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

3 Setting Up Nonconformance 2 . How you will use DPMO. SAP Manufacturing Execution 5.1.Introduction How you want the POD to behave and appear for operators who log nonconformances. How you want the PCA Dashboard in the POD to behave and appear for operators who work with nonconformances against PCA boards.

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

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

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

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

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.

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

see the “Creating Primary and Secondary NC Codes” topic in the “Setting Up Nonconformance” section of this guide. You can use closing of NC codes in several ways: To simply track that the nonconformance was logged (auto close the primary NC). This is often done when the unit is expensive to build. When an NC code exceeds this limit you may optionally override this value. Secondary Required for Close Defines the NC code to require a secondary code to be logged against it to close. the NC is open. To show that an incident is pending until an experienced operator manually closes it. When selected. SAP Manufacturing Execution 5. Closure Required Defines the NC code to require additional action to close. You can also have the system automatically close a primary NC as soon as an operator logs it. For more information. Depending on the nonconformance client they are using and how the NC code is set up. To require an operator with authority. For information about creating primary and secondary NC codes. The NC_TRACKING nonconformance client allows operators to close nonconformances and incidents manually. for example at a PMR station. for many NC codes that come with the system. operators can close both individual NC codes that have been logged and entire incidents.1. such as a supervisor. Closing NC Codes When an operator logs an NC against one or more SFCs. to close an incident. the system will close the NC code automatically after being logged. 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.3 Setting Up Nonconformance 10 . If cleared. Auto Close Primary NC Defines the NC code to close its parent NC code when the current NC is closed. 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. see the “Setting Up Nonconformance” section of this guide. This operator is often performing a REPAIR operation. 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.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. 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.

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

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

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

Designed for operators who log both primary and secondary NC codes. Operators cannot edit the information associated with NC codes. Operators can also edit the information associated with NC codes. 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. Designed for operators who log both primary and secondary NC codes. 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 5.3 Setting Up Nonconformance 16 . For information about setting up the Fast Barcode Interface.1. see the “Setting Up Nonconformance” section near the end of this guide. Designed for operators who log only primary NC codes and work with scanners. 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. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client. The Log NC FBI with Multi RefDes (NC515) activity. Standard POD * (default). the Fast Barcode Interface (FBI) allows users to input information quickly. Operators cannot edit the information associated with NC codes.Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. open a closed NC.

the system displays the Add Component window. * (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 5.3 Setting Up Nonconformance 17 . When the user clicks OK in this window.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. For more information about workstations. ANALYZE. see the “Setting Up Nonconformance” section near the end of this guide. Use the nonconformance clients and workstations that mirror how you handle defects on your routers. For information about setting up this feature. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. Typical Scenarios for the Standard Nonconformance Clients The following illustration shows three scenarios for the standard nonconformance clients at different steps on the router. see Setting Up PODs guide. If the operator chooses to remove the component.1. If the operator chooses to add a new component. the system displays the Remove Component window. and REPAIR. 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.

3 Setting Up Nonconformance 18 . This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes.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.

The SFC is then sent through the repair loop again. For example. repair cycles that do not fix the problem. Some nonconformance clients that come with the system display a Verified Defects chart to the operator in the POD.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. CABLECONWRONG (Defect). when the unit is retested. you can create a nonconformance client that displays the Verified Defects chart. and RECONNECT (Repair) sequence as the verified defect. SAP Manufacturing Execution 5. The system logs the NO_POWER. operators may log the following NC codes: NO_POWER (Failure) Operation Fail TEST Operation ANALYZE SHORT (Defect) REPAIR REWIRE (Repair) However. 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.3 Setting Up Nonconformance 19 .1. As operators troubleshoot problems with units (SFCs) in a repair loop on your router. they may log many failure. 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. In NC Client Maintenance. You can assign incident numbers to incidents for tracking purposes. This last defect and repair is then verified to be the actual case and is called the verified defect. and operators log other NC codes that reflect their actions the second time through: NO_POWER (Failure) Operation Fail TEST Operation ANALYZE CABLECONWRONG (Defect) REPAIR RECONNECT (Repair) The third time the unit is tested it passes. it still fails. during the first cycle through a repair loop.

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

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

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

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

and REPAIR. 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.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.3 Setting Up Nonconformance 24 .

