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 NCs 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 NCd 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

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Introduction
The Nonconformance feature helps you improve product quality and customer responsiveness by allowing you to: Track failure, defect, and repair information about SFCs. Control the routing of nonconforming products. With Nonconformance, you can also: Collect test and inspection data for analysis, integrity checking, and other uses. Assign incident numbers to logged nonconformances. Calculate defects with the standardized DPMO (defects per million opportunities) methodology as defined in the IPC-9261 standard for printed board assembly manufacturing. Display up-to-date engineering schematics graphically in the PCA Dashboard, allowing you to display engineering changes in real time.

What Is Nonconformance?
At various steps on your routers, you can include operations where product is tested for defects. When a product fails a test, the operator or machine at that step nonconforms, or logs a nonconformance (NC) against that particular SFC. Note: You can indicate not only test failures, but also nonconformance to any standard, such as a scratch on a chassis. When an operator logs an NC, the system can automatically send the nonconformed SFC to: The first step on a disposition router. A disposition function. Another step on the current router for analysis or repair. Operators at these steps can log additional NCs against the SFC to detail its current condition. You can also have operators or machines log NCs to pull products randomly for sampling.

Decisions to Make
When you set up Nonconformance, you must decide: How you want router branching and dispositioning to behave in the system. What information you want to collect for analysis, integrity checking, and other uses when operators log nonconformances. Which nonconformance (NC) codes you want operators to use when they log NCs, and how you want to organize them. How you will use Real-Time Warnings.

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

Introduction How you want the POD to behave and appear for operators who log nonconformances. How you want the PCA Dashboard in the POD to behave and appear for operators who work with nonconformances against PCA boards. How you will use DPMO.

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

Branching and Dispositioning on Routers

When you set up Nonconformance, you must decide how you want router branching and dispositioning to behave. When an operator logs an NC against an SFC at a router step, you can: Allow the operator to determine where the system should send the SFC. Allow the system to automatically determine where to send the SFC. For more information about branching and dispositioning, see the Setting Up Production Lines guide.

Operator Determination
If you allow the operator to determine where the system should send the SFC, the system displays a list of choices the operator can select from. These choices can include: A next step on the same router. The first step on a separate router. A SCRAP step. A Return step. Keeping the SFC at the current step.

System Determination
If you allow the system to automatically determine where to send the SFC, you can: Use scripting to send the SFC to a SCRAP step, a Return step, a next step on the same router, or other location, based on criteria, such as how many times the SFC has failed the test. 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, or allow the operator to choose from a menu of several destinations.

More Information About Routers

For more information about setting up routers and scripting, see the Setting Up Production Lines guide and the online help for Router Maintenance.

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

Collecting Information
The NC category in Data Type Maintenance allows you to collect information for analysis, integrity checking, and other uses when operators log nonconformances.

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, such as assembly, disassembly, inventory receipt, nonconformance, packing, or working with RMAs. You define data types in Data Type Maintenance.

Assigning NC Data Types

When you create NC codes, you must assign an NC data type to each code. The system comes with several NC data types to which fields have already been allocated. You can add or delete fields to the existing NC data type. Note: If you do not want to collect data at nonconformance operations, leave the default value, SIMPLE, in the NC Data Type field in NC Code Maintenance. The SIMPLE data type displays no fields to the operator by default. The following list is a sampling of fields you can have the system display in the POD for each type. For a complete list, in Data Type Maintenance, select NC in the Category field, browse on the Data Type field, and retrieve the record. Click Edit > Insert New, and browse in the Data Field column of the new row. 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. When the operator logs a nonconformance, the system displays the field(s) you specified based on the data type of the NC code. The operator enters the information you want to collect in each field. You can make each field required or optional for the operator.

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

Collecting Information Note: Use the Root Cause Operation field only with DPMO.

