QM Business Blue Print V4 0

BUSINESS BLUEPRINT DOCUMENT
Quality Management
Version: V4.0
Date: 11th Dec 2007
Page 1 of 69
Document Information
Document Name Business Blue Print

Title QYM_QM_BBP_V4.0
Document Purpose
Key Words
Document Status Complete
Contact for Enquiries
Document Change Control :

Release Description Created Date Reviewed Date Approve Date
by by d by
1.0 Quality Pavan 21/01/2008
Management Kumar
Management Kumar
Management Kumar
Management Kumar
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TABLE OF CONTENT
1. Master data..............................................................................................................4
2. Inspection in Procurement..................................................................................12
3. Inprocess Inspection...........................................................................................18
4. Inspection after Production................................................................................24
5. Retesting of Finished goods...............................................................................30
6. Vendor approval process....................................................................................35
7. Recurring Inspection...........................................................................................41
8. Washwater testing................................................................................................46
9. Quality Notifications............................................................................................51
10. Calibration of Equipments...................................................................................63
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1. Master data
1. Requirements/Expectations
A brief / bulleted list of requirements and expectations
 In KIMMCO & ROCKWOOL, all the Raw materials, Facing materials, Packaging
materials, In-process Bulk material and Finished materials which are procured,
produced and sold are subjected to certain quality inspections
 These inspections are carried out based on the Specifications defined
 Specification can be numerical values and characteristic attributes
 For all the materials fixed samples are drawn depending on the material
 Inspection manuals will be attached to the specifications
 Vendor records are maintained for approval process
 Inspection procedures will be maintained for all materials
2. General Explanations (For Masters and Enterprise structure include Naming

Convention)
Describe the business process in detail. This typically does not include any SAP specific terms,
it should relate purely to the business rules.
Describe the naming and numbering convention in case of masters and enterprise structure
 The naming convention for Master inspection characteristics will be external

 The naming convention for the Inspection methods will be external
 The naming convention for the Sampling procedures will be external
3. Explanations of Functions and Events

Explain what events and processes trigger this process
 Not Applicable
4. Organizational Considerations
Address any issues agreed in the workshop concerning the SAP organizational structure and this
process.
 Not Applicable
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5. Process Diagrams
Provide all related process maps or diagrams
Material Master QM
view Code groups /
Selected sets
Qualitative
Characteristics
Inspection Method Master Inspection
Characteristics
Quantitative
Characteristics
Sampling Procedure Inspection Plan
6. Changes to Existing Organization processes

Change management issues as appropriate.
 Not Applicable
7. Description of Improvements
Describe improvements which will result from implementation of the SAP System. Be sure to
include any impact on business drivers.
 Not applicable
8. Solution in SAP.
Describe how this process will be addressed in the product.
Quality Management Master Data
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Material Master
The material master contains information of all the materials that a company procures,
produces, stores, and sells. It is the company's central source for retrieving material-specific
data. This information is stored in individual material master records.
The data related to the material can be stored at the relevant organizational levels. The material
master record is structured in accordance with the organizational units like plant and storage
location.
Quality Management view

The Quality Management data is maintained at plant level. QM inspection data is the
prerequisite for creation of inspection lots in Quality Management.
GR Processing time: Number of workdays required after receiving the material for inspection
and placement into storage.
Inspection type: It defines how an inspection is performed. The following inspection types
would be used depending upon the material movements.
Different Inspection types are assigned to each material

No. Inspection Description
type
01 Z1 Goods Receipt inspection against Purchase Order
02 Z3 In-process Inspection
03 Z4 Goods Receipt from production
04 Z9 Recurring Inspection of Batches
05 Z89 Other Inspection
06 Z101 Vendor approval process
07 Z14 Calibration inspection
Post to Inspection Stock: The system posts a material to the Stock in Quality Inspection
Inspection with task list: The inspection is performed based on a Task list (Quality Plan).
Catalog
The Catalogs are used to explicitly define and store information in code form (e.g. data that
describes inspection results, observations, tasks, or decisions made during an inspection).
A Catalog Contains unique, non-numeric data that is stored in a system. Catalogs would be
ensuring that this information is maintained uniformly by assigning a unique key and a
descriptive text to each entry.
Catalog is used to store information at the characteristic level in Quality Plan, at the time of
inspection lot processing, at the time of usage decision, and in quality notification.
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The Catalog for Usage decision for all inspection types will be maintained as below
codification
No. Plant UD Code Description
01 A Accepted
02 A1 Accepted with one deviation
03 A2 Accepted with two deviations
04 A3 Accepted with three deviations
03 R Rejected
04 R1 Scrap
Codes
Codes describe qualitative contents in machine form that can be easily processed. Codes make
up the lowest level of a catalog. They can describe, for example, a characteristic attribute, a
defect type, a defect location or a usage decision. The code is distinctive in conjunction with the
catalog and code group.
A code is always assigned to a code group. A code can be assigned to one or several selected
sets.
Code groups
Code groups are used to combine and structure codes within a catalog type
Code groups are used at client level to group codes that have the same contents or relate to one
another, within a catalog types.
Code groups can be used in inspection plans or master inspection characteristics.
Code group Codes

Color Black
Green
Blue
Other colors
Selected sets
A selected set contains a combination of different codes at plant level. Selected sets can be used
to combine codes from several code groups for processing that are allowed or useful for a
particular application. Codes that are copied into a selected set are known as set codes. We can
select codes from different code groups within a catalog type. Selected sets from the catalog
types Characteristic attribute and Usage decision also contain a valuation for each code, as
additional information (Accepted or Rejected).
Selected set Codes Valuation

