Quality Management System (QMS) and Its Impact on Manufacturing Order Processing

The 'Manufacturing Order Type' (PMS120) program includes a setting to determine the test frequency basis in QMS for each manufacturing order (MO) type. The 'MO test frequency basis' (MTFB) field options are: '0 - Use Quality Plan', '1 - Create test sequence' (where a test sequence is created on an existing QI request) and '2 - Create a separate QI request' (where a QI request is created when a test frequency needs to be generated).

In addition, there is a 'QI request timing' (QIRT) field in the Manufacturing Order Type (MWORDT) table where a value of '1' indicates the QI request is created upon MO release, and where a value of '2' sets the timing of creating a QI request upon reporting the MO receipt.

Outcome

There is a function program (QMS701Fnc) that auto-attaches a specification for the MO output. See the detailed description of the QMS701Fnc program in Auto-attaching Specifications to Orders

It is possible that a manufactured item can inherit some specifications from one of its component items. The