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

Defining Nonconformance (NC) Codes

What Is an NC Code?
An NC, or nonconformance, code is set of characters that indicates the state of an SFC with respect to a nonconformance. An NC code can indicate: That something is wrong with an SFC. For example, the NC code FAIL indicates that an SFC failed a test. A diagnosis of the problem. For example, the NC code WIRE DAMAGE indicates that a wire is damaged on the SFC. The NC code CON NOT SOLDER indicates an unsoldered connection. That the problem with an SFC has been or will be repaired. For example, the NC codes DONE, LATER, and ANOP indicate that the repair is complete, will be done later, or will be done by another operator. Operators and machines log NCs against SFCs by assigning a nonconformance (NC) code to the SFC. NC codes can indicate: Test or inspection failure (failure), what the problem is (defect), or how it was fixed (repair). The level of the nonconformance and its relationship to other codes in the hierarchy. You create the NC codes for your site in NC Code Maintenance. If you have a large number of NC codes, you can create groups for them in NC Group Maintenance. Note: In System Rule Maintenance, if you set the Nonconformance > Use NC Groups for Production Clients rule to true, you must assign all NC codes to a group before operators can use them to log NCs.

Categorizing NC Codes
When you create an NC code in NC Code Maintenance, 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. Defect: Indicates what is wrong with the SFC, and possibly how to fix it. Repair: Indicates how the defect on the SFC has been repaired. In the previous example, the NC code FAIL has the category Failure, WIRE DAMAGE and CON NOT SOLDER have the category Defect, and DONE, LATER, and ANOP have the category Repair. If needed for your shop floor, you can also create a hierarchy among NC codes to show their relationships to each other. If you do not create a hierarchy for your NC codes, all three categories of NC codes will have a flat relationship to each other:
Failure Defect Repair

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

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 5.1.3 Setting Up Nonconformance

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. You base the place of an NC code in the hierarchy on its category and the level of granularity you want. A two- or three-level NC hierarchy is most typical when you use the PCA Dashboard. 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, associated with the Defect code)

For example, the following illustration shows a three-level hierarchy with two sets of NC codes logged against the primary NC, NO_POWER. The first unit failed because of a short and was rewired. The second unit failed because of incorrectly connected cables and was re-cabled.

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, click Actions > Tree View in NC Code Maintenance.

Primary and Secondary NC Codes

You create an NC hierarchy by creating primary and secondary NC codes in NC Code Maintenance.

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.

SAP Manufacturing Execution 5.1.3 Setting Up Nonconformance

Defining Nonconformance (NC) Codes

What is a Secondary NC Code?

A secondary NC code is an NC code you create in NC Code Maintenance that: Is at any level other than the top level of a hierarchy. For information about creating primary and secondary NC codes, see the Creating Primary and Secondary NC Codes topic in the Setting Up Nonconformance section of this guide.

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. When an NC code exceeds this limit you may optionally override this value. For more information, see the Setting Up Nonconformance section of this guide.

Closing NC Codes
When an operator logs an NC against one or more SFCs, for many NC codes that come with the system, the NC is open. Depending on the nonconformance client they are using and how the NC code is set up, operators can close both individual NC codes that have been logged and entire incidents. You can also have the system automatically close a primary NC as soon as an operator logs it. 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. This operator is often performing a REPAIR operation. To require an operator with authority, such as a supervisor, to close an incident. This is often done when the unit is expensive to build, for example at a PMR station. The NC_TRACKING nonconformance client allows operators to close nonconformances and incidents manually.

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. Any secondary codes logged under a primary will be considered part of the same non-conformance incident. Closure Required Defines the NC code to require additional action to close. If cleared, the system will close the NC code automatically after being logged. Auto Close Primary NC Defines the NC code to close its parent NC code when the current NC is closed. 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. Secondary Required for Close Defines the NC code to require a secondary code to be logged against it to close. When selected, the system will not allow the NC code to be closed from the Edit tab of the NC client.

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Defining Nonconformance (NC) Codes Note: You can also allow operators to manually log NCs against a closed NC in NC Client Maintenance. The following table shows the check boxes you would typically select for the PCA Dashboard with a three-level hierarchy: Category Failure Defect Repair Check boxes to select Can Be Primary Code and Closure Required Closure Required and Auto Close Primary NC Auto Close Primary NC or Auto Close Incident

When the Can Be Primary Code check box is cleared, this NC code can only be a secondary NC code (if the primary/secondary NC hierarchy is set up). When the Closure Required check box is cleared, the system automatically closes the nonconformance as soon as the operator logs it. When the Auto Close Incident check box is selected, the system closes all defects logged against the failure if none of them has the Secondary Required for Closure check box selected. If at least one of the defects (in the same incident) has the Secondary Required for Closure check box selected, the system will close the defect against which the Repair code has been logged. The incident and other defects will stay open.