Color of PE bags Black Accepted
Green Accepted
Blue Accepted
Other colors Rejected
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Master Inspection characteristics
Master inspection characteristic describes what needs to be inspected. It defines the inspection
requirements for materials. To facilitate and standardize inspection planning, master records for
inspection characteristics would be created in the Quality Management (QM) system as a
master data.
A master inspection characteristic can be of quantitative characteristics or qualitative

characteristics and it can be even a derived (calculated) characteristics.
Quantitative Characteristic: The Master Inspection characteristic is treated as a quantitative

characteristic which has a specific measurable value. You can define tolerance limits and a
target value for a quantitative characteristic.
Qualitative Characteristic: The Master inspection characteristic is treated as qualitative having

descriptive in Nature. Inspection results are recorded as codes from inspection catalogs, with
the valuation OK or not OK.
Quantitative / Qualitative Master inspection Values / Range

characteristics
Quantitative Length Lower limit – 10 m2
Upper limit – 15 m2
Target value – 13 m2
Qualitative Color Yellow - Accepted
White – Accepted
Green - Rejected
Black – Rejected
Sampling Procedure
A Sampling Procedure defines the rules that specify how the system calculates the sample size
and it contains information about the valuation of an inspection characteristic during result
recording (Valuation mode).
In KIMMCO & ROCKWOOL the sample size for all the incoming materials will be fixed or
based on the lot size. We will maintain different Sampling procedures for different type of
materials based on the Material and its Base unit of measure.
Sampling Scheme
The sampling scheme contains information for drawing samples based on the size of the
inspection lot. You can assign a sampling scheme to a sampling procedure.
Inspection Methods
Describes the procedure for inspecting a characteristic. You create inspection methods as master
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records and assign them to master inspection characteristics, or inspection plans. A long text
field is available in the Inspection method, which can be used for maintaining inspection
manuals. You can assign several inspection methods to a master inspection characteristic.
Quality Info Records (Optional)

The Q-Info records would be maintained if the material requires Quality assurance agreement,
vendor release for procurement or a Vendor approval process. The Q-info record would be
created with a combination of material, plant and vendor.
The Q-Info record contains following information

No. Field Description
01 Release by Date until which the material for the plant can be ordered
from the vendor
02 Release Quantity Is If this indicator is set, the system checks if the purchase
Active orders, the sum of the material ordered from the vendor
for this plant is greater than the released quantity
03 Status profile Status profile is maintained for Vendor approval process
Inspection Plan
Inspection planning functions to define inspection criteria, for example, material to be
inspected, how the inspection is to take place, characteristics to be inspected, and inspection
specifications. SAP offers inspection plans for different uses, for example, goods receipt
inspection, in process inspection and recurring inspection etc.
Inspection plans help to describe how a quality inspection of one or several materials is to take
place. In the inspection plan, you define the sequence of inspection operations and the range of
specifications available for inspecting inspection characteristics.
Inspection plans will be created for following usages

Inspection type Usage Description
Z1, Z4 (Goods receipt) 5 Goods receipt
Z3 (In process) 1 Production
Z9(Recurring inspection) 9 Material check
Z89 (Manual lot) 3 Universal
Inspection plans will be created with following control key

No. Usage Description
01 QM01 Insp. operation: Characteristics
Inspection plan will be created in following number ranges by automatically.

No. From number To number
01 00000001 49999999
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9. Description of Functional Deficits
Where appropriate, identify any gaps. This section is important when assessing risk, as well as
estimating the need for ABAP (or similar) resources.
 Not applicable
10. Approaches to Covering Functional Deficits

Documentation of any work-around or assumptions that have been made when outlining
functional deficits.
 Not applicable
11. Integration considerations

Specify what integration you need with other modules / sub modules
 Not applicable
12. Reporting Requirements

Document the various reports that you would require.
 List of Master Inspection characteristics

 Where used list of Master Inspection characteristics
 Where used list of Sampling procedures
 List of Inspection methods
 Where used list Inspection methods
 Missing Inspection plans
 List of Quality info records
13. Authorization Requirements

Document the level of authorizations that you need for each process in the system
 Quality head – Creating & Changing Master data

 Quality Supervisor - Creating & Changing Master data
 Quality control chemist – Display Master data
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14. File Conversion / Interface Considerations
Document file conversion / interface requirements. Where the information is to come from,
what data is to be converted manually/automatically and at what point in time. This is critical
information that is used later.
 Code groups and selected set – Manual creation

 Master inspection characteristics – Manual creation
 Inspection methods – Manual creation
 Sampling procedures – Manual creation
 Quality info records – Manual creation
 Inspection plans for raw materials – Manual creation
 Inspection plans for finished goods – LSMW
2. Inspection in Procurement
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 All the incoming Raw materials, Facing materials and Packaging materials are analyzed
based on the specifications defined
 Purchase department will procure the materials from the vendor
 Once the materials are received from the Vendor, warehouse person takes the materials
into Quality inspection stock and inform the Quality personnel
 The Quality person will draw a sample
 After the sample is drawn it will be inspected based on the specifications defined
 Based on the results of the inspection, the received goods will be accepted or rejected
 Once the received goods are accepted by the Quality personnel the goods will be
available for Production
 For some raw materials samples will be sent to the external laboratories for inspection
 It may take 25 - 30 days for the samples to get inspected
 Even before the results arrive from the external laboratory, the raw material will be used
for production
 After the results from the external laboratory are arrived, the results will be recorded
 In case of any rejections, the quality department will inform the purchase department
about the defects
 The problem is analyzed and further action will be taken by the purchase department
 When the material is received from the Vendor, until the material is approved by the
quality department, the payment to the vendor should be blocked

Convention)
 Inspection of raw materials should be triggered automatically

 Unless the quality inspection is completed, the system should not accept the material to
be issued to the production

 When Raw materials, Facing materials and Packaging materials are received from a
Vendor, Inspections will be carried out
 Unless the inspection results are recorded and decision is made by the quality head, the
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materials will not be used for production
process.
 Not Applicable
5. Process Diagrams
Create
Purchase order
Goods receipt against

Purchase order
Inspection Lot creation
Result Recording
Usage
Rejected Decision Accepted
Blocked Stock Unrestricted Stock
Defect Recording Can be issued to

