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

Introduction How you want the POD to behave and appear for operators who log nonconformances. SAP Manufacturing Execution 5. How you want the PCA Dashboard in the POD to behave and appear for operators who work with nonconformances against PCA boards. How you will use DPMO.1.3 Setting Up Nonconformance 2 .

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

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

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

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

The system displays this hierarchy graphically in the Failure Data area of the nonconformance client in the POD: SAP Manufacturing Execution 5.1.3 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.

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

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

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

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

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

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

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

NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5. * (default) or PASS_FAIL workstation (uses NC_LOG) Operation Fail TEST Pass Operation ANALYZE-REPAIR DIAGNOSIS workstation (uses NC_TRACKING) Scenario C Scenario C illustrates the case when you combine the TEST and ANALYZE steps into one operation and have a separate REPAIR operation. 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.1.3 Setting Up Nonconformance 18 .

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

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

To allow the operators to use the PCA Dashboard you need to install the PCA server. The PCA Dashboard allows operators who test. GenCAM or . inspect. You use the graphical (PCA) nonconformance clients to set up the PCA Dashboard for operators.a3p files for those boards. 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. analyze. For more information. This allows you to incorporate engineering changes quickly. and repair PCA boards to view and interact with GenCAD.Working with Graphical (PCA) Nonconformance Clients Operators who work with PCA boards may require graphical schematics of the product. see Appendix section of this guide. You can provide this with the PCA Dashboard POD.1.3 Setting Up Nonconformance 21 .

and repair boards at the same operation: Operators can log primary and secondary NC codes (failures. Operators can view previously entered comments in the Comments tab. PCA (after changing the NC Client field on the Main tab to PCA_ANALYSIS) PCA (after changing the NC Client field on the Main tab to PCA_INSPECTION) Standard POD PCA SAP Manufacturing Execution 5. Operators can view previously entered comments in the Comments tab. Operators can log only secondary NC codes (defects). Operators cannot use IPASS or FPASS. or with an automatic tester: Operators can log only primary NC codes.3 Setting Up Nonconformance 22 . The Failure Data area displays NC codes. Nonconformance client PCA_TEST Description Use for operators who pass or fail boards by testing them manually.1. Operators cannot use IPASS or FPASS. and Ref Des’s. 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. and repairs). and the standard PODs that come with the system: Note: For all details. PCA_INSPECTION Use for operators who test. The PCA Dashboard displays the Verified Defects chart. Failure IDs.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 enter comments in the Comments tab. visually. The Failure Data area displays NC codes and Ref Des’s. defects. analyze. 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 Failure IDs.

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

3 Setting Up Nonconformance 24 . PCA workstation Operation Fail TEST Pass Operation ANALYZE PCA workstation with PCA_ANALYSIS REPAIR PCA workstation with PCA_REPAIR SAP Manufacturing Execution 5.1.Working with Graphical (PCA) Nonconformance Clients Typical Scenarios for the Graphical (PCA) Nonconformance Clients The following illustration shows three typical scenarios using the graphical (PCA) nonconformance clients at different steps on the router. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. and REPAIR. ANALYZE.

PCA workstation Operation Fail TEST Pass Operation ANALYZE-REPAIR PCA workstation with PCA_COMBINED Scenario C Scenario C illustrates the case when an operator performs the TEST. 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. ANALYZE.1.3 Setting Up Nonconformance 25 .

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

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

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see the online help for NC Code Maintenance and NC Group Maintenance. 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. your installer selects Yes in the Application Server NC codes for DPMO screen.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard.3 Setting Up Nonconformance 29 . during installation.1. Commonly used with quality systems such as Six Sigma.000. Note: The system installs DPMO codes and categories only if. DPMO helps you measure defects so you can reduce them. use the browse in NC Code Maintenance and NC Group Maintenance to check whether the DPMO codes and categories listed in the online help appear. To ensure this. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1. 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. focused on printed board assembly manufacturing. What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO.000.000. Combined with the system’s nonconformance capabilities. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. SAP Manufacturing Execution 5. 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.

You identify which category the system uses to calculate DPMO for the item. 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. where components are placed. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process.000.000. the operation is selected automatically.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 operator has to choose the operation.000. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation.1.3 Setting Up Nonconformance 30 . SAP Manufacturing Execution 5. Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item.000. the operation at which defects for the item can be assigned. Applicable for only those processes. If only one root cause operation is available. and the number of opportunities defined for the item that have the possibility of being defective. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1. If multiple root cause operations are available.

In System Rule Maintenance. In the NC category in Data Type Maintenance. 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. Create disposition routers and/or set up function-based dispositioning. In NC Code table of Default Value Maintenance. If desired. 5. define the parameters and default values of NC codes.1. or Repair. 3. If desired. in Router Maintenance: Create repair loops. 8. Write scripts to automatically send nonconformed SFCs to a next step based on criteria. 6. in NC Code Maintenance 1. In NC Code Maintenance and NC Group Maintenance. 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 activity hooks for NC codes. If you want to use DPMO. Creating Primary and Secondary NC Codes To create a primary NC Code. SAP Manufacturing Execution 5. set up the Fast Barcode Interface and how operators can close NC codes. change any NC-related rule as needed for your shop floor. Create any custom fields you require. assign DPMO categories to NC codes. 4. Set up the POD for Nonconformance. set up DPMO. If desired.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. Categorize each NC code as a Failure. 2. If desired. As needed. assign NC data types to NC codes. 2.3 Setting Up Nonconformance 31 . 7. 3. Select the Can Be Primary Code check box on the Main tab. Defect. do the following: Group and create NC codes. Create or retrieve the NC code to be a primary code. set up Standalone Failure Tracking.

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

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

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

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

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and the Choose Folder dialog box appears. The License Agreement dialog box appears. When you are finished. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution PCA Server program files. and the GR Force/D2B ReadOnly – InstallShield Wizard dialog box appears. The default installation directory location is: C:\Visiprise\VisipriseMfg\PCA Server. SAP Manufacturing Execution 5. Click Yes to accept the software license agreement.Appendix: Installing PCA Server Step 1.3 Setting Up Nonconformance 37 . Read the Welcome screen and click Next. 4. and the GR Force/D2B Setup dialog box appears. located in the PCA directory. click the Browse button.exe. Use the scroll bar to view the entire agreement. Action Insert the SAP Manufacturing Execution installation CD into the server machine and run the setup file. Visiprise\VisipriseMfg\PCA Server. Click Next to accept the default program folder. 5. 2. followed shortly by the Welcome screen. click OK to return to the Choose Destination Location dialog box. Click Next on the Choose Destination Location dialog box. The Update message appears. Use this screen to specify the program folder for the PCA Server. Read the welcome information and click Next. The Select Program Folder dialog box appears. The system launches the install program for the read-only version of the GR Force/D2B. The Choose Destination Location dialog box appears. 6. is displayed in the Program Folders field. 3. Read the welcome information and click Next. To select an alternate product directory. The Extracting Files message appears. VisipriseMfg_PCAD_50. 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.1. 7. Use this screen to specify the location on the hard drive where the SAP Manufacturing Execution PCA Server program files will be located. The system launches the install program for the read-only version of the GR Force/D2B. The default program folder.

Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server. the PCA Server has finished selecting Components dialog box appears. is displayed in the Program Folders field. The Choose Folder dialog box appears. Click Next. Click the Browse button to select an alternate folder. you may obtain a license key by accessing http://www. you do not need a separate license. 14. 13.teradyne. then click Next to start copying files. Click Finish. Refer to the System Administration Guide for instructions on obtaining and installing a license.Appendix: Installing PCA Server Step 8. SAP Manufacturing Execution 5. 9. 12. The default program folder.3 Setting Up Nonconformance 38 . click OK to return to the Choose Destination Location dialog box. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located. such as: C:\Visiprise\GR Force D2B When you are finished. c:\GenRad\GR Force D2B. At the completion of the installation. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. Select the option you want for restarting your computer and click Finish to complete the installation.com/test-design/design-to-build/viewer. The default program folder. The installation program displays the Select Program Folder dialog box.1. Action The Choose Destination Location dialog box appears. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files.html. Click Next. Review the settings. If you select No. GenRad\GR Force D2B. is displayed. The D2B install starts and displays the Setup Status of the installation. 15. you must restart your computer later. 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. Enter Visiprise\GR Force D2B. Click Next. After a few moments. The installation program displays the Start Copying Files dialog box. After installing the D2B viewer. 16. 11. The Setup Complete message appears. 10. the InstallShield Wizard Complete message appears.

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

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

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