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

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

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

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The system comes with several NC data types to which fields have already been allocated. For a complete list.1. in Data Type Maintenance. leave the default value. the system displays the field(s) you specified based on the data type of the NC code. SAP Manufacturing Execution 5. packing. and browse in the Data Field column of the new row. You define data types in Data Type Maintenance. nonconformance.Collecting Information The NC category in Data Type Maintenance allows you to collect information for analysis. in the NC Data Type field in NC Code Maintenance. inventory receipt. and other uses when operators log nonconformances. The operator enters the information you want to collect in each field. such as assembly. The SIMPLE data type displays no fields to the operator by default. SIMPLE. You can make each field required or optional for the operator. Note: If you do not want to collect data at nonconformance operations. or working with RMAs. integrity checking. The following list is a sampling of fields you can have the system display in the POD for each type. and retrieve the record. 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. You can add or delete fields to the existing NC data type. When the operator logs a nonconformance. 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. select NC in the Category field. you must assign an NC data type to each code. Assigning NC Data Types When you create NC codes.3 Setting Up Nonconformance 5 . browse on the Data Type field. disassembly. Click Edit > Insert New.

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

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

3 Setting Up Nonconformance 8 .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. The system displays this hierarchy graphically in the Failure Data area of the nonconformance client in the POD: SAP Manufacturing Execution 5.

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.or three-level NC hierarchy is most typical when you use the PCA Dashboard. Primary and Secondary NC Codes You create an NC hierarchy by creating primary and secondary NC codes in NC Code Maintenance. Can have other codes underneath it. 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. The second unit failed because of incorrectly connected cables and was re-cabled. 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. The first unit failed because of a short and was rewired. associated with the Defect code) For example. SAP Manufacturing Execution 5. the following illustration shows a three-level hierarchy with two sets of NC codes logged against the primary NC.3 Setting Up Nonconformance 9 . NO_POWER.1. click Actions > Tree View in NC Code Maintenance. You base the place of an NC code in the hierarchy on its category and the level of granularity you want. A two.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.

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. To show that an incident is pending until an experienced operator manually closes it. Auto Close Primary NC Defines the NC code to close its parent NC code when the current NC is closed. For more information.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. The NC_TRACKING nonconformance client allows operators to close nonconformances and incidents manually. Secondary Required for Close Defines the NC code to require a secondary code to be logged against it to close. Any secondary codes logged under a primary will be considered part of the same non-conformance incident. Closing NC Codes When an operator logs an NC against one or more SFCs. When selected. 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. such as a supervisor. You can also have the system automatically close a primary NC as soon as an operator logs it. the NC is open. for many NC codes that come with the system. Closure Required Defines the NC code to require additional action to close. the system will close the NC code automatically after being logged. see the “Setting Up Nonconformance” section of this guide. This is often done when the unit is expensive to build. To require an operator with authority. operators can close both individual NC codes that have been logged and entire incidents. Depending on the nonconformance client they are using and how the NC code is set up. When an NC code exceeds this limit you may optionally override this value. SAP Manufacturing Execution 5. see the “Creating Primary and Secondary NC Codes” topic in the “Setting Up Nonconformance” section of this guide. for example at a PMR station. the system will not allow the NC code to be closed from the Edit tab of the NC client. to close an incident. This operator is often performing a REPAIR operation. For information about creating primary and secondary NC codes.3 Setting Up Nonconformance 10 . 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. If cleared.1.

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

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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. With this information. For more information about setting up Events and real-time warnings. see the Setting Up Events guide and the online help for Event Maintenance and Real-Time Warnings Maintenance. The message to be stored and sent. you define: Event types (classifications for occurrences that happen during production). You set up real-time warnings in conjunction with the Events feature.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.1.3 Setting Up Nonconformance 13 . Define the parameters for consecutive identical nonconformance real-time warnings. SAP Manufacturing Execution 5. In Real-Time Warnings Maintenance you: Define the parameters for yield processing real-time warnings. Associate an event type with a real-time warning. When to clear messages from the Event Viewer. shop floor personnel can also send event messages when others need notification with the Event Send Client. When you set up Events in the system. In addition. The set of people who will receive the messages through e-mail or real-time notification.

