sap-qm

# SAP Quality Management (QM) Skill ## 1. Environment Intake Checklist Before starting QM troubleshooting or configuration, collect: - **SAP Release**: ECC 6.0 (SP number), S/4HANA 1909+, S/4HANA Cloud - **Deployment**: On-premise (ECC/S/4 OP) | Private Cloud (RISE) | Public Cloud (SAP QMS) - **QM Activation**: `SPRO > SAP Customizing for Quality Management` configured? - **Scope**: 구매(MM) 수입검사 | 생산(PP) 공정검사 | 판매(SD) 납품검사 - **Industry**: 제조업(일반) | 화학 | 제약(GMP) | 식품(HACCP) | 자동차(IATF 16949) - **Quality Strategy**: 100% 검사 | Sampling plan (AQL-based) | Zero-inspection (trusted supplier) - **Integration**: MM-QM 구매검사 | PP-QM 공정검사 | SD-QM 납품검사 | QM-PM 통지서 연동 **Skill will adapt all answers to user's specific SAP release, deployment, and industry context.** --- ## 2. Quality Planning (QP01/QP02/QP03, QS21/QS31, QDV1) ### 2.1 Inspection Plan Structure (검사계획) **Transaction**: QP01 (Create), QP02 (Change), QP03 (Display) **Logical hierarchy**: ``` Inspection Plan Header (PLKO) ├─ Plan Number (PLNNR): 자동 또는 수동 부여 ├─ Material (PLKO-MATNR) + Plant (PLKO-WERKS) ├─ Inspection Type (PLKO-LOART): │ ├─ 01: Purchasing (구매 입고 검사) │ ├─ 03: Production (공정 검사) │ ├─ 04: Sales (판매 출고 검사) │ └─ 08/09: Recurring/Source ├─ Valid from/to (PLKO-GDATU ~ PLKO-GDATU_END) └─ Status: 1=Created, 2=Released, 3=Locked └─ Inspection Operations (PLPO) — 검사 단계별 ├─ Operation number (OPNR): 10, 20, 30... ├─ MICs (Master Inspection Characteristics — PLMK) └─ Sampling Procedure (QDV1 reference) ``` **Key Tables**: - `PLKO`: Plan header (Inspection plan name, type, dates) - `PLPO`: Plan operations (Operation sequencing, MIC assignment) - `PLMK`: Plan-MIC assignment (QPMK reference) - `QPMK`: Master Inspection Characteristics (검사특성 마스터) **한국 현장 팁**: IATF 16949 대비 각 Operation마다 _검사기준(Specification)_ 명확히 입력 필수. LSL/Target/USL 3개 다 입력. ### 2.2 Master Inspection Characteristics (MIC) — QS21/QS31 **QS21 Transaction** (Create MIC): - MIC Code (QPMK-MERKM): 산도, 경도, 수분율, Tensile strength 등 - Type (QPMK-MERTY): 1=Quantitative (수치), 2=Qualitative (합격/불합격) - Unit of measure (QPMK-MEINS): mg/L, HV, %, ppm - Valuation (QPMK-BWFL): A=Automatic, B=Manual, C=Reference sample **Specification Definition** (QS31 — Material에 대한 MIC 기준값): - LSL (Lower Spec Limit): QPSP-LSL - Target (Nominal): QPSP-ZIELW - USL (Upper Spec Limit): QPSP-USL - Tolerance (±): QPSP-ABWG **예시** (제약 API 수분율): ``` MIC Code: MOISTURE Type: Quantitative Unit: % Specification: LSL: 1.0% Target: 2.5% USL: 5.0% Valuation: Automatic (측정값 vs LSL/USL 자동 비교) ``` ### 2.3 Sampling Procedure Configuration (QDV1) **Purpose**: Lot size에 따른 샘플 크기 결정 (ISO 2859-1 AQL 기반) **Three sampling schemes**: - **Single**: 1차 샘플링으로 최종 판정 (Accept/Reject) - **Double**: 1차 inconclusive → 2차 샘플링 - **Sequential**: 합격 판정될 때까지 계속 샘플링 **AQL Parameters**: - AQL (Acceptable Quality Level): 예) 1.0% = 최대 1% 불량 허용 - Sample size letter (A~M): ISO 2859-1 lookup table (QPSA 테이블) - Acceptance number (Ac): "합격" 수량 - Rejection number (Re): "불합격" 수량 **Configuration Path**: `SPRO > QM > Quality Planning > Sampling > Define Sampling Procedure` **Key Tables**: - QPSA: Sampling header - QPSX: Sampling level (Normal/Tightened/Reduced) **한국 자동차**: 보통 AQL 2.5% or 4.0% (supplier 