Batch classification and Recurring inspection

 Batch classification : Every inspection lot that is created for a batch-managed material will have a batch assigned to it. Batch classification ensures that the inspection results from the inspection lot are updated into the batch characteristics. Batch classification is a cross-module functionality in SAP and is used across multiple modules such as QM, MM, PP, and EWM. In SAP QM, batch classification is required to transfer inspection results to the batch. For this to work, batch classification must be activated in the material master.

Here the focus is to update the results of the lot automatically into the batch after result recording completion without any human intervention.

Prerequisites required to update results in batch master:

1. Material master with necessary inspection setup and batch management must be active - MM01/MM02

2. Create characteristics - CT04

3. Create a class - CL01

4. Assign characteristics to class

5. Assign this class to the material master "Classification" view.

5. Create MIC and the MIC should be linked to this characteristics - QS21

6. Create a sampling procedure - QDV1

7. Create inspection plan and assign the material and plant to the inspection plan

8. Create inspection lot and assign the inspection plan

9. Perform results and UD

10. Check the batch master if the results are updated

1. Go to MM02 if there is any material that is created already and check if all the mandatory settings are maintained. If not maintain it.

Inspection setup is active

Classification view is present in the material

Batch management is active

2. Go to CT04 to create characteristics. I want to create a characteristics to measure the length of a bottle. And the value should be between 5 cm to 15 cm and the target value should be 10 cm. Hence I have maintained data type as Numeric and UoM as cm and intervals allowed.

In the values tab, I have entered the intervals

We can also restrict this char to be used only in batch class. Save after adding all the details.

3. Go to CL01 to create a class and assign this char to the class. Enter basic data

Assign the char created to the class and save the class

4. Go to MM02 and assign this class to the material

5. Create MIC using QS21 tcode and assign this characteristics to the MIC.

Maintain control indicators, Upper specific limit, lower specific limit, target values and other necessary details and save

Next go to QS23 to add the characteristics that was created to MIC and save.

6. Create a sampling procedure if necessary and if there is already one, then that can be used. Go to QP01 to create an inspection plan and assign MIC and sampling procedure to the plan.

Enter MIC and sampling procedure to the inspection plan and save

7. Create an inspection lot and assign this inspection plan to the material.

Inspection plan is assigned and sample is calculated

Perform result recording to the lot and save

Perform UD to the lot

Go to MSC3N to check if the result is transferred to the batch

 

Quality Certificate

To meet quality standards and to comply with regulations, it is mandatory for some products to be accompanied by a quality certificate containing details specific to the batch. To create a quality certificate, first we need to create a certificate profile in the system. To do that go to tcode QC01.

Enter the certificate profile name and choose the certificate type and press enter. In this example, I will be choosing E21. Certificate type is also one of the fields in QM material master view. While performing GR, it is necessary to confirm whether the certificate is enclosed or not

Add SAPscript Form Name as QM_QCERT_01. If there is any requirement to create certificates for Accepted lots only then click on the checkbox. Enter inspection lot origin and inspection type for which the certificate has to be created. 

Next click on Characteristics overview

Enter the serial number, in the characteristic category either choose MIC or class characteristics.

Enter plant and MIC that has to be printed in the certificate. All other details will be popped up after pressing enter. If needed they can be changed as per business requirements.

We can also assign materials for which this profile can be used.

After adding all the details, release profile and save.

Next go to tcode QC15 and assign profile to material/customer combination or material or material group.

Enter material or materials and check valid on date. Click on execute.

Enter the profile name, version and certificate type and press save

Next go to QC21. Enter the inspection lot number for which UD has to be performed.

Next when you click on execute, this pop up appears. Choose the recipient.

This is how the certificate looks.

Quality Inspection after Production

 When a product is manufactured in-house, the finished goods must be moved from the shop floor to the warehouse. To achieve this, a Goods Receipt (GR) must be performed for the production order. Once the GR is posted, the stock will be linked to an inspection lot that is automatically created. For this process, the 04 inspection type (GR inspection for production order) must be activated in the Quality Management (QM) view of the material master.

Process flow:

Setup required : Activation of 04 inspection type in the material master QM view

1. Create a production order using tcode CO01

2. Once the production order is created, perform GR for the order.

3. Once the GR is performed, material document will be posted and inspection lot will be created and the stock will move to QI

4. Inspect the lot and based on the UD, the stock will move from QI

Quality Inspection at regular intervals

Quantity-Based Inspection: When the system triggers an inspection after a certain quantity of material has been produced, received, or moved, instead of at fixed time intervals.

Pre-requisites : 

Changes in Routing header: Assign Insp. Points to the routing header. In this case select 150.

Sampling Procedure : Inspection Points has to be selected. Here the is no free Insp points so I have selected Others

Routing Operations : For the routing operation where MIC and sampling procedure is assigned, in this case operation 0030, double click on that and under Quality Management : Inspection Points, select QTY-RELATED and enter QUANTITY INTERVAL and UOM.

Once the necessary settings are done, create a production order and release, an inspection lot will be created. To process the inspection lot go to QA32/QE51N to enter the results.

Since the quantity interval is maintained as 20 and the inspection lot quantity is 100, result recording has to be done 5 times, but the UD will be done only once.

While performing UD, there will not be any stock posting, instead the inspection points will be displayed.

After all the results are recorded, then the UD will be made for the inspection lot.

Time-Based Inspection: If there is a requirement to inspect a quantity at regular intervals, the system allows this to be scheduled automatically.

Pre-requisites required : For the routing operation where MIC and sampling procedure is assigned, in this case operation 0030, double click on that and under Quality Management : Inspection Points, select Time related and enter time and UoM and select QUANTITY CONFIRMATION FOR EACH PARTIAL LOT.

When this is selected, delete all the other entries as shown below

If there is a need for random inspection and not based on any parameters like time or quantity then select NO REFERENCE and delete all other entries

Quality Inspection during Production

 There are two types of inspection process in production:

• In-process inspection : When the product is being manufactured but the manufacturing process is not completed, then in process inspection is performed. For that 03 inspection type has to be activated in the material master.
• Inspection at the end of production : Before releasing the product to the market, inspection takes place in order to check if the quality standards are met.

Business scenario : Create an inspection lot of type 03 and process the lot. 

 

QM setup required

Material master with inspection type 03 activated

MIC to measure the characteristics of bottle size

Sampling procedure to calculate sample and decide whether the sample passes or fails the inspection

PP setup required

Material master with required MRP setup

BOM

Work center

Routing

Production Version

Process order creation and release to create an inspection lot

Material master setup:

Inspection type 03 is activated which is in-process inspection for production order. Here post to inspection stock field is missing as the inspection takes place when the production is in process and hence no stock will be associated.

MIC:

Sampling procedure : 

Material master MRP setup:

Production version:

BOM:

Work center:

 

Routing : 

Here the requirement is to inspect the bottle after cooling process. Hence the MIC and sampling procedure will be assigned to this operation i.e. 0030. 

Production order creation and release : 

Inspection lot processing:

While performing UD, the below message appears as the production of this product is yet to complete

 

In the UD screen, there is no provision to perform stock posting as there is no stock associated