1、QPCP - QM control plan0 IntroductionControl Plan is used to perform inspection planning as per the ISO Standards ISO/TS16949.Control Plan is used in combination with Failure Modes and Effects Analysis. The combination of CP & FMEA plays vital role in integrated Inspection Planning for GR inspections
2、 & Inspections during Production.Abbreviations Used:TC Transaction CodeFMEA Failure Modes & Effects AnalysisCP Control PlanEWB Engineering Workbench.MIC Master Inspection CharacteristicsRequirementTo prevent defects at an early stage in Goods Receipt Inspections and Inspections during Production.Int
3、egration:Control Plan is integrated with the following components1.Failure Modes and Effects Analysis.2.Master Inspection Characteristics i.e. Process related Risk Characteristics.3.Task Lists & Inspection Plans.4.cProjects & Quality Notifications.ProcedureSteps to be followed in creating the Contro
4、l PlanCreation of control plan involves the following steps:Step 1: Create or Edit the Control plan. (TC QPCP)1.Control Plan is created from the following path:SAP Easy Access Logistics Quality Management Quality Planning Control Plan Cockpit2.Enter the Control Plan ID.3.Input the Control Plan type
5、i.e. Production or Prelaunch or Prototype.4.Click on the create icon to create the Control PlanSAP COMMUNITY NETWORK SDN - | BPX - | BOC - 2009 SAP AG 3Creation of Control Plan - Transfer of Characteristics from FMEA to Control PlanStep 2: Assign or Copy FMEA to the Control plan.1.Click on FMEA Tab.
6、2.Choose the FMEA column and assign the relevant FMEA in the Control Plan.3.The Traffic light statuses in the Control Plan indicates the completeness of the Transfer of Characteristics as well as Lower level FMEAs present both in FMEA as well as Control PlanStep 3: Transfer or copy of Critical Chara
7、cteristics from source into Control Plan.1.Transfer or Copy the critical characteristics from FMEA into the control plan.2.Establish the link between FMEA Characteristics & Master Inspection Characteristics of the corresponding Inspection plan or Task list that is assigned in the control plan.3.Edit
8、 the Task list or Inspection Plan operations by branching from the Control Plan through EWB.4.Click the Structure Tab to display Inspection Plans & Task lists that are applicable to the Control Plan.5.Select the Inspection Plan & choose copy characteristics in the Context menu of the Inspection Plan
9、.SAP COMMUNITY NETWORK SDN - | BPX - | BOC - 2009 SAP AG 4Creation of Control Plan - Transfer of Characteristics from FMEA to Control Plan6.Select the Characteristic origin as FMEA & click the Tab Load Characteristics.7.Choose the Critical characteristics to be transferred from the list display & cl
10、ick Choose Add characteristic to the Plan.8.The Characteristics that are transferred are displayed in the Inspection characteristics table.9.Check the copied Characteristics using Consistency check. SAP COMMUNITY NETWORK SDN - | BPX - | BOC - 2009 SAP AG 5Creation of Control Plan - Transfer of Chara
11、cteristics from FMEA to Control Plan10.Save the transferred characteristics & close.11.Click Back Icon to return to the Control Plan.Step 4: Consistency check and Release of the Control Plan.1.Click the Basic Data Tab page to perform Consistency check of the control plan.2.Consistency check under st
12、atus ensures the Transfer of Characteristics occurred successfully.3.Status with Green Traffic light indicates that the Control Plan is Consistent.4.Status with Yellow Traffic light indicates that the Control Plan is with Warnings; click Display Inspection Result to view the Logs.5.Status with Red T
13、raffic light indicates that the Control Plan is with Errors. This is because of Non transfer of Characteristics from FMEA to Control Plan. Click on Display Inspection Result to view Logs.6.Control plan is consistent means, corresponding task lists and inspection plans contain all characteristics fro
14、m an FMEA are assigned to the control plan.SAP COMMUNITY NETWORK SDN - | BPX - | BOC - 2009 SAP AG 6Creation of Control Plan - Transfer of Characteristics from FMEA to Control PlanStep 5: Print preview of the Control Plan structure with the Master Data selection1.Click on the Print Preview of the Co
15、ntrol Plan to view the CP structure with the Master data selection.2.The form that is used to display the control plan is in accordance with the international standards QS9000.SAP COMMUNITY NETWORK SDN - | BPX - | BOC - 2009 SAP AG 7Creation of Control Plan - Transfer of Characteristics from FMEA to
16、 Control PlanStep 6: Save the Control Plan1.Click on the save Icon to save the Control Plan Ensuring the Consistency check for the Control Plan is Successful.Video: 1 Operation stepsWork Steps1. Double Click on QM_FMEA - Cockpit2. Creation of Structure, Function and Defect NetworksClick on Create FM