Production
Create Quality
Notification

 Inspections are identified by the purchase order number or batch number in the current
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system
 Now the inspections will be identified by the Inspection lot number in SAP
 There are three major types of stocks in SAP like Unrestricted, Quality and Blocked
stock
 When the goods are received from the vendor, they will be posted to the quality stock,
from where the goods cannot be issued to production
 After completing the inspections, results will be recorded and Usage decision will be
made as Accepted or Rejected
 Once the inspection lot is accepted, the goods will be posted to Unrestricted stock, from
where the goods can be issued to the production
 In case the inspection lot is rejected, the goods will be posted to Blocked stock
 In Rockwool India ltd, when the facing materials are received from the Vendor, the
supplier number is written on the material in the current system
 For traceability purpose, now in SAP, the inspection lot number will be written on the
facing material
 Once the material is received from the Vendor, the material will directly posted to
Quality stock from where we cannot issue the material to production
 Once the Usage decision is made for the inspection lot, the stock will be posted to
unrestricted stock
 Quality scores will be provided to the inspection lot.
 Based on the quality scores, vendor evaluation will be done
 Analytical reports can be generated which can be used by personnel from all user groups
to aid them in their daily activities
8. Solution in SAP.
In the Quality Management component, processing the quality inspections are on the basis of
inspection lot. If you want to inspect a specific quantity of a material, an inspection lot must be
created in the system. Once an inspection lot has been created, using inspection lot we can
inspect the goods, record the inspection results, and complete the inspection with a usage
decision.
Whenever materials are received from procurement process (external source), as soon as GR is
made for the material, an inspection lot is generated automatically. The incoming material
immediately moves into the QUALITY INSPECTION STOCK. This is a special kind of stock –
i.e., this is a restricted stock where material cannot be issued for any purpose.
All the quality activities are carried out for the inspection lot generated. The Quality Inspector
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would inspect the material based on the specifications of inspection lot, record the results of the
characteristics of the inspection lot and based on the valuation of the recorded characteristics
(parameters), the inspection lot would be either accepted or rejected. This acceptance or
rejection is termed as USAGE DECISION.
Only if the material is accepted in the Usage Decision, the stock would be posted from
Inspection stock to Un restricted stock from which the material could be freely issued. If the
materials were to be rejected the same would be posted to blocked stock from where the
material would be sent back to the vendor or as the decision would be taken.
Purchase department will procure the materials from the vendor using purchase order. Vendor
will supply the material against the purchase order.
The following material types are procured

No. Material type Description
01 ZROH Raw Materials
02 ZPAC Packaging Materials
03 ZFAC Facing Material
Once the material is received, warehouse person takes the materials into Quality inspection
stock and system generates inspection lot number automatically.
The following inspection lot number ranges are used in QM in Procurement process
No. Inspection Description From Number To Number
lot origin
01 01 Goods Receipt 010000000000 019999999999
Inspection lot contains following information

01 Plant Plant of the inspection lot
02 Inspection lot Inspection lot number for material
03 Material Material code and description
04 System status Inspection lot status
05 Inspection start date Date when the material received in warehouse
06 Inspection end date Inspection start date + average inspection duration in
material master
07 Inspection type Goods Receipt Insp. against Purchase Order
08 Vendor From which vendor material is received
09 Inspection Plan From which plan the inspection lot is created
10 Inspection lot quantity Quantity received in warehouse
11 Sample size It is determined from sampling procedure maintained in
quality plan
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 Inspection lot is created automatically (Quality Management)
 Pending inspection lots will be displayed in a report
 Stock will automatically posted to Quality stock
 Inspection instructions and Sample drawing instructions can be printed
Result recording
 Samples are inspected in quality control laboratory as per the specifications defined in
the task list (Inspection plan)
 Test results are entered in the result recording transaction
 Valuation of the results (Accepted / Rejected) is done
 If the inspection results are Rejected, then the defects will be recorded and a Quality
notification will be created with notification type ZV (Complaints against Vendor)
 Close the results entered
 The inspection lot status will change from REL (Released) to INSP (Inspected)
Usage decision
 Usage decision transaction is executed for selected inspection lot in work list
 Verifies the results of inspection lot entered by QC analyst
 Depending upon the results the usage decision code is entered
 If the inspection lot is accepted (A-Accepted) then the stock will be posted to
unrestricted stock.
 If the inspection lot is rejected(R-Rejected) then the stock will be posted to blocked
stock
 Quality scores will be provided to the inspection lot based on the Usage decision code
Code Short text Valuation code Quality score
A Accept Accepted 100
A1 Accept, with one deviation Accepted 90
A2 Accept, with two deviations Accepted 70
A3 Accept, with three deviations Accepted 50
A4 Accept, with four deviations Accepted 40
R Rejected Rejected 01
R1 Scrap Rejected 01
 These quality scores will be used in Vendor evaluation
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Long term inspection
 For some raw material, samples will be sent to the external laboratory for inspections
 For the Master inspection characteristics which are inspected outside, in the control
indicators Long term inspection will be activated
 At the time of result recording, the results for long term characteristics will not be
entered and Usage decision will be made (Accepted)
 Usage Decision will be made and the goods can be used for production
 Once the results are received from the external laboratory, the results of those
characteristics will be entered in the system
In a long-term inspection:
 There can already be a usage decision for the inspected material during the long-term
inspection
 You can still record inspection results for long-term characteristics, once you have made
the usage decision
 The system sets a separate status in the inspection lot to identify the long-term
inspection and it provides special work lists for this purpose
Invoice Blocking:
 In the Material master QM view, QM procurement key will be activated and Control key
– 0007 will be assigned.
 The payment of the invoice is blocked with blocking reason I (I = Inspection), if you
want to prevent automatic payment of the invoice from a QM standpoint.
 When the invoice is created, the system determines whether an inspection lot exists and
if necessary, sets blocking reason I. This occurs in the following instances:
There is still no usage decision for the inspection lot
The inspection lot is rejected
 The automatic payment program checks whether the blocking reason I still exists
 Invoice verification takes place with reference to the goods receipt.
If there are several partial deliveries for an order item, the system checks for each GR
item whether blocking reason I exists. This means that automatic payment of the invoice
is only prevented for partial deliveries that do not fulfill requirements.
 The system does not automatically remove blocking reason I, if an acceptance decision
is made for the inspection lot concerned. You must remove blocking reason I at invoice
verification or invoice release.
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 Not applicable

 Not applicable

 Integrated with Materials management, as the inspection lot is generated after the
goods are received against a purchase order

 List of pending Inspection lots (Standard)

 Results display (Standard)
 Display of Results for each inspection lot in a single screen (Development)

