SAP Manufacturing Execution 5.1.

3
Setting Up Nonconformance
Including PCA Dashboard and DPMO

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Table of Contents
Introduction ..........................................................................................................................................1 What Is Nonconformance? ................................................................................................................1 Decisions to Make..............................................................................................................................1 Branching and Dispositioning on Routers .......................................................................................3 Operator Determination .....................................................................................................................3 System Determination........................................................................................................................3 More Information About Routers........................................................................................................3 Collecting Information.........................................................................................................................5 What Is a Data Type? ........................................................................................................................5 Assigning NC Data Types..................................................................................................................5 Defining Nonconformance (NC) Codes .............................................................................................7 What Is an NC Code? ........................................................................................................................7 Categorizing NC Codes .....................................................................................................................7 Creating a Hierarchy ..........................................................................................................................8 Setting Up and Overriding Maximum NC Limit................................................................................10 Closing NC Codes ...........................................................................................................................10 Assigning Operations.......................................................................................................................11 Setting Up Activity Hooks ................................................................................................................11 Logging an NC Reject in the Rich POD...........................................................................................11 Working with Real-Time Warnings...................................................................................................13 Working with Standard Nonconformance Clients..........................................................................15 Standard Nonconformance Clients..................................................................................................15 Working with the Fast Barcode Interface.........................................................................................16 Allowing Operators to Auto Remove/Replace NC’s Components...................................................17 Typical Scenarios for the Standard Nonconformance Clients .........................................................17 Verifying Defects..............................................................................................................................19 Setting Up Incident Numbers...........................................................................................................20 Working with Graphical (PCA) Nonconformance Clients..............................................................21 Typical Scenarios for the Graphical (PCA) Nonconformance Clients .............................................24 PCA Dashboard Buttons..................................................................................................................26 Using DPMO (Defects per Million Opportunities)...........................................................................29 What Is DPMO? ...............................................................................................................................29 What Comes with the System?........................................................................................................29 Setting Up Nonconformance ............................................................................................................31 Setting Up Nonconformance............................................................................................................31 Creating Primary and Secondary NC Codes...................................................................................31 Setting Up and Overriding Maximum NC Limit................................................................................32 Setting Up the POD for Nonconformance........................................................................................32 Setting Up the Fast Barcode Interface for Operators ......................................................................33 Allowing Operators to Auto Remove/Replace NC’d Components...................................................33 Allowing Operators to Close Multiple Primary NCs with One Secondary NC .................................34 Setting Up Standalone Failure Tracking ..........................................................................................34 Setting Up DPMO ............................................................................................................................34 Appendix: Installing PCA Server......................................................................................................37 Index....................................................................................................................................................41

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

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

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

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

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

3 Setting Up Nonconformance 6 . SAP Manufacturing Execution 5.1.Collecting Information Note: Use the Root Cause Operation field only with DPMO.

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

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 .1.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.

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

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

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

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see the Setting Up Events guide and the online help for Event Maintenance and Real-Time Warnings Maintenance. The message to be stored and sent. For more information about setting up Events and real-time warnings. Define the parameters for consecutive identical nonconformance 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. When to clear messages from the Event Viewer. personnel can analyze and address the problem at the operation as quickly as possible. 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. shop floor personnel can also send event messages when others need notification with the Event Send Client.1. Associate an event type with a real-time warning. The set of people who will receive the messages through e-mail or real-time notification. In Real-Time Warnings Maintenance you: Define the parameters for yield processing real-time warnings. In addition. You set up real-time warnings in conjunction with the Events feature.3 Setting Up Nonconformance 13 . you define: Event types (classifications for occurrences that happen during production). SAP Manufacturing Execution 5. When you set up Events in the system.

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

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

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

Working with Standard Nonconformance Clients Scenario B Scenario B illustrates the case when you have a separate TEST operation but you combine the ANALYZE and REPAIR steps into one operation. This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes.1.3 Setting Up Nonconformance 18 . * (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. NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5.

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

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

3 Setting Up Nonconformance 21 .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. The PCA Dashboard allows operators who test. The following illustration shows the PCA Dashboard: The graphical (PCA) nonconformance clients that come with the system are: PCA_TEST PCA_INSPECTION PCA_ANALYSIS SAP Manufacturing Execution 5.a3p files for those boards. 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. This allows you to incorporate engineering changes quickly. You can provide this with the PCA Dashboard POD. For more information. To allow the operators to use the PCA Dashboard you need to install the PCA server.1. analyze. GenCAM or .