신뢰도에 따라 분화) ### 2.4 Dynamic Modification Rules (QDR1) **목적**: 연속 검사 결과에 따라 샘플 크기 동적 조정 **Transition Rules**: - **Normal → Tightened**: N개 불합격 로트 발견 시 (예: 5회) - **Tightened → Normal**: M개 연속 합격 로트 (예: 5회) - **Normal → Reduced**: K개 연속 합격 + 조건 만족 시 (예: 25회) - **Reduced → Normal**: 불합격 또는 OOS 검출 **설정 예**: ``` Tightened entry: 불합격 횟수 = 5 Tightened exit: 합격 횟수 = 5 Reduced entry: 합격 횟수 = 25 AND 불합격률 < 0.5% Reduced exit: 불합격 1회 (즉시) ``` **생산 관점**: Tightened 진입 시 생산 속도 저하 (샘플 size ↑) → 원인 파악 및 시정 urgency ↑ --- ## 3. Quality Inspection — Inspection Lot & Results Recording ### 3.1 Inspection Lot Creation (QA01) **Inspection types** (검사유형, QALS-LOART): - **01**: GR Inspection (구매 입고 검사) — MIGO 후 자동 또는 수동 - **03**: In-process (생산 공정 검사) — 공정 단계별 타이밍 - **04**: GI Inspection (판매 출고 검사) — MIGO GI 전 - **08**: Recurring inspection (반복 검사) — 정기적 재검사 - **09**: Source inspection (원산지 검사) — 공급사 공장에서 **Automatic Creation Flow**: ``` Material Master (MM02): QM Control Level (IQMC) = "01" 또는 "02" ↓ Purchasing Info Record (ME11) 또는 Quality Info Record (QI01): Inspection plan flag = "X" ↓ MIGO (GR posting): 자동 → Inspection Lot 생성 (QALS) ↓ QA25 (Background job): Daily/Hourly run → 대량 검사로트 생성 ``` **Manual Creation** (QA01 T-code): ``` QA01 Screen: ├─ Material Number (QALS-MATNR) ├─ Quantity (QALS-MENGE) ├─ UoM (QALS-MEINS) ├─ Supplier (QALS-LIFNR) — Type 01 구매의 경우 ├─ Inspection Type: 01/03/04/08/09 ├─ Inspection Plan: 자동 상속 (PLKO → QALS-PLNNR) └─ Lot number (QALS-LOSNR): Auto/Manual ``` **Key Table**: QALS (Inspection Lot Header) ### 3.2 Sample Definition (QPR1/QPR2) **Sample Determination** (샘플 결정): 1. Inspection Plan → Sampling Procedure (QDV1) lookup 2. Lot size입력 → Sample size 자동 계산 (ISO 2859-1) 3. Sample selection strategy: - Sequential: Units 1, 2, 3... n - Random: SAP random number generator - Every nth: e.g. 매 5번째 unit **Sample Recording** (QPR1 Transaction): ``` QPR1: ├─ Select Inspection Lot (QALS) ├─ System proposes sample size & strategy ├─ Assign sample units (팔레트/박스 ID 또는 연번) └─ Print sample labels (for inspection lab) ``` **Key Tables**: QASE (Sample header), QASV (Individual sample values) ### 3.3 Results Recording (QE01/QE51N) **QE01 Transaction** (Classic GUI): ``` QE01: ├─ Select Inspection Lot (QALS) ├─ Record per Characteristic (MIC): │ ├─ Quantitative: 수치 입력 (예: 98.5 mg/L) │ │ → 자동 vs LSL/USL 비교 → Pass/Fail │ └─ Qualitative: Accept/Reject 선택 ├─ Record Defects (optional): │ ├─ Defect code (QMFE-MFEHL, e.g. CRACK, BURN) │ └─ Quantity affected └─ Save (QASR 테이블에 기록) ``` **QE51N (Fiori App — Mobile inspection input)**: - 모바일 친화 UI - QR code 스캔 → sample 빠른 접근 - 검사기기 API 직접 연동 (자동 수치 입력) - Offline mode 지원 **Result Evaluation** (자동): - Individual MIC result: Pass (수치가 LSL~USL 범위) / Fail (Out of spec) - Lot-level judgment: 별도 UD (Usage Decision) transaction에서 수행 **Key Tables**: - QASR (Result header — Lot별) - QASV (Sample value — 개별 샘플 수치) - QAVE (Evaluation — 최종 Pass/Fail 기록) ### 3.4 Statistical Process Control (SPC) — 관리도 **SPC Configuration** (Quality Control 메뉴): ``` SPRO > QM > Quality Control > Define Control Chart ``` **Chart Types**: - **X-bar & R chart**: 연속 공정 (mean ± std dev tracking) - **p-chart**: Proportion defective (불량률 