SAP Manufacturing Execution 5.1.

3
Setting Up Nonconformance
Including PCA Dashboard and DPMO

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Table of Contents
Introduction ..........................................................................................................................................1 What Is Nonconformance? ................................................................................................................1 Decisions to Make..............................................................................................................................1 Branching and Dispositioning on Routers .......................................................................................3 Operator Determination .....................................................................................................................3 System Determination........................................................................................................................3 More Information About Routers........................................................................................................3 Collecting Information.........................................................................................................................5 What Is a Data Type? ........................................................................................................................5 Assigning NC Data Types..................................................................................................................5 Defining Nonconformance (NC) Codes .............................................................................................7 What Is an NC Code? ........................................................................................................................7 Categorizing NC Codes .....................................................................................................................7 Creating a Hierarchy ..........................................................................................................................8 Setting Up and Overriding Maximum NC Limit................................................................................10 Closing NC Codes ...........................................................................................................................10 Assigning Operations.......................................................................................................................11 Setting Up Activity Hooks ................................................................................................................11 Logging an NC Reject in the Rich POD...........................................................................................11 Working with Real-Time Warnings...................................................................................................13 Working with Standard Nonconformance Clients..........................................................................15 Standard Nonconformance Clients..................................................................................................15 Working with the Fast Barcode Interface.........................................................................................16 Allowing Operators to Auto Remove/Replace NC’s Components...................................................17 Typical Scenarios for the Standard Nonconformance Clients .........................................................17 Verifying Defects..............................................................................................................................19 Setting Up Incident Numbers...........................................................................................................20 Working with Graphical (PCA) Nonconformance Clients..............................................................21 Typical Scenarios for the Graphical (PCA) Nonconformance Clients .............................................24 PCA Dashboard Buttons..................................................................................................................26 Using DPMO (Defects per Million Opportunities)...........................................................................29 What Is DPMO? ...............................................................................................................................29 What Comes with the System?........................................................................................................29 Setting Up Nonconformance ............................................................................................................31 Setting Up Nonconformance............................................................................................................31 Creating Primary and Secondary NC Codes...................................................................................31 Setting Up and Overriding Maximum NC Limit................................................................................32 Setting Up the POD for Nonconformance........................................................................................32 Setting Up the Fast Barcode Interface for Operators ......................................................................33 Allowing Operators to Auto Remove/Replace NC’d Components...................................................33 Allowing Operators to Close Multiple Primary NCs with One Secondary NC .................................34 Setting Up Standalone Failure Tracking ..........................................................................................34 Setting Up DPMO ............................................................................................................................34 Appendix: Installing PCA Server......................................................................................................37 Index....................................................................................................................................................41

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

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Which nonconformance (NC) codes you want operators to use when they log NCs. You can also have operators or machines log NCs to pull products randomly for sampling. When an operator logs an NC. you must decide: How you want router branching and dispositioning to behave in the system. A disposition function. or logs a nonconformance (NC) against that particular SFC. Another step on the current router for analysis or repair. Note: You can indicate not only test failures. How you will use Real-Time Warnings. integrity checking. and repair information about SFCs. When a product fails a test. Decisions to Make When you set up Nonconformance.Introduction The Nonconformance feature helps you improve product quality and customer responsiveness by allowing you to: Track failure. What information you want to collect for analysis. Assign incident numbers to logged nonconformances.1. and how you want to organize them. but also nonconformance to any standard. SAP Manufacturing Execution 5. With Nonconformance.3 Setting Up Nonconformance 1 . Operators at these steps can log additional NCs against the SFC to detail its current condition. Control the routing of nonconforming products. such as a scratch on a chassis. allowing you to display engineering changes in real time. Calculate defects with the standardized DPMO (defects per million opportunities) methodology as defined in the IPC-9261 standard for printed board assembly manufacturing. Display up-to-date engineering schematics graphically in the PCA Dashboard. you can also: Collect test and inspection data for analysis. the operator or machine at that step nonconforms. defect. What Is Nonconformance? At various steps on your routers. and other uses. integrity checking. you can include operations where product is tested for defects. the system can automatically send the nonconformed SFC to: The first step on a disposition router. and other uses when operators log nonconformances.

How you will use DPMO. SAP Manufacturing Execution 5.Introduction How you want the POD to behave and appear for operators who log nonconformances.3 Setting Up Nonconformance 2 .1. How you want the PCA Dashboard in the POD to behave and appear for operators who work with nonconformances against PCA boards.

a next step on the same router. a Return step. Set up disposition functions to either send the SFC automatically to a specific destination when it is nonconformed.3 Setting Up Nonconformance 3 . or allow the operator to choose from a menu of several destinations. you must decide how you want router branching and dispositioning to behave. A Return step. the system displays a list of choices the operator can select from.Branching and Dispositioning on Routers When you set up Nonconformance. you can: Allow the operator to determine where the system should send the SFC. Set up a disposition router to automatically send the SFC there when it is nonconformed. System Determination If you allow the system to automatically determine where to send the SFC. For more information about branching and dispositioning. Operator Determination If you allow the operator to determine where the system should send the SFC. Keeping the SFC at the current step. such as how many times the SFC has failed the test. The first step on a separate router. More Information About Routers For more information about setting up routers and scripting. Allow the system to automatically determine where to send the SFC. A SCRAP step. These choices can include: A next step on the same router. you can: Use scripting to send the SFC to a SCRAP step.1. see the Setting Up Production Lines guide. When an operator logs an NC against an SFC at a router step. see the Setting Up Production Lines guide and the online help for Router Maintenance. SAP Manufacturing Execution 5. based on criteria. or other location.