 Quality head – Creating & Changing Inspection lot, Result recording, Usage decision
and Stock posting
 Quality Supervisor - Creating & Changing Inspection lot, Result recording, Usage
decision and Stock posting
 Quality control chemist – Display Inspection lot and Result recording
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 Not applicable
3. Inprocess Inspection
 During the production of semi finished and finished products, in process inspections are
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carried out by quality department
 Quality inspections will be carried out at regular intervals of time (For example - Once
in every 15 mins)
 Quality person will inspect the sample according to the specifications defined and
record the results
 In case of any deviations the quality department will inform the Production department
about the deviations
 The production department will make necessary changes and start producing the
finished goods
 The defects will be analyzed and further action will be taken
 In case the results are within the specified range the production process will be
continued further
 Certificate of Analysis is created, printed and it will be sent to the customer along with
the finished goods

Convention)
 The inspection lot should be created automatically

 After the process order is created and released, the inspection lot is generated
automatically
process.
 Not Applicable
5. Process Diagrams
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Create
Process order
Release
Process order
Result Recording /
Valuation
(Inspection points)
Usage
Decision
Rejected Accepted
Defect Recording Confirm

Process order
Create
Quality Notification

 Not Applicable
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 Immediately after releasing the Process order, the inspection lot will get generated
 Inspection point identification will be the date and time
8. Solution in SAP.
During production activities against the process order, in-process inspections can be carried out.
For the inspection relevant operations / phases during production, inspection characteristics
would be maintained in the ‘Master Recipe’. Inspection points will be defined based on time (to
enter results at regular intervals).
Once the Process order is released by the production person, inspection lot would automatically
be created for the in-process inspection. Quality Inspection would be carried out and the results
observed during inspection will be recorded against each operation in the inspection lot. Many
Inspection results can be recorded for the same inspection lot of the process order, as many as
the inspections carried out (Inspection Points).
The following inspection lot number ranges are used in QM in Production process
No. Inspection lot Description From Number To Number
origin
01 03 In-process insp. for 030000000000 039999999999
process order

02 Inspection lot Inspection lot number for material and batch
05 Inspection start date Date when the process order is released
06 Inspection end date Inspection start date + average inspection
duration in material master
07 Inspection type In process Inspection
08 Order Process Order number
10 Inspection lot quantity Quantity of process order
11 Sample size It is determined from sampling procedure
maintained in inspection plan
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 Inspection lot is created automatically after releasing the process order by the
production person
 Process order number is displayed in the Inspection lot number
Result recording
 Samples are inspected based on the specifications defined in the Master Recipe
 Result recording will be done at different inspection points
 Valuate the results (Accepted / Rejected) for each inspection point
 If the results are rejected, then the defects will be recorded and a quality notification will
be created with notification type ZM (Internal problem notification)
Usage decision
 Based on the results the usage decision code will be entered
 If the Inspection lot is accepted, then the process order operation will be confirmed

 Not applicable

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 Not applicable

 Integrated with Production planning, as the inspection lot is generated after releasing
the process order


 Display of Results of all the inspection points and all the characteristics in one
screen (Development)

 Quality head – Creating & Changing Inspection lot, Result recording and Usage
decision
 Quality Supervisor - Creating & Changing Inspection lot, Result recording and Usage
decision

 Not applicable
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4. Inspection after Production
 In Rockwool, there are some inspections which are carried out after completion of
production
 Inspection for specifications like Sulphur content, Chloride content, Moisture absorption
etc are carried out once in four days
 These results will be valid for four days
 For all the dispatches, Certificate of Analysis will be printed and sent along with the
goods
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 The results of the above specifications are printed in the certificate
 Once the results are accepted, then the finished goods will be ready for dispatch
 In case the material is rejected, the material will be posted to blocked stock
 The quality department will inform the production department and further action will be
taken

Convention)
Describe the business process in detail. This typically does not include any SAP specific terms, it should
relate purely to the business rules.
 Inspection of finished goods should be triggered automatically

be delivered to the customer

 When finished goods are received from the production, Inspections will be carried out
 Unless the inspection results are recorded and decision is made by the quality head, the
materials will not be dispatched to the customer
process.
 Not Applicable
5. Process Diagrams
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Create
Process order
Goods receipt from

Process order
Result Recording
Usage
Defect Recording Can be delivered to the

customer
Create Quality
Notification

 All the inspections will be identified by the Inspection lot number in SAP
 When the produced goods are received from production, an inspection lot will be
generated and stock will be posted to quality stock
 From Quality stock the goods cannot be delivered to the customer
 After completing the inspections, results will be recorded and Usage decision will be
made for the inspection lot
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 Once the inspection lot is accepted, the stock will be posted to unrestricted stock from
where the goods can be delivered to the customer
 In case the inspection lot is rejected, the stock will be posted to Blocked stock
 The characteristics will be inspected once in four days
 But the results of the characteristics will be recorded in all the inspection lots which are
generated within that four days
Describe improvements which will result from implementation of the SAP System. Be sure to include any
impact on business drivers.
8. Solution in SAP.
Whenever materials are received from production process, as soon as GR is made for the
material, an inspection lot is generated automatically. The material immediately moves into the
QUALITY INSPECTION STOCK. This is a special kind of stock – i.e., this is a restricted stock
where material cannot be issued for any purpose.
rejection is termed as USAGE DECISION.
Only if the material is accepted in the Usage Decision, the stock would be posted from
Inspection stock to Un restricted stock from which the material could be freely issued. If the
materials were to be rejected the same would be posted to blocked stock from where the
material would be reworked or scraped or as the decision would be taken.
Once the material is received, warehouse person takes the materials into Quality inspection
stock and system generates inspection lot number automatically.
The following inspection lot number ranges are used in Inspection after Production process
lot origin
01 04 Goods Receipt 040000000000 049999999999
02 Inspection lot Inspection lot number for material
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05 Inspection start date Date when the material received in warehouse
06 Inspection end date Inspection start date + average inspection duration in
material master
07 Inspection type Goods Receipt Inspection from production
09 Inspection lot quantity Quantity received in warehouse
10 Sample size It is determined from sampling procedure maintained in
quality plan
 Inspection lot is created automatically (Quality Management)
Result recording
 Samples are inspected in quality control laboratory as per the specifications define in the
task list
 Valuation of the results (Accepted / Rejected) is done
 If the inspection results are Rejected, then the defects will be recorded and a Quality
notification will be created with notification type ZM(Internal problem notification)
Usage decision
 Depending upon the results the usage decision code is entered
unrestricted stock
stock
 The UD codes will be as follows
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Code Short text Valuation code
A Accept Accepted
A1 Accept with one deviation Accepted
AX Accept, other material Accepted
R Rejected Rejected
R1 Scrap Rejected

