample inspection lots as a follow-up action of the usage decision or for usage decision 1102 for series inspection lots.

The inspection report printed via the menu is the SAP inspection report. The SAP inspection report can be printed without a usage decision (for internal use only).

To initiate a reprint of an information report use report ZQ36PB90. The printer used for the printout is defined in customizing.

7.3.1 Field description inspection report

In this chapter the fields of an inspection and information report are described. An inspection report of a quality notification and an information report for sampling are included as examples.

Field name(printed on inspection report)

Explanation Possible entries

Plant adress (big letters)Taken from table T001WThe department description is taken plant-specific from table ZQPARA.

Continental TEVES AG & Co. oHG Werk FrankfurtQualitätssicherung BeschaffungGuerickestraße 7D-60448 Frankfurt am Main

Phone. taken from plant-specific table ZQPARA + 49 (69) 7603-1Fax. Fax No. from user data of responsible user or

head of department (Setting acc. table ZQPARA).069-7603-3887

Plant adress above vendor adress (small letters)taken from plant-specific table ZQPARA

Continental TEVES AG & Co. oHG Postfach 90 01 20 D-60441 Frankfurt

Vendor adress, automatically taken from the purchasing view of the material master record

Continental Teves AG & CO. oHG act Werk Gifhorn ACTAlfred-Teves-Strasse38518 Gifhorn

Supplier no. automatically taken from the purchasing view of the material master record

900303

Supplier fax Fax Number of the vendor 05371-832118

Inspection report for printout from quality notification Information reportFor printout from inspection lot with

Notification type Q2: ’Series’Notification type Q4 or Q5: ’complaint’

For UD code 1102 ’Annahme Info an Lieferant’ (printed from inspection lot): ’Series’

For UD of an inspection lot with inspection type

SampleSeriesComplaint


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Documents and forms

corresponding UD code or sample inspection lot

0101: ’sample’

Place of inspection

Notification type Q2: ’Goods receipt’Notification type Q4: ’Production’Notification type Q5: ’Customer’For inspection lot:’ ‘Goods receipt’

Goods receiptProductionCustomer

Message no. Number of the corresponding notification, if existing

100358862

Inspection lot no. No. of correspondent inspection lotFor notification type Q4 determined by the material document number (GR document) entered within the notification.

010000363622

Date Print date of inspection report 19.05.2003

Page Page number of the text 001Material no. Taken from notification or inspection lot 10-0208-0581-1-08

DV / MI Document version and change index material from view plant change service / work scheduling for series inspection lotsFor sample inspection lots taken from table ZQBE

02 / 02

Part name Taken from notification or inspection lot, description of the part

valve

Goods rec. no. The GR document number should be entered if possible, because the delivery note is determined using the GR document. This way the vendor is able to allocate the defect to a delivery. If the GR document number is not known, the information’from stock’ will be displayed.

50026146,from stock

Delivery date Date of the goods receipt 28.03.2003

Order No. Scheduling agreement or purchasing order as reference for the goods receipt

56003082

Delivery note no. delivery note number of the vendor (determined with ref. to the GR document)

83399319(alpha numerical entries possible)

Batch no. not used

Quantity delivered

delivered quantity from GR documentusually similar to inspection lot quantity

832

Unit of measure Base unit of measure from material master record usually pce for piece

pce

Quantity accepted

’delivered quantity’ minus ’complained quantity’ from notification

For information report using UD code 1102:Quantity’unrestricted-use’ from inventory posting of inspection lot (similar to delivered quantity minus returned quantity minus ‘to sample usage’).

830


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Documents and forms

Provisional defective quantity

’complained quantity’ from notification

For information report using UD code 1102: Entry in field defect quantity.

2

Destroyed sample

Quantity ’to sample usage’ from inspection lot.

The value of the parts, inspected destructively, is posted to a cost center.

0

Quantity returned ’Returned quantity’ from notification

For information report using UD code 1102: Quantity ’to blocked stock’ from inventory posting of inspection lot

Complies with the quantity returned to the vendor.

2

Failure description

Additional text on code and code group of additionally maintained defects. Settings can be made plant-specific

Failure description

Starts with text of code group and text of defect code of all items that are part of the notificationFirst row of text of defect itemAfterwards short and long text of notification header.The long text of the UD can be used to maintain additional texts for internal information. To make sure that this text is not printed, the indicator /* has to be set left of the text section in the control field of the editor.

Dimensionsdrill diameter exceededdrill hole to large.

Usage decision If the inspection report is printed for a Q4 or Q5 notification, this field is empty.

