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

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

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

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

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

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

The system displays this hierarchy graphically in the Failure Data area of the nonconformance client in the POD: SAP Manufacturing Execution 5.3 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.1.

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

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

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

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The message to be stored and sent. The set of people who will receive the messages through e-mail or real-time notification. The predefined events in the system that relate to Nonconformance are: RTW_CONSEC_NC RTW_YIELD_RATE (only for low yield scenarios) You can also define your own event messages in the system. With this information. For more information about setting up Events and real-time warnings. SAP Manufacturing Execution 5.3 Setting Up Nonconformance 13 .Working with Real-Time Warnings Real-time warnings notify appropriate manufacturing personnel that planned conditions have not been met at an operation. personnel can analyze and address the problem at the operation as quickly as possible. In addition. see the Setting Up Events guide and the online help for Event Maintenance and Real-Time Warnings Maintenance. Define the parameters for consecutive identical nonconformance real-time warnings. When to clear messages from the Event Viewer. You set up real-time warnings in conjunction with the Events feature. 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. you define: Event types (classifications for occurrences that happen during production). Associate an event type with a real-time warning. When you set up Events in the system.1.

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another for operators who log them at ANALYZE operations. 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. You create nonconformance clients in NC Client Maintenance. 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. In List Maintenance. retrieve the nonconformance client you want in NC Client Maintenance and review its setting. Standard Nonconformance Clients Although you can create nonconformance clients in NC Client Maintenance. The nonconformance clients that come with the system fall into two categories: Standard nonconformance clients. you may want one POD for operators who log nonconformances at TEST operations.Working with Standard Nonconformance Clients The system allows you to set up the POD various ways for different types of operators who nonconform SFCs. For example. there are several nonconformance clients that come with the system.1. 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. you can also create or change the Nonconformance lists that appear in the Failure Data area of the POD when operators log NCs.3 Setting Up Nonconformance 15 . If these PODs meet your needs. and another for operators who log them at REPAIR operations. You can use these nonconformance clients for many typical scenarios. see the Setting Up PODs guide. You can create different PODs in POD Maintenance. Note: For more information about PODs and Nonconformance lists. Graphical (PCA) nonconformance clients. SAP Manufacturing Execution 5. In POD Maintenance.

Designed for operators who log only primary NC codes and work with scanners.Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. see the “Setting Up Nonconformance” section near the end of this guide. open a closed NC. Hotkeys for the Fast Barcode Interface The following table lists the hotkeys mapped to the buttons in the Fast Barcode Interface: Hotkey ALT+B ALT+D ALT+E ALT+U ALT+M ALT+L ALT+R ALT+W Button Add Add and Done/Done Cancel (exit plug-in) Update Remove Cancel (cancel update mode) NC Report Work Instruction SAP Manufacturing Execution 5.1. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code.3 Setting Up Nonconformance 16 . PASS_FAIL None NC_LOG_W_SECONDARY NC_TRACKING DIAGNOSIS LOG_NC_FBI None Working with the Fast Barcode Interface Designed for operators who log only primary NC codes and work with scanners. Operators cannot edit the information associated with NC codes. Operators cannot edit the information associated with NC codes. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client. the Fast Barcode Interface (FBI) allows users to input information quickly. For information about setting up the Fast Barcode Interface. Designed for operators who log both primary and secondary NC codes. They can close an open NC. Standard POD * (default). Designed for operators who log both primary and secondary NC codes. and cancel any NC. The Log NC FBI with Multi RefDes (NC515) activity. Operators can also edit the information associated with NC codes.

the system displays the Remove Component window. see Setting Up PODs guide. ANALYZE.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.1. and REPAIR.3 Setting Up Nonconformance 17 . see the “Setting Up Nonconformance” section near the end of this guide. the system displays a dialog box asking the user whether he or she wants to remove the component. If the operator chooses to add a new component. When the user clicks OK in this window. Typical Scenarios for the Standard Nonconformance Clients The following illustration shows three scenarios for the standard nonconformance clients at different steps on the router. For information about setting up this feature. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. Use the nonconformance clients and workstations that mirror how you handle defects on your routers. the system displays a dialog box asking the user whether he or she wants to add a new component. * (default) or PASS_FAIL workstation (uses NC_LOG) Operation Fail TEST Pass Operation ANALYZE NC_LOG_W_SECONDARY workstation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5. If the operator chooses to remove the component. the system displays the Add Component window. For more information about workstations.

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 . 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.

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

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

a3p files for those boards.1. GenCAM or . 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. inspect. 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. For more information. You can provide this with the PCA Dashboard POD. analyze. see Appendix section of this guide. The PCA Dashboard allows operators who test. This allows you to incorporate engineering changes quickly.3 Setting Up Nonconformance 21 . To allow the operators to use the PCA Dashboard you need to install the PCA server.

