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

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 .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.

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

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

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

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

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. The system displays this hierarchy graphically in the Failure Data area of the nonconformance client in the POD: SAP Manufacturing Execution 5.

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

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

the system automatically closes the nonconformance as soon as the operator logs it. For example. When the Closure Required check box is cleared. The following table shows the check boxes you would typically select for the PCA Dashboard with a three-level hierarchy: Category Failure Defect Repair Check boxes to select Can Be Primary Code and Closure Required Closure Required and Auto Close Primary NC Auto Close Primary NC or Auto Close Incident When the Can Be Primary Code check box is cleared. you can assign your NC codes to those operations in the Operation/Disposition Group tab in NC Code Maintenance. see the “Setting Up Nonconformance” section of this guide. By default. the system will close the defect against which the Repair code has been logged. see the Routers section of the Setting Up Production Lines guide. You can also specify the disposition group associated with the operation. When the Auto Close Incident check box is selected. SAP Manufacturing Execution 5.1. Assigning Operations If you want to prevent operators from logging NC codes at all operations. the system allows NC codes to be logged at all operations. see the Setting Up Activity Hooks guide. in order to record that the same action was taken to fix several failures. If at least one of the defects (in the same incident) has the Secondary Required for Closure check box selected. some operators may need to log the same repair code.Defining Nonconformance (NC) Codes Note: You can also allow operators to manually log NCs against a closed NC in NC Client Maintenance. Setting Up Activity Hooks You can set up NC code-specific activity hooks that execute custom code when operators log NCs. the system closes all defects logged against the failure if none of them has the Secondary Required for Closure check box selected. Allowing Users to Close Multiple Primary NCs with one Secondary NC You can set up nonconformance clients to allow users to close multiple primary NC codes with the same secondary NC code. Users can also log one secondary NC code against multiple primary NC codes without closing them. such as REPLACED against several primary NC codes indicating test failure. 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. For more information. For more information. this NC code can only be a secondary NC code (if the primary/secondary NC hierarchy is set up). For more information about disposition groups. For more information. see online help for Logging an NC Reject. The incident and other defects will stay open.3 Setting Up Nonconformance 11 .

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

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

Operators cannot edit the information associated with NC codes. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client.1. Designed for operators who log both primary and secondary NC codes. open a closed NC. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. and cancel any NC. Designed for operators who log both primary and secondary NC codes. Designed for operators who log only primary NC codes and work with scanners. Operators cannot edit the information associated with NC codes. The Log NC FBI with Multi RefDes (NC515) activity.3 Setting Up Nonconformance 16 .Working with Standard Nonconformance Clients Nonconformance client NC_LOG Description Designed for operators who log only primary NC codes. see the “Setting Up Nonconformance” section near the end of this guide. 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. For information about setting up the Fast Barcode Interface. Operators can also edit the information associated with NC codes. Standard POD * (default). the Fast Barcode Interface (FBI) allows users to input information quickly. 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. They can close an open NC.

the system displays a dialog box asking the user whether he or she wants to add a new component. If the operator chooses to add a new component. For more information about workstations.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. ANALYZE. Scenario A Scenario A illustrates the case when you use three separate operations for TEST. If the operator chooses to remove the component. Use the nonconformance clients and workstations that mirror how you handle defects on your routers. the system displays a dialog box asking the user whether he or she wants to remove the component. and REPAIR. see the “Setting Up Nonconformance” section near the end of this guide. For information about setting up this feature. see Setting Up PODs guide. the system displays the Add Component window. When the user clicks OK in this window.3 Setting Up Nonconformance 17 . * (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 5.1. Typical Scenarios for the Standard Nonconformance Clients The following illustration shows three scenarios for the standard nonconformance clients at different steps on the router.

NC_LOG_W_SECONDARY workstation Operation TEST-ANALYZE Fail Pass Operation REPAIR DIAGNOSIS workstation (uses NC_TRACKING) SAP Manufacturing Execution 5.3 Setting Up Nonconformance 18 .Working with Standard Nonconformance Clients Scenario B Scenario B illustrates the case when you have a separate TEST operation but you combine the ANALYZE and REPAIR steps into one operation.1. This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes. * (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.

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

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

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

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

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

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

3 Setting Up Nonconformance 25 . 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. 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.1. PCA workstation with PCA_INSPECTION Operation TEST-ANALYZEREPAIR Pass Operation SAP Manufacturing Execution 5.

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

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

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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. see the online help for NC Code Maintenance and NC Group Maintenance. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard. Component – Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1.000. Calculating DPMO Assigning DPMO categories to NC codes in NC Code Maintenance determines how the system calculates DPMO for that NC code.1. What Comes with the System? The system comes with about a hundred NC codes you can use for DPMO. SAP Manufacturing Execution 5. Note: The system installs DPMO codes and categories only if. Combined with the system’s nonconformance capabilities.Using DPMO (Defects per Million Opportunities) What Is DPMO? DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. This screen asks whether to install additional NC codes associated with the IPC 9261 specification.3 Setting Up Nonconformance 29 . your installer selects Yes in the Application Server NC codes for DPMO screen. The following DPMO categories come with the system and correspond to the names of the DPMO-related NC groups that come with the system: Assembly – Assembly DPMO is the number of assembly defects divided by the number of assembly opportunities (number of assemblies processed) multiplied by 1. focused on printed board assembly manufacturing. DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. 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.000. To ensure this. DPMO helps you measure defects so you can reduce them.000. Commonly used with quality systems such as Six Sigma. during installation.