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

Operators can use IPASS and FPASS.1. PCA_COMBINED Use for operators who recommend corrective actions and repair boards at the same location: Operators can log only secondary NC codes (defects and repairs).3 Setting Up Nonconformance 23 . The PCA Dashboard displays the Verified Defects chart above 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 does not display verified defects. The Failure Data area displays NC codes. and Ref Des’s. Failure IDs. 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 enter comments in the Comments tab. Operators can enter comments in the Comments tab. Operators can use FPASS. The Failure Data area displays NC codes. Operators can log only secondary NC codes (repairs). and Ref Des’s. Failure IDs.

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. and REPAIR. Scenario A Scenario A illustrates the case when you use three separate operations for TEST.1. ANALYZE. 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 .

1.3 Setting Up Nonconformance 25 . PCA workstation with PCA_INSPECTION Operation TEST-ANALYZEREPAIR Pass Operation SAP Manufacturing Execution 5. 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 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. ANALYZE.

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

Note: Enabled only in Repair or Combined mode. See the section on routers in Setting Up Production Lines. Note: The system removes scrapped SFCs from the WIP database when they are archived. Used most often when a repair operator has retested an SFC and verified the defect. SENDEVENT SY550 SAP Manufacturing Execution 5. you must use the FPASS variable in scripts in Router Maintenance. Displays the Event Send Client.Working with Graphical (PCA) Nonconformance Clients Button FPASS Description Forced pass. Operators can use the Event Send Client to create and send event notification messages. SCRAP Scraps the SFC(s). Note: To correctly route an FPASS. POD Button Activity Not associated. You must set up work instruction before users can view them. Completes the SFC and sends it to the next operation instead of back to the test operation. WI500 Not associated.1.3 Setting Up Nonconformance 27 . WORKINSTRUCTION Allows the operator to view work instructions.

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focused on printed board assembly manufacturing.000. see the online help for NC Code Maintenance and NC Group Maintenance. Note: The system installs DPMO codes and categories only if. SAP Manufacturing Execution 5. 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. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard. Commonly used with quality systems such as Six Sigma.000.1. To ensure this.3 Setting Up Nonconformance 29 .Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. DPMO helps you measure defects so you can reduce them.000. Combined with the system’s nonconformance capabilities. This screen asks whether to install additional NC codes associated with the IPC 9261 specification.000. 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. your installer selects Yes in the Application Server NC codes for DPMO screen. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system: Assembly Component Placement Termination For a list of these codes and their categories. Calculating DPMO Assigning DPMO categories to NC codes in NC Code Maintenance determines how the system calculates DPMO for that NC code. during installation. What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO.

Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation. and the number of opportunities defined for the item that have the possibility of being defective. You identify which category the system uses to calculate DPMO for the item.1. the operator has to choose the operation.000. The operations you define appear in the Root Cause Operation browser when an operator clicks on the Root Cause Op field’s browse button in the PCA Dashboard and/or the Nonconformance activities. the operation is selected automatically. Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item. SAP Manufacturing Execution 5.000.000. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. If multiple root cause operations are available. If only one root cause operation is available. 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 operation at which defects for the item can be assigned.Using DPMO (Defects per Million Opportunities) Placement – The number of placement defects divided by the number of placement opportunities multiplied by 1.000. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1. Applicable for only those processes. where components are placed.3 Setting Up Nonconformance 30 .