Only for inspection report of origin goods receipt, i.e. Q2 notificatiopn, information report for completion of a sample inspection lot or information report using UD code1102:UD code and text of UD code, along with date, on which the UD was made

1106 acceptance after rework05.08.1998

Inspection report Information report

Info field.Standard texts (ZQ_PB_STELL_QM_xxxx) for tasks of codes 0020, 0080, 0090, 0100 and 0220 from notification.Fixed text according to matrix QBESA035.XLS (see below)

Maintained at the end of the filed description (i.e. at the bottom of this table)

For information report of UD ’1102’ or information report of sample inspection lots (except W04):The report would generated auto. and therefore it

The report …


Automotive Systems

Documents and forms

bears no signature.(For W04 no text, because the information report will be signed by the purchasing department.)For inspection report of notification (except W04):The report would generated auto. and therefore it bears no signature. (For W04 no text, because the information report will be signed by the purchasing department.)

The report .....

Department For inspection report of notification:Department from user data of responsible user or head of department (settings acc. table ZQPARA).

For information report at completion of sample inspection lot or information report for UD code 1102:Department from user data of person, making the UD, or head of department (settings acc. table ZQPARA).

Telephone no. For inspection report of notification:Tel.-No. from user data of responsible user or head of department (settings acc. table ZQPARA).

For information report at completion of sample inspection lot or information report for UD code 1102:Tel.-Nr. from user data of person, making the UD, or head of department (settings acc. table ZQPARA).

e-mail For inspection report of notification:E-Mail from user data of responsible user or head of department (settings acc. table ZQPARA).

For information report at completion of sample inspection lot or information report for UD code 1102:E-Mail from user data of person, making the UD, or head of department (settings acc. table ZQPARA).

Contact person For inspection report of notification:Responsible user according notification header

For information report at completion of sample inspection lot or information report for UD code 1102:person, making the UD, according inspection lot

Department head head of department acc. table ZQPARA

The head of department can be defined seperately for the three origins ’Goods receipt’, ’Production’ and ’Customer’ in table ZQPARA (by


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Documents and forms

maintaining the corresponding User-ID).


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Documents and forms

Distributor Distribution list from table ZQPARA

The distribution list can be defined seperately for the three origins ’Goods receipt’, ’Production’ and ’Customer’ in table ZQPARA.Information, that the report exceeds one page. following page 002

Info field, fixed texts acc. matrix QBESA035.XLS

Text „Response“ acc. inspection report after selecting a task on level quality notification header

Inspection reportWe expect a response to the above failure(s) by …

For tasks of code group QM-09999 and Code 0090 in the quality notification header.

InfoberichtWe report the above failure only for your information.We do not expect a response.

As follow-up action for UD code 1102 (Acceptance Information to vendor)

Text „Response“ of inspection report from quality notification(In general texts for codes of task code group QM-09999)

Initiated bySubmission of an 8D report is required by. QM-09999, 0020The delivery was reworked at your expense.. QM-09999, 0080Please respond by QM-09999, 0090The delivery was sorted at your expense. QM-09999, 0100The delivery was reworked at your expense. QM-09999, 0110The delivery will be returned to you. QM-09999, 0200


Automotive Systems

Documents and forms

7.3.2 Example for an inspection report and information report


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Documents and forms


Automotive Systems

Documents and forms

7.4 Inspection plan printout

For inspection plans two kinds of processing exist (see chapter 3.2.3).Plans can be selected and printed by different criteria or by a certain material.

To print an inspection plan call up transaction ZQ36PD10, enter necessary selection criteria and execute it (see chapter 3.2.3.3). To fill the corresponding fields on the printout, the following data has to be entered in the long text of the inspection plan header.

7.4.1 Field description inspection plan printout

Field name(Long text in insp.plan)

explanation Possible entries

DV Document version, for which the inspection plan is valid

04

MI Material index, for which the inspection plan is valid

04

VT Entry next to field distribution list 1MW-Q

PZ Plan change counter in footer 01

T1 1. text row in field note: Release: F08-00110709

T2 2. text row in field note Change: F21-00111918

T3 3. text row in field note

T4 4. text row in field note

LL Text for life cycle card Inspection pan created: 27.03.2002 B.Polomski

LL Text for life cycle card PZ 01 operation 30 deleted

LL Text for life cycle card Wire diameter and length L0 in operation 40

LL Text for life cycle card PZ01 changed, 07.05.2002, Polomski, 1MW-Q

LL Text for life cycle card


Automotive Systems

Documents and forms

7.4.2 Example for an inspection plan printout


Automotive Systems

Documents and forms

7.4.3 Printout inspection plan - header data

Data field Description Data origin NotesDistribution list

Distribution list for the insp. Plan

From long text Key “VT:“

Inspection plan.