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. For example, some operators may need to log the same repair code, such as REPLACED against several primary NC codes indicating test failure, in order to record that the same action was taken to fix several failures. Users can also log one secondary NC code against multiple primary NC codes without closing them. For more information, see the Setting Up Nonconformance section of this guide.

Assigning Operations
If you want to prevent operators from logging NC codes at all operations, you can assign your NC codes to those operations in the Operation/Disposition Group tab in NC Code Maintenance. You can also specify the disposition group associated with the operation. For more information about disposition groups, see the Routers section of the Setting Up Production Lines guide. By default, the system allows NC codes to be logged at all operations.

Setting Up Activity Hooks

You can set up NC code-specific activity hooks that execute custom code when operators log NCs. For more information, see the Setting Up Activity Hooks guide.

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, see online help for Logging an NC Reject.

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Working with Real-Time Warnings

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

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Working with Standard Nonconformance Clients

The system allows you to set up the POD various ways for different types of operators who nonconform SFCs. For example, you may want one POD for operators who log nonconformances at TEST operations, another for operators who log them at ANALYZE operations, and another for operators who log them at REPAIR operations. You can create different PODs in POD Maintenance. In POD Maintenance, you control how operators can log nonconformances by assigning a nonconformance client to a particular POD. You create nonconformance clients in NC Client Maintenance. In List Maintenance, you can also create or change the Nonconformance lists that appear in the Failure Data area of the POD when operators log NCs. Note: For more information about PODs and Nonconformance lists, see the Setting Up PODs guide.

Standard Nonconformance Clients

Although you can create nonconformance clients in NC Client Maintenance, there are several nonconformance clients that come with the system. You can use these nonconformance clients for many typical scenarios. The nonconformance clients that come with the system fall into two categories: Standard nonconformance clients. Graphical (PCA) nonconformance clients. 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. If these PODs meet your needs, you do not need to create new nonconformance clients or PODs. 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, retrieve the nonconformance client you want in NC Client Maintenance and review its setting.

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Working with Standard Nonconformance Clients

Nonconformance client NC_LOG

Description Designed for operators who log only primary NC codes. Operators cannot edit the information associated with NC codes. Designed for operators who log both primary and secondary NC codes. Operators cannot edit the information associated with NC codes. Designed for operators who log both primary and secondary NC codes. Operators can also edit the information associated with NC codes. They can close an open NC, open a closed NC, and cancel any NC. Designed for operators who log only primary NC codes and work with scanners.

Standard POD * (default), 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, the Fast Barcode Interface (FBI) allows users to input information quickly. In addition FBI allows the operator to enter more than one reference designator for a component while logging a primary NC code. The Fast Barcode Interface is configured with: The LOG_NC_FBI nonconformance client. The Log NC FBI with Multi RefDes (NC515) activity. For information about setting up the Fast Barcode Interface, see the Setting Up Nonconformance section near the end of this guide.

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

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Working with Standard Nonconformance Clients

Allowing Operators to Auto Remove/Replace NCs 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 a dialog box asking the user whether he or she wants to remove the component. If the operator chooses to remove the component, the system displays the Remove Component window. When the user clicks OK in this window, 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, the system displays the Add Component window. For information about setting up this feature, see the Setting Up Nonconformance section near the end of this guide.

Typical Scenarios for the Standard Nonconformance Clients

The following illustration shows three scenarios for the standard nonconformance clients at different steps on the router. Use the nonconformance clients and workstations that mirror how you handle defects on your routers. For more information about workstations, see Setting Up PODs guide.