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

Select the NC code for which you want to override the Maximum NC Limit and click the details icon in the corresponding row. 4. select NC Code from the Type drop-down list. 5. In Default Value Maintenance. 2.3 Setting Up Nonconformance 32 . Retrieve the primary code you want to associate the secondary with. Note: If you do not want to create a hierarchy. In the SFC field. in NC Code Maintenance 1. in System Rule Maintenance make sure there are values for the mail server and the mail source address. identify the SFC for which you want to override the maximum NC limit and click Retrieve. 2. To override the maximum NC limit when NC code exceeds this value: 1.Setting Up Nonconformance To create a secondary NC Code. Click Save. If you are using the PCA Dashboard: In Item Maintenance. Note: Because Event Types are most often connected to nonconformance. and move the secondary’s name to the Valid Secondaries list on the Secondaries tab. change the current value to a greater one and click OK. See online help for the Drawing Name field on the Main tab for information about how to enter the path and file name for the CAD file on the D2B server. Result: The system displays the table containing a record for NC Code logged against this SFC. Result: The system opens the NC Code Details window. 3. enter information about the drawing in the Drawing Name field. 3.1. enter the value of the D2B server. Result: The system closes the window and returns to the Nonconformance Limit Override window. 3. In Nonconformance Limit Override. you can leave the Can Be Primary Code check box cleared when you create NC codes. 2. In the Maximum NC Limit field. Change the maximum NC limit to the desired value other than 0. browse for NC_Code in the Parent Table Name field and click Retrieve. Setting Up the POD for Nonconformance To set up the POD for Nonconformance: 1. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. In System Rule Maintenance or NC Client Maintenance. Click Save. Setting Up and Overriding Maximum NC Limit To restrict the number of times an NC code can be logged against the particular SFC: 1. Create or retrieve the NC code to be a secondary code. Note: You can also click the browse icon to select an SFC. You can use different D2B servers for some clients for load balancing. Ensure the Can Be Primary Code check box on the Main tab is cleared. SAP Manufacturing Execution 5.

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

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

If desired. The system writes the results in the DPMO report along with the Root Cause operation entered by the analysis operator. 3. 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. the NC data type is PCA. Results When an operator logs an NC against an SFC representing an item with information in the DPMO tab. SAP Manufacturing Execution 5. For example. the category appears in NC Group Maintenance.000.1. These DPMO NC groups come with the system. Specify the NC Data Type you created in the previous step. For the DPMO codes that come with the system. Therefore. the system performs the calculation specified by the DPMO category and writes the results in the DPMO report. Note: Once you assign DPMO categories to defect NC codes. revision A multiplied by 1.000. you can assign some or all NC codes in a DPMO category to an NC group of the same name. 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. In the DPMO tab of Item Maintenance. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category. The operation at which operators can log a defect NC code with a DPMO category.Setting Up Nonconformance Assign DPMO categories to NC codes. the system calculates the number of placement defects divided by the number of placement opportunities entered in Item Maintenance for PCBOARD. The system also sends this information to several DPMO-related ODS reports. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD. revision A.3 Setting Up Nonconformance 35 .

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

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

SAP Manufacturing Execution 5. 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. You will find the necessary value in the Server Code field: Once you receive the license key from the website by email.1.3 Setting Up Nonconformance 39 . Note: When running the PCA Viewer Server.Appendix: Installing PCA Server Choose the Register Now option and provide the required information. The standalone viewer will use your license key and the PCA Viewer called by the POD will not be able to run. Do this by selecting Start > Programs > Visiprise > GR Force D2B > Tools > License Manager. You will need the GRA3LM Server Code for your installation. make sure that you do not have an instance of the standalone D2B viewer running. This will activate your D2B viewer.

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7. 9 Fast Barcode Interface (FBI). 20 S Secondary NC codes. 7. 26 Nonconformance. 16. 31 setting up DPMO. 1 routers. 3 Routers. 33 graphical (PCA). 7. 30 specific items. 1 nonconformance. 16. 7. 3 I Incidents closing. 1 benefits. 32 M maximum NC limit. 9 R Repair. 33 Buttons PCA Dashboard. 30 O Operations. 10. 34 setting up the POD. 32 N NC codes categories. 9 Defects per million opportunities (DPMO).1.3 Setting Up Nonconformance 41 . 24 standard. 26 Primary NC codes. 9 Setting up DPMO. 3 setting up. 9 F Failure. 9 Repair loops. 33 H Hierarchy NC codes. 11 P PCA Dashboard. 31 Setting up Standalone Failure Tracking. 34 Setting up Nonconformance. 10 Closing NC codes. 32 Nonconformance clients Fast Barcode Interface. 19 SAP Manufacturing Execution 5. 17 C Closing incidents. 29 DPMO (defects per million opportunities). 9 closing. 16. 15 standard scenarios. 29 root cause. 21 buttons.Index B Barcodes and NCs. 9 V Verifying defects. 10 D Defect. 34 Setting up the POD for Nonconformance. 10 primary and secondary. 10 numbers. 21 graphical (PCA) scenarios.

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