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. You identify which category the system uses to calculate DPMO for the item.000. the operator has to choose the operation. where components are placed. Required – Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation.000. If multiple root cause operations are available. Applicable for only those processes. If only one root cause operation is available. Defining the Root Cause Operation You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. SAP Manufacturing Execution 5. You must select one of the following in the Root Cause Operation field: Optional – Displays the Root Cause Op field in the nonconformance activity so that the operator can optionally choose the root cause operation. 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 1.000.000.1. the operation is selected automatically. and the number of opportunities defined for the item that have the possibility of being defective. Termination – Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1.3 Setting Up Nonconformance 30 . Defining DPMO for Specific Items You use Item Maintenance to control how DPMO is defined for an item.

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

Note: Because Event Types are most often connected to nonconformance. identify the SFC for which you want to override the maximum NC limit and click Retrieve. Click Save. Ensure the Can Be Primary Code check box on the Main tab is cleared. 2. In the SFC field. In Default Value Maintenance. Result: The system closes the window and returns to the Nonconformance Limit Override window. you can leave the Can Be Primary Code check box cleared when you create NC codes. Create or retrieve the NC code to be a secondary code. In Nonconformance Limit Override. 3. Result: The system displays the table containing a record for NC Code logged against this SFC. In System Rule Maintenance or NC Client Maintenance. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. Note: If you do not want to create a hierarchy. enter information about the drawing in the Drawing Name field. in NC Code Maintenance 1. enter the value of the D2B server. SAP Manufacturing Execution 5. You can use different D2B servers for some clients for load balancing. 3. and move the secondary’s name to the Valid Secondaries list on the Secondaries tab. 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. 2. Setting Up and Overriding Maximum NC Limit To restrict the number of times an NC code can be logged against the particular SFC: 1. Select the NC code for which you want to override the Maximum NC Limit and click the details icon in the corresponding row. If you are using the PCA Dashboard: In Item Maintenance. Click Save. select NC Code from the Type drop-down list. Setting Up the POD for Nonconformance To set up the POD for Nonconformance: 1. 5. Retrieve the primary code you want to associate the secondary with. Change the maximum NC limit to the desired value other than 0.3 Setting Up Nonconformance 32 . 4. in System Rule Maintenance make sure there are values for the mail server and the mail source address. 2. browse for NC_Code in the Parent Table Name field and click Retrieve. Result: The system opens the NC Code Details window. In the Maximum NC Limit field. To override the maximum NC limit when NC code exceeds this value: 1. 3.Setting Up Nonconformance To create a secondary NC Code.1. Note: You can also click the browse icon to select an SFC. change the current value to a greater one and click OK.

create a row for the nonconformance button and associate it with the nc500 POD button activity. In NC Code Maintenance. see “Determining Operator User Groups” and “Controlling How Users Open the POD” in the Setting Up PODs guide. Note: You can retrieve an existing nonconformance client to use as a template and save it under another name. SAP Manufacturing Execution 5.Setting Up Nonconformance 2. 2. enter a nonconformance client in the NC Client field in Operation Maintenance. If desired. 3. Allowing Operators to Auto Remove/Replace NC’d Components To allow operators to auto remove/replace NC’d components: 1. ensure a System Administrator has set the FailureHistoryExtract. select None in the As-Built Link Location field. This value overrides the value in POD Maintenance. If the nonconformance clients that come with the system do not meet your needs. In POD Maintenance: On the Buttons tab. When an operator using this workstation clicks the nonconformance button. the system uses the settings in the nonconformance client to determine what to display to the user. 4. In POD Maintenance. On the Basic Log NC (FBI) and/or Advanced Log NC tab in NC Client Maintenance: Select the Auto Remove/Replace NC Components check box. 3.1. create a button associated with Log NC with Multi RefDes (NC515).3 Setting Up Nonconformance 33 . Also create any nonconformance lists you need in List Maintenance. Give the operators you want to use the Fast Barcode Interface access to this POD. On the Buttons tab. Note: The As-Built link is not necessary for operators using this feature. Running this batch file is necessary to display the Verified Defects chart in the PCA Dashboard in Repair mode. For more information. Note: If any PCA Dashboard users are to use Analysis or Repair mode. create new ones in NC Client Maintenance. Specify the disposition router where you want the system to send the removed component in the Component Disposition Router field. enter the client you want for this POD in the NC Client field on the Main tab. 2. On the Advanced Log NC tab in NC Client Maintenance. On the Main tab.bat file to run in a scheduler and that the file has been run at least once. enter LOG_NC_FBI in the NC Client field. Setting Up the Fast Barcode Interface for Operators To set up the Fast Barcode Interface: 1. 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).

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

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

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

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

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

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

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