- SAP Managed Tags
Introduction
In manufacturing, every deviation from quality standards can cascade issues across the supply chain, increase costs, and risk customer satisfaction. SAP Digital Manufacturing helps manufacturers proactively manage such deviations by automating the routing of defective parts to rework processes immediately upon detecting out-of-limit conditions during data collection on the shop floor.
Data Collection capability of SAP Digital Manufacturing enable workers to collect product and production process-related data against Shop Floor Controls (aka SFCs) in Production Operator Dashboards (aka PODs). It can also validate the collected data against predefined limits (minimum and maximum thresholds values) and ensure that all required data has been collected, for example.
When a collected Data Collection parameter is out of min/max thresholds, the system can automatically initiate the logging of a nonconformance, which can automatically disposition the defective part to a rework routing.
The Business Problem
Imagine a production line where operators collect dimensional or performance data during assembly. A single deviation beyond the acceptable range may go unnoticed until a downstream failure or audit occurs. This leads to costly scrap, delayed deliveries, and quality compliance risks.
Traditionally, rework initiation involves manual intervention: the operator spots the issue, logs a nonconformance, and a quality engineer reviews and routes the part. This delay can be costly.
Automatic Rework Disposition
SAP Digital Manufacturing introduces a proactive and automated quality safeguard: if any data point collected during production is outside predefined min/max thresholds, the system automatically logs a nonconformance and routes the part to a predefined rework path. This uses standard functionality including:
Data Collection Groups: Used to capture parameters such as torque, temperature, or dimensions.
Thresholds with Auto Logging: Define acceptable limits. When breached, SAP DM logs a nonconformance.
Rework Routing: Predefined alternative paths to fix issues without restarting the entire process.
Business Benefits
1. Real-time Quality Control
Operators no longer need to decide what to do when data falls outside limits. The system ensures immediate action, minimizing delays and human error.
2. Reduced Scrap and Rework Costs
By catching issues at the point of data entry and rerouting them instantly, defective products are reworked early, avoiding scrap and reducing production losses.
3. Compliance and Traceability
All events, including out-of-limit detections, nonconformance logging, disposition and rework routing execution are recorded, supporting audits, regulatory compliance, and root cause analysis.
4. Workforce Efficiency
This approach frees operators to focus on value-adding activities, while the system ensures adherence to quality procedures.
Use Case: Automotive Assembly Line
An automotive manufacturer measures torque for each fastener during chassis assembly. SAP Digital Manufacturing records each torque value. If any value exceeds defined safety thresholds, the system logs a “Torque Out of Limit” nonconformance and routes the part to a rework station for reassembly. No manual steps, no delay. This ensures safety-critical parts are verified and corrected before leaving the line.
Demo
Conclusion
This set of features together show SAP Digital Manufacturing’s vision of intelligent, automated, and integrated manufacturing operations. By empowering quality enforcement at the data collection point, it not only improves production efficiency but also helps ensure that only conforming products move forward, every time.
If you're exploring ways to strengthen your quality process without adding overhead, automated rework routing in SAP Digital Manufacturing is a simple but high-impact enhancement worth considering.
Do you like this post? Please let me know in the comments section what you think. Any feedback is highly appreciated.
Or, if you have any questions, please check SAP Community Q&A Area, or comment down below.
Thanks,
Manoel Costa
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