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For a complete list. SIMPLE. nonconformance. You can add or delete fields to the existing NC data type. You define data types in Data Type Maintenance. The system comes with several NC data types to which fields have already been allocated. in the NC Data Type field in NC Code Maintenance. browse on the Data Type field. What Is a Data Type? A data type is a set of fields you can display to users to collect information about individual components or higher-level assemblies during a process. Defect Count Ref Des Failure ID Location Comments Component Component SFC Component SFC Item Root Cause Operation Pin Note: You can also create custom fields in Data Type Maintenance to collect data that is not listed in Data Type Maintenance. the system displays the field(s) you specified based on the data type of the NC code. integrity checking. such as assembly. select NC in the Category field. SAP Manufacturing Execution 5.Collecting Information The NC category in Data Type Maintenance allows you to collect information for analysis. Note: If you do not want to collect data at nonconformance operations. and other uses when operators log nonconformances. and retrieve the record. you must assign an NC data type to each code. Assigning NC Data Types When you create NC codes. leave the default value. Click Edit > Insert New. in Data Type Maintenance. When the operator logs a nonconformance. disassembly. inventory receipt.1. The SIMPLE data type displays no fields to the operator by default. You can make each field required or optional for the operator. and browse in the Data Field column of the new row. or working with RMAs. packing.3 Setting Up Nonconformance 5 . The operator enters the information you want to collect in each field. The following list is a sampling of fields you can have the system display in the POD for each type.

SAP Manufacturing Execution 5.3 Setting Up Nonconformance 6 .1.Collecting Information Note: Use the Root Cause Operation field only with DPMO.

or how it was fixed (repair). and ANOP indicate that the repair is complete. what the problem is (defect).Defining Nonconformance (NC) Codes What Is an NC Code? An NC. If needed for your shop floor. Repair: Indicates how the defect on the SFC has been repaired. you must assign all NC codes to a group before operators can use them to log NCs. The level of the nonconformance and its relationship to other codes in the hierarchy. Defect: Indicates what is wrong with the SFC. if you set the Nonconformance > Use NC Groups for Production Clients rule to true. the NC codes DONE. and DONE.3 Setting Up Nonconformance 7 . or nonconformance. all three categories of NC codes will have a flat relationship to each other: Failure Defect Repair SAP Manufacturing Execution 5. Operators and machines log NCs against SFCs by assigning a nonconformance (NC) code to the SFC. code is set of characters that indicates the state of an SFC with respect to a nonconformance.1. That the problem with an SFC has been or will be repaired. you can also create a hierarchy among NC codes to show their relationships to each other. Categorizing NC Codes When you create an NC code in NC Code Maintenance. For example. you must specify one of the following categories: Failure: Indicates the SFC has failed some type of test or has been pulled for sampling purposes. LATER. will be done later. the NC code FAIL indicates that an SFC failed a test. An NC code can indicate: That something is wrong with an SFC. LATER. If you do not create a hierarchy for your NC codes. NC codes can indicate: Test or inspection failure (failure). the NC code WIRE DAMAGE indicates that a wire is damaged on the SFC. or will be done by another operator. and possibly how to fix it. For example. A diagnosis of the problem. In the previous example. and ANOP have the category Repair. you can create groups for them in NC Group Maintenance. WIRE DAMAGE and CON NOT SOLDER have the category Defect. the NC code FAIL has the category Failure. For example. Note: In System Rule Maintenance. If you have a large number of NC codes. You create the NC codes for your site in NC Code Maintenance. The NC code CON NOT SOLDER indicates an unsoldered connection.

3 Setting Up Nonconformance 8 . The system displays this hierarchy graphically in the Failure Data area of the nonconformance client in the POD: SAP Manufacturing Execution 5.1.Defining Nonconformance (NC) Codes Creating a Hierarchy An NC code hierarchy shows the relationship among the NC codes that operators have logged in the system.

You base the place of an NC code in the hierarchy on its category and the level of granularity you want. Primary and Secondary NC Codes You create an NC hierarchy by creating primary and secondary NC codes in NC Code Maintenance.or three-level NC hierarchy is most typical when you use the PCA Dashboard. click Actions > Tree View in NC Code Maintenance.1. The first unit failed because of a short and was rewired. Can have other codes underneath it. SAP Manufacturing Execution 5. the following illustration shows a three-level hierarchy with two sets of NC codes logged against the primary NC. What Is a Primary NC Code? A primary code is an NC code you create in NC Code Maintenance that: Is at the top level of a hierarchy. associated with the Defect code) For example. The following illustration shows a two-level hierarchy: Defect (Primary NC) Repair (Secondary NC) The following illustration shows a three-level hierarchy: Failure (Primary NC) Defect (Secondary NC) Repair (Secondary NC. NO_POWER (Failure) SHORT (Defect) REWIRE (Repair) NO_POWER (Failure) CABLECONWRONG (Defect) RECONNECT (Repair) Note: To view the current hierarchical relationships of all your NC codes.Defining Nonconformance (NC) Codes You create a hierarchy among your NC codes by making them either primary or secondary codes and associating them with each other. NO_POWER. The second unit failed because of incorrectly connected cables and was re-cabled.3 Setting Up Nonconformance 9 . A two.

You can use closing of NC codes in several ways: To simply track that the nonconformance was logged (auto close the primary NC). Auto Close Incident Defines the NC code to close the entire branch of the NC tree including any additional secondary codes and the primary code. Closure Required Defines the NC code to require additional action to close. This is often done when the unit is expensive to build. to close an incident. for example at a PMR station. You can also have the system automatically close a primary NC as soon as an operator logs it. The NC_TRACKING nonconformance client allows operators to close nonconformances and incidents manually. SAP Manufacturing Execution 5. If cleared. For more information. This operator is often performing a REPAIR operation. the system will not allow the NC code to be closed from the Edit tab of the NC client. see the “Creating Primary and Secondary NC Codes” topic in the “Setting Up Nonconformance” section of this guide.1. operators can close both individual NC codes that have been logged and entire incidents. for many NC codes that come with the system. To require an operator with authority. To show that an incident is pending until an experienced operator manually closes it. For information about creating primary and secondary NC codes. Depending on the nonconformance client they are using and how the NC code is set up.Defining Nonconformance (NC) Codes What is a Secondary NC Code? A secondary NC code is an NC code you create in NC Code Maintenance that: Is at any level other than the top level of a hierarchy. Setting Up and Overriding Maximum NC Limit You can restrict the number of times an NC code can be logged against the particular SFC by setting up the maximum NC limit in NC Code table of Default Value Maintenance. How the System Closes Nonconformances and Incidents You control how the system automatically closes nonconformances and incidents with the following check boxes on the Main tab of NC Code Maintenance: Can Be Primary Code Defines the NC code to be used as the initial NC code to start a nonconformance tree. Closing NC Codes When an operator logs an NC against one or more SFCs. see the “Setting Up Nonconformance” section of this guide. the system will close the NC code automatically after being logged. the NC is open. such as a supervisor. Secondary Required for Close Defines the NC code to require a secondary code to be logged against it to close.3 Setting Up Nonconformance 10 . When selected. When an NC code exceeds this limit you may optionally override this value. Auto Close Primary NC Defines the NC code to close its parent NC code when the current NC is closed. Any secondary codes logged under a primary will be considered part of the same non-conformance incident.

For more information. Setting Up Activity Hooks You can set up NC code-specific activity hooks that execute custom code when operators log NCs. You can also specify the disposition group associated with the operation. Assigning Operations If you want to prevent operators from logging NC codes at all operations.1. The incident and other defects will stay open.Defining Nonconformance (NC) Codes Note: You can also allow operators to manually log NCs against a closed NC in NC Client Maintenance. Logging an NC Reject in the Rich POD You can log primary NC Codes in the Rich POD for a selected SFC at selected operation(s) to indicate that additional work must be performed at the same operation and to automatically reopen all previously closed buyoffs. For more information about disposition groups. For example. see the Routers section of the Setting Up Production Lines guide. the system will close the defect against which the Repair code has been logged. The following table shows the check boxes you would typically select for the PCA Dashboard with a three-level hierarchy: Category Failure Defect Repair Check boxes to select Can Be Primary Code and Closure Required Closure Required and Auto Close Primary NC Auto Close Primary NC or Auto Close Incident When the Can Be Primary Code check box is cleared. By default. this NC code can only be a secondary NC code (if the primary/secondary NC hierarchy is set up). the system allows NC codes to be logged at all operations. the system automatically closes the nonconformance as soon as the operator logs it. see the “Setting Up Nonconformance” section of this guide. If at least one of the defects (in the same incident) has the Secondary Required for Closure check box selected. the system closes all defects logged against the failure if none of them has the Secondary Required for Closure check box selected. some operators may need to log the same repair code. For more information. see the Setting Up Activity Hooks guide. For more information. When the Auto Close Incident check box is selected. you can assign your NC codes to those operations in the Operation/Disposition Group tab in NC Code Maintenance. see online help for Logging an NC Reject. SAP Manufacturing Execution 5. Users can also log one secondary NC code against multiple primary NC codes without closing them. When the Closure Required check box is cleared. Allowing Users to Close Multiple Primary NCs with one Secondary NC You can set up nonconformance clients to allow users to close multiple primary NC codes with the same secondary NC code. in order to record that the same action was taken to fix several failures. such as REPLACED against several primary NC codes indicating test failure.3 Setting Up Nonconformance 11 .

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SAP Manufacturing Execution 5.3 Setting Up Nonconformance 13 . The message to be stored and sent.Working with Real-Time Warnings Real-time warnings notify appropriate manufacturing personnel that planned conditions have not been met at an operation. personnel can analyze and address the problem at the operation as quickly as possible. Associate an event type with a real-time warning. see the Setting Up Events guide and the online help for Event Maintenance and Real-Time Warnings Maintenance. When you set up Events in the system. With this information. You set up real-time warnings in conjunction with the Events feature. For more information about setting up Events and real-time warnings. The set of people who will receive the messages through e-mail or real-time notification.1. Define the parameters for consecutive identical nonconformance real-time warnings. shop floor personnel can also send event messages when others need notification with the Event Send Client. When to clear messages from the Event Viewer. you define: Event types (classifications for occurrences that happen during production). In addition. In Real-Time Warnings Maintenance you: Define the parameters for yield processing real-time warnings. The predefined events in the system that relate to Nonconformance are: RTW_CONSEC_NC RTW_YIELD_RATE (only for low yield scenarios) You can also define your own event messages in the system.

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and another for operators who log them at REPAIR operations. you may want one POD for operators who log nonconformances at TEST operations. You can create different PODs in POD Maintenance. retrieve the nonconformance client you want in NC Client Maintenance and review its setting. You create nonconformance clients in NC Client Maintenance. Standard Nonconformance Clients Although you can create nonconformance clients in NC Client Maintenance.1. The following table describes the standard nonconformance clients and how they relate to the standard PODs that come with the system: Note: For all details. another for operators who log them at ANALYZE operations.Working with Standard Nonconformance Clients The system allows you to set up the POD various ways for different types of operators who nonconform SFCs. The standard nonconformance clients that come with the system are: LOG_NC LOG_NC_W_SECONDARY NC_TRACKING LOG_NC_W_FBI Nonconformance Client Features and PODs Some nonconformance clients that come with the system are associated with the standard PODs that come with the system. see the Setting Up PODs guide. In List Maintenance. If these PODs meet your needs. Graphical (PCA) nonconformance clients. there are several nonconformance clients that come with the system. you do not need to create new nonconformance clients or PODs. You can use these nonconformance clients for many typical scenarios. The nonconformance clients that come with the system fall into two categories: Standard nonconformance clients. you control how operators can log nonconformances by assigning a nonconformance client to a particular POD.3 Setting Up Nonconformance 15 . you can also create or change the Nonconformance lists that appear in the Failure Data area of the POD when operators log NCs. In POD Maintenance. Note: For more information about PODs and Nonconformance lists. SAP Manufacturing Execution 5. For example.

Hotkeys for the Fast Barcode Interface The following table lists the hotkeys mapped to the buttons in the Fast Barcode Interface: Hotkey ALT+B ALT+D ALT+E ALT+U ALT+M ALT+L ALT+R ALT+W Button Add Add and Done/Done Cancel (exit plug-in) Update Remove Cancel (cancel update mode) NC Report Work Instruction SAP Manufacturing Execution 5. Designed for operators who log both primary and secondary NC codes. For information about setting up the Fast Barcode Interface. Operators cannot edit the information associated with NC codes. open a closed NC. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client.1. Operators can also edit the information associated with NC codes. Designed for operators who log both primary and secondary NC codes.Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes.3 Setting Up Nonconformance 16 . and cancel any NC. They can close an open NC. see the “Setting Up Nonconformance” section near the end of this guide. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. Designed for operators who log only primary NC codes and work with scanners. PASS_FAIL None NC_LOG_W_SECONDARY NC_TRACKING DIAGNOSIS LOG_NC_FBI None Working with the Fast Barcode Interface Designed for operators who log only primary NC codes and work with scanners. The Log NC FBI with Multi RefDes (NC515) activity. the Fast Barcode Interface (FBI) allows users to input information quickly. Standard POD * (default). Operators cannot edit the information associated with NC codes.

* (default) or PASS_FAIL workstation (uses NC_LOG) Operation Fail TEST Pass Operation ANALYZE NC_LOG_W_SECONDARY workstation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5. the system displays a dialog box asking the user whether he or she wants to remove the component.1. Typical Scenarios for the Standard Nonconformance Clients The following illustration shows three scenarios for the standard nonconformance clients at different steps on the router. the system displays the Add Component window. Use the nonconformance clients and workstations that mirror how you handle defects on your routers. see Setting Up PODs guide. the system displays the Remove Component window. ANALYZE. When the user clicks OK in this window. If the operator chooses to remove the component. see the “Setting Up Nonconformance” section near the end of this guide. For more information about workstations. For information about setting up this feature. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. the system displays a dialog box asking the user whether he or she wants to add a new component. and REPAIR.3 Setting Up Nonconformance 17 . If the operator chooses to add a new component.Working with Standard Nonconformance Clients Allowing Operators to Auto Remove/Replace NC’s Components You can set up the system so that when an operator logs a primary or secondary NC code against an SFC that is an assembled component.

This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes. NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5.1. * (default) or PASS_FAIL workstation (uses NC_LOG) Operation Fail TEST Pass Operation ANALYZE-REPAIR DIAGNOSIS workstation (uses NC_TRACKING) Scenario C Scenario C illustrates the case when you combine the TEST and ANALYZE steps into one operation and have a separate REPAIR operation.3 Setting Up Nonconformance 18 .Working with Standard Nonconformance Clients Scenario B Scenario B illustrates the case when you have a separate TEST operation but you combine the ANALYZE and REPAIR steps into one operation.

3 Setting Up Nonconformance 19 . defect. they may log many failure. during the first cycle through a repair loop. When a unit that has previously failed a test passes it. you can create a nonconformance client that displays the Verified Defects chart. it still fails. the last defect and repair logged against the unit indicates what was actually wrong with the unit and how it was repaired. when the unit is retested. and RECONNECT (Repair) sequence as the verified defect. repair cycles that do not fix the problem.1. Operation TEST Pass Operation Note: The set of all NC codes associated with a single SFC (or a group of SFCs or a process lot being tested at the same time) is called an incident. As operators troubleshoot problems with units (SFCs) in a repair loop on your router.Working with Standard Nonconformance Clients Verifying Defects The system automatically logs a verified defect when a unit has moved through a repair loop and passed the test operation. For example. This last defect and repair is then verified to be the actual case and is called the verified defect. The system logs the NO_POWER. You can assign incident numbers to incidents for tracking purposes. CABLECONWRONG (Defect). and operators log other NC codes that reflect their actions the second time through: NO_POWER (Failure) Operation Fail TEST Operation ANALYZE CABLECONWRONG (Defect) REPAIR RECONNECT (Repair) The third time the unit is tested it passes. operators may log the following NC codes: NO_POWER (Failure) Operation Fail TEST Operation ANALYZE SHORT (Defect) REPAIR REWIRE (Repair) However. Some nonconformance clients that come with the system display a Verified Defects chart to the operator in the POD. SAP Manufacturing Execution 5. The SFC is then sent through the repair loop again. In NC Client Maintenance.

the system archives both the SFC and its assigned incident number at the same time. they appear in the Log NC report. and including one or more NC codes. If you use incident numbers. It is also possible for one SFC to include multiple incident numbers.Working with Standard Nonconformance Clients Setting Up Incident Numbers What Is a Nonconformance Incident? A nonconformance incident is a nonconformance issue associated with one or more SFCs.1. SAP Manufacturing Execution 5. Using incident numbers. If you select Manual. However. What Is an Incident Number? An incident number uniquely identifies a nonconformance incident. the operator must enter an incident number in the POD when he or she logs an NC with a primary NC code. the system automatically assigns the same incident number to all associated secondary NC codes. the system verifies that the number matches the numbering pattern defined in Next Number Maintenance. The incident number is the same for all SFCs associated with the incident and for all primary and secondary NC codes associated with these SFCs. the system automatically generates the incident number based on the numbering pattern you define with the Incident Number Number Type in Next Number Maintenance. if the incident number is assigned to another SFC. When you archive SFCs. For more information about defining numbering patterns. Primary and Secondary NC Codes When an operator logs an NC against an SFC in a nonconformance client that uses incident number. see the online help for Next Number Maintenance. then the system archives only the SFC. Incident Numbers and Archiving It is possible for one incident number to span multiple SFCs and multiple nonconformances of the same SFC. If you select Automatic in the Incident Number field. you can group or organize nonconformances to help identify problem areas in your production process.3 Setting Up Nonconformance 20 . you can allow operators to enter incident numbers by selecting Manual in the Incident Number field on the Main tab. Note: If operators enter incident numbers manually. Creating Incident Numbers When you create nonconformance clients in NC Client Maintenance.

