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

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

System Determination If you allow the system to automatically determine where to send the SFC. When an operator logs an NC against an SFC at a router step. The first step on a separate router. These choices can include: A next step on the same router. For more information about branching and dispositioning. More Information About Routers For more information about setting up routers and scripting. based on criteria. A Return step. you can: Use scripting to send the SFC to a SCRAP step. Operator Determination If you 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.1.3 Setting Up Nonconformance 3 . Allow the system to automatically determine where to send the SFC. such as how many times the SFC has failed the test. a Return step. Keeping the SFC at the current step.Branching and Dispositioning on Routers When you set up Nonconformance. see the Setting Up Production Lines guide. a next step on the same router. or other location. SAP Manufacturing Execution 5. you can: Allow the operator to determine where the system should send the SFC. see the Setting Up Production Lines guide and the online help for Router Maintenance. or allow the operator to choose from a menu of several destinations. Set up disposition functions to either send the SFC automatically to a specific destination when it is nonconformed. the system displays a list of choices the operator can select from. you must decide how you want router branching and dispositioning to behave. A SCRAP step.

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

1.Collecting Information Note: Use the Root Cause Operation field only with DPMO.3 Setting Up Nonconformance 6 . SAP Manufacturing Execution 5.

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

1.3 Setting Up Nonconformance 8 .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.

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

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. for many NC codes that come with the system. This is often done when the unit is expensive to build. the system will not allow the NC code to be closed from the Edit tab of the NC client. Any secondary codes logged under a primary will be considered part of the same non-conformance incident. For more information. see the “Setting Up Nonconformance” section of this guide. 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. Secondary Required for Close Defines the NC code to require a secondary code to be logged against it to close.1. SAP Manufacturing Execution 5. When selected. To require an operator with authority.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. This operator is often performing a REPAIR operation. for example at a PMR station. such as a supervisor. If cleared. Closure Required Defines the NC code to require additional action to close. to close an incident. the system will close the NC code automatically after being logged.3 Setting Up Nonconformance 10 . 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. For information about creating primary and secondary NC codes. see the “Creating Primary and Secondary NC Codes” topic in the “Setting Up Nonconformance” section of this guide. the NC is open. Closing NC Codes When an operator logs an NC against one or more SFCs. 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. You can use closing of NC codes in several ways: To simply track that the nonconformance was logged (auto close the primary NC). operators can close both individual NC codes that have been logged and entire incidents. 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. Depending on the nonconformance client they are using and how the NC code is set up.

For more information about disposition groups. you can assign your NC codes to those operations in the Operation/Disposition Group tab in NC Code Maintenance. You can also specify the disposition group associated with the operation. For more information. By default. in order to record that the same action was taken to fix several failures. If at least one of the defects (in the same incident) has the Secondary Required for Closure check box selected. see the “Setting Up Nonconformance” section of this guide. For more information. When the Auto Close Incident check box is selected. Users can also log one secondary NC code against multiple primary NC codes without closing them. For more information. 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 Setting Up Activity Hooks guide. The incident and other defects will stay open.1. 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. the system automatically closes the nonconformance as soon as the operator logs it.Defining Nonconformance (NC) Codes Note: You can also allow operators to manually log NCs against a closed NC in NC Client Maintenance. Setting Up Activity Hooks You can set up NC code-specific activity hooks that execute custom code when operators log NCs. 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. this NC code can only be a secondary NC code (if the primary/secondary NC hierarchy is set up). When the Closure Required check box is cleared. SAP Manufacturing Execution 5.3 Setting Up Nonconformance 11 . some operators may need to log the same repair code. such as REPLACED against several primary NC codes indicating test failure. the system allows NC codes to be logged at all operations. Assigning Operations If you want to prevent operators from logging NC codes at all operations. For example. see online help for Logging an NC Reject. the system closes all defects logged against the failure if none of them has the Secondary Required for Closure check box selected. see the Routers section of the Setting Up Production Lines guide.

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shop floor personnel can also send event messages when others need notification with the Event Send Client. Associate an event type with a real-time warning. For more information about setting up Events and real-time warnings. Define the parameters for consecutive identical nonconformance real-time warnings. personnel can analyze and address the problem at the operation as quickly as possible. SAP Manufacturing Execution 5. you define: Event types (classifications for occurrences that happen during production). 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.3 Setting Up Nonconformance 13 . The message to be stored and sent. You set up real-time warnings in conjunction with the Events feature. When you set up Events in the system. In addition.Working with Real-Time Warnings Real-time warnings notify appropriate manufacturing personnel that planned conditions have not been met at an operation. In Real-Time Warnings Maintenance you: Define the parameters for yield processing real-time warnings. see the Setting Up Events guide and the online help for Event Maintenance and Real-Time Warnings Maintenance. When to clear messages from the Event Viewer.1. The set of people who will receive the messages through e-mail or real-time notification. With this information.