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You can use these nonconformance clients for many typical scenarios. In POD Maintenance.1. Note: For more information about PODs and Nonconformance lists. another for operators who log them at ANALYZE operations. 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. For example. Graphical (PCA) nonconformance clients. The nonconformance clients that come with the system fall into two categories: Standard nonconformance clients. see the Setting Up PODs guide. and another for operators who log them at REPAIR 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. You can create different PODs in POD Maintenance. you do not need to create new nonconformance clients or PODs. If these PODs meet your needs. Standard Nonconformance Clients Although you can create nonconformance clients in NC Client Maintenance. retrieve the nonconformance client you want in NC Client Maintenance and review its setting. You create nonconformance clients in NC Client Maintenance. 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.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. there are several nonconformance clients that come with the system. In List Maintenance. SAP Manufacturing Execution 5. you may want one POD for operators who log nonconformances at TEST operations. you control how operators can log nonconformances by assigning a nonconformance client to a particular POD.

the Fast Barcode Interface (FBI) allows users to input information quickly. and cancel any NC. 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. The Log NC FBI with Multi RefDes (NC515) activity. 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. Operators can also edit the information associated with NC codes. Designed for operators who log both primary and secondary NC codes. For information about setting up the Fast Barcode Interface. Standard POD * (default). open a closed NC.1.3 Setting Up Nonconformance 16 .Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. Operators cannot edit the information associated with NC codes. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client. They can close an open NC. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. see the “Setting Up Nonconformance” section near the end of this guide. Operators cannot edit the information associated with NC codes.

see the “Setting Up Nonconformance” section near the end of this guide. If the operator chooses to remove the component. Use the nonconformance clients and workstations that mirror how you handle defects on your routers. the system displays the Add Component window.3 Setting Up Nonconformance 17 . see Setting Up PODs guide. the system displays a dialog box asking the user whether he or she wants to remove the component. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. and REPAIR.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. ANALYZE. the system displays a dialog box asking the user whether he or she wants to add a new component. * (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. For more information about workstations. When the user clicks OK in this window. Typical Scenarios for the Standard Nonconformance Clients The following illustration shows three scenarios for the standard nonconformance clients at different steps on the router.1. For information about setting up this feature. the system displays the Remove Component window. If the operator chooses to add a new component.

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. 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. This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes.

In NC Client Maintenance. 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. repair cycles that do not fix the problem. the last defect and repair logged against the unit indicates what was actually wrong with the unit and how it was repaired. defect. The system logs the NO_POWER. it still fails. CABLECONWRONG (Defect).3 Setting Up Nonconformance 19 . when the unit is retested. When a unit that has previously failed a test passes it. This last defect and repair is then verified to be the actual case and is called the verified defect. The SFC is then sent through the repair loop again. and RECONNECT (Repair) sequence as the verified defect. For example. SAP Manufacturing Execution 5. 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. As operators troubleshoot problems with units (SFCs) in a repair loop on your router. You can assign incident numbers to incidents for tracking purposes. during the first cycle through a repair loop. you can create a nonconformance client that displays the Verified Defects chart. they may log many failure.1.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. 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.

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

For more information.Working with Graphical (PCA) Nonconformance Clients Operators who work with PCA boards may require graphical schematics of the product. see Appendix section of this guide. analyze. This allows you to incorporate engineering changes quickly. You use the graphical (PCA) nonconformance clients to set up the PCA Dashboard for operators.1. 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 5.3 Setting Up Nonconformance 21 . To allow the operators to use the PCA Dashboard you need to install the PCA server. The PCA Dashboard allows operators who test. inspect.a3p files for those boards. GenCAM or . You can provide this with the PCA Dashboard POD. and repair PCA boards to view and interact with GenCAD.

analyze. 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.1. and Ref Des’s. 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. Operators can enter comments in the Comments tab. Operators can log only secondary NC codes (defects). visually. or with an automatic tester: Operators can log only primary NC codes. defects. The Failure Data area displays NC codes and Ref Des’s. The Failure Data area displays NC codes and Failure IDs. Operators can use IPASS.Working with Graphical (PCA) Nonconformance Clients PCA_REPAIR PCA_COMBINED The following table describes how the graphical (PCA) nonconformance clients relate to nonconformance. Nonconformance client PCA_TEST Description Use for operators who pass or fail boards by testing them manually. and repairs). Operators can view previously entered comments in the Comments tab. Operators can view previously entered comments in the Comments tab. The PCA Dashboard displays the Verified Defects chart. PCA_INSPECTION Use for operators who test. Failure IDs. The Failure Data area displays NC codes. and repair boards at the same operation: Operators can log primary and secondary NC codes (failures.3 Setting Up Nonconformance 22 . Operators cannot use IPASS or FPASS. and the standard PODs that come with the system: Note: For all details. Operators cannot use IPASS or FPASS. retrieve the nonconformance client you want in NC Client Maintenance and review its setting.

and Ref Des’s. 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). Failure IDs. The Failure Data area displays NC codes. and Ref Des’s. Operators can enter comments in the Comments tab.3 Setting Up Nonconformance 23 .1. The Failure Data area displays NC codes. Operators can log only secondary NC codes (repairs). Operators can use FPASS.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. Failure IDs. The PCA Dashboard does not display verified defects. The PCA Dashboard displays the Verified Defects chart above the Comments tab. Operators can enter comments in the Comments tab. 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 use IPASS and FPASS.

