SAP Digital Manufacturing supports manufacturers to maintain the highest standards of precision and quality control. A critical aspect of maintaining these standards, is identifying and managing defects during the manufacturing processes, which in the context of SAP DM can be captured as Nonconformances, or "NCs" for short.
Nonconformances, essentially deviations or discrepancies from predetermined quality standards or specifications, can emerge due to various factors during manufacturing operations, such as human errors, defective materials, malfunctions in shop floor machinery or processes, etc, and can automatically trigger a couple of different actions and flows in the system, like scrap or rework for example, while keeping full traceability records.
In this blog post, we will explore the basics about Nonconformance capabilities within SAP Digital Manufacturing.
SAP Digital Manufacturing nonconformance capability provides a mechanism for logging, tracking and dispositioning of failed or defective parts or assemblies, enabling the following outcomes:
Document the nonconformance management process using a closed loop system
Exclude nonconforming parts / materials from the production process
Trigger nonconformance work tasks for the assigned resources and provide traceability
In general, nonconformance flow can fit in the overall manufacturing process as shown in the diagram below:
Nonconformance configuration starts with the creation of Nonconformance Groups, which can be used to group similar NC codes together, and Nonconformance Codes, which are a distinct set of characters that represent a failure, defect, or repair code indicating that the specific part does not meet the approved quality standards.
Nonconformance Groups and Codes can be transfered directly from ERP Quality Management (QM) module via Nonconformance Groups, see Transferring QM Defect Code Groups and Codes from S/4HANA Cloud or S/4HANA On Prem for more details, as follows:
* When you log a nonconformance using a defect code originated from ERP Quality Management (QM) module, it is automatically transferred back to SAP ERP and a generic defect record is created.
Or manually created directly in SAP Digital Manufacturing via Manage Nonconformance Groups and Manage Nonconformance Codes apps.
You can use this app to create NC groups, define operation activities for which the NC group is available, and synchronize QM groups.
Out of the box simple NC logging in Default Work Center POD
Out of the box NC logging in Default Work Center POD with Disposition to Rework or Scrap
Out of the box NC logging in Standalone Nonconformance POD, including Done (Completed) SFCs
Secondary NC logging in a Custom Rework POD enabling Root Cause Analysis, capturing Repair Codes and closing Nonconformances
NC logging to specific Components by selecting components directly in 3d Work Instructions
In the examples above, you will notice that SAP Digital Manufacturing Nonconformance capabilities include:
Capture single, multiple, secondary NC levels.
Perform Root Cause Analysis and capture Repair Codes as Secondary NCs.
Close NCs once the repair / rework is completed.
Attach files like images or lab reports.
Add comments and capture other data for traceability purposes.
Capture NC codes against Done (Completed) SFCs.
Disposition SFCs using a specific NC code to a Rework routing or Scrap them.
Capture NC codes for specific Components using 3d Work Instructions.
and much more!
Nonconformances can be also handled (logged, closed, checked, etc) using standard APIs and Services directly from Shop Floor / Automation layer or 3rd Party systems like Laboratory Systems or Measurement Equipment via Production Processes out of the box, as shown in the simple example below:
Where to go from here?
There is a lot more to learn regarding SAP Digital Manufacturing nonconformance capabilities. Therefore, I suggest you take a look on the following SAP Help entries: