FMEA and Control Plan creation SAP

[former_member364899]

How to create FMEA and Control plan in SAP ECC 6.0? We want to use this facility in our organisation. Pl help.

[former_member282682]

Prerequisite : ECC 6.0 with Ehp 3 (minimum)

Introduction

Control 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 & Inspections during Production.

Abbreviations Used:

•

TC    Transaction Code

•

FMEA    Failure Modes & Effects Analysis

•

CP    Control Plan

•

EWB    Engineering Workbench.

•

MIC    Master Inspection Characteristics

Requirement

To prevent defects at an early stage in Goods Receipt Inspections and Inspections during Production.

Integration:

Control Plan is integrated with the following components

1.

Failure Modes and Effects Analysis.

2.

Master Inspection Characteristics i.e. Process related Risk Characteristics.

3.

Task Lists & Inspection Plans.

4.

cProjects & Quality Notifications.

Procedure

Steps to be followed in creating the Control Plan

Creation 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    Cockpit

2.

Enter the Control Plan ID.

3.

Input the Control Plan type i.e. Production or Prelaunch or Prototype.

4.

Click on the create icon to create the Control Plan

SAP COMMUNITY NETWORK SDN - sdn.sap.com | BPX - bpx.sap.com | BOC - boc.sap.com

© 2009 SAP AG 3

Creation of Control Plan - Transfer of Characteristics from FMEA to Control Plan

Step 2: Assign or Copy FMEA to the Control plan.

1.

Click on FMEA Tab.

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 FMEA’s present both in FMEA as well as Control Plan

Step 3: Transfer or copy of Critical Characteristics 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 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.

SAP COMMUNITY NETWORK SDN - sdn.sap.com | BPX - bpx.sap.com | BOC - boc.sap.com

© 2009 SAP AG 4

Creation of Control Plan - Transfer of Characteristics from FMEA to Control Plan

6.

Select the Characteristic origin as FMEA & click the Tab Load Characteristics.

7.

Choose the Critical characteristics to be transferred from the list display & click 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 - sdn.sap.com | BPX - bpx.sap.com | BOC - boc.sap.com

© 2009 SAP AG 5

Creation of Control Plan - Transfer of Characteristics from FMEA to Control Plan

10.

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 status 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 Traffic 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 from an FMEA are assigned to the control plan.

SAP COMMUNITY NETWORK SDN - sdn.sap.com | BPX - bpx.sap.com | BOC - boc.sap.com

© 2009 SAP AG 6

Creation of Control Plan - Transfer of Characteristics from FMEA to Control Plan

Step 5: Print preview of the Control Plan structure with the Master Data selection

1.

Click on the Print Preview of the Control 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 - sdn.sap.com | BPX - bpx.sap.com | BOC - boc.sap.com

© 2009 SAP AG 7

Creation of Control Plan - Transfer of Characteristics from FMEA to Control Plan

Step 6: Save the Control Plan

1.

Click on the save Icon to save the Control Plan Ensuring the Consistency check for the Control Plan is Successful.

[former_member364899]

Saravanakumar Ponnayan,

Can you show me any test case for this through screen shot. This will help is a lot.

[Former Member]

Hi,

Work Steps

1.  Double Click on QM_FMEA - Cockpit

2.  Creation of Structure, Function and Defect Networks

Click on Create FMEA

Update the following required and optional fields:

Field Name	Values
FMEA	XXXXXXX
Description	XXXXX
Basic data: FMEA Type Object: Material PlnndStartDate Pld Fin	82 System FMEA Product XXXXXX 01.01.2012 31.12.2012
Result: Rating Procedures Rating Profile Minimum Result	02 Medium Risk 80 Calculation of Risk Priority Number (RPN) 81 Rating: No Risk, Medium Risk, High Risk 80
Status tab: Status	Set to "Released"

3.  Assign the Master Inspection Characteristics

Give the Description for the Characteristic, characteristic type & weighting. Description of the Characteristic should be unique.

Assign the Master Inspection Characteristic and plant which is a part of the FMEA.

4.  Create Preventive and Detection Actions

Create 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 Occurrence & Detection that are required for the Calculation of Risk Priority Number.

5.  Assign FMEA to the Control Plan

Create 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 by Evaluating the Defect Causes & Actions

Formula for calculating RPN = Severity X Probability of Occurrence X Probability of

1. Detection.

Enter the Severity of Defect along with the Probability of Occurrence & Probability of

Detection Ratings.

Click on the valuate Tab that triggers the Calculation of Risk Priority Number for the

1. Defects.

Severity (8) X Probability of Occurrence (7) X Probability of Detection (9) = RPN

(504)

RPN value in the Defects screen of FMEA

7.  Print format of FMEA with Risk Priority Numbers for Defects

8.  Click Save 

9.  Click Exit button to leave the transaction

Regards

Rajkumar.

[nitin_jinagal]

The way you have explained, you should make a document and post it.

It will help everyone

ntn