 Not applicable

 Not applicable

 Integrated with Production planning, as the inspection lot is generated after the
produced goods are received from production


 Display of Results for each inspection lot in a single screen (Development)

and Stock posting
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 Not applicable
5. Retesting of Finished goods
 In KIMMCO, finished goods stocks are available in the storage location, which are not
reserved to any sales order
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 After the receipt of a sales order for that material, before delivering the material to that
sales order, the material will be inspected
 Then inspections will be carried out based on the specifications defined
 If the results complies with the specifications, the goods will be dispatched to the
customer
 In case of any defects, the deviations will be recorded and material will be blocked
 Further action will be taken based on the problem analysis
 These inspections are not related to any sales order or production order

Convention)
 Not Applicable

 In KIMMCO, there are some cases, where the finished goods are not produced for any
particular sales order. These materials are produced and kept in stock
 After a sales order for this material is received, before delivering the finished goods to
the customer, inspection are carried out
process.
 Not Applicable
5. Process Diagrams
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Initiate Inspection of
Finished goods
Create Inspection lot

Manually
Result Recording
Usage
Decision
Accepted
Rejected
Defects Recording Deliver Finished Goods
Create
Quality Notification

 Not Applicable
 Not applicable
Page 33 of 69
8. Solution in SAP.
Whenever the materials which are in stocks require inspection before delivery, the stores person
will inform the quality control department to inspect the materials. Then the quality person will
create an inspection lot manually. While creating the inspection lot the quantity of the material
which has to be inspected will be entered.
rejection is termed as USAGE DECISION. Once the quality person record the results and make
a Usage decision as ACCEPTED, the material can be delivered.
 Inspection lot is created manually for the stock quantity
Result recording
 Samples are inspected in quality control laboratory based on the specifications defined
in the task list
 Valuate the results (Accepted / Rejected)
 If the inspection results are rejected, then the defects will be recorded and a Quality
notification will be created with notification type ZM (Internal problem notification)
Usage decision
 Depend upon the results the usage decision code is entered
 If the Inspection lot is Accepted, then the goods can be delivered to the Sales order
 If the Inspection lot is Rejected, then the goods will be blocked and further action will
Page 34 of 69
be taken
While creating the inspection lot manually, the person who is creating the inspection lot
has to select the inspection plan from the list.

 Not applicable

 Not applicable

 Not applicable

 List of pending Inspection lots

 Results display

decision
Page 35 of 69
decision

 Not applicable
6. Vendor approval process
 In KIMMCO, when the Raw materials are procured from a new Vendor, approval
process will be carried out
Page 36 of 69
 Initially samples of the Raw material will be taken from the vendor. This sample will be
inspected based on the specifications defined
 If the results are meeting the requirements, then the purchase department will send a
Trial order to the Vendor for a smaller quantity
 Once the goods are received from the vendor against that purchase order, inspection are
carried out
 If the results are meeting the specific requirements, then they will approve the Vendor
on quality aspects
 In case of any defects in the material, quality department will inform the purchase
department
 The purchase department will block the goods and further action will be taken

Convention)
 Not Applicable

 This process should trigger only for a new Vendor.
process.
 Not Applicable
5. Process Diagrams
Page 37 of 69
Receive Sample from
New Vendor

Manually
Result Recording
Accepted
Create quality info
Usage record & Initiate Vendor
Decision approval process
Rejected
Create
Purchase order &
Request for another
Assign Status profile
sample
Goods receipt against

Purchase order
Result Recording
Rejected Usage Accepted

Decision
Create
Quality Notification Vendor Approved
Page 38 of 69
 Not Applicable
 Reports on Overview of Inspection lots, Quantities, Quality scores, Defects and
Notifications can be generated
8. Solution in SAP.
Whenever the Samples are taken from a new Vendor, the Purchasing department person will
inform the quality control department to inspect the sample. Then the quality person will create
an inspection lot manually.
rejection is termed as USAGE DECISION. Once the quality person record the results and make
a Usage decision as ACCEPTED, the material can be procured from the new Vendor.
 Inspection lot is created manually for the sample received from the Vendor
Result recording
 Samples are inspected in quality control laboratory based on the specifications defined
in the task list
Usage decision
Page 39 of 69
 Based on the results the usage decision code is entered
 If the Inspection lot is Accepted, then the materials can be procured from the Vendor
Vendor approval process
Vendor approval process in carried out in QM based on the results of the inspection lot. Quality
info record will be created in the system with the combination of material, vendor and plant. In
material master QM view, QM procurement key will be activated. Status profile will be created
and assigned to the quality info record. When the purchase order is created for the material to
that new vendor, the status in the quality info record will be – Vendor approval process initiated.
When the material is procured from the vendor, an inspection lot will be generated
automatically. Result recording will be done. Based on the results, usage decision code will be
entered by the quality manager. Immediately after entering the Usage decision code as accepted,
the status in the quality info record will be changed to – Vendor approved.
 Inspection lot is created automatically (Quality Management).
 Status in the quality info record will be – Vendor approval process initiated
Result recording
 Samples are inspected in quality control laboratory based on the specifications define in
the task list
 If the inspection results are rejected, then the defects will be recorded and a Quality
notification will be created with notification type ZV (Complaints against a Vendor)
Usage decision
Page 40 of 69
unrestricted stock.
stock (QC Manager).
 If the inspection lot is Accepted then the status in the quality info record will changed to
– Vendor is approved

 Not applicable

 Not applicable

 Integrated with Materials management, as the quality info record can be created only if a
Vendor master is created for the new Vendor


 Results display
Page 41 of 69
and Stock posting

 Not applicable
7. Recurring Inspection
 Some raw materials like Adhesives and Binder raw materials are batch managed
 These batches will have shelf life and expiry dates
 The quality parameters of these batches will be monitored at regular intervals
Page 42 of 69
 After every 90 days, the batches which are available in storage location will be
inspected
 At the time of inspection, the material will be placed in quality stock
 Once the inspection specifications are accepted, then the material can be issued for
production
 If the inspection specifications are rejected, then the material will be blocked and further
action will be taken