Scenario A
Scenario A illustrates the case when you use three separate operations for TEST, ANALYZE, and REPAIR.
* (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)

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Working with Standard Nonconformance Clients

Scenario B
Scenario B illustrates the case when you have a separate TEST operation but you combine the ANALYZE and REPAIR steps into one operation.
* (default) or PASS_FAIL workstation (uses NC_LOG)

Operation
Fail

TEST

Pass

Operation

ANALYZE-REPAIR
DIAGNOSIS workstation (uses NC_TRACKING)

Scenario C
Scenario C illustrates the case when you combine the TEST and ANALYZE steps into one operation and have a separate REPAIR operation. This scenario can mirror a two-level hierarchy with defects as primary codes and repairs as secondary codes.

NC_LOG_W_SECONDARY workstation

Operation

TEST-ANALYZE
Fail

Pass

Operation

REPAIR
DIAGNOSIS workstation (uses NC_TRACKING)

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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. As operators troubleshoot problems with units (SFCs) in a repair loop on your router, they may log many failure, defect, repair cycles that do not fix the problem. For example, during the first cycle through a repair loop, operators may log the following NC codes:
NO_POWER (Failure)

Operation
Fail

TEST

Operation

ANALYZE
SHORT (Defect)

REPAIR
REWIRE (Repair)

However, when the unit is retested, it still fails. The SFC is then sent through the repair loop again, 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. The system logs the NO_POWER, CABLECONWRONG (Defect), and RECONNECT (Repair) sequence as the verified 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 assign incident numbers to incidents for tracking purposes. When a unit that has previously failed a test passes it, the last defect and repair logged against the unit indicates what was actually wrong with the unit and how it was repaired. This last defect and repair is then verified to be the actual case and is called the verified defect. Some nonconformance clients that come with the system display a Verified Defects chart to the operator in the POD. In NC Client Maintenance, you can create a nonconformance client that displays the Verified Defects chart.

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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, and including one or more NC codes.

What Is an Incident Number?

An incident number uniquely identifies a nonconformance incident. The incident number is the same for all SFCs associated with the incident and for all primary and secondary NC codes associated with these SFCs. Using incident numbers, you can group or organize nonconformances to help identify problem areas in your production process. If you use incident numbers, they appear in the Log NC report.

Creating Incident Numbers

When you create nonconformance clients in NC Client Maintenance, you can allow operators to enter incident numbers by selecting Manual in the Incident Number field on the Main tab. If you select Manual, the operator must enter an incident number in the POD when he or she logs an NC with a primary NC code. If you select Automatic in the Incident Number field, the system automatically generates the incident number based on the numbering pattern you define with the Incident Number Number Type in Next Number Maintenance. For more information about defining numbering patterns, see the online help for Next Number Maintenance. Note: If operators enter incident numbers manually, the system verifies that the number matches the numbering pattern defined in Next Number Maintenance. Primary and Secondary NC Codes When an operator logs an NC against an SFC in a nonconformance client that uses incident number, the system automatically assigns the same incident number to all associated secondary NC codes. Incident Numbers and Archiving It is possible for one incident number to span multiple SFCs and multiple nonconformances of the same SFC. It is also possible for one SFC to include multiple incident numbers. When you archive SFCs, the system archives both the SFC and its assigned incident number at the same time. However, if the incident number is assigned to another SFC, then the system archives only the SFC.

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Working with Graphical (PCA) Nonconformance Clients

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

The graphical (PCA) nonconformance clients that come with the system are: PCA_TEST PCA_INSPECTION PCA_ANALYSIS

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

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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 log only secondary NC codes (repairs). The Failure Data area displays NC codes, Failure IDs, and Ref Dess. Operators can use FPASS. Operators can enter comments in the Comments tab. The PCA Dashboard does not display verified defects. 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). The Failure Data area displays NC codes, Failure IDs, and Ref Dess. Operators can use IPASS and FPASS. The PCA Dashboard displays the Verified Defects chart above the Comments tab. Operators can enter comments in the Comments tab. 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)

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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.

Scenario A
Scenario A illustrates the case when you use three separate operations for TEST, ANALYZE, and REPAIR.
PCA workstation

Operation
Fail

TEST

Pass

Operation

ANALYZE
PCA workstation with PCA_ANALYSIS

REPAIR
PCA workstation with PCA_REPAIR

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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.
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, ANALYZE, and REPAIR steps at one location.

