SAP Manufacturing Execution 5.1.

3
Setting Up Nonconformance
Including PCA Dashboard and DPMO

© Copyright 2008 SAP AG. All rights reserved. No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice. Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors. Microsoft, Windows, Outlook, and PowerPoint are registered trademarks of Microsoft Corporation. IBM, DB2, DB2 Universal Database, OS/2, Parallel Sysplex, MVS/ESA, AIX, S/390, AS/400, OS/390, OS/400, iSeries, pSeries, xSeries, zSeries, z/OS, AFP, Intelligent Miner, WebSphere, Netfinity, Tivoli, Informix, i5/OS, POWER, POWER5, OpenPower and PowerPC are trademarks or registered trademarks of IBM Corporation. Adobe, the Adobe logo, Acrobat, PostScript, and Reader are either trademarks or registered trademarks of Adobe Systems Incorporated in the United States and/or other countries. Oracle is a registered trademark of Oracle Corporation. UNIX, X/Open, OSF/1, and Motif are registered trademarks of the Open Group. Citrix, ICA, Program Neighborhood, MetaFrame, WinFrame, VideoFrame, and MultiWin are trademarks or registered trademarks of Citrix Systems, Inc. HTML, XML, XHTML and W3C are trademarks or registered trademarks of W3C®, World Wide Web Consortium, Massachusetts Institute of Technology. Java is a registered trademark of Sun Microsystems, Inc.

JavaScript is a registered trademark of Sun Microsystems, Inc., used under license for technology invented and implemented by Netscape. MaxDB is a trademark of MySQL AB, Sweden. SAP, R/3, mySAP, mySAP.com, xApps, xApp, SAP NetWeaver, and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and in several other countries all over the world. All other product and service names mentioned are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary. These materials are subject to change without notice. These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty. Disclaimer Some components of this product are based on Java™. Any code change in these components may cause unpredictable and severe malfunctions and is therefore expressively prohibited, as is any decompilation of these components. Any Java™ Source Code delivered with this product is only to be used by SAP’s Support Services and may not be modified or altered in any way.

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

iii

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

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

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

.

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

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

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

Defining Nonconformance (NC) Codes Creating a Hierarchy An NC code hierarchy shows the relationship among the NC codes that operators have logged in the system. The system displays this hierarchy graphically in the Failure Data area of the nonconformance client in the POD: SAP Manufacturing Execution 5.3 Setting Up Nonconformance 8 .1.

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

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

For more information about disposition groups. Users can also log one secondary NC code against multiple primary NC codes without closing them.1. For more information. If at least one of the defects (in the same incident) has the Secondary Required for Closure check box selected. When the Closure Required check box is cleared. For example. SAP Manufacturing Execution 5. Assigning Operations If you want to prevent operators from logging NC codes at all operations. The incident and other defects will stay open. see the Setting Up Activity Hooks guide. 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 online help for Logging an NC Reject. the system automatically closes the nonconformance as soon as the operator logs it. For more information. see the Routers section of the Setting Up Production Lines guide.3 Setting Up Nonconformance 11 . 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. in order to record that the same action was taken to fix several failures. such as REPLACED against several primary NC codes indicating test failure. 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. see the “Setting Up Nonconformance” section of this guide. you can assign your NC codes to those operations in the Operation/Disposition Group tab in NC Code Maintenance. 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. When the Auto Close Incident check box is selected. some operators may need to log the same repair code. For more information. Setting Up Activity Hooks You can set up NC code-specific activity hooks that execute custom code when operators log NCs. By default. You can also specify the disposition group associated with the operation. 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.Defining Nonconformance (NC) Codes Note: You can also allow operators to manually log NCs against a closed NC in NC Client Maintenance.

.

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

.

You create nonconformance clients in NC Client Maintenance. Graphical (PCA) nonconformance clients. Standard Nonconformance Clients Although you can create nonconformance clients in NC Client Maintenance. you do not need to create new nonconformance clients or PODs. The nonconformance clients that come with the system fall into two categories: Standard nonconformance clients. retrieve the nonconformance client you want in NC Client Maintenance and review its setting. In POD Maintenance. You can use these nonconformance clients for many typical scenarios. and another for operators who log them at REPAIR 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. Note: For more information about PODs and Nonconformance lists. there are several nonconformance clients that come with the system. you control how operators can log nonconformances by assigning a nonconformance client to a particular POD. If these PODs meet your needs. 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. In List Maintenance.1. You can create different PODs in POD Maintenance. SAP Manufacturing Execution 5.3 Setting Up Nonconformance 15 . another for operators who log them at ANALYZE operations. The following table describes the standard nonconformance clients and how they relate to the standard PODs that come with the system: Note: For all details. The standard nonconformance clients that come with the system are: LOG_NC LOG_NC_W_SECONDARY NC_TRACKING LOG_NC_W_FBI Nonconformance Client Features and PODs Some nonconformance clients that come with the system are associated with the standard PODs that come with the system. you may want one POD for operators who log nonconformances at TEST operations.