Plan description and usage

From usage and long text key “FN:“FN F06 = description + “provisorisch“FN F07 = description + “vorläufig“Otherwise = description + “Series“

For plant Gifhorn Insp. Plan header: for task list type N Use text from task list type Q (Inspection plan) (GF uses routings only)

Description Material description

Material master data

Mat. no. Material number Prüfplan Kopfdaten Table MAPL-MATNR

MI Change index material

From Long text key “MI:“

Notice Note (4 rows) From Long text key general: “T1:“, “T2:“, “T3:“ od. “T4:“

Sheet of Page counter Continous page numberCreated: Date of plan

creationChanged: Date of last

changeDept.: Department of

person who chaged last

Name Name of person who changed last

(Status) Release status of plan

From status0 = “Not released/ In work“1 = “Released“

Plant Plant default setting

Insp. area/Cost center/Work center /FZST

Inspection area/Cost center/Work center /State of production

Department of work centerCost center of work centerWork centerProduction step

Drawing no. Drawing number

DV Document version From Long text key “DV:“


Automotive Systems

Documents and forms

7.4.4 Printout inspection plan - operation / inspection characteristic

Data field Description Data origin NotesInspection operation

Number and description of inspection operation

Operation short text Without leading zeros

Inspection characteristic

Number and description of inspection characteristic

Inspection characteristic short textBy format “ND“ no print of characteristic long text

Without leading zeros

ICA Flag. “documentation required “ or “important characteristic“

From general inspection characteristic data (wheighting), “D“, “W“ or blank

Charact. value, Target, Tolerance, Attribute

Specific data of the characteristic

Inspection characteristic data

Test equipment

Description of the test equipment, that should be used

Allocation TOOL on operation/characteristic level# = test equipment from test equipment storeControl key 1000 => print “ #“ + test equipment textControl key 1001 => print only test equipment text

Norm, Regulation, Instruction

Reference to relevant documents

Allocation TOOL as document on operation/characteristic level

PC Taskl ist change counter characteristic

Characteristic-related -> content from info field-1

Insp. size/ Insp. rate/ Sampling proc..

Quantity of parts to be inspected, interval for inspections, allocated sampling prodcedure

Characteristic –related data maintained in sampling procedure


Automotive Systems

Documents and forms

7.4.5 Printout inspection plan – inspection plan footer

Data field Description Data origin Notes< Task list group > /< group counter>

Task list group and group counter

From task list master data

CC plan Task list change counter from inspection plan

From long text key “PZ:“ (header)

Text Footer Standard text in footer, plant specific

Via plant table

System (Client)

System and client System


Automotive Systems

Documents and forms

7.4.6 Inspection plan - Layout

Distribution list: 3BP6, ...

Inspection plan data Series 03-2125-8200-1-00

Continental Teves

Description:

THZ casingMat.-No.

03-2125-8200-1

MI

04Notice:

T1: ...T2: ...

Sheet 1 of 1

Created: 13.06.1998Changed: 09.04.1998

Plant Gifhorn

Insp.area/ Cost center/ Work center/ FZST:3BP6.3/31753/Hüller Hülle/8030

Drawing.No.

03-2125-8000-1

DV T3: ...

T4: ...

Dept.: ZSQName: Lotze

In work/Inactive or Released

Inspection operation Insp. characteristic* = during production

I

C

A

Charact. value, Target,Tolerance,Attribute

DIM.

Test equipment# = test equipment store

Norm,Regulation,Instruction

PC

Insp.size /Insp.rate/Sampling proc..

20 Anarbeitung 10 Height Anschlagbezugslinie

20 Processing

“W“

190,80 + / - 0,20

I. O.

mm # Meßvorrichtung 6-075913-001-000Lehrdorn 6-069013-303-000Visual inspection

From .9 Drawing

02

1 pce / 2h

30 Flansch 10 Flanschloch-Durchmesser

“D“

9,00 + 0,18

mm Lehrdorn 6-069013-303-000

ATE N 11134.15

01

4 pce / 2h

40 Anschlüsse

50000113 / 51 CC plan02 The inspection plan has always to be used with the valid drawing CGF (650)


Automotive Systems

Authorizations

8 Authorizations

Authorizations are used to allow access to certain transaction in the SAP system or to restrict transactions for certain users. Authorizations are grouped in profiles and assigned to the user master data of a user.

The documentation concerning the authorization concept of Continental TEVES can be found in the intranet via Automotive Systems CAS Homepage Information Technology Business Systems SAP Basis.


Automotive Systems

Appendix

9 Appendix


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Glossary

10 Glossary


QM Manual English

Documents

Transcript of QM Manual English