For more information. You use the graphical (PCA) nonconformance clients to set up the PCA Dashboard for operators. The following illustration shows the PCA Dashboard: The graphical (PCA) nonconformance clients that come with the system are: PCA_TEST PCA_INSPECTION PCA_ANALYSIS SAP Manufacturing Execution 5.a3p files for those boards. The PCA Dashboard allows operators who test. This allows you to incorporate engineering changes quickly.3 Setting Up Nonconformance 21 . inspect.Working with Graphical (PCA) Nonconformance Clients Operators who work with PCA boards may require graphical schematics of the product. and repair PCA boards to view and interact with GenCAD. see Appendix section of this guide.1. analyze. You can provide this with the PCA Dashboard POD. To allow the operators to use the PCA Dashboard you need to install the PCA server. GenCAM or .

and Ref Des’s.1.3 Setting Up Nonconformance 22 . Operators can view previously entered comments in the Comments tab. and the standard PODs that come with the system: Note: For all details. and repairs). Operators can use IPASS. PCA (after changing the NC Client field on the Main tab to PCA_ANALYSIS) PCA (after changing the NC Client field on the Main tab to PCA_INSPECTION) Standard POD PCA SAP Manufacturing Execution 5. or with an automatic tester: Operators can log only primary NC codes. The Failure Data area displays NC codes and Ref Des’s. The PCA Dashboard displays the Verified Defects chart.Working with Graphical (PCA) Nonconformance Clients PCA_REPAIR PCA_COMBINED The following table describes how the graphical (PCA) nonconformance clients relate to nonconformance. Failure IDs. Operators can view previously entered comments in the Comments tab. PCA_ANALYSIS Use for operators who recommend corrective actions for boards: Operators can view failure information generated by a testing station or entered by other operators. Nonconformance client PCA_TEST Description Use for operators who pass or fail boards by testing them manually. Operators can enter comments in the Comments tab. PCA_INSPECTION Use for operators who test. and repair boards at the same operation: Operators can log primary and secondary NC codes (failures. analyze. Operators cannot use IPASS or FPASS. retrieve the nonconformance client you want in NC Client Maintenance and review its setting. visually. defects. The Failure Data area displays NC codes and Failure IDs. Operators cannot use IPASS or FPASS. The Failure Data area displays NC codes. Operators can log only secondary NC codes (defects).

Working with Graphical (PCA) Nonconformance Clients Nonconformance client PCA_REPAIR Description Use for operators who repair boards: Operators can view information entered by other operators at analysis operations. and Ref Des’s. The Failure Data area displays NC codes. Operators can enter comments in the Comments tab. and Ref Des’s. Failure IDs. PCA_COMBINED Use for operators who recommend corrective actions and repair boards at the same location: Operators can log only secondary NC codes (defects and repairs). The PCA Dashboard displays the Verified Defects chart above the Comments tab. Operators can use FPASS. Operators can use IPASS and FPASS. Operators can enter comments in the Comments tab.3 Setting Up Nonconformance 23 . The Failure Data area displays NC codes. PCA (after changing the NC Client field on the Main tab to PCA_COMBINED) Standard POD PCA (after changing the NC Client field on the Main tab to PCA_REPAIR) SAP Manufacturing Execution 5. Operators can log only secondary NC codes (repairs). Failure IDs.1. The PCA Dashboard does not display verified defects.

and REPAIR. ANALYZE.1.Working with Graphical (PCA) Nonconformance Clients Typical Scenarios for the Graphical (PCA) Nonconformance Clients The following illustration shows three typical scenarios using the graphical (PCA) nonconformance clients at different steps on the router. Scenario A Scenario A illustrates the case when you use three separate operations for TEST.3 Setting Up Nonconformance 24 . PCA workstation Operation Fail TEST Pass Operation ANALYZE PCA workstation with PCA_ANALYSIS REPAIR PCA workstation with PCA_REPAIR SAP Manufacturing Execution 5.

ANALYZE.Working with Graphical (PCA) Nonconformance Clients Scenario B Scenario B illustrates the case when you have a separate TEST operation but you combine the ANALYZE and REPAIR steps into one operation.3 Setting Up Nonconformance 25 . and REPAIR steps at one location.1. PCA workstation with PCA_INSPECTION Operation TEST-ANALYZEREPAIR Pass Operation SAP Manufacturing Execution 5. PCA workstation Operation Fail TEST Pass Operation ANALYZE-REPAIR PCA workstation with PCA_COMBINED Scenario C Scenario C illustrates the case when an operator performs the TEST.