17、EAUpdate the following required and optional fields:Field NameValuesFMEAXXXXXXXDescriptionXXXXXBasic data: FMEA TypeObject: Material PlnndStartDate Pld Fin82 System FMEA ProductXXXXXX1. 01.01.20122. 31.12.2012Result: Rating Procedures Rating Profile Minimum Result02 Medium Risk80 Calculation of Risk
18、 Priority Number(RPN)81 Rating: No Risk, Medium Risk, HighRisk80Status tab:StatusSet to Released3. Assign the Master Inspection CharacteristicsGive the Description for the Characteristic, characteristic type & weighting. Description of the Characteristic should be unique.Assign the Master Inspection
19、 Characteristic and plant which is a part of the FMEA. 4. Create Preventive and Detection ActionsCreate Preventive and Detection Actions with reference to the Defect. Give the Planned Start Date details.Ensure to confirm the Preventive and Detection Actions to update the valuations of Probability of
20、 Occurrence & Detection that are required for the Calculation of Risk Priority Number. 5. Assign FMEA to the Control PlanCreate Control Plan for FMEA.Assign FMEA in the FMEA Tab of Control Plan.Transfer of Data takes place from FMEA to Control Plan & vice versa. 6. Carry out Action & Risk Analysis b
21、y Evaluating the Defect Causes & ActionsFormula for calculating RPN = Severity X Probability of Occurrence X Probability ofA. Detection.Enter the Severity of Defect along with the Probability of Occurrence & Probability ofDetection Ratings.Click on the valuate Tab that triggers the Calculation of Ri
22、sk Priority Number for theA. Defects.Severity (8) X Probability of Occurrence (7) X Probability of Detection (9) = RPN(504)RPN value in the Defects screen of FMEA7. Print format of FMEA with Risk Priority Numbers for Defects8. Click Save 9. Click Exit button to leave the transaction2 SAP Documentati
23、onControl Plan (QM-PT-CP)This component provides functions that you can use to perform comprehensive inspection planning, as required according to the international standard, ISO/TS16949. It is used in combination with the Failure Mode and Effects Analysis (QM-PT-FA) component. The control plan (CP)
24、 and the FMEA play a central role in integrated inspection planning for goods receipt inspections and inspections during production.Both components allow you to prevent production defects at an early stage during product development, in particular for new developments. This reduces quality costs.A c
25、ontrol plan is implemented for the whole production process. The control plan provides the basis for creating the inspection plans and inspection operations during the subsequent production process.IntegrationThis component is integrated with the following components: Failure Mode and Effects Analys
26、is (QM-PT-FA):You can copy an FMEA, all of its lower-level FMEAs, and their determined product and process-related risk characteristics into a control plan. Task lists (PP-BD-RTG) and inspection plans in inspection planning (QM-PT-IP):The control plan ensures that the determined FMEA characteristics
27、 are also considered as inspection characteristics in the corresponding task lists and inspection plans. Object link from SAP Collaboration Projects (cProjects) to the control plan:You can link a project in cProjects to a control plan in SAP ERP.NoteYou can also enter your own project number to link
28、 a control plan to a project from another project management system.End of the note.For more information, see Assigning a Project Number in the Control Plan. Quality Notification (QM-QN)You can branch from a quality notification to the FMEA display or the control plan display.For more information, s
29、ee Accessing a Control Plan from a Quality Notification.FeaturesThis component supports the implementation of a control plan as part of APQP (Advanced Product Quality Planning). This is particularly required in the automobile industry. The production process is split into three phases: prototype, pr
30、elaunch and production You can create and edit individual control plans for inspections in these three phases.This component provides the following functions that you can use when working with a control plan:FunctionAdditional InformationControl plan functionsEdit the control planYou can create, cha
31、nge, display and simulate a control plan. You can also allocate different authorizations for processing a control plan.Status managementYou can display a system status and a user status.Copy FMEA to control planYou can assign one or more FMEA(s) to the control plan.Copy characteristicsYou can copy c
32、ritical characteristics from an FMEA or other source into the control plan. You use this function to decide which characteristics are to be copied to the corresponding task lists or inspection plans. You also decide at which stage in the process the characteristics are to be included to the inspecti