PCA workstation with PCA_INSPECTION

Operation

TEST-ANALYZEREPAIR

Pass

Operation

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

SFCACT SIGNOFF COMP D2B

TR700 PR520 Not associated. Not associated.

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

SENDEVENT

SY550

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Using DPMO (Defects per Million Opportunities)

What Is DPMO?
DPMO (defects per million opportunities) is a standardized quality measurement that calculates defect levels. Commonly used with quality systems such as Six Sigma, DPMO helps you measure defects so you can reduce them. Combined with the systems nonconformance capabilities, DPMO can provide feedback and track defects seen at inspection and test to the appropriate root cause operation. The system supports the standardized DPMO methodology as defined in the IPC-9261 standard, focused on printed board assembly manufacturing.

What Comes with the System?

The system comes with about a hundred NC codes you can use for DPMO. 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, see the online help for NC Code Maintenance and NC Group Maintenance. Note: The system installs DPMO codes and categories only if, during installation, your installer selects Yes in the Application Server NC codes for DPMO screen. This screen asks whether to install additional NC codes associated with the IPC 9261 specification. To ensure this, 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.

Calculating DPMO
Assigning DPMO categories to NC codes in NC Code Maintenance determines how the system calculates DPMO for that NC code. 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 1,000,000. Component Component DPMO is the number of component defects divided by the number of component opportunities multiplied by 1,000,000.

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Using DPMO (Defects per Million Opportunities) Placement The number of placement defects divided by the number of placement opportunities multiplied by 1,000,000. Applicable for only those processes, where components are placed. Termination Termination DPMO is the number of termination defects divided by the number of termination opportunities multiplied by 1,000,000.

Defining DPMO for Specific Items

You use Item Maintenance to control how DPMO is defined for an item. You identify which category the system uses to calculate DPMO for the item, the operation at which defects for the item can be assigned, and the number of opportunities defined for the item that have the possibility of being defective. The operations you define appear in the Root Cause Operation browser when an operator clicks on the Root Cause Op fields browse button in the PCA Dashboard and/or the Nonconformance activities.

Defining the Root Cause Operation

You use Data Type Maintenance to determine whether the DPMO root cause operation is defined during the nonconformance process. You must select one of the following in the Root Cause Operation field: Optional Displays the Root Cause Op field in the nonconformance activity so that the operator can optionally choose the root cause operation. Required Displays the Root Cause Op field in the nonconformance activity so that the operator can choose the root cause operation. If only one root cause operation is available, the operation is selected automatically. If multiple root cause operations are available, the operator has to choose the operation.

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

Creating Primary and Secondary NC Codes

To create a primary NC Code, in NC Code Maintenance 1. Create or retrieve the NC code to be a primary code. 2. Select the Can Be Primary Code check box on the Main tab. 3. Move the secondary NC codes you want on the next level to the Valid Secondaries list on the Secondaries tab.

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Setting Up Nonconformance To create a secondary NC Code, in NC Code Maintenance 1. Create or retrieve the NC code to be a secondary code. 2. Ensure the Can Be Primary Code check box on the Main tab is cleared. 3. Retrieve the primary code you want to associate the secondary with, and move the secondarys name to the Valid Secondaries list on the Secondaries tab. Note: If you do not want to create a hierarchy, you can leave the Can Be Primary Code check box cleared when you create NC codes.

Setting Up and Overriding Maximum NC Limit

To restrict the number of times an NC code can be logged against the particular SFC: 1. In Default Value Maintenance, browse for NC_Code in the Parent Table Name field and click Retrieve. 2. Change the maximum NC limit to the desired value other than 0. 3. Click Save. To override the maximum NC limit when NC code exceeds this value: 1. In Nonconformance Limit Override, select NC Code from the Type drop-down list. 2. In the SFC field, identify the SFC for which you want to override the maximum NC limit and click Retrieve. Result: The system displays the table containing a record for NC Code logged against this SFC. Note: You can also click the browse icon to select an SFC. 3. Select the NC code for which you want to override the Maximum NC Limit and click the details icon in the corresponding row. Result: The system opens the NC Code Details window. 4. In the Maximum NC Limit field, change the current value to a greater one and click OK. Result: The system closes the window and returns to the Nonconformance Limit Override window. Note: You can repeat steps 3-4 to change the Maximum NC Limit for additional NC codes. 5. Click Save.

Setting Up the POD for Nonconformance

To set up the POD for Nonconformance: 1. If you are using the PCA Dashboard: In Item Maintenance, enter information about the drawing in the Drawing Name field. 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. In System Rule Maintenance or NC Client Maintenance, enter the value of the D2B server. You can use different D2B servers for some clients for load balancing. Note: Because Event Types are most often connected to nonconformance, in System Rule Maintenance make sure there are values for the mail server and the mail source address.

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Setting Up Nonconformance 2. If the nonconformance clients that come with the system do not meet your needs, create new ones in NC Client Maintenance. Also create any nonconformance lists you need in List Maintenance. Note: You can retrieve an existing nonconformance client to use as a template and save it under another name. 3. In POD Maintenance, enter the client you want for this POD in the NC Client field on the Main tab. On the Buttons tab, create a row for the nonconformance button and associate it with the nc500 POD button activity. 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. Note: If any PCA Dashboard users are to use Analysis or Repair mode, ensure a System Administrator has set the FailureHistoryExtract.bat file to run in a scheduler and that the file has been run at least once. Running this batch file is necessary to display the Verified Defects chart in the PCA Dashboard in Repair mode. 4. If desired, enter a nonconformance client in the NC Client field in Operation Maintenance. This value overrides the value in POD Maintenance.

Setting Up the Fast Barcode Interface for Operators

To set up the Fast Barcode Interface: 1. In POD Maintenance: On the Buttons tab, create a button associated with Log NC with Multi RefDes (NC515). On the Main tab, enter LOG_NC_FBI in the NC Client field. 2. Give the operators you want to use the Fast Barcode Interface access to this POD. For more information, see Determining Operator User Groups and Controlling How Users Open the POD in the Setting Up PODs guide.

Allowing Operators to Auto Remove/Replace NCd Components

To allow operators to auto remove/replace NCd components: 1. 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. Specify the disposition router where you want the system to send the removed component in the Component Disposition Router field. 2. On the Advanced Log NC tab in NC Client Maintenance, select None in the As-Built Link Location field. Note: The As-Built link is not necessary for operators using this feature. 3. In NC Code Maintenance, 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).

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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. In NC Code Maintenance, define the primary NC and select the Secondary Required for Close check box on the Main tab. 2. In NC Client Maintenance, 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. Select the Show Select NC Batch Button check box. 3. On the Main tab in POD Maintenance, retrieve the POD(s) you will use for these operators and enter the nonconformance client in the previous step in the NC Client field. 4. Give the operators you want to allow to close multiple primary NCs with one secondary NC access to this POD. For more information, see Determining Operator User Groups and Controlling How Users Open the POD in the Setting Up PODs guide.

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. To set up Standalone Failure Tracking: 1. In Activity Maintenance, enter NC 540 (Standalone Failure Tracking) in the Activity field. 2. On the Main tab, ensure that Enabled and Visible in Activity Manager check boxes are selected. 3. On the Rules tab: Define NC client as an activity rule. This NC Client must exist as having been defined in NC Client Maintenance. Define the Operation option and set it to true or false. Define the Resource option and set it to true or false. Click Save.

Setting Up DPMO
Note: The system comes with about a hundred NC codes you can use for DPMO. Each of these codes is already assigned a DPMO category and to one of the DPMO-related NC groups that come with the system. To set up DPMO: 1. Create an NC data type in Data Type Maintenance that includes the Root Cause Operation field set to either Optional or Required. Operators must enter the root cause operation when they use DPMO-related NC codes. The root cause operation is the upstream failure operation in the repair loop, and thereby indicates the root cause of the problem. 2. If you need to create additional NC codes to use in conjunction with DPMO, in NC Code Maintenance:

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Setting Up Nonconformance Assign DPMO categories to NC codes. You can assign a DPMO category only to an NC code of category Defect. Specify the NC Data Type you created in the previous step. For the DPMO codes that come with the system, the NC data type is PCA. Note: Once you assign DPMO categories to defect NC codes, the category appears in NC Group Maintenance. If desired, you can assign some or all NC codes in a DPMO category to an NC group of the same name. These DPMO NC groups come with the system. 3. In the DPMO tab of Item Maintenance, identify: Which category the system uses to calculate DPMO for the item. The operation at which operators can log a defect NC code with a DPMO category. The number of opportunities on this item that has the possibility of being defective. For example, a particular PC board may have 200 areas in its circuitry where it could fail.

Results
When an operator logs an NC against an SFC representing an item with information in the DPMO tab, the system performs the calculation specified by the DPMO category and writes the results in the DPMO report. The system also sends this information to several DPMO-related ODS reports. Example Scenario An analysis operator logs the PARTMISALIGNED NC code to SFC ABC123 that represents PCBOARD, revision A. The PARTMISALIGNED NC code is assigned the PLACEMENT DPMO category. Therefore, the system calculates the number of placement defects divided by the number of placement opportunities entered in Item Maintenance for PCBOARD, revision A multiplied by 1,000,000. The system writes the results in the DPMO report along with the Root Cause operation entered by the analysis operator.

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Appendix: Installing PCA Server

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

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Appendix: Installing PCA Server Step 8. Action The Choose Destination Location dialog box appears. Use this screen to specify the location on the hard drive where the GR Force/D2B program files will be located. The default program folder, c:\GenRad\GR Force D2B, is displayed. 9. Click the Browse button to select an alternate folder. The Choose Folder dialog box appears. Navigate to the drive and directory in which you want to install the SAP Manufacturing Execution files, such as: C:\Visiprise\GR Force D2B When you are finished, click OK to return to the Choose Destination Location dialog box. 10. Click Next. The installation program displays the Select Program Folder dialog box. The default program folder, GenRad\GR Force D2B, is displayed in the Program Folders field. Enter Visiprise\GR Force D2B. Click Next. 11. The installation program displays the Start Copying Files dialog box. Review the settings, then click Next to start copying files. The D2B install starts and displays the Setup Status of the installation. 12. At the completion of the installation, the InstallShield Wizard Complete message appears. Click Finish. 13. After a few moments, the PCA Server has finished selecting Components dialog box appears. Click Next. 14. The Setup Complete message appears. Select the option you want for restarting your computer and click Finish to complete the installation. If you select No, you must restart your computer later. 15. 16. Refer to the System Administration Guide for instructions on obtaining and installing a license. Start the server by selecting Start > Programs > Visiprise > VisipriseMfg > PCA Server > Start PCA Server.

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, you do not need a separate license. Refer to the following procedure only after working with your PSO representative to determine if you need a D2B license. After installing the D2B viewer, you may obtain a license key by accessing http://www.teradyne.com/test-design/design-to-build/viewer.html.

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

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Index
B
Barcodes and NCs, 16, 33 Buttons PCA Dashboard, 26 Nonconformance, 1 benefits, 1 nonconformance, 1 routers, 3 setting up, 31 setting up DPMO, 34 setting up the POD, 32 Nonconformance clients Fast Barcode Interface, 16, 33 graphical (PCA), 21 graphical (PCA) scenarios, 24 standard, 15 standard scenarios, 17

C
Closing incidents, 10 Closing NC codes, 10

D
Defect, 7, 9 Defects per million opportunities (DPMO), 29 DPMO (defects per million opportunities), 29 root cause, 30 specific items, 30

O
Operations, 11

P
PCA Dashboard, 21 buttons, 26 Primary NC codes, 9

F
Failure, 7, 9 Fast Barcode Interface (FBI), 16, 33

H
Hierarchy NC codes, 9

R
Repair, 7, 9 Repair loops, 3 Routers, 3

I
Incidents closing, 10 numbers, 20

S
Secondary NC codes, 9 Setting up DPMO, 34 Setting up Nonconformance, 31 Setting up Standalone Failure Tracking, 34 Setting up the POD for Nonconformance, 32

M
maximum NC limit, 10, 32

N
NC codes categories, 7, 9 closing, 10 primary and secondary, 9

V
Verifying defects, 19

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