3 Setting Up Nonconformance 24 .1. PCA workstation Operation Fail TEST Pass Operation ANALYZE PCA workstation with PCA_ANALYSIS REPAIR PCA workstation with PCA_REPAIR SAP Manufacturing Execution 5. ANALYZE. Scenario A Scenario A illustrates the case when you use three separate operations for TEST.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. and REPAIR.

1. and REPAIR steps at one location. PCA workstation with PCA_INSPECTION Operation TEST-ANALYZEREPAIR Pass Operation SAP Manufacturing Execution 5. ANALYZE. 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.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 .

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

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

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

000. the operation is selected automatically.000.3 Setting Up Nonconformance 30 . Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item.Using DPMO (Defects per Million Opportunities) Placement – The number of placement defects divided by the number of placement opportunities multiplied by 1. 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. If only one root cause operation is 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.1. Applicable for only those processes. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. SAP Manufacturing Execution 5.000. the operator has to choose the operation. where components are placed. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation. and the number of opportunities defined for the item that have the possibility of being defective. If multiple root cause operations are available. the operation at which defects for the item can be assigned. You identify which category the system uses to calculate DPMO for the item. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1.000.

SAP Manufacturing Execution 5.1. In the NC category in Data Type Maintenance. or Repair. 7. Set up the POD for Nonconformance. 2. 4. Create disposition routers and/or set up function-based dispositioning. If you want to use DPMO. If desired. in NC Code Maintenance 1. Creating Primary and Secondary NC Codes To create a primary NC Code. Create or retrieve the NC code to be a primary code. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab. assign NC data types to NC codes. 6. Defect. create the data types you want to associate with NC codes and select the predefined fields you want to appear in the POD. set up DPMO. Write scripts to automatically send nonconformed SFCs to a next step based on criteria. If desired. In NC Code Maintenance and NC Group Maintenance. Select the Can Be Primary Code check box on the Main tab. Set up activity hooks for NC codes. set up the Fast Barcode Interface and how operators can close NC codes. Create primary and secondary NC codes according to the NC hierarchy you want to use on your floor. In System Rule Maintenance. 8. assign DPMO categories to NC codes. Create any custom fields you require. If desired. change any NC-related rule as needed for your shop floor. If desired. do the following: Group and create NC codes. set up Standalone Failure Tracking. In NC Code table of Default Value Maintenance.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. 5.3 Setting Up Nonconformance 31 . in Router Maintenance: Create repair loops. 3. Categorize each NC code as a Failure. define the parameters and default values of NC codes. 2. 3. As needed.

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

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. On the Advanced Log NC tab in NC Client Maintenance. On the Main tab. If the nonconformance clients that come with the system do not meet your needs.3 Setting Up Nonconformance 33 . create new ones in NC Client Maintenance. Specify the disposition router where you want the system to send the removed component in the Component Disposition Router field. enter a nonconformance client in the NC Client field in Operation Maintenance. 2. For more information. ensure a System Administrator has set the FailureHistoryExtract. 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). select None in the As-Built Link Location field. Note: The As-Built link is not necessary for operators using this feature. 4. Setting Up the Fast Barcode Interface for Operators To set up the Fast Barcode Interface: 1. In POD Maintenance: On the Buttons tab. Note: You can retrieve an existing nonconformance client to use as a template and save it under another name. If desired.bat file to run in a scheduler and that the file has been run at least once. In NC Code Maintenance. In POD Maintenance. 3.1. Also create any nonconformance lists you need in List Maintenance. Running this batch file is necessary to display the Verified Defects chart in the PCA Dashboard in Repair mode. 3. the system uses the settings in the nonconformance client to determine what to display to the user.Setting Up Nonconformance 2. When an operator using this workstation clicks the nonconformance button. Note: If any PCA Dashboard users are to use Analysis or Repair mode. Give the operators you want to use the Fast Barcode Interface access to this POD. enter LOG_NC_FBI in the NC Client field. Allowing Operators to Auto Remove/Replace NC’d Components To allow operators to auto remove/replace NC’d components: 1. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. SAP Manufacturing Execution 5. This value overrides the value in POD Maintenance. 2. enter the client you want for this POD in the NC Client field on the Main tab. create a button associated with Log NC with Multi RefDes (NC515). create a row for the nonconformance button and associate it with the nc500 POD button activity. On the Buttons tab.