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

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

PCA workstation Operation Fail TEST Pass Operation ANALYZE PCA workstation with PCA_ANALYSIS REPAIR PCA workstation with PCA_REPAIR SAP Manufacturing Execution 5.3 Setting Up Nonconformance 24 .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.1. 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.1.3 Setting Up Nonconformance 25 .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.

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

SCRAP Scraps the SFC(s). You must set up work instruction before users can view them. Used most often when a repair operator has retested an SFC and verified the defect. Note: Enabled only in Repair or Combined mode. Operators can use the Event Send Client to create and send event notification messages. Note: To correctly route an FPASS. Note: The system removes scrapped SFCs from the WIP database when they are archived. POD Button Activity Not associated. you must use the FPASS variable in scripts in Router Maintenance. WI500 Not associated. See the section on routers in Setting Up Production Lines. WORKINSTRUCTION Allows the operator to view work instructions. SENDEVENT SY550 SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance 27 . Completes the SFC and sends it to the next operation instead of back to the test operation. Displays the Event Send Client.Working with Graphical (PCA) Nonconformance Clients Button FPASS Description Forced pass.

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

If only one root cause operation is available.1.000. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. where components are placed. SAP Manufacturing Execution 5. 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. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1. Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation. You identify which category the system uses to calculate DPMO for the item.3 Setting Up Nonconformance 30 . Applicable for only those processes. the operation is selected automatically. the operator has to choose the operation. and the number of opportunities defined for the item that have the possibility of being defective.000.Using DPMO (Defects per Million Opportunities) Placement – The number of placement defects divided by the number of placement opportunities multiplied by 1. the operation at which defects for the item can be assigned. If multiple root cause operations are available.000.000. 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.

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

enter information about the drawing in the Drawing Name field. Note: Because Event Types are most often connected to nonconformance. Ensure the Can Be Primary Code check box on the Main tab is cleared. Setting Up and Overriding Maximum NC Limit To restrict the number of times an NC code can be logged against the particular SFC: 1. 3. 2.1. Change the maximum NC limit to the desired value other than 0. Select the NC code for which you want to override the Maximum NC Limit and click the details icon in the corresponding row. In the SFC field. SAP Manufacturing Execution 5. You can use different D2B servers for some clients for load balancing. in System Rule Maintenance make sure there are values for the mail server and the mail source address. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. 4. 2. in NC Code Maintenance 1.Setting Up Nonconformance To create a secondary NC Code. Click Save. Setting Up the POD for Nonconformance To set up the POD for Nonconformance: 1. you can leave the Can Be Primary Code check box cleared when you create NC codes. 3. In Default Value Maintenance. Click Save. In Nonconformance Limit Override. In System Rule Maintenance or NC Client Maintenance. Result: The system closes the window and returns to the Nonconformance Limit Override window. select NC Code from the Type drop-down list. Result: The system opens the NC Code Details window. Result: The system displays the table containing a record for NC Code logged against this SFC. To override the maximum NC limit when NC code exceeds this value: 1. 2. 5. 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. and move the secondary’s name to the Valid Secondaries list on the Secondaries tab. If you are using the PCA Dashboard: In Item Maintenance. browse for NC_Code in the Parent Table Name field and click Retrieve. identify the SFC for which you want to override the maximum NC limit and click Retrieve. Note: If you do not want to create a hierarchy. Retrieve the primary code you want to associate the secondary with.3 Setting Up Nonconformance 32 . 3. change the current value to a greater one and click OK. Note: You can also click the browse icon to select an SFC. In the Maximum NC Limit field. Create or retrieve the NC code to be a secondary code. enter the value of the D2B server.

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

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

3.1. the category appears in NC Group Maintenance. the NC data type is PCA. Therefore.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. For example. SAP Manufacturing Execution 5. revision A. 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. a particular PC board may have 200 areas in its circuitry where it could fail. In the DPMO tab of Item Maintenance. Note: Once you assign DPMO categories to defect NC codes. These DPMO NC groups come with the system. revision A multiplied by 1. The operation at which operators can log a defect NC code with a DPMO category. the system calculates the number of placement defects divided by the number of placement opportunities entered in Item Maintenance for PCBOARD. 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. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD.Setting Up Nonconformance Assign DPMO categories to NC codes. The system also sends this information to several DPMO-related ODS reports. the system performs the calculation specified by the DPMO category and writes the results in the DPMO report. If desired. You can assign a DPMO category only to an NC code of category Defect.000.000. Specify the NC Data Type you created in the previous step. For the DPMO codes that come with the system. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category.

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

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

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

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