Convention)
 Inspection lot should be triggered automatically when the next inspection interval
arrives
be issued to the production

 Not Applicable
process.
 Not Applicable
5. Process Diagrams
Page 43 of 69
Batch Deadline Monitoring of
(Next inspection interval) Batches
Batch posted to
Quality stock
Inspection Lot
Created automatically
Result Recording
Usage
Defect Recording Can be issued to

Production
Create Notification

Page 44 of 69
 In the present system, based on the next inspection date of batches, the inspection are
carried out manually
 Now in SAP, when the next inspection date is arrived, the batch will be automatically
posted to quality stock and system creates an inspection lot automatically
 Deadline monitoring will be scheduled in background

 The batches for which the next inspection interval is arrived, the inspection lot gets
generated automatically
 The batch will be automatically posted to quality stock
8. Solution in SAP.
The system can automatically create inspection lots at predefined intervals for selected batch
materials. You can plan such inspections by having the system monitor the date for a recurring
inspection.
The system creates inspection lots automatically for recurring inspections if the following
conditions have been met:
 Each material to be inspected is defined as a batch material in the material master record
 An inspection interval is specified in the Quality Management view of the material
master record
 An inspection type is active for inspection lot origin 09 in the inspection settings of the
material master record
 The inspection settings in the material master record specify an inspection using a task
list or material specification (if you want to record results for inspection characteristics)
 A Next inspection date is specified for the batch in the batch master
Recurring inspections are triggered by a report that we can execute manually

 The system can automatically create inspection lots Based on the “Next Inspection
Date” field in the Batch master (which is initially set during the original inspection).
 Inspection lot will be automatically created when the next inspection date is reached
 The following inspection lot number ranges are used in Recurring Inspection process
Page 45 of 69
lot origin
01 09 Recurring 090000000000 099999999999
Inspection
 The stock of that particular batch will be automatically posted to quality stock
 The quality person draws the sample
 The samples are tested in the quality control laboratory according to the specifications
defined in the Inspection plan
 Test results are entered in the results recording transaction of inspection lot
 Depending upon the results the usage decision code will be entered
 If the inspection lot is accepted(A-Accepted) then the stock will be posted to
unrestricted stock
 If the inspection lot is rejected(R-Rejected) then the stock will be posted to
blocked stock

 Not applicable

 Not applicable

 Not applicable

Page 46 of 69

and Stock posting

 Not applicable
8. Washwater testing
Page 47 of 69
 While producing binder material, wash water is used in the production

 This wash water will be recycled
 The solid content of the wash water is inspected in each shift
 This inspection is carried out once in a shift
 After 7 or 8 days, when the solid content is out of specification, then the water will be
discarded and fresh water will be taken

Convention)
 Not Applicable

 Not Applicable
process.
 Not Applicable
5. Process Diagrams
Page 48 of 69
Initiate Inspection of
Wash water

Manually
Result Recording in each

shift
Usage
Decision
Accepted
Rejected
Discard the wash water Use the Water further

 Not Applicable
 Inspection results will be recorded in each shift based on the inspection points
 The identification of the inspection points will be the date and time
Page 49 of 69
8. Solution in SAP.
The quality person will create an inspection lot manually for wash water testing. While creating
the inspection lot the quantity of the material which has to be inspected will be entered.
would inspect the wash water based on the specifications of inspection lot, record the results of
the characteristics of the inspection lot and based on the valuation of the recorded
characteristics (parameters), the inspection lot would be either accepted or rejected. The result
recording will be done in each shift as an inspection point. The identification of the inspection
point would be date and time. This acceptance or rejection is termed as USAGE DECISION.
Once the quality person record the results and make a Usage decision as ACCEPTED, the water
can be used in the production activity.
 Inspection lot is created manually for the wash water
Result recording
 Samples are inspected in quality control laboratory based on the specifications define in
the task list
 Test results are entered in the result recording transaction for each inspection point
(Once in a shift)
 If the inspection results are rejected, then defects will be recorded and will be informed
to concerned person to change the water
Usage decision

Page 50 of 69
 Not applicable

 Not applicable

 Not applicable


 Results display

decision
decision

Page 51 of 69
 Not applicable
9. Quality Notifications
Page 52 of 69
Customer complaints
 The CSD department will receive the complaints from the customer
 CSD department will inform the Quality department about the complaint received, if the
complaint is technical
 The Quality department will trace back the inspection results of the produced goods
 The Quality department will analyze the problem
 The Quality department will inform the CSD department about the results of the goods
 The CSD department will take a decision (Ex – Return delivery, Subsequent delivery or
Price reduction)
 The corrective action will be taken by the Sales department
 After completing the corrective action, the complaint will be closed by the CSD
department
Complaints against Vendor

 When the material received from a Vendor is found defective, the quality department
will record the defects
 The Quality department will inform the Purchase department about the defective
material received
 The Purchasing department will take a decision (Ex – Return delivery or Accept with
deviation etc)
 The corrective action will be taken by the Purchasing department
 After completing the corrective action, the complaint will be closed by the purchase
department
Internal problems
 While producing the finished goods, if any defects are found, the material will be kept
on hold
 The Quality department will inform the Production department about the defects
 The Quality department will define some corrective actions (Ex – Rework or Scrap etc)
 The Production department will perform the corrective actions
 After completing the corrective actions, the complaint will be closed by the quality
department
Page 53 of 69
Convention)
 The number range for Notifications will be internal

Quality notifications will be created in the following cases
 Defective material received from the Vendor

 Complaint received from the Customer
 Defects found in Produced material
process.
 Not Applicable
5. Process Diagrams
Notification Overview
Page 54 of 69
Information related to the
overall notification
Notification Header
General data
Tasks
Activities
Notification Header level
Item Overview Notification Item level
Item
Individual notification-
Item related defects
Item
Causes
Information related to a
single defect item
Tasks
Activities
Customer complaint Notifications
Page 55 of 69
Receive Customer Creation of Customer Reference object is
complaint by CSD dept complaint notification Sales order number Or
(ZC) by CSD dept Process order number
Customer name
Material number
Purchase order number
Process order number
Inform Quality department
Sales order number
about the customer
Complaint quantity
complaint
Defect types
Causes
Trace back the results and