Does not log a repair or verify defects. Returns selected SFCs to the Task list with the In Queue status. Use also when pulling samples. Completes the SFC and sends it to the next operation as though it passed the test. To work with these SFCs. Not associated. the user selects them in the Active Work List and clicks the PCA button. IPASS Implied pass.a3p). you must use the IPASS variable in scripts in Router Maintenance. SAP Manufacturing Execution 5. Completes selected SFCs and sends them to the next step on the router.3 Setting Up Nonconformance 26 . GenCAM or . the system displays active SFCs in the Active Work List. The user can then work with the selected SFCs. The user clicks this button after selecting active SFCs in the Active Work List. then displays the PCA Dashboard in the lower half of the POD in the mode specified by the nonconformance client for the POD. Note: To correctly route an IPASS. When the user opens the PCA Dashboard.Working with Graphical (PCA) Nonconformance Clients PCA Dashboard Buttons The following table describes the buttons that appear on the PCA Dashboard: Button START Description Starts the selected SFCs at the entered operation and resource. Most often used when an operator or machine logs a test failure NC in error. Not associated. See the section on routers in Setting Up Production Lines. Note: Enabled only in Analysis or Combined mode. Displays the SFC report. NC500 (with a PCA nonconformance client) SFCACT SIGNOFF COMP D2B TR700 PR520 Not associated.1. PCA Displays the PCA Dashboard in the lower half of the POD in the mode specified by the nonconformance client for the POD. Enables and disables the D2B Viewer for displaying graphical files (GenCAD. NC500 (with a PCA nonconformance client) POD Button Activity PR500. Note: You must install and run the D2B server before the system can display graphical files.

you must use the FPASS variable in scripts in Router Maintenance. You must set up work instruction before users can view them. SENDEVENT SY550 SAP Manufacturing Execution 5. Operators can use the Event Send Client to create and send event notification messages. Note: To correctly route an FPASS. Note: The system removes scrapped SFCs from the WIP database when they are archived. POD Button Activity Not associated. Used most often when a repair operator has retested an SFC and verified the defect. WI500 Not associated. WORKINSTRUCTION Allows the operator to view work instructions. Displays the Event Send Client. SCRAP Scraps the SFC(s). See the section on routers in Setting Up Production Lines. Completes the SFC and sends it to the next operation instead of back to the test operation. Note: Enabled only in Repair or Combined mode.3 Setting Up Nonconformance 27 .Working with Graphical (PCA) Nonconformance Clients Button FPASS Description Forced pass.1.

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SAP Manufacturing Execution 5. see the online help for NC Code Maintenance and NC Group Maintenance. This screen asks whether to install additional NC codes associated with the IPC 9261 specification. What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels.000. Combined with the system’s nonconformance capabilities. Commonly used with quality systems such as Six Sigma. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1. use the browse in NC Code Maintenance and NC Group Maintenance to check whether the DPMO codes and categories listed in the online help appear. To ensure this.3 Setting Up Nonconformance 29 . The following DPMO categories come with the system and correspond to the names of the DPMO-related NC groups that come with the system: Assembly – Assembly DPMO is the number of assembly defects divided by the number of assembly opportunities (number of assemblies processed) multiplied by 1.000. DPMO helps you measure defects so you can reduce them.1. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard.000. during installation. focused on printed board assembly manufacturing.000. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system: Assembly Component Placement Termination For a list of these codes and their categories. Calculating DPMO Assigning DPMO categories to NC codes in NC Code Maintenance determines how the system calculates DPMO for that NC code. your installer selects Yes in the Application Server NC codes for DPMO screen. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. Note: The system installs DPMO codes and categories only if.

If only one root cause operation is available. SAP Manufacturing Execution 5. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item. and the number of opportunities defined for the item that have the possibility of being defective. the operator has to choose the operation.000.000. If multiple root cause operations are available. The operations you define appear in the Root Cause Operation browser when an operator clicks on the Root Cause Op field’s browse button in the PCA Dashboard and/or the Nonconformance activities. You identify which category the system uses to calculate DPMO for the item. the operation at which defects for the item can be assigned. You must select one of the following in the Root Cause Operation field: Optional – Displays the Root Cause Op field in the nonconformance activity so that the operator can optionally choose the root cause operation.000. where components are placed. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1.000.1. Applicable for only those processes.3 Setting Up Nonconformance 30 .Using DPMO (Defects per Million Opportunities) Placement – The number of placement defects divided by the number of placement opportunities multiplied by 1. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation. the operation is selected automatically.

If desired. in Router Maintenance: Create repair loops.3 Setting Up Nonconformance 31 . or Repair. Write scripts to automatically send nonconformed SFCs to a next step based on criteria. Defect. In the NC category in Data Type Maintenance. set up Standalone Failure Tracking. set up the Fast Barcode Interface and how operators can close NC codes. assign DPMO categories to NC codes. 4. 2. Select the Can Be Primary Code check box on the Main tab. If desired. define the parameters and default values of NC codes.1. 3. Categorize each NC code as a Failure. 3. Create disposition routers and/or set up function-based dispositioning. Create any custom fields you require. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab. Creating Primary and Secondary NC Codes To create a primary NC Code. Create primary and secondary NC codes according to the NC hierarchy you want to use on your floor. If desired. As needed. 5. If desired. In NC Code table of Default Value Maintenance. in NC Code Maintenance 1. 8.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. In NC Code Maintenance and NC Group Maintenance. 6. change any NC-related rule as needed for your shop floor. If you want to use DPMO. Create or retrieve the NC code to be a primary code. do the following: Group and create NC codes. Set up the POD for Nonconformance. 7. assign NC data types to NC codes. In System Rule Maintenance. set up DPMO. SAP Manufacturing Execution 5. create the data types you want to associate with NC codes and select the predefined fields you want to appear in the POD. 2. Set up activity hooks for NC codes.

