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

3 Setting Up Nonconformance 2 .1. How you will use DPMO.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. SAP Manufacturing Execution 5.

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

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

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

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

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 5.1.

click Actions > Tree View in NC Code Maintenance. SAP Manufacturing Execution 5.3 Setting Up Nonconformance 9 . You base the place of an NC code in the hierarchy on its category and the level of granularity you want.or three-level NC hierarchy is most typical when you use the PCA Dashboard. 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. The second unit failed because of incorrectly connected cables and was re-cabled. Can have other codes underneath it. A two.1. Primary and Secondary NC Codes You create an NC hierarchy by creating primary and secondary NC codes in NC Code Maintenance. the following illustration shows a three-level hierarchy with two sets of NC codes logged against the primary NC. 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. associated with the Defect code) For example.Defining Nonconformance (NC) Codes You create a hierarchy among your NC codes by making them either primary or secondary codes and associating them with each other. NO_POWER.

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

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

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

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

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. PASS_FAIL None NC_LOG_W_SECONDARY NC_TRACKING DIAGNOSIS LOG_NC_FBI None Working with the Fast Barcode Interface Designed for operators who log only primary NC codes and work with scanners. Operators can also edit the information associated with NC codes. The Log NC FBI with Multi RefDes (NC515) activity.3 Setting Up Nonconformance 16 . see the “Setting Up Nonconformance” section near the end of this guide. Designed for operators who log both primary and secondary NC codes. Standard POD * (default). and cancel any NC. Designed for operators who log only primary NC codes and work with scanners. open a closed NC. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client. Designed for operators who log both primary and secondary NC codes.Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. Operators cannot edit the information associated with NC codes. They can close an open NC. Operators cannot edit the information associated with NC codes. the Fast Barcode Interface (FBI) allows users to input information quickly. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. For information about setting up the Fast Barcode Interface.1.

If the operator chooses to add a new component. see Setting Up PODs guide. Use the nonconformance clients and workstations that mirror how you handle defects on your routers.Working with Standard Nonconformance Clients Allowing Operators to Auto Remove/Replace NC’s Components You can set up the system so that when an operator logs a primary or secondary NC code against an SFC that is an assembled component. ANALYZE. the system displays a dialog box asking the user whether he or she wants to add a new component.3 Setting Up Nonconformance 17 . the system displays a dialog box asking the user whether he or she wants to remove the component. the system displays the Remove Component window.1. For more information about workstations. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. see the “Setting Up Nonconformance” section near the end of this guide. the system displays the Add Component window. 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. For information about setting up this feature. If the operator chooses to remove the 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.

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. This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes. NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5.3 Setting Up Nonconformance 18 .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.

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

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

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

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

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

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. ANALYZE. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. PCA workstation Operation Fail TEST Pass Operation ANALYZE PCA workstation with PCA_ANALYSIS REPAIR PCA workstation with PCA_REPAIR SAP Manufacturing Execution 5.1. and REPAIR.3 Setting Up Nonconformance 24 .

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

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

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

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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. SAP Manufacturing Execution 5. 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. 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.000. This screen asks whether to install additional NC codes associated with the IPC 9261 specification.000. Combined with the system’s nonconformance capabilities. Note: The system installs DPMO codes and categories only if.000. during installation. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard. focused on printed board assembly manufacturing.3 Setting Up Nonconformance 29 . What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. 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. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1. your installer selects Yes in the Application Server NC codes for DPMO screen.1. see the online help for NC Code Maintenance and NC Group Maintenance. 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. To ensure this.

Applicable for only those processes. If multiple root cause operations are available. the operator has to choose the operation.1. and the number of opportunities defined for the item that have the possibility of being defective. SAP Manufacturing Execution 5. 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. Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item. You identify which category the system uses to calculate DPMO for the item.000. the operation is selected automatically.000. If only one root cause operation is available. the operation at which defects for the item can be assigned.Using DPMO (Defects per Million Opportunities) Placement – The number of placement defects divided by the number of placement opportunities multiplied by 1. where components are placed.000. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation.000. 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 Setting Up Nonconformance 30 . 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.

2. SAP Manufacturing Execution 5. in Router Maintenance: Create repair loops. As needed. set up Standalone Failure Tracking. If desired. 2. 4. 3. change any NC-related rule as needed for your shop floor. 6. create the data types you want to associate with NC codes and select the predefined fields you want to appear in the POD. set up DPMO. assign NC data types to NC codes. Defect. 3. In NC Code table of Default Value Maintenance. 5. Set up activity hooks for NC codes. Select the Can Be Primary Code check box on the Main tab. If desired. In System Rule Maintenance. assign DPMO categories to NC codes. Set up the POD for Nonconformance. in NC Code Maintenance 1. do the following: Group and create NC codes. Creating Primary and Secondary NC Codes To create a primary NC Code. 7.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. define the parameters and default values of NC codes. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab. Create primary and secondary NC codes according to the NC hierarchy you want to use on your floor.1.3 Setting Up Nonconformance 31 . set up the Fast Barcode Interface and how operators can close NC codes. Categorize each NC code as a Failure. In the NC category in Data Type Maintenance. If desired. Create any custom fields you require. If desired. If you want to use DPMO. Create disposition routers and/or set up function-based dispositioning. Create or retrieve the NC code to be a primary code. Write scripts to automatically send nonconformed SFCs to a next step based on criteria. In NC Code Maintenance and NC Group Maintenance. or Repair. 8.