Analysis of the complaint
by Quality dept
Revert back to the CSD

department
Define corrective actions

by CSD dept and assign
person responsible
Performing the Tasks by
Sales dept
Forward notification to
CSD dept
Closing of the notification

by CSD dept
Vendor related Notifications
Page 56 of 69
Inspection lot with Accepted
Usage
reference to the Purchase
Decision
order
Post the goods to

Vendor name Rejected unrestricted stock
Material number
Purchase order number
Goods receipt number
Record defects and Create
Complaint quantity
Notification (ZV) by
Defect types
Quality dept
Causes
Analyze the problem and

inform Purchasing
department
Define Tasks and assign

person responsible by
Purchasing dept
Purchasing department
takes a decision on
received materials
Perform the Tasks and
Completing the Tasks by
purchasing dept
Completion of Tasks by
purchasing department
Close the Notification by

purchasing dept
Internal problem Notification
Page 57 of 69
In process Inspection lot Accepted
Usage
with reference to the
Decision
Process order
Confirm Operation
Process order number Rejected
Material number
Inspection lot number
Complaint quantity
Record Defects and Create
Defect types
Notification (ZM) by
Causes
Quality dept
Analyze the problem and

inform Production
department
Define Tasks and assign

person responsible by
Quality dept
Take corrective actions &
Implement in production
Perform the Tasks and

Complete the Tasks by
Production dept
Feedback from Production

department
Close the Notification by

Quality dept
Page 58 of 69
 In the existing system, there is no procedure to handle Complaints against vendor,

Customer complaints and Internal problems
 Now in SAP, we can handle above complaints using Quality notifications
 Using quality notifications we can describe a problem and identify the affected
reference objects
 Defects can be recorded and causes for the problem can be analyzed
 The system will record the names of all the persons who are involved with the problem
 Log all activities that have been carried out for the problem
 Print various types of reports related to the problem
 Generate list of notifications for processing and evaluation purpose
 Reports on Overview of Notification can be generated Vendor wise, Customer wise,
Material wise, Notification type wise, Plant wise and Period wise
8. Solution in SAP.
Customer complaint Notification

A customer complaint is a quality notification type (ZC) that deals with a problem involving
poor-quality goods or services delivered to a customer.
You can use a notification for a customer complaint to record and process a problem that is
reported by a customer.
In a quality notification for a customer complaint, you can specify one or more reference
objects. A reference object has a relationship to the problem in a quality notification. A
customer complaint may include the following reference objects:
 Sales order number
 Process order number

When you process a quality notification for a customer complaint, you can also display the
following supplementary information for a customer:
 Sales summary
Page 59 of 69
 Summary of important customer information (for example, order data, terms of
payment, transaction data, and so on).
 Related notifications for the Customer, Material and the combination of both.
Processing of Notification
 The Customer complaint will be received by the CSD department
 After receiving the customer complaint, the CSD department will create a notification
with notification type ZC
 The notification will be create with reference to the Sales order number or Process order
number which will be printed on the label
 While creating the notification, all the data from the sales order or process order will be
copied to the notification
 The CSD department will inform the Quality department about the customer complaint,
using the external mailing system
 The Quality department will trace back the results of the complained goods using based
on the process order number or the sales order number
 The Quality department will analyze the causes of the complaint
 Traceability – In the process order display transaction, in the assignment tab, the in
process inspection lot number will be available
 Using this inspection lot number, the inspection results will be monitored in the display
results transaction
 After monitoring the inspection results, the quality department will inform the CSD
department about the results
 The information will be forwarded through SAP to the external mailing system
 The CSD department will define the corrective tasks depending the upon the complaint
 The person responsible will be assigned against each task and release the task
 The corrective tasks will be performed in or outside the notification by the user
responsible for the task
 Once the corrective action is performed by the concerned user, the task will be
completed in the notification
 The status profile of the Tasks is as follows
Status Description
Page 60 of 69
TSOS Task outstanding
TSRL Task released
TSCO Task completed
TSSC Task successful
 The notification will be closed by the CSD department after all the tasks are completed
 The status profile of the Notification is as follows
Status Description
OSNO Outstanding notification
OSTS Outstanding tasks
ATCO All tasks completed
NOCO Notification completed
Vendor complaint Notification

A complaint against a vendor is a quality notification type (ZV) that deals with a problem
involving poor-quality goods or services delivered by a Vendor or Manufacturer.
You can use a notification for a complaint against a Vendor to record and process a problem that
was confirmed in a delivery.
In a quality notification for a complaint against a Vendor, you can specify one or more reference
objects. A reference object has a relationship to the problem in a quality notification.
When you process a quality notification for a complaint against a Vendor, you can also display
the following supplementary information for a customer:
 Summary of important information for the Vendor / Material (for example, quantities of
Material ordered from the Vendor etc).
 Related notifications for the Vendor, Material and the combination of both
Processing of Notification
 When the raw materials are received from the Vendor, the stocks will go into quality
stock and an inspection lot is generated automatically
 At the time of result recording for the inspection lot, if any defects are found, the quality
Page 61 of 69
control chemist will record the defects
 After recording the defects, a notification will be created with notification type ZV
 All the data relating to that purchase order will be copied to the notification
 The quality department will monitor the defects and analyses the causes of the problem
 The quality department can take a usage decision, if they want to block the stock
 Once the notification is created and analysis is done on the problem, the quality
department will inform the Purchase department about the complaint using the external
mailing system
 The purchasing department will trace back the purchasing documents
 The Purchase department will define the corrective tasks and assigns person responsible
against the tasks
 These tasks will be performed by the purchasing users in or outside of the notification
 After completing the tasks, the purchase department will complete the tasks
 Finally the purchasing department will close the notification
Internal Problem Notification