In Default Value Maintenance. Result: The system displays the table containing a record for NC Code logged against this SFC. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. enter information about the drawing in the Drawing Name field. 2. In System Rule Maintenance or NC Client Maintenance. 2. Click Save. In the Maximum NC Limit field. Note: Because Event Types are most often connected to nonconformance. enter the value of the D2B server. Setting Up the POD for Nonconformance To set up the POD for Nonconformance: 1. browse for NC_Code in the Parent Table Name field and click Retrieve.3 Setting Up Nonconformance 32 . In Nonconformance Limit Override. Retrieve the primary code you want to associate the secondary with. select NC Code from the Type drop-down list. identify the SFC for which you want to override the maximum NC limit and click Retrieve. Select the NC code for which you want to override the Maximum NC Limit and click the details icon in the corresponding row. 3. To override the maximum NC limit when NC code exceeds this value: 1. 4. 3. SAP Manufacturing Execution 5. In the SFC field. change the current value to a greater one and click OK. 2. 3. Result: The system closes the window and returns to the Nonconformance Limit Override window. and move the secondary’s name to the Valid Secondaries list on the Secondaries tab. Change the maximum NC limit to the desired value other than 0. Note: You can also click the browse icon to select an SFC. you can leave the Can Be Primary Code check box cleared when you create NC codes. See online help for the Drawing Name field on the Main tab for information about how to enter the path and file name for the CAD file on the D2B server. Ensure the Can Be Primary Code check box on the Main tab is cleared. If you are using the PCA Dashboard: In Item Maintenance. in System Rule Maintenance make sure there are values for the mail server and the mail source address. Note: If you do not want to create a hierarchy. Result: The system opens the NC Code Details window. Setting Up and Overriding Maximum NC Limit To restrict the number of times an NC code can be logged against the particular SFC: 1. Create or retrieve the NC code to be a secondary code. You can use different D2B servers for some clients for load balancing. Click Save. in NC Code Maintenance 1. 5.Setting Up Nonconformance To create a secondary NC Code.1.

3 Setting Up Nonconformance 33 . select None in the As-Built Link Location field. In NC Code Maintenance. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. If desired. 2. Note: The As-Built link is not necessary for operators using this feature. On the Advanced Log NC tab in NC Client Maintenance. This value overrides the value in POD Maintenance. Setting Up the Fast Barcode Interface for Operators To set up the Fast Barcode Interface: 1. In POD Maintenance. SAP Manufacturing Execution 5. enter a nonconformance client in the NC Client field in Operation Maintenance. create a button associated with Log NC with Multi RefDes (NC515). enter LOG_NC_FBI in the NC Client field. On the Buttons tab. 3. ensure a System Administrator has set the FailureHistoryExtract. Give the operators you want to use the Fast Barcode Interface access to this POD. enter the client you want for this POD in the NC Client field on the Main tab. Allowing Operators to Auto Remove/Replace NC’d Components To allow operators to auto remove/replace NC’d components: 1. 2. On the Basic Log NC (FBI) and/or Advanced Log NC tab in NC Client Maintenance: Select the Auto Remove/Replace NC Components check box. create a row for the nonconformance button and associate it with the nc500 POD button activity. the system uses the settings in the nonconformance client to determine what to display to the user. Running this batch file is necessary to display the Verified Defects chart in the PCA Dashboard in Repair mode. Also create any nonconformance lists you need in List Maintenance. Note: You can retrieve an existing nonconformance client to use as a template and save it under another name. When an operator using this workstation clicks the nonconformance button.Setting Up Nonconformance 2. make sure the NC codes you want operators to log with this feature are associated with data types that contain the Component and/or Ref Des field(s).bat file to run in a scheduler and that the file has been run at least once. Specify the disposition router where you want the system to send the removed component in the Component Disposition Router field. create new ones in NC Client Maintenance. For more information. On the Main tab. If the nonconformance clients that come with the system do not meet your needs. 3. In POD Maintenance: On the Buttons tab. 4.1. Note: If any PCA Dashboard users are to use Analysis or Repair mode.

1. If you need to create additional NC codes to use in conjunction with DPMO. 2. Create an NC data type in Data Type Maintenance that includes the Root Cause Operation field set to either Optional or Required. Setting Up DPMO Note: The system comes with about a hundred NC codes you can use for DPMO. In Activity Maintenance. 2. 2. 3.Setting Up Nonconformance Allowing Operators to Close Multiple Primary NCs with One Secondary NC To allow an operator to close multiple primary NCs with one secondary NC: 1. 3. The root cause operation is the upstream failure operation in the repair loop. Give the operators you want to allow to close multiple primary NCs with one secondary NC access to this POD. Define the Resource option and set it to true or false. To set up Standalone Failure Tracking: 1. Operators must enter the root cause operation when they use DPMO-related NC codes. To set up DPMO: 1. ensure that Enabled and Visible in Activity Manager check boxes are selected. On the Main tab. In NC Code Maintenance. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. in NC Code Maintenance: SAP Manufacturing Execution 5. and thereby indicates the root cause of the problem. This NC Client must exist as having been defined in NC Client Maintenance.3 Setting Up Nonconformance 34 . Define the Operation option and set it to true or false. 4. On the Main tab in POD Maintenance. Select the Show Select NC Batch Button check box. Click Save. Setting Up Standalone Failure Tracking Standalone Failure Tracking can be used to log and edit nonconformances against a single or multiple SFCs outside of the POD without some of the customary validation enforced when logging nonconformance from the POD. retrieve a client where the user can log secondary NCs and on the Advanced Log NC tab: Select the Display Failure Data Tree check box. For more information. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system. enter NC 540 (Standalone Failure Tracking) in the Activity field. retrieve the POD(s) you will use for these operators and enter the nonconformance client in the previous step in the NC Client field. On the Rules tab: Define NC client as an activity rule. In NC Client Maintenance. define the primary NC and select the Secondary Required for Close check box on the Main tab.

the system calculates the number of placement defects divided by the number of placement opportunities entered in Item Maintenance for PCBOARD. a particular PC board may have 200 areas in its circuitry where it could fail. Therefore. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category. the category appears in NC Group Maintenance. the NC data type is PCA.1. identify: Which category the system uses to calculate DPMO for the item. The system also sends this information to several DPMO-related ODS reports. For the DPMO codes that come with the system. Specify the NC Data Type you created in the previous step. revision A multiplied by 1.Setting Up Nonconformance Assign DPMO categories to NC codes. In the DPMO tab of Item Maintenance. you can assign some or all NC codes in a DPMO category to an NC group of the same name.000. Note: Once you assign DPMO categories to defect NC codes.3 Setting Up Nonconformance 35 . The number of opportunities on this item that has the possibility of being defective. These DPMO NC groups come with the system.000. revision A. You can assign a DPMO category only to an NC code of category Defect. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD. the system performs the calculation specified by the DPMO category and writes the results in the DPMO report. SAP Manufacturing Execution 5. The system writes the results in the DPMO report along with the Root Cause operation entered by the analysis operator. 3. Results When an operator logs an NC against an SFC representing an item with information in the DPMO tab. For example. The operation at which operators can log a defect NC code with a DPMO category. If desired.