33、on.Perform a consistency checkYou use the consistency check to see whether the relevant task lists and inspection plans contain all of the assigned FMEA characteristics.Display change documents for the control planYou can display all changes made to a control plan.Display CP structure with master da
34、ta selectionAn overview of the relevant master data is displayed in the structure display.Display or change an objectYou can choose an object from the CP structure view (such as material, BOM or document). You can branch to change or edit mode for the object by using the context menu.Print a control
35、 plan in a formYou can print a control plan as a PDF-based print form, according to the international standard QS9000.Functions when working with the control plan (CP)Create task list or inspection planYou can create a task list or inspection plan for a control plan item or for processes.Change task
36、 list or inspection planYou can branch from the control plan into the change mode for a task list or inspection plan.Assign a project number in the control planYou can assign a cProjects project number to a control plan.Access a control plan or an FMEA from a quality notificationYou can access a con
37、trol plan or an FMEA from a quality notificationControl plan settingsYou can make settings in Customizing for Quality Management, by choosing Quality Planning Control Plan .Control PlanThe control plan (CP) describes how products and processes are monitored. It contains actions that are executed for
38、 each phase of the process. In addition, the requirements for goods entry and goods issue inspections, for process controls, and for recurring inspections and controls are stored in the control plan so that the process can be controlled.The Control Plan contains tasks for inspecting and monitoring p
39、roducts and processes during product development. These tasks cover goods receipt, goods issue, process requirements, and periodic requirements for the inspection and for monitoring.Together with the FMEA, the control plan provides an overview of the critical characteristics that are included in all
40、 relevant inspections for an end product. This also includes all product components contained in the end product.Control plans can be created with or without a material. They are used in three production phases. The following control plan types are provided for each phase. These are defined in Custo
41、mizing: Prototype Pre-launch ProductionStructureThe control plan comprises of a control plan header and a processing and display field that is operated via the tab page.Control plan screen areasControl plan headerThe control plan ID and the language is displayed in the control plan header.Tab pages
42、and processing or display fieldsThe following table gives an overview of the individual tab pages and the corresponding processing or display fields:TabProcessing or display fieldsBasic dataAll of the basic data defined for a control plan is visible at a glance, for example, short text, project numb
43、er, material and system status. You can select the data using the mouse, or you can open the input help and process it here.Long textYou can create a long text from the control plan to give more details.PartnersYou can choose business partners and their specific role for the control plan.StructureAl
44、l of the objects that belong to the control plan are displayed. You can expand the structure.The last level expanded can be a recursive object.NoteIn Customizing, you can use the structure type defined with the control plan type to define flexible assignment of various master data. The master data i
45、s linked using processes.End of the note.You can copy the characteristics from here.(Control plan items)A piece list is normally not available in the “Prototype” production phase. You can define control plan items for the product component and process these items, without having to set up material n
46、umbers.NoteYou must always assign process types to a control plan item. If this assignment is missing, the control plan item is process-dependent and is listed in the structure of all processes.End of the note.FMEAAn overview of all the FMEAs that are assigned to the control plan is displayed. Two s
47、tatus displays are available: A traffic light status shows whether the control plan contains all FMEA characteristics. A further traffic light status shows whether the lower-level FMEAs are referenced in the control plan.You can branch to the FMEA from the display field.Print previewIn the print preview, you can display and print the control plan as a PDF-based print form, according to the international standard QS9000.Integration