Operators can also edit the information associated with NC codes. PASS_FAIL None NC_LOG_W_SECONDARY NC_TRACKING DIAGNOSIS LOG_NC_FBI None Working with the Fast Barcode Interface Designed for operators who log only primary NC codes and work with scanners. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. open a closed NC. Standard POD * (default). see the “Setting Up Nonconformance” section near the end of this guide. and cancel any NC. Designed for operators who log both primary and secondary NC codes. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client.3 Setting Up Nonconformance 16 . The Log NC FBI with Multi RefDes (NC515) activity. For information about setting up the Fast Barcode Interface. Operators cannot edit the information associated with NC codes. Designed for operators who log both primary and secondary NC codes. Designed for operators who log only primary NC codes and work with scanners. the Fast Barcode Interface (FBI) allows users to input information quickly. Operators cannot edit the information associated with NC codes.1. They can close an open NC.Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. Hotkeys for the Fast Barcode Interface The following table lists the hotkeys mapped to the buttons in the Fast Barcode Interface: Hotkey ALT+B ALT+D ALT+E ALT+U ALT+M ALT+L ALT+R ALT+W Button Add Add and Done/Done Cancel (exit plug-in) Update Remove Cancel (cancel update mode) NC Report Work Instruction SAP Manufacturing Execution 5.

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

NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5. This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes.3 Setting Up Nonconformance 18 .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. * (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.1.

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

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

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

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

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 use IPASS and FPASS. Operators can enter comments in the Comments tab. and Ref Des’s. Operators can enter comments in the Comments tab. Failure IDs.1.3 Setting Up Nonconformance 23 . Operators can log only secondary NC codes (repairs). Failure IDs. The PCA Dashboard does not display verified defects. The Failure Data area displays NC codes. 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 Failure Data area displays NC codes. PCA (after changing the NC Client field on the Main tab to PCA_COMBINED) Standard POD PCA (after changing the NC Client field on the Main tab to PCA_REPAIR) SAP Manufacturing Execution 5. Operators can use FPASS.

1.Working with Graphical (PCA) Nonconformance Clients Typical Scenarios for the Graphical (PCA) Nonconformance Clients The following illustration shows three typical scenarios using the graphical (PCA) nonconformance clients at different steps on the router. and REPAIR. ANALYZE.3 Setting Up Nonconformance 24 . PCA workstation Operation Fail TEST Pass Operation ANALYZE PCA workstation with PCA_ANALYSIS REPAIR PCA workstation with PCA_REPAIR SAP Manufacturing Execution 5. Scenario A Scenario A illustrates the case when you use three separate operations for TEST.

and REPAIR steps at one location.3 Setting Up Nonconformance 25 . 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. PCA workstation with PCA_INSPECTION Operation TEST-ANALYZEREPAIR Pass Operation SAP Manufacturing Execution 5.Working with Graphical (PCA) Nonconformance Clients Scenario B Scenario B illustrates the case when you have a separate TEST operation but you combine the ANALYZE and REPAIR steps into one operation.1.

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

WORKINSTRUCTION Allows the operator to view work instructions.Working with Graphical (PCA) Nonconformance Clients Button FPASS Description Forced pass.1. You must set up work instruction before users can view them. See the section on routers in Setting Up Production Lines. Completes the SFC and sends it to the next operation instead of back to the test operation. Note: Enabled only in Repair or Combined mode. Operators can use the Event Send Client to create and send event notification messages. POD Button Activity Not associated. Note: The system removes scrapped SFCs from the WIP database when they are archived. Displays the Event Send Client. SCRAP Scraps the SFC(s). you must use the FPASS variable in scripts in Router Maintenance. Note: To correctly route an FPASS. Used most often when a repair operator has retested an SFC and verified the defect. SENDEVENT SY550 SAP Manufacturing Execution 5.3 Setting Up Nonconformance 27 . WI500 Not associated.

.

DPMO helps you measure defects so you can reduce them. use the browse in NC Code Maintenance and NC Group Maintenance to check whether the DPMO codes and categories listed in the online help appear.000.000.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. SAP Manufacturing Execution 5. Commonly used with quality systems such as Six Sigma. What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO.000.000. This screen asks whether to install additional NC codes associated with the IPC 9261 specification.3 Setting Up Nonconformance 29 . Combined with the system’s nonconformance capabilities. your installer selects Yes in the Application Server NC codes for DPMO screen. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. during installation. 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. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system: Assembly Component Placement Termination For a list of these codes and their categories. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1.1. Calculating DPMO Assigning DPMO categories to NC codes in NC Code Maintenance determines how the system calculates DPMO for that NC code. focused on printed board assembly manufacturing. Note: The system installs DPMO codes and categories only if. see the online help for NC Code Maintenance and NC Group Maintenance. To ensure this.