추적) - **c-chart**: Defect count (결함 개수) **Triggers**: - 관리한계(Control limit) 벗어남 → QM notification 자동 생성 - 추세(Trend): 8개 연속 point가 center line 한쪽 → 경고 - Rule violations → Root cause investigation 유도 **생산 현장 활용**: 공정능력(Cpk) 사전 평가 후 매 로트마다 모니터링 — 즉시 이상 감지 --- ## 4. Usage Decision (QA11/QA12/QA13) ### 4.1 UD Creation & Codes **Transactions**: - QA11: Create Usage Decision - QA12: Change - QA13: Display **UD Codes** (최종 판정): - **A**: Accept (합격) — 재고로 입고 가능, 다음 공정/판매 진행 - **R**: Reject (불합격) — 재고 차단, 반품/폐기 예정 - **B**: Conditional (조건부) — 고객 승인 대기 또는 재작업 - **S**: Return to supplier (공급사 반송 — 수입검사 Type 01에서만) **UD Creation Flow**: ``` QA11: ├─ Select Inspection Lot (QALS-LOSNR) ├─ System shows all MIC results (QASR 요약) ├─ Judge UD Code: │ ├─ All MIC pass + No defects → "A" (Auto-recommend) │ ├─ Any MIC fail OR Defects found → "R" │ └─ Marginal case → "B" (with reason text) ├─ Optional: Partial acceptance (Accepted qty ≠ Lot qty) └─ Save (QAVE 테이블) ``` **Key Table**: QAVE (Usage Decision record) ### 4.2 Post-UD Actions (Follow-up Processing) **Accept (A) → Stock Posting**: ``` MIGO blocked GR → Auto-completed ↓ Inventory: Material received into active stock ↓ Next process (Production consume, Sales ship) can proceed ``` **Reject (R) → Stock Management**: ``` QALS → QAVE (UD=R) ↓ Blocked stock (QMSL, 품질보류 재고) ↓ Options: ├─ Scrap posting (MIGO Scrap) ├─ Return to supplier (Vendor credit memo) └─ Rework (if internally caused failure) ``` **Conditional (B) → Quality Hold**: ``` QAVE (UD=B, reason= "고객확인대기") ↓ Stock in Quality Hold (QM block) ↓ Customer approval → Update UD to "A" → GR completes OR Denial → Change to "R" → Scrap ``` **Quality Notification Trigger** (자동): ``` If UD = R: → QM01 자동 생성 (Customizing 설정) → Defect history 기록 → Supplier evaluation score 반영 ``` ### 4.3 Partial Lot Acceptance (부분 합격) **Scenario**: 100개 로트 → 98개 OK, 2개 불량 **QA11 Handling**: ``` QA11: ├─ Select QALS (Qty=100) ├─ UD Code = "A" (Accept partial) ├─ Enter "Accepted qty" = 98 ├─ Enter "Rejected qty" = 2 └─ Save ↓ MIGO posting: +98 to active stock, +2 to blocked stock ↓ 결과: 총 100개 중 98개만 사용 가능 (GR 재무 기장도 98개 기준) ``` **Key Field**: QAVE-MNGEA (Accepted qty), QAVE-MNGEB (Rejected qty) ### 4.4 Automatic UD Processing (QA32) **Purpose**: 검사 완료되었으나 UD 수동 미생성 로트 자동 판정 **설정**: ``` SPRO > QM > Quality Inspection > Inspection Lot > Define Automatic Usage Decision ↓ Rule 설정: ├─ All samples passed AND no defects → Auto "A" ├─ Any sample failed OR Defects → Auto "R" └─ Automatic update flag = X ``` **QA32 실행**: ``` QA32 Report: ├─ Selection: Lot status 04 (Results recorded, UD pending) ├─ Execute → Background job └─ Result: UD records created for matching lots ``` **생산 관점**: 월마감 전 일괄 처리로 미결 검사로트 정리 ### 4.5 Usage Decision Block — Evidence Loop #### Mandatory diagnostic order When no evidence is available, the leading provisional cause is **incomplete required results/valuation**, not configuration. Ask for environment context, but include the following read-only path in the same answer: ```text QA03 lot status + required characteristic/sample/inspection-point state → QE51N open Recorded/Valuated work → QA13 existing UD / terminal state → QA11 selected set and authorization boundary → MMBE/MIGO post-UD stock and material document ``` Do not skip to code-set configuration while a required result is open. Falsify the leading cause only when both `QA03` and `QE51N` show every required characteristic, sample, inspection point, and applicable long-term characteristic as complete/valuated, yet `QA11` still stops before code selection with the same message. Minimum evidence bundle: release/deployment, lot/type/plant, exact message class and number, timestamp, full `QA03` status, open-result count, existing `QA13` decision, current `MMBE` quality-stock quantity, and manual versus automatic UD path. #### Intake and state boundary Collect release/deployment/industry, inspection type, user-provided inspection lot/material/plant/batch, exact message class/number, attempted surface (`QA11` or automatic/mass UD), current lot status, required characteristic/sample/inspection-point completion, selected set/code, stock-posting choice, and current quality stock. First classify the boundary: 1. **Before UD save** — status, results, code, authorization, or lock prevents `QAVE` creation. 2. **After UD save** — `QAVE` exists but follow-up action or stock posting failed. 3. **Already completed/cancelled** — requested operation conflicts with terminal lot status. #### Read-only evidence chain | Step | T-code + menu path | Evidence | |---|---|---| | Lot | `QA03` — Logistics > Quality Management > Quality Inspection > Inspection Lot > Display | lot status, results, samples, inspection points, stock and existing UD status | | Results | `QE51N` — Logistics > Quality Management > Quality Inspection > Results > Worklist | display required characteristics, recorded/valuated state and open samples | | Existing UD | `QA13` — Logistics > Quality Management > Quality Inspection > Inspection Lot > Usage Decision > Display | code, valuation, follow-up action and posting outcome | | Stock | `MMBE` — Logistics > Materials Management > Inventory Management > Environment > Stock > Stock Overview | quality/unrestricted/blocked quantity by plant/storage/batch | | Material doc | `MIGO` — Logistics > Materials Management > Inventory Management > Goods Movement > Display | reference document and posting/reversal chain | Read-only tables/fields: `QALS-PRUEFLOS/MATNR/WERK/ART/OBJNR`, `QAVE-PRUEFLOS/VCODEGRP/VCODE`, `QAMV-PRUEFLOS`, `QASR-PRUEFLOS`, `QASE-PRUEFLOS`, `JEST-OBJNR/STAT/INACT`. Direct production edits are forbidden. #### Hypotheses and falsifiers **H1 — required results or valuations are incomplete.** - Supports: `QA03/QE51N` has open required characteristics, unvaluated results, samples, or inspection points. - Falsifier 1: every required characteristic/sample is recorded and valuated. - Falsifier 2: a representative QA lot with the same statuses reaches UD code selection normally. **H2 — lot status does not permit a new/change UD.** - Supports: created/cancelled/skipped/completed status conflicts with the attempted action. - Falsifier 1: `QA03` shows UD-ready status and `QA13` finds no prior UD. - Falsifier 2: failure occurs after valid code selection at follow-up/stock posting. **H3 — selected set, UD code, or follow-up action is invalid for context.**