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

3 Setting Up Nonconformance 16 .Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. open a closed NC.1. Designed for operators who log only primary NC codes and work with scanners. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client. see the “Setting Up Nonconformance” section near the end of this guide. 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. Standard POD * (default). Operators cannot edit the information associated with NC codes. and cancel any NC. Designed for operators who log both primary and secondary NC codes. The Log NC FBI with Multi RefDes (NC515) activity. They can close an open NC. 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 cannot edit the information associated with NC codes. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. the Fast Barcode Interface (FBI) allows users to input information quickly. Designed for operators who log both primary and secondary NC codes. For information about setting up the Fast Barcode Interface. Operators can also edit the information associated with NC codes.

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

NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5. * (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.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 18 . This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes.1.

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

However. see the online help for Next Number Maintenance. if the incident number is assigned to another SFC. When you archive SFCs. If you select Manual. If you use incident numbers. What Is an Incident Number? An incident number uniquely identifies a nonconformance incident. you can group or organize nonconformances to help identify problem areas in your production process. 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 operator must enter an incident number in the POD when he or she logs an NC with a primary NC code. If you select Automatic in the Incident Number field. then the system archives only the SFC. It is also possible for one SFC to include multiple incident numbers. Creating Incident Numbers When you create nonconformance clients in NC Client Maintenance. they appear in the Log NC report.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 system archives both the SFC and its assigned incident number at the same time. the system automatically assigns the same incident number to all associated secondary NC codes. For more information about defining numbering patterns. the system automatically generates the incident number based on the numbering pattern you define with the Incident Number Number Type in Next Number Maintenance. and including one or more NC codes. SAP Manufacturing Execution 5.1. Note: If operators enter incident numbers manually. you can allow operators to enter incident numbers by selecting Manual in the Incident Number field on the Main tab. Using incident numbers. Primary and Secondary NC Codes When an operator logs an NC against an SFC in a nonconformance client that uses incident number. the system verifies that the number matches the numbering pattern defined in Next Number Maintenance. Incident Numbers and Archiving It is possible for one incident number to span multiple SFCs and multiple nonconformances of the same SFC.3 Setting Up Nonconformance 20 .

This allows you to incorporate engineering changes quickly.3 Setting Up Nonconformance 21 . To allow the operators to use the PCA Dashboard you need to install the PCA server. inspect. GenCAM or . The PCA Dashboard allows operators who test. and repair PCA boards to view and interact with GenCAD.Working with Graphical (PCA) Nonconformance Clients Operators who work with PCA boards may require graphical schematics of the product. 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. see Appendix section of this guide. You use the graphical (PCA) nonconformance clients to set up the PCA Dashboard for operators. analyze. For more information. You can provide this with the PCA Dashboard POD.1.

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

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

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. and REPAIR.3 Setting Up Nonconformance 24 .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.

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.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.1. and REPAIR steps at one location. ANALYZE.3 Setting Up Nonconformance 25 .

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

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

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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. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1.3 Setting Up Nonconformance 29 .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 1.000. focused on printed board assembly manufacturing. DPMO helps you measure defects so you can reduce them.1. SAP Manufacturing Execution 5. What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO. see the online help for NC Code Maintenance and NC Group Maintenance. your installer selects Yes in the Application Server NC codes for DPMO screen.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. Note: The system installs DPMO codes and categories only if. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard. To ensure this. This screen asks whether to install additional NC codes associated with the IPC 9261 specification.000. Combined with the system’s nonconformance capabilities. Commonly used with quality systems such as Six Sigma.000. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. 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.

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

3. In NC Code table of Default Value Maintenance. in NC Code Maintenance 1. change any NC-related rule as needed for your shop floor. 2. In the NC category in Data Type Maintenance. Create disposition routers and/or set up function-based dispositioning. 7. Create primary and secondary NC codes according to the NC hierarchy you want to use on your floor. assign NC data types to NC codes. Create or retrieve the NC code to be a primary code. If desired. in Router Maintenance: Create repair loops. As needed. 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 the POD for Nonconformance. If desired. or Repair. Set up activity hooks for NC codes. Creating Primary and Secondary NC Codes To create a primary NC Code. If desired. SAP Manufacturing Execution 5. If desired. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab. 4. 2. 3. In NC Code Maintenance and NC Group Maintenance. If you want to use DPMO. do the following: Group and create NC codes.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. set up Standalone Failure Tracking. Defect. assign DPMO categories to NC codes. 8.3 Setting Up Nonconformance 31 . set up DPMO. 5. In System Rule Maintenance. Create any custom fields you require.1. 6. Categorize each NC code as a Failure. set up the Fast Barcode Interface and how operators can close NC codes. Select the Can Be Primary Code check box on the Main tab. define the parameters and default values of NC codes. Write scripts to automatically send nonconformed SFCs to a next step based on criteria.

select NC Code from the Type drop-down list. you can leave the Can Be Primary Code check box cleared when you create NC codes. 4. You can use different D2B servers for some clients for load balancing. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. 2. 2. enter the value of the D2B server. 2. Setting Up and Overriding Maximum NC Limit To restrict the number of times an NC code can be logged against the particular SFC: 1.3 Setting Up Nonconformance 32 . If you are using the PCA Dashboard: In Item Maintenance. Retrieve the primary code you want to associate the secondary with. In System Rule Maintenance or NC Client Maintenance. In Default Value Maintenance. and move the secondary’s name to the Valid Secondaries list on the Secondaries tab. identify the SFC for which you want to override the maximum NC limit and click Retrieve. enter information about the drawing in the Drawing Name field. 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. browse for NC_Code in the Parent Table Name field 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.Setting Up Nonconformance To create a secondary NC Code. Result: The system displays the table containing a record for NC Code logged against this SFC. SAP Manufacturing Execution 5. Setting Up the POD for Nonconformance To set up the POD for Nonconformance: 1. To override the maximum NC limit when NC code exceeds this value: 1. 3. Click Save.1. In Nonconformance Limit Override. in NC Code Maintenance 1. Note: Because Event Types are most often connected to nonconformance. Click Save. Note: You can also click the browse icon to select an SFC. Change the maximum NC limit to the desired value other than 0. In the SFC field. 3. In the Maximum NC Limit field. change the current value to a greater one and click OK. Ensure the Can Be Primary Code check box on the Main tab is cleared. Note: If you do not want to create a hierarchy. 5. Create or retrieve the NC code to be a secondary code. Result: The system opens the NC Code Details window. Result: The system closes the window and returns to the Nonconformance Limit Override window. 3. in System Rule Maintenance make sure there are values for the mail server and the mail source address.

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

Select the Show Select NC Batch Button check box. On the Rules tab: Define NC client as an activity rule. 2. For more information. enter NC 540 (Standalone Failure Tracking) in the Activity field.3 Setting Up Nonconformance 34 .1. 2. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. In Activity Maintenance.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. retrieve the POD(s) you will use for these operators and enter the nonconformance client in the previous step in the NC Client field. To set up Standalone Failure Tracking: 1. In NC Client Maintenance. This NC Client must exist as having been defined in NC Client Maintenance. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system. Operators must enter the root cause operation when they use DPMO-related NC codes. In NC Code Maintenance. 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. ensure that Enabled and Visible in Activity Manager check boxes are selected. On the Main tab in POD Maintenance. 3. The root cause operation is the upstream failure operation in the repair loop. and thereby indicates the root cause of the problem. To set up DPMO: 1. 4. 3. Click Save. define the primary NC and select the Secondary Required for Close check box on the Main tab. On the Main tab. 2. Setting Up DPMO Note: The system comes with about a hundred NC codes you can use for DPMO. 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. in NC Code Maintenance: SAP Manufacturing Execution 5. Create an NC data type in Data Type Maintenance that includes the Root Cause Operation field set to either Optional or Required. Define the Operation option and set it to true or false. Define the Resource option and set it to true or false. If you need to create additional NC codes to use in conjunction with DPMO. Give the operators you want to allow to close multiple primary NCs with one secondary NC access to this POD.

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

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

If you select No. The D2B install starts and displays the Setup Status of the installation. Enter Visiprise\GR Force D2B. The installation program displays the Start Copying Files dialog box. Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files. Refer to the System Administration Guide for instructions on obtaining and installing a license. 12.html. The default program folder. Action The Choose Destination Location dialog box appears. Click Next. Click the Browse button to select an alternate folder. the PCA Server has finished selecting Components dialog box appears. The installation program displays the Select Program Folder dialog box. SAP Manufacturing Execution 5. 16. click OK to return to the Choose Destination Location dialog box. Click Finish. After a few moments. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. 14.3 Setting Up Nonconformance 38 . you do not need a separate license. c:\GenRad\GR Force D2B. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located.com/test-design/design-to-build/viewer. 9. The Choose Folder dialog box appears. is displayed in the Program Folders field. 15. 10. GenRad\GR Force D2B. Review the settings. such as: C:\Visiprise\GR Force D2B When you are finished. Click Next. you must restart your computer later. The default program folder. Select the option you want for restarting your computer and click Finish to complete the installation. is displayed. the InstallShield Wizard Complete message appears. then click Next to start copying files. At the completion of the installation. 11. 13. 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. Click Next.teradyne.Appendix: Installing PCA Server Step 8. The Setup Complete message appears. After installing the D2B viewer. you may obtain a license key by accessing http://www.1.

make sure that you do not have an instance of the standalone D2B viewer running. The standalone viewer will use your license key and the PCA Viewer called by the POD will not be able to run. which can be obtained using the D2B software's License Manager. You will find the necessary value in the Server Code field: Once you receive the license key from the website by email. Do this by selecting Start > Programs > Visiprise > GR Force D2B > Tools > License Manager.3 Setting Up Nonconformance 39 . You will need the GRA3LM Server Code for your installation. This will activate your D2B viewer.Appendix: Installing PCA Server Choose the Register Now option and provide the required information. SAP Manufacturing Execution 5.1. enter the value into the Key field displayed by the License Manager and click Install Key. Note: When running the PCA Viewer Server.

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

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