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

Set up the POD for Nonconformance. do the following: Group and create NC codes.Setting Up Nonconformance Setting Up Nonconformance To set up Nonconformance: 1. As needed. Set up activity hooks for NC codes. define the parameters and default values of NC codes. in NC Code Maintenance 1. or Repair. Create any custom fields you require. set up DPMO. In the NC category in Data Type Maintenance. assign NC data types to NC codes. Select the Can Be Primary Code check box on the Main tab. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab. assign DPMO categories to NC codes. If desired. Defect. create the data types you want to associate with NC codes and select the predefined fields you want to appear in the POD. set up Standalone Failure Tracking. in Router Maintenance: Create repair loops. Write scripts to automatically send nonconformed SFCs to a next step based on criteria. Create disposition routers and/or set up function-based dispositioning. 5. 3. 2. 3.3 Setting Up Nonconformance 31 . Categorize each NC code as a Failure. If desired. In NC Code Maintenance and NC Group Maintenance. 6. Create primary and secondary NC codes according to the NC hierarchy you want to use on your floor. Creating Primary and Secondary NC Codes To create a primary NC Code. 7. 8. If you want to use DPMO. change any NC-related rule as needed for your shop floor. If desired. set up the Fast Barcode Interface and how operators can close NC codes. In System Rule Maintenance. If desired. In NC Code table of Default Value Maintenance. SAP Manufacturing Execution 5.1. 4. 2. Create or retrieve the NC code to be a primary code.

Note: If you do not want to create a hierarchy. Setting Up the POD for Nonconformance To set up the POD for Nonconformance: 1.3 Setting Up Nonconformance 32 . 2. SAP Manufacturing Execution 5.1. Result: The system closes the window and returns to the Nonconformance Limit Override window. Retrieve the primary code you want to associate the secondary with. Result: The system opens the NC Code Details window. If you are using the PCA Dashboard: In Item Maintenance. 5. in System Rule Maintenance make sure there are values for the mail server and the mail source address. in NC Code Maintenance 1. In System Rule Maintenance or NC Client Maintenance. 4. You can use different D2B servers for some clients for load balancing. 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. browse for NC_Code in the Parent Table Name field and click Retrieve. enter the value of the D2B server. enter information about the drawing in the Drawing Name field. Ensure the Can Be Primary Code check box on the Main tab is cleared. identify the SFC for which you want to override the maximum NC limit and click Retrieve. you can leave the Can Be Primary Code check box cleared when you create NC codes. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. 3. Setting Up and Overriding Maximum NC Limit To restrict the number of times an NC code can be logged against the particular SFC: 1. Note: Because Event Types are most often connected to nonconformance. In the Maximum NC Limit field. select NC Code from the Type drop-down list. 2. Select the NC code for which you want to override the Maximum NC Limit and click the details icon in the corresponding row. 3. In the SFC field. Click Save. To override the maximum NC limit when NC code exceeds this value: 1. Click Save. 3. Result: The system displays the table containing a record for NC Code logged against this SFC. change the current value to a greater one and click OK. Note: You can also click the browse icon to select an SFC. In Nonconformance Limit Override. Create or retrieve the NC code to be a secondary code. 2. In Default Value Maintenance. Change the maximum NC limit to the desired value other than 0. and move the secondary’s name to the Valid Secondaries list on the Secondaries tab.Setting Up Nonconformance To create a secondary NC Code.

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

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

the category appears in NC Group Maintenance. For the DPMO codes that come with the system. Therefore. revision A multiplied by 1.1. In the DPMO tab of Item Maintenance. SAP Manufacturing Execution 5.Setting Up Nonconformance Assign DPMO categories to NC codes. Specify the NC Data Type you created in the previous step. The operation at which operators can log a defect NC code with a DPMO category. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD.000.3 Setting Up Nonconformance 35 . identify: Which category the system uses to calculate DPMO for the item. you can assign some or all NC codes in a DPMO category to an NC group of the same name. For example.000. If desired. revision A. a particular PC board may have 200 areas in its circuitry where it could fail. 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. Results When an operator logs an NC against an SFC representing an item with information in the DPMO tab. The number of opportunities on this item that has the possibility of being defective. Note: Once you assign DPMO categories to defect NC codes. These DPMO NC groups come with the system. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category. The system writes the results in the DPMO report along with the Root Cause operation entered by the analysis operator. the system performs the calculation specified by the DPMO category and writes the results in the DPMO report. 3. the NC data type is PCA. You can assign a DPMO category only to an NC code of category Defect.

.

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

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

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

.

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