Manage Test Equipment Calibration Processes With SAP Plant Maintenance and Quality Management
Manage Test Equipment Calibration Processes With SAP Plant Maintenance and Quality Management
Manage Test Equipment Calibration Processes With SAP Plant Maintenance and Quality Management
Learn how to manage the calibration processes for a plant’s test equipment using the Plant
Maintenance (PM) and Quality Management (QM) functionalities with options available in the SAP
system. In particular, find out how to manage your calibration activities to complete business
transactions using master data from integrated modules and configuration done based on a
company’s business processes and strategies using standard options available in the SAP
system.
Key Concept
In a company, the test equipment (i.e., measurement tools) should be checked regularly. Planning and
execution are performed using a maintenance plan that automatically generates an inspection lot. In the
SAP Quality Management (QM) component, the measurement readings for the characteristics Length
and Diameter of a test probe pin are entered for this inspection lot. A test probe pin is a physical device
used to connect electronic test equipment to a device under test (DUT). Usually these devices are used in
case of electronic test requirements. If measurement readings lie outside of the tolerances, for example,
and adjustment is necessary, the status of the gauge is changed accordingly and a malfunction report is
generated with the appropriate error code. The integration of Plant Maintenance (PM) and QM is divided
into two areas: test equipment management (calibration inspection) and enhanced measurement
reading entry.
To ensure that specified performance criteria are always met, the test equipment being used must be
regularly checked and calibrated. You can use the functions of test equipment management to perform
the following actions:
Manage equipment
Plan and schedule inspections
Execute orders and inspection lots for processing calibration inspections on equipment
The business transactional flow for the calibration activities is managed mainly by the Plant Maintenance
(PM) and Quality Management (QM) modules, as shown in Figure 1.
Figure 1
Main activities related to calibration services in SAP QM and PM
The business activities that are shown in the system are outlined in Table 1.
Work center: The task list usage is important here so that the
relevant test equipment can be used in maintenance-specific task Display PM Notification
lists.
Create an MIC
The QM department can create an MIC by using transaction code QS21 or by following menu path SAP
Menu > Logistics > Quality Management > Quality Planning > Basic Data > Inspection Characteristic >
Create. This path takes you to the screen in Figure 3. For my example, you use an already existing
characteristic as shown in the screen in Figure 3.
Figure 3
MIC ZERO (General Data View)
To create an MIC, enter the following information:
Click the Quant. (quantitative) data button in Figure 3 and the system shows the screen in Figure 4.
Here, for your characteristic, you can define the following main options: Decimal places, unit of measure,
lower and upper limits, Target value, and lower and upper plausibility limits. In Figure 3, the MIC is ZERO
because in this example it is the name for the characteristic to define zero point deviation during the
equipment test procedures.
Figure 4
MIC ZERO (Quantitative Data)
Click the Control indicators option in Figure 3 and the system shows the screen in Figure 5.
Figure 5
MIC ZERO (Control Indicators) details
In this screen, you can specify the following details:
Lower specif. limit: If set, you must enter a lower specification limit for the inspection
characteristic.
Upper specif. limit: If set, you must enter an upper specification limit for the inspection
characteristic.
Sampling procedure: If set, a sampling procedure must be assigned to the characteristic in the
task list.
Required char. (characteristic): If set, the inspection characteristic must be inspected, which leads
to the fact that a UD can only be posted if you have confirmed the inspection results for this
inspection characteristic.
Classed recording: If set, the inspection results for the inspection characteristic are recorded as
classed values.
Defects recording: If set, an inspection characteristic is rejected. During results recording, the
function for recording defects for a characteristic is automatically called up and a recording
procedure can either be initialized by the user or performed in the background.
Click the continue icon in Figure 5 and the system shows the screen in Figure 6.
Figure 6
MIC ZERO (Control indicators) additional details
In this screen, you can specify the following details:
Fixed scope: If set, the number of inspected units must correspond to the precalculated number
of units to be inspected for results recording.
Test-equi assignment: If this indicator is set, you can assign test equipment to the inspection
characteristic in the task list.
Docu. if rejected: If set, additional text has to be entered in case the characteristic has been
rejected during the results recording.
RR change docs (create change documents during results recording): If set, change documents
are created for this inspection characteristic when results are recorded based on characteristics.
Record measured vals: If set, measured values for this quantitative characteristic have to be
inspected and confirmed.
Print: If set, the inspection characteristic is printed on the inspection instruction.
Click the Catalogs option in Figure 3 and the system shows the screen in Figure 7.
Figure 7
MIC ZERO (Assign defect codes to catalogs)
In this screen, you can specify the defaulted defect codes for rejection.
If you click the Catalog button in Figure 7, the system lists the defect codes, as shown in Figure 8.