In Activity Maintenance. Setting Up DPMO Note: The system comes with about a hundred NC codes you can use for DPMO. If you need to create additional NC codes to use in conjunction with DPMO. To set up DPMO: 1. For more information. Define the Resource option and set it to true or false. define the primary NC and select the Secondary Required for Close check box on the Main tab. 2. in NC Code Maintenance: SAP Manufacturing Execution 5.1. 3. 2. On the Main tab in POD Maintenance. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. Define the Operation option and set it to true or false. 4. ensure that Enabled and Visible in Activity Manager check boxes are selected. On the Main tab. Give the operators you want to allow to close multiple primary NCs with one secondary NC access to this POD. 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. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system. and thereby indicates the root cause of the problem. 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. On the Rules tab: Define NC client as an activity rule.3 Setting Up Nonconformance 34 . In NC Code Maintenance. The root cause operation is the upstream failure operation in the repair loop. 3. Create an NC data type in Data Type Maintenance that includes the Root Cause Operation field set to either Optional or Required. Select the Show Select NC Batch Button check box. To set up Standalone Failure Tracking: 1. Click Save. This NC Client must exist as having been defined in NC Client Maintenance. In NC Client Maintenance. retrieve the POD(s) you will use for these operators and enter the nonconformance client in the previous step in the NC Client field. 2. enter NC 540 (Standalone Failure Tracking) in the Activity field. Operators must enter the root cause operation when they use DPMO-related NC codes.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.

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

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

GenRad\GR Force D2B. Click Next. Select the option you want for restarting your computer and click Finish to complete the installation. is displayed in the Program Folders field.teradyne. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located.1. 10. Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server. you do not need a separate license. 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. Refer to the System Administration Guide for instructions on obtaining and installing a license. the InstallShield Wizard Complete message appears. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. If you select No. 15.3 Setting Up Nonconformance 38 . The default program folder. Review the settings. Click the Browse button to select an alternate folder. such as: C:\Visiprise\GR Force D2B When you are finished. After a few moments. 9. The installation program displays the Start Copying Files dialog box. The default program folder. the PCA Server has finished selecting Components dialog box appears. Click Next. Click Next. Enter Visiprise\GR Force D2B. click OK to return to the Choose Destination Location dialog box. c:\GenRad\GR Force D2B.com/test-design/design-to-build/viewer. 16. After installing the D2B viewer. you must restart your computer later. SAP Manufacturing Execution 5.html. The Setup Complete message appears. is displayed. 13. you may obtain a license key by accessing http://www. At the completion of the installation. then click Next to start copying files. The installation program displays the Select Program Folder dialog box. The Choose Folder dialog box appears. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files. 11. 14. Action The Choose Destination Location dialog box appears. Click Finish. 12. The D2B install starts and displays the Setup Status of the installation.Appendix: Installing PCA Server Step 8.

Do this by selecting Start > Programs > Visiprise > GR Force D2B > Tools > License Manager. You will find the necessary value in the Server Code field: Once you receive the license key from the website by email. This will activate your D2B viewer. You will need the GRA3LM Server Code for your installation. enter the value into the Key field displayed by the License Manager and click Install Key. which can be obtained using the D2B software's License Manager.3 Setting Up Nonconformance 39 . Note: When running the PCA Viewer Server.1.Appendix: Installing PCA Server Choose the Register Now option and provide the required information. The standalone viewer will use your license key and the PCA Viewer called by the POD will not be able to run. make sure that you do not have an instance of the standalone D2B viewer running. SAP Manufacturing Execution 5.

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31 Setting up Standalone Failure Tracking. 1 routers. 29 root cause. 16. 3 setting up. 9 Fast Barcode Interface (FBI). 29 DPMO (defects per million opportunities). 31 setting up DPMO. 34 setting up the POD. 7. 32 Nonconformance clients Fast Barcode Interface.Index B Barcodes and NCs. 34 Setting up Nonconformance. 32 M maximum NC limit. 30 specific items. 17 C Closing incidents. 20 S Secondary NC codes. 3 I Incidents closing.1. 7. 9 Defects per million opportunities (DPMO). 26 Nonconformance. 9 V Verifying defects. 26 Primary NC codes. 9 R Repair. 3 Routers. 9 Setting up DPMO. 33 Buttons PCA Dashboard. 9 F Failure. 10 Closing NC codes. 1 nonconformance. 16. 33 H Hierarchy NC codes. 32 N NC codes categories. 30 O Operations. 9 Repair loops. 7. 1 benefits. 33 graphical (PCA). 16. 10 numbers. 10. 21 buttons. 19 SAP Manufacturing Execution 5. 10 D Defect. 10 primary and secondary. 24 standard. 34 Setting up the POD for Nonconformance.3 Setting Up Nonconformance 41 . 15 standard scenarios. 11 P PCA Dashboard. 7. 21 graphical (PCA) scenarios. 9 closing.

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