An internal problem report is a quality notification type (ZM) that deals with quality related
problems that originate within our own Organization. We can use this notification for an
internal problem report to record and process company internal problems (for example, defects
confirmed for a material or a product in a production process).
In a quality notification for an internal problem report, we can specify one or more reference
objects. A reference object has a relationship to the problem in a quality notification.
Processing the Notification
 When a Process order is released, an inspection lot will be automatically generated
 We can record the result at different intervals of time
 While recording the results, if any defects are found, then the defects will be recorded
 The notification with notification type ZM will be created
Page 62 of 69
 All the data related to that process order will be copied to the notification
 The quality department will analyze the problem and identify the causes of the problem
 The quality department will inform the Production department about the notification
 The quality department will define corrective tasks in the notification and assign the
person responsible against the task
 The production department will perform the tasks defined in the notification
 The production department will complete the tasks
 The quality department will close the notification

 Not applicable

 Not applicable

 Intergrated with SD, MM and PP modules

 List of pending Notifications

 List of Tasks with status
Page 63 of 69
 Quality head – Creating Quality notifications, assigning tasks and closing the
notifications
 Quality Supervisor – Creating Quality notifications, assigning tasks and closing the
notifications
 Quality control chemist – Creating Quality notifications

 Not applicable
10. Calibration of Equipments
Page 64 of 69
 All the measuring and test equipments which affects quality will be periodically
calibrated for accuracy
 Calibrations takes place both internally and externally
 The facility to define allowable range of equipment / instrument should be available
 The calibration reading should be recorded in the system
 Provision to maintain history of calibration should be possible

Convention)
 Not Applicable

 Not Applicable
process.
 Not Applicable
5. Process Diagrams
Page 65 of 69
Create
Maintenance order
Release
Maintenance order
Result Recording /
Valuation
(Equipment)
Usage
Decision
Rejected Accepted
Recalibrate the Confirm

Equipment Maintenance order

 Not Applicable
Page 66 of 69
 Not applicable
8. Solution in SAP.
This scenario describes how to process test or measurement equipment in a calibration

inspection.
The objective of a calibration inspection is to determine whether each piece of equipment
specified in the maintenance order meets the predefined performance specification.
This process contains

 Inspecting the equipment specified in the maintenance order
 Record inspection results of each piece of the equipment
 Valuate each piece of equipment
 Make a Usage decision for the inspection lot
Inspection lot creation
 When a Maintenance order is released, system creates an inspection lot automatically

 Maintenance order number will be copied to the inspection lot
 Generates inspection specifications for each piece of the equipment
 Determines the inspection lot quantity based on the number of pieces of equipment
specified in the maintenance order
 Determines which inspection characteristics to be inspected
 The following inspection lot number ranges are used in Equipment Calibration process
lot origin
01 14 Plant 140000000000 149999999999
Maintenance
Result recording
 After inspecting each piece of test equipment, we will record inspection results for each
characteristics in each operation to determine whether the recorded values are within the
predefined inspection specifications
 On the basis of inspection results, we valuate and close each characteristic and then
Page 67 of 69
valuate each piece of equipment
 The valuation specifies whether we accept or reject the equipment at operation level
Usage decision
 Usage decision code will be entered in Usage decision transaction as Accepted or

Rejected
 Usage decision for an inspection lot confirms that an inspection has been completed
 The following UD codes will be used
Code Short text Valuation code

A Usable Accepted
R Cannot be used Rejected
R1 Recalibration Rejected
R2 Rework + Calibration Rejected
 Once the inspection lot is completed, the maintenance order will be confirmed

 Not applicable

 Not applicable

 This scenario is integrated with Plant maintenance. When the maintenance order is
created and released, an inspection lot will be generated automatically.

Page 68 of 69
 Results display
 Calibration history

 Maintenance head – Creating & Changing Inspection lot, Result recording and Usage
decision
 Instrumentation Engineer - Creating & Changing Inspection lot, Result recording and
Usage decision
 Instrumentation Technician – Display Inspection lot and Result recording

 Not applicable
Page 69 of 69

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BUSINESS BLUEPRINT DOCUMENT

Date: 11th Dec 2007

Document Name Business Blue Print

Document Change Control :

2. General Explanations (For Masters and Enterprise structure include Naming

 The naming convention for Master inspection characteristics will be external

3. Explanations of Functions and Events

Sampling Procedure Inspection Plan

6. Changes to Existing Organization processes

Quality Management Master Data

Quality Management view

Different Inspection types are assigned to each material

Code group Codes

Selected set Codes Valuation

A master inspection characteristic can be of quantitative characteristics or qualitative

Quantitative Characteristic: The Master Inspection characteristic is treated as a quantitative

Qualitative Characteristic: The Master inspection characteristic is treated as qualitative having

Quantitative / Qualitative Master inspection Values / Range

Quality Info Records (Optional)

The Q-Info record contains following information

Inspection plans will be created for following usages

Inspection plans will be created with following control key

Inspection plan will be created in following number ranges by automatically.

10. Approaches to Covering Functional Deficits

11. Integration considerations

12. Reporting Requirements

 List of Master Inspection characteristics

13. Authorization Requirements

 Quality head – Creating & Changing Master data

 Code groups and selected set – Manual creation

2. General Explanations (For Masters and Enterprise structure include Naming

 Inspection of raw materials should be triggered automatically

3. Explanations of Functions and Events

Goods receipt against

Inspection Lot creation

Blocked Stock Unrestricted Stock

Defect Recording Can be issued to

6. Changes to Existing Organization processes

The following material types are procured

Inspection lot contains following information

Inspection Lot creation

 Pending inspection lots will be displayed in a report

 Stock will automatically posted to Quality stock

 Inspection instructions and Sample drawing instructions can be printed

 Verifies the results of inspection lot entered by QC analyst

 Depending upon the results the usage decision code is entered

10. Approaches to Covering Functional Deficits

11. Integration considerations

12. Reporting Requirements

 List of pending Inspection lots (Standard)

13. Authorization Requirements

2. General Explanations (For Masters and Enterprise structure include Naming

 The inspection lot should be created automatically

3. Explanations of Functions and Events

Inspection Lot creation

Defect Recording Confirm

6. Changes to Existing Organization processes

Inspection lot contains following information

 Inspection instructions and Sample drawing instructions can be printed

 Process order number is displayed in the Inspection lot number

 Verifies the results of inspection lot entered by QC analyst

 Based on the results the usage decision code will be entered