Figure 8
Display possible values for defects of measuring instruments
In Figure 9, you can find the details of the General Data screen related to the characteristic FULL. FULL
is the name of the characteristic to define full-scale deviation during the equipment test procedures.
Figure 9
MIC FULL (General Data)
In Figure 10, you can view the details of the Quantitative Data screen related to the characteristic FULL.
Figure 10
MIC FULL (Quantitative Data)
In Figure 11, you can view the details of the first screen for the Control Indicators Data related to the
characteristic FULL.
Figure 11
MIC FULL (Control Indicators) first screen
In Figure 12, you can find the details of the second screen for the Control Indicators Data related to the
characteristic FULL.
Figure 12
MIC FULL (Control Indicators) second screen
In Figure 13, you can find the details of the assigned inspection catalogs codes related to the
characteristic FULL.
Figure 13
MIC FULL (assign a defect code for rejection)
Figure 16
Operation details for the task list
In Figure 16, you can define or check the relevant operation details, such as control key, duration, unit of
measures, and activity type. Then, to save the data, click the save icon .
Figure 17
Create a maintenance plan
No reference object is required. The order type is responsible for generating the inspection lot (an
inspection type for the order type is created in Customizing). The order type must be configured so that
the order generated is released immediately.
In the Maint. plan cat. (maintenance plan category) field in Figure 17, select Maintenance Order from the
options and then press Enter. The system then displays the screen in the Figure 18.
Figure 18
Specify details for a maintenance plan (single-cycle plan)
Specify details in the following fields in Figure 18:
Cycle/Unit
Planning plant
Order Type: Enter PM06 for calibration
Main WorkCtr (work center)
Priority
Maint. (maintenance) Planner Group
MaintActivity Type (maintenance activity type)
Business Area
In the Task List section, enter the data that you entered in Figure 15. After you press Enter the system
opens the screen shown in Figure 19 in which you can select the Yes radio button and enter a date to
specify the cycle start date. Click the enter icon (the green check mark) to save the record.
Figure 19
Enter a start date for the maintenance plan
Transactional Data
I now walk you through the steps for main transactional data listed in Table 1.
Figure 22
Display the inspection lot (data for the lot origin)
Select the line item and then click the choose object’s details icon to display the inspection point data,
as shown in the pop-up screen in Figure 23.
Figure 24
Enter and save record results for the inspection lot
Note: Upon the saving of the rejection, the system automatically creates PM notifications.
Record the UD
You can record the UD either by using transaction code QA11 or by following menu path Logistics >
Quality Management > Quality Inspection > Inspection Lot > Usage Decision > Record. The screen
in Figure 25 then appears.
Figure 25
Record the UD (enter the UD code)
The inspection lot last processed appears by default (or enter the inspection lot number). Choose the
relevant code in the UD code field (for example, A for usable) and save. Note that when you save the UD,
the window for changing the status of objects and the cycle modification factor appears.
One response to the valuation of equipment 10003541 could be, for example, a reduction of the cycle
modification factor, which results in the maintenance cycle being shortened. A malfunction report
(category MQ) was generated with two items (zero point error and end of scale error) and corresponding
error codes. (I discuss the malfunction report for category MG in the next section.) Measurement
documents were still generated for all the measurement readings.
Note that after you save the UD, the system displays the details of the status change for objects or
equipment, as shown in the Figure 26. You can also view these details by using transaction code IE03
and verifying that the status of the equipment has been updated to NPRT PRT, which is not ready for
use.
Figure 26
Status change for objects or equipment
After you press Enter to save your data, the system shows the confirmation message shown in Figure 27.
Figure 27
Confirmation message that the UD was saved
Display PM Notifications
Usually, you can display the PM notifications either by using transaction code IWS3 or by following menu
path Logistics > Plant Maintenance > Maintenance Processing > Notification > Display.
In my example, however, use transaction code QA13 and in the initial screen (not shown) enter the
Inspection Lot document number and press Enter. The system opens the screen shown in the Figure 28.
Figure 28
Trigger a display notification
Click the Defects tab and select the item you want to consider to trigger the notification display. Click the
Display Notification button, as shown in Figure 28. The system then displays the information as shown
in Figure 29. Note that the Notification Type is MQ - Error msg. from QM.
Figure 29
Display PM notification (item overview)
Personnel no.: The employee ID for the person who actually performed the work
Actual Work: The number of hours spent to complete the work
Reason: The reason for variance
Confirm. (Confirmation) text: Any reasonable text to justify the work done
Then, check that the rest of the defaulted entries are appropriate and save the data. The system displays
a confirmation message as shown in Figure 30.
Figure 31
Order is technically complete
In the menu bar in Figure 31 click the Order button and follow menu path Functions > Complete >
Complete (technically) and save the data. The status of the order is then updated to TECO – technically
completed.
Run Reports
All affected and authorized departments can display the details of the QM and PM documents related to
the calibration processes (for example, Quality Notification, Inspection Lot, and PM Orders) using the
information system reports available under the QM and PM modules.
These two menu paths can be used to retrieve transaction documents created in the QM and PM
modules:
In QM, follow Plant Maintenance > Information System > Report Selection > Information Systems
Information Systems system reports available under the QM Centers Capacity/Maintenance.
In PM, follow Processing/Maintenance Planning/Maintenance Task Lists Quality Management > Test
Equipment Management > Information System > Equipment/Maintenance/Calibration Inspection.
Customizing Activities
Now I describe the most important customizing activities that you need to check or complete to enable the
external processes.
Figure 32
Define a calibration order type
Figure 33
Assign the calibration order type to the inspection type
In Figure 33, you can see that the plant 1000 and calibration order type PM06 combination has been
assigned to inspection type 14 (inspection in PM).
Inspection Point
In QM Customizing, you need to define an inspection point of category Equipment or Functional location.
The inspection point is entered in the task list header. To complete this step, follow menu path Quality
Management > Quality Planning > Inspection Planning > General > Define Identifier for Inspection Points.
This path displays the screen shown in Figure 34. In the Fields tab populate the fields as shown
in Figure 34.
Figure 34
Display inspection point for equipment (fields)
Now click the Valuation tab (Figure 35) to maintain the following default values:
Follow-Up Actions
In QM Customizing, follow-up actions can be defined that can then be linked to the codes for UDs. If a
particular code is assigned when the UD is made, the assigned follow-up actions (for example, updating
measurement readings, status changes, and so on) are executed automatically. To complete this step,
follow menu path Tools > Customizing > IMG > Edit Project (SPRO) Pushbutton: SAP Reference IMG.
Quality Management > Define Follow-Up Actions. Then select in the pop-up screen (not shown) the
activity’s option Follow-Up Actions. This action opens the screen in Figure 38.
Figure 38
Define QM_PM follow-up actions
In Figure 38 select the line item and select the folder Function modules. The system opens the screen
in Figure 39. In this screen you can define the list of function modules that will be triggered upon the UD.
I now describe the follow-up actions for the three function modules shown in Figure 39:
Figure 39
Define function modules relevant to the QM_PM follow-up action
Figure 40
Display inspection type 14
For my example, I have used the standard Inspection Type 14 - Inspection in Plant Maintenance. This
inspection type is linked with the notification type MQ – Error msg. from QM.
Figure 42
Display the link between inspection type 14 and origin 14
Note that the entry listed in the Figure 42 should have already been created by the SAP system upon the
activation of the QM module. In my example, the entry you need to enable is 14 as origin of the Plant
Maintenance and 14 as inspection type.
With these entries, the system automatically creates an inspection lot upon the scheduling of a
maintenance plan.
Figure 43
Default values for inspection type 14
In the inspection lot, with inspection type 14, enable the usage of Inspect by task list, Record
characteristic results, and Automatic usage decision indicator. Leave the rest of the fields as defaulted. In
an SAP system, the data is always saved using the save icon.
02 as Notification origin. It defines the screen sequence control for a Notification Type.
1000_QM as Catalog profile. It restricts the list of values for the information contained in the
quality notification based on your business requirements.
26 as Update group statistics. It is used to determine the fields that will be created for the
statistics in the Logistics Information System (LIS).
Gaetano Altavilla
Dr. Gaetano Altavilla is a senior SAP practice manager. His focus is on pre-sales, delivery of SAP
application solutions for large international corporations, and SAP knowledge management in Europe, the
Middle East, and Africa (EMEA).
In his 18 years of SAP application experience working for many multinational companies, such as Procter
& Gamble and Hewlett-Packard, he has covered a wide range of ERP logistic areas, focusing on the MM,
WM, SD, LES, PP, PP-PI, PLM (QM, PM, PS) modules, as welll as CRM (TFM), SRM (EBP), SCM (SAP
APO), and MES (ME) components.
Dr. Altavilla holds a degree with first-class honors in mathematics from the University of Naples and is
certified in many SAP modules: SAP Logistics Bootcamp, SAP MM, SD, LE (SHP/WM/LE), PP, PLM (PM,
QM, PS), SRM, CRM, SCM (APO), SCM (TM), FI, CO, and Solution Manager. He also has experience in
ABAP/4 and application link enabling (ALE) and IDocs. He has participated in numerous industry
conferences, such as the SAP Skills Conference in Walldorf at SAP SE.
See more by this author
You may contact the author at Gaetano_altavilla@hotmail.com.
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