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The Update message appears. click the Browse button. This screen contains the end-user software license agreement for PCA Server. 4. VisipriseMfg_PCAD_50. 6. To select an alternate product directory. Note: This message appears only if the server does not have the correct version of JRE installed. The system launches the install program for the read-only version of the GR Force/D2B. Action Insert the SAP Manufacturing Execution installation CD into the server machine and run the setup file. is displayed in the Program Folders field. The system launches the install program for the read-only version of the GR Force/D2B. SAP Manufacturing Execution 5. The Extracting Files message appears. Click Yes to accept the software license agreement. The Choose Destination Location dialog box appears. 5. Visiprise\VisipriseMfg\PCA Server. The License Agreement dialog box appears. and the GR Force/D2B ReadOnly – InstallShield Wizard dialog box appears.exe. 3. located in the PCA directory. and the GR Force/D2B Setup dialog box appears.Appendix: Installing PCA Server Step 1. The default installation directory location is: C:\Visiprise\VisipriseMfg\PCA Server. 7. Use this screen to specify the location on the hard drive where the SAP Manufacturing Execution PCA Server program files will be located. followed shortly by the Welcome screen. click OK to return to the Choose Destination Location dialog box.1.3 Setting Up Nonconformance 37 . Use this screen to specify the program folder for the PCA Server. Read the welcome information and click Next. Use the scroll bar to view the entire agreement. and the Choose Folder dialog box appears. Read the welcome information and click Next. When you are finished. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution PCA Server program files. Read the Welcome screen and click Next. Click Next on the Choose Destination Location dialog box. 2. The Select Program Folder dialog box appears. Click Next to accept the default program folder. The default program folder.

you may obtain a license key by accessing http://www. After installing the D2B viewer. 11. Click Next. The installation program displays the Start Copying Files dialog box. Click Next. The Setup Complete message appears. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. 16. you do not need a separate license. the InstallShield Wizard Complete message appears. you must restart your computer later. If you select No. The default program folder. c:\GenRad\GR Force D2B. Click the Browse button to select an alternate folder. The installation program displays the Select Program Folder dialog box. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files. 15. is displayed in the Program Folders field. Action The Choose Destination Location dialog box appears. 10.1. such as: C:\Visiprise\GR Force D2B When you are finished. GenRad\GR Force D2B. Using the PCA Viewer Server Note: If you plan to use the PCA Dashboard capabilities of SAP Manufacturing Execution without running the underlying D2B Viewer as a standalone application. the PCA Server has finished selecting Components dialog box appears. The default program folder. then click Next to start copying files.3 Setting Up Nonconformance 38 . After a few moments. Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located.html. Click Next. Select the option you want for restarting your computer and click Finish to complete the installation. Refer to the System Administration Guide for instructions on obtaining and installing a license.teradyne. At the completion of the installation. Click Finish. 9. 12. The D2B install starts and displays the Setup Status of the installation. The Choose Folder dialog box appears.Appendix: Installing PCA Server Step 8. 13. click OK to return to the Choose Destination Location dialog box.com/test-design/design-to-build/viewer. 14. SAP Manufacturing Execution 5. is displayed. Review the settings. Enter Visiprise\GR Force D2B.

This will activate your D2B viewer. You will need the GRA3LM Server Code for your installation. make sure that you do not have an instance of the standalone D2B viewer running.1. which can be obtained using the D2B software's License Manager. Do this by selecting Start > Programs > Visiprise > GR Force D2B > Tools > License Manager. Note: When running the PCA Viewer Server.Appendix: Installing PCA Server Choose the Register Now option and provide the required information. SAP Manufacturing Execution 5.3 Setting Up Nonconformance 39 . The standalone viewer will use your license key and the PCA Viewer called by the POD will not be able to run. You will find the necessary value in the Server Code field: Once you receive the license key from the website by email. enter the value into the Key field displayed by the License Manager and click Install Key.

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21 graphical (PCA) scenarios. 30 O Operations. 3 Routers. 34 Setting up Nonconformance. 30 specific items. 10 primary and secondary. 31 setting up DPMO. 7. 1 routers. 33 graphical (PCA). 1 benefits. 3 setting up. 10 numbers. 9 R Repair. 34 setting up the POD. 9 Defects per million opportunities (DPMO). 29 root cause. 9 closing.Index B Barcodes and NCs. 34 Setting up the POD for Nonconformance. 15 standard scenarios. 33 H Hierarchy NC codes. 24 standard. 26 Nonconformance. 3 I Incidents closing. 29 DPMO (defects per million opportunities). 17 C Closing incidents. 32 N NC codes categories. 7. 20 S Secondary NC codes. 31 Setting up Standalone Failure Tracking. 21 buttons. 10. 9 V Verifying defects. 1 nonconformance. 10 D Defect. 16. 9 Setting up DPMO. 11 P PCA Dashboard. 9 Fast Barcode Interface (FBI). 19 SAP Manufacturing Execution 5.1. 10 Closing NC codes. 32 M maximum NC limit. 16. 32 Nonconformance clients Fast Barcode Interface. 7.3 Setting Up Nonconformance 41 . 9 F Failure. 7. 9 Repair loops. 26 Primary NC codes. 16. 33 Buttons PCA Dashboard.

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