Case study 4 Quality control and quality management

Objectives

Enable quality management; create tests, item sampling, definitions and process of the quality management process.
Create a manual quality order with a specification.
Work with non-conformance issues like faulty items by defining several required specifications.
Create and process a non-conformance order to have an item repaired and to adjust a faulty machine.
Run a non-conformance report, a non-conformance tag report, and a corrections report

Exercise #1 Enable quality management process that specifies items to be inspected at the time of picking

Objective: Enable quality management; create tests, item sampling, definitions and process of the quality management process.

The quality manager in USMF wants to know how to enable a quality management process requiring that incoming inventory for all TV products be inspected immediately at the time of picking.

When she create a sales order for item T0002 and during the picking step, a quality order will be automatically created.

To be able to proceed with picking and packing the sales order she will have to process the quality order.

Can you assess her to do the following?

Enable quality management in Inventory management parameters.
Create tests.
Create test variables to define the test results are recorded.
Set up item sampling.
Create quality and item groups.
Create a test group.
Define when quality orders will be created.
Process quality orders.

Enable quality management

Go to Inventory management > Setup > Inventory and warehouse management parameters.
Select the Quality management tab.
Set the Use quality management option to Yes.
Select Report setup. In USMF, the report setup for quality management is already defined. If this wasn’t done, you’d add new lines here for the different report types, and select the type of document to be used for each report.
Close all pages.

Create a test

Go to Inventory management > Setup > Quality control > Tests.
Select New.
In the Test field, type eBookTest.
In the Description field, type Test eBook.
In the Type field, select Option to assign the test results based on pre-defined values.
Select Save.
Close all pages.

Create Test variables to define the way test results are recorded

Go to Inventory management > Setup > Quality control > Test variables.
Select New.
In the Variable field, type Power.
In the Description field, type Power up.
Select Save.
Select Outcomes.
Select New.
In the Outcome field, type ON.
In the Description field, type Device starts normally.
In the Outcome status field, select Pass.
Select Save.
Select New.
In the Outcome field, type OFF.
In the Description field, type Device does not power up.
In the Outcome status field, select Fail.
Select Save.
Close all pages.

Set up item sampling

Go to Inventory management > Setup > Quality control > Item sampling.
Select New.
In the Item sampling field, type One.
In the Description field, type One sample.
In the Quantity specification field select Fixed quantity.
In the Value field, enter 1.

Note This value relates to the Quantity specification that’s selected in the adjacent field.
Expand or collapse the Process section.
Select or clear the Full blocking option.

Note If you select this option, the whole lot or order line quantity is blocked if a test is failed. If you don’t select it, only the items in the quality order are blocked.
Select Save.
Close all pages.

Create a quality and item group

Go to Inventory management > Setup > Quality control > Quality groups.
Select New.
In the Quality group field, type eBookQG.
In the Description field, type Quality group for TVs.
Select Save.
Select Add items.
Select the row for Items in the Tables column.
In the Criteria field, type T* to filter on the item numbers that start with T.
Select OK.
Select OK.
Close all pages.

Create a test group

Go to Inventory management > Setup > Quality control > Test groups.
Select New.
In the Test group field, type eBookTG.
In the Description field, type Test group for TVs.
In the Item sampling field, select One.
Under the Overview tab, select Add.
In the Sequence number field, enter 1.
In the Test field, select eBookTest.
Select the Test tab.
In the Variable field, select Power.
In the Default outcome field, select ON.
Select Save.
Close all pages.

Define when quality orders will be created

Go to Inventory management > Setup > Quality control > Quality associations.
Select New.
In the Reference type field, select Sales.
In the Item code field, select Group.
In the Item field, enter or select eBookQG.
Expand the Process FastTab.
In the Event type field, select Picking process is scheduled.
Expand the Quality order process FastTab.
In the Event blocking field, enter or select Picking process.
Expand the Specifications FastTab.
In the Test group field, enter or select eBookTG.
Select Save.
Close all pages.

Process quality orders

Before you begin this exercise, blocking rules would need to be enabled for processing quality orders.

NOTE There’s an exclusion on sales orders lesser than $10,000 for all customers. The sales order may provide an informational message that the order amount may be less than or equal to the sales order exclusion amount in the sales order rule and will not be sent to credit management. Before the execution of this task, view blocking rules and exclusion rules on the Credit and collections > Setup > Credit management setup > Blocking rules page.

Go to Sales and marketing > Sales orders > All sales orders.
Select New.
In the Customer account field, select US-013.
Select OK.
In the Item number field, enter or select T0002.
On the Action Pane, select Pick and pack.
Select Quality orders.

Note There are no quality order for this customer.
Close the page.
Select Generate picking list.
Select OK.
Select OK.

Note A message may appear stating “You are about to post the document without printing it. Select OK to continue.” Read the error message details generated preventing you from continuing the process of picking and packing because you now have a quality order.
Select OK.
Select Quality orders.

Note A quality order has been automatically generated.
Review the test.
Select Results.
Set Result quantity to 1.
Set Outcome to ON.
Select Validate to validate the quality order line results for the test.
Close the page.
Select Validate to validate the quality order.

Note The process operation has removed the error as the the test results of the quality order test passed.
Select OK.
Close the quality order page.
Select Generate picking list to post picking list.
Select OK.
Select OK.
Once back on the Sales order page, clear the messages via the X.
Select Picking list registration.
Select Updates.
Select Update all.
Close the form.
Select Post packing slip.
Select OK.
Select OK.
Close all pages.

Exercise #2 Create a manual quality order with a specification

Objective: Create a manual quality order with a specification.

The quality manager must deal with non conformance and quality issues and track the cause of any problems.

He wants make sure that the shipped products have a quality expected by USMF so he asked an employee in sales, to make an additional selection for the HDMI cable item A0002 for impedance by creating a manual quality order with a specification.

The sales employee is new and not sure what to do. You were called to help the sales employee. What features you will be using to perform the above tasks?

You will need to do the following:

Create a manual quality order

Open Inventory management > Periodic tasks > Quality management > Quality orders.
Select New.
Select Inventory as the Reference type.
Select Item number A0002.
Select eBookTG as the Test group.
Type 1.00 in the Quantity field.
Select 2 in the Site field.
Select 24 in the Warehouse field.
Select Available in the Inventory status field.
Select OK.
Select the line for Item number A0002, and then select Results.
In the Result quantity field, type 1.00.
Select Validate and close the form.

Exercise #3 Define conditions to work with non-conformance issues

Objective: Work with non-conformance issues like faulty items by defining several required specifications.

Due to recent issues with customers returning faulty computers, you want to setup some processes to deal with faulty items in the system.

You will need to define several conditions to work with non-conformance: problems and diagnostic types, operations, quality charges, and quarantine zones.

You will need to do the following:

Add diagnostic types.

Add a quarantine zone.

Work with nonconformance

Open Inventory management > Setup > Quality management > Problem types.
Select New.
Enter Temperature in both Problem type and Description fields.
Select Save.

Add diagnostic types

Open Inventory management > Setup > Quality management > Diagnostic types.
Select New.
Enter Machine temperature in both Diagnostic and Description fields.
Select Save.
Open Inventory management > Setup > Quality management > Operations.
Select New.
Enter Adjustment temp in both Operation and Description fields.
Select Purchase order in the type field.
Select Save.
Open Inventory management > Setup > Quality management > Quality charges.
Select New.
Enter Repair in both Problem type and Description fields.
Select Save.

Add a quarantine zone

Open Inventory management > Setup > Quality management > Quarantine zones.
Select New.
Enter Repair in both Quarantine zone and Description fields.
Select Save.

Exercise #4 Use non-conformance order to repair an item and a faulty machine (Bonus)

Objective: Create and process a non-conformance order to have an item repaired and to adjust a faulty machine.

The company discovered a faulty computer in the inventory, and you will need to raise a non-conformance order to get it fixed.

The item you found will need to be to be taken out of stock and repaired.

A machine has caused this fault and will need to be adjusted to prevent more items to be faulty.

You will need to do the following:

Create and process a non-conformance order

Open Inventory management > Periodic tasks > Quality management > Non Conformances.
Select New.
Select Internal in Non conformance field.
Enter 1000 in the Item number field.
Enter Enclosure as the problem type.
Enter 5.00 in the Defective quantity field.
Enter 1 in the Site field.
Enter 13 in the Warehouse field.
Select OK.
Select the Function button (you may need to select the ellipsis toward the top right of the screen) and select Approve non conformance.
Select Yes.
Select the Related operations button.
Select New.
Select Enclosure in the Operation field.
Enter Damaged in the Reason field.
Select Save.
Select the Items button.
Select New.
Select A0001 as the item number.
Enter 1.00 in the Quantity field.
Select Save and close form.
Select Quality Charges button.
Select New.
Select Rework in the Charges code field.
Enter Rework in the Description field.
Enter 100.00 in the Charges value field.
Select Save and exit form.
Select Timesheet button.
Select New.
Enter 5.0 in the Operation hours field.
Select Save and exit form.
Close the Related operations form.
Select the Corrections button.
Select New.
Select Machine adjustment in the Diagnostic field.
Select 000002 (Charlie Carson) in the Worker field. Press Select.
Select High in the Correction priority field.
Select the Save button.
Select the Mark Complete button.
Select OK and close the form.
Select the Functions button and select Close non conformance.
Select Yes.

Exercise #5 Run non-conformance reports

Objective: Run a non-conformance report, a non-conformance tag report, and a corrections report.

The quality manager must review conformance items created during the month as well as any corrections made that are related to conformance.

At the end of each month, he will need to run the reports and validate the output.

The quality manager is not sure where or how to do so. You were called to help.

You will need to do the following:

Run a non-conformance report.
Run a non-conformance tag report.
Run a correction report.

Run a non-conformance report

Open Inventory management > Inquiries and reports > Quality management > Non Conformance.
Select OK.

Run a non-conformance tag report

Open Inventory management > Inquiries and reports > Quality management > Non Conformance tag.
Select OK.

Run a correction report

Open Inventory management > Inquiries and reports > Quality management > Corrections.
Select OK.