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

create new ones in NC Client Maintenance. SAP Manufacturing Execution 5. If desired. 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. 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). 3. In POD Maintenance: On the Buttons tab. On the Advanced Log NC tab in NC Client Maintenance. When an operator using this workstation clicks the nonconformance button. ensure a System Administrator has set the FailureHistoryExtract. create a row for the nonconformance button and associate it with the nc500 POD button activity. On the Main tab. Also create any nonconformance lists you need in List Maintenance. Running this batch file is necessary to display the Verified Defects chart in the PCA Dashboard in Repair mode. For more information. This value overrides the value in POD Maintenance. 2. 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: 1.3 Setting Up Nonconformance 33 .Setting Up Nonconformance 2. Note: The As-Built link is not necessary for operators using this feature. Give the operators you want to use the Fast Barcode Interface access to this POD. 2. On the Buttons tab. 3. In POD Maintenance. enter LOG_NC_FBI in the NC Client field. Specify the disposition router where you want the system to send the removed component in the Component Disposition Router field. In NC Code Maintenance. create a button associated with Log NC with Multi RefDes (NC515).bat file to run in a scheduler and that the file has been run at least once. select None in the As-Built Link Location field. enter a nonconformance client in the NC Client field in Operation Maintenance. Note: If any PCA Dashboard users are to use Analysis or Repair mode. If the nonconformance clients that come with the system do not meet your needs. enter the client you want for this POD in the NC Client field on the Main tab. Allowing Operators to Auto Remove/Replace NC’d Components To allow operators to auto remove/replace NC’d components: 1. the system uses the settings in the nonconformance client to determine what to display to the user. 4.1. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide.

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

Note: Once you assign DPMO categories to defect NC codes. revision A. These DPMO NC groups come with the system. the system calculates the number of placement defects divided by the number of placement opportunities entered in Item Maintenance for PCBOARD. you can assign some or all NC codes in a DPMO category to an NC group of the same name. the system performs the calculation specified by the DPMO category and writes the results in the DPMO report.000.Setting Up Nonconformance Assign DPMO categories to NC codes. If desired. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category. the category appears in NC Group Maintenance. For example. The operation at which operators can log a defect NC code with a DPMO category. revision A multiplied by 1. SAP Manufacturing Execution 5. The system also sends this information to several DPMO-related ODS reports.3 Setting Up Nonconformance 35 . Therefore. a particular PC board may have 200 areas in its circuitry where it could fail. Specify the NC Data Type you created in the previous step. You can assign a DPMO category only to an NC code of category Defect. In the DPMO tab of Item Maintenance. For the DPMO codes that come with the system. 3.000. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD. The system writes the results in the DPMO report along with the Root Cause operation entered by the analysis operator. the NC data type is PCA.1. Results When an operator logs an NC against an SFC representing an item with information in the DPMO tab. identify: Which category the system uses to calculate DPMO for the item. The number of opportunities on this item that has the possibility of being defective.

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

you must restart your computer later. the InstallShield Wizard Complete message appears.Appendix: Installing PCA Server Step 8. 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. Select the option you want for restarting your computer and click Finish to complete the installation.com/test-design/design-to-build/viewer. Click Next. Refer to the System Administration Guide for instructions on obtaining and installing a license. SAP Manufacturing Execution 5. 15.1. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files. After a few moments. is displayed in the Program Folders field. The installation program displays the Select Program Folder dialog box. then click Next to start copying files. 11. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located. The Setup Complete message appears. Action The Choose Destination Location dialog box appears.teradyne. click OK to return to the Choose Destination Location dialog box. The D2B install starts and displays the Setup Status of the installation. 13. The installation program displays the Start Copying Files dialog box. Review the settings. 10. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. The Choose Folder dialog box appears.3 Setting Up Nonconformance 38 . 12. Click Next. Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server. Click the Browse button to select an alternate folder. 14. the PCA Server has finished selecting Components dialog box appears. Click Finish.html. The default program folder. you may obtain a license key by accessing http://www. The default program folder. Enter Visiprise\GR Force D2B. At the completion of the installation. 9. you do not need a separate license. such as: C:\Visiprise\GR Force D2B When you are finished. If you select No. is displayed. Click Next. c:\GenRad\GR Force D2B. GenRad\GR Force D2B. After installing the D2B viewer. 16.

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

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

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