3 Setting Up Nonconformance 25 . 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.1. ANALYZE. and REPAIR steps at one location.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. PCA workstation with PCA_INSPECTION Operation TEST-ANALYZEREPAIR Pass Operation SAP Manufacturing Execution 5.

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

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

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The system supports the standardized DPMO methodology as defined in the IPC-9261 standard.1.000. SAP Manufacturing Execution 5.000. Note: The system installs DPMO codes and categories only if. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation.000.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. see the online help for NC Code Maintenance and NC Group Maintenance. To ensure this. Commonly used with quality systems such as Six Sigma. during installation. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1.3 Setting Up Nonconformance 29 . 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. Combined with the system’s nonconformance capabilities. DPMO helps you measure defects so you can reduce them. Calculating DPMO Assigning DPMO categories to NC codes in NC Code Maintenance determines how the system calculates DPMO for that NC code. your installer selects Yes in the Application Server NC codes for DPMO screen.000. This screen asks whether to install additional NC codes associated with the IPC 9261 specification. focused on printed board assembly manufacturing. 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. 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. and the number of opportunities defined for the item that have the possibility of being defective. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. where components are placed. the operation at which defects for the item can be assigned.000.000. If only one root cause operation is available. Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item. SAP Manufacturing Execution 5.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. 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. If multiple root cause operations are available. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation. You identify which category the system uses to calculate DPMO for the item.000. Applicable for only those processes. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1.3 Setting Up Nonconformance 30 . the operator has to choose the operation. the operation is selected automatically.1.

create the data types you want to associate with NC codes and select the predefined fields you want to appear in the POD. In NC Code Maintenance and NC Group Maintenance. SAP Manufacturing Execution 5. Set up activity hooks for NC codes.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. 4. If desired. 2. In System Rule Maintenance. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab. If desired. Categorize each NC code as a Failure. define the parameters and default values of NC codes. set up Standalone Failure Tracking. change any NC-related rule as needed for your shop floor. 2. Set up the POD for Nonconformance. Select the Can Be Primary Code check box on the Main tab. 3. In the NC category in Data Type Maintenance. If desired. In NC Code table of Default Value Maintenance. 5.3 Setting Up Nonconformance 31 . assign DPMO categories to NC codes. As needed. If you want to use DPMO.1. Create disposition routers and/or set up function-based dispositioning. in NC Code Maintenance 1. 8. Create any custom fields you require. in Router Maintenance: Create repair loops. assign NC data types to NC codes. or Repair. Create primary and secondary NC codes according to the NC hierarchy you want to use on your floor. 7. If desired. Creating Primary and Secondary NC Codes To create a primary NC Code. Write scripts to automatically send nonconformed SFCs to a next step based on criteria. Defect. 3. do the following: Group and create NC codes. Create or retrieve the NC code to be a primary code. set up the Fast Barcode Interface and how operators can close NC codes. set up DPMO. 6.

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

Note: The As-Built link is not necessary for operators using this feature.Setting Up Nonconformance 2. Running this batch file is necessary to display the Verified Defects chart in the PCA Dashboard in Repair mode. Give the operators you want to use the Fast Barcode Interface access to this POD. In POD Maintenance: On the Buttons tab.1.3 Setting Up Nonconformance 33 . SAP Manufacturing Execution 5. On the Main tab. Note: If any PCA Dashboard users are to use Analysis or Repair mode. 4.bat file to run in a scheduler and that the file has been run at least once. On the Buttons tab. 3. enter a nonconformance client in the NC Client field in Operation Maintenance. Note: You can retrieve an existing nonconformance client to use as a template and save it under another name. Setting Up the Fast Barcode Interface for Operators To set up the Fast Barcode Interface: 1. create new ones in NC Client Maintenance. ensure a System Administrator has set the FailureHistoryExtract. 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). In NC Code Maintenance. If the nonconformance clients that come with the system do not meet your needs. create a row for the nonconformance button and associate it with the nc500 POD button activity. select None in the As-Built Link Location field. In POD Maintenance. 2. Specify the disposition router where you want the system to send the removed component in the Component Disposition Router field. This value overrides the value in POD Maintenance. create a button associated with Log NC with Multi RefDes (NC515). When an operator using this workstation clicks the nonconformance button. enter LOG_NC_FBI in the NC Client field. the system uses the settings in the nonconformance client to determine what to display to the user. 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. Also create any nonconformance lists you need in List Maintenance. enter the client you want for this POD in the NC Client field on the Main tab. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. On the Advanced Log NC tab in NC Client Maintenance. 2. For more information. If desired. 3.

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

These DPMO NC groups come with the system.1.3 Setting Up Nonconformance 35 . For example. The number of opportunities on this item that has the possibility of being defective. The system also sends this information to several DPMO-related ODS reports. SAP Manufacturing Execution 5. revision A. the system calculates the number of placement defects divided by the number of placement opportunities entered in Item Maintenance for PCBOARD. the category appears in NC Group Maintenance. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category.000. a particular PC board may have 200 areas in its circuitry where it could fail. 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. In the DPMO tab of Item Maintenance. you can assign some or all NC codes in a DPMO category to an NC group of the same name. revision A multiplied by 1. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD. The operation at which operators can log a defect NC code with a DPMO category. Therefore. Results When an operator logs an NC against an SFC representing an item with information in the DPMO tab. Specify the NC Data Type you created in the previous step. the NC data type is PCA. The system writes the results in the DPMO report along with the Root Cause operation entered by the analysis operator. Note: Once you assign DPMO categories to defect NC codes. 3.000. For the DPMO codes that come with the system. identify: Which category the system uses to calculate DPMO for the item. If desired.

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

then click Next to start copying files. 9. 11. Click Next. click OK to return to the Choose Destination Location dialog box. Click Next. Action The Choose Destination Location dialog box appears. The Choose Folder dialog box appears. Enter Visiprise\GR Force D2B.Appendix: Installing PCA Server Step 8. the InstallShield Wizard Complete message appears. After installing the D2B viewer. Review the settings. The Setup Complete message appears. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. 16. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files. The installation program displays the Start Copying Files dialog box.teradyne. 14.1. GenRad\GR Force D2B. you may obtain a license key by accessing http://www. the PCA Server has finished selecting Components dialog box appears. 15. If you select No. Select the option you want for restarting your computer and click Finish to complete the installation. such as: C:\Visiprise\GR Force D2B When you are finished. Click Finish. SAP Manufacturing Execution 5. you do not need a separate license. Click the Browse button to select an alternate folder.html. Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located. is displayed in the Program Folders field. After a few moments. Click Next. is displayed. The default program folder. you must restart your computer later. c:\GenRad\GR Force D2B. Refer to the System Administration Guide for instructions on obtaining and installing a license. 10. 12. At the completion of the installation. The D2B install starts and displays the Setup Status of the installation. The installation program displays the Select Program Folder dialog box. The default program folder.3 Setting Up Nonconformance 38 . 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. 13.com/test-design/design-to-build/viewer.

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

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Index B Barcodes and NCs. 20 S Secondary NC codes. 10 primary and secondary. 33 graphical (PCA). 9 Defects per million opportunities (DPMO). 3 Routers. 30 O Operations. 29 DPMO (defects per million opportunities). 9 R Repair. 33 Buttons PCA Dashboard. 19 SAP Manufacturing Execution 5. 30 specific items. 26 Nonconformance. 17 C Closing incidents. 32 N NC codes categories. 9 F Failure. 3 setting up. 34 Setting up the POD for Nonconformance. 16.1. 21 graphical (PCA) scenarios. 26 Primary NC codes. 9 V Verifying defects. 9 Fast Barcode Interface (FBI). 9 closing. 33 H Hierarchy NC codes.3 Setting Up Nonconformance 41 . 7. 31 setting up DPMO. 10 Closing NC codes. 7. 7. 15 standard scenarios. 21 buttons. 7. 1 routers. 9 Setting up DPMO. 3 I Incidents closing. 29 root cause. 32 Nonconformance clients Fast Barcode Interface. 1 nonconformance. 11 P PCA Dashboard. 10 numbers. 32 M maximum NC limit. 10. 34 setting up the POD. 24 standard. 10 D Defect. 16. 34 Setting up Nonconformance. 16. 1 benefits. 9 Repair loops. 31 Setting up Standalone Failure Tracking.

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