Dynamic modification rule - quality level update

[Former Member]

Hello Guys,

We have couple of DMR set up "At lot creation" assigned to inspection plan at char level. I understand quality level will update next stage upon the inspection lot created but what happens if they reverse the GR being lot put to LTCA status. System is still updating Quality level to next stage ( which shouldn't be) and it doesn't revert it back during reversals. Because of this we have big issues. And also let's say they have inpection lot to test 3 chars out of which 1 char  was rejected in RR( set to DMR) but still quality level keeps updating to next stage as it updates right after the inspection lot.

My question how can we prevent this and tell system not to update quality level when reversal is performed and also if there is a rejection in RR

I knew if we set at UD level, this wouldn;t be an issue but want to know how it works for lot creation.

Regards,

Mahee

[former_member207800]

For dynamic modification at lot creation, the quality level is updated when an inspection lot is created. The system assumes that the forthcoming inspection will lead to an acceptance of the inspection lot or characteristic.

An inspection lot, which is created immediately after the quality level is updated, uses the information in the updated quality level without a usage decision having been made.

If dynamic modification is carried out at lot creation and the inspection lot is subsequently rejected, the system updates the quality level again when the usage decision is made. The new inspection stage is used by the system to calculate the sample sizes for the next inspection lot.

Changing the quality level does not affect inspection lots that were created in the meantime.

That is why QM consultant suggests at UD in common business process.

Regards

[Former Member]

Thanks Guys, That makes totally sense. One question if I set on UD level.

Rule : test one lot and go to SKIP for 365 days and if it fails go to stage 1 for inspection.

Let's say if I have 3 open lots which has not been tested yet. And quality level will never update and waiting on UD. So If I do the UD on my 2nd lot, does the system considers the quality level update or it expects only the previous receipt of UD and not the prior ones ?

The business reason for setting up at lot creation because they will get consecutive lots on and on and doesn't want to do the inspection for the lots which does not require full testing.

Regards,

Mahee

[former_member42743]

If you do the UD on the second lot there will be no effect on the outstanding lots 1 and 3.  The system will still expect them to be processed.  They do not turn into SKIP lots.

The quality level will be updated when the second lot's UD is made.  Additional lots will be skipped if that's what your rule calls for.

Again, if they are getting consecutive lots, they need to reduce inspection time and UD decisions.  You don't indicate how often they get new lots or how long inspection typically takes.

If you get three shipments a day in of the same material and it takes you two days to complete the UD you are going to have problems.  You may need to look at the process again or your testing requirements.

You might consider making some of the characteristics as long term characteristics that would allow you to make the UD based on some initial testing and to record the remaining results later. 

You might suggest some new testing equipment to speed throughput of the testing.

Bottom line is when you are creating lots faster than you can test them, you can't expect any system to be able to refigure all the possible corrections to existing lots and new lots being created.  You would always be aiming at a moving target.

BTW: With the update being done at the time of UD you can still get a similar problem.  Lot 1 requires inspection.  Lot 2 is created as a skip lot while Lot 1 is still open because the system assumes lot 1 will pass.  Lot 1 is now rejected and quality level updated.  Lot 2 remains a skip lot as do any other lot created in the meantime.  The next lot to be created after the rejected UD on the Lot 1 will be the next lot to require inspection.

FF

[former_member42743]

It's all manual. 

There is no perfect situation.  SAP does not have the ability to "roll-back" the quality levels.  However, the rejected result SHOULD be picked up on the next lot and influence DMR.  It'll be basically a lot behind.

This mostly results in problems when you have high volumes and you are creating lots so fast that you always have open lots in process.

Look at trying to reduce the time to make a UD through business processes or SAP.  If you aren't using auto UD's consider using them.  If you are, run the auto UD more often and/or reduce the wait time in config.  If you manually make the UD's try to push responsibility for that as far down as possible.  See if you can empower the techs to make the UD and not wait for a lab manager.  Maybe add a means for the lab manager to review the UD's made instead of having to actually make everyone.

When lots wind up as LTCA you have to manually reset the quality levels  You SHOULD NOT have many LTCA lots.  If you are finding that to be an issue, you have a basic business process or design issue that needs to be reevaluated.  I would consider having more then one LTCA lot a month as totally unacceptable.  It means something is not right.  Often times these are a result of a poor planning process resulting in the creation and subsequent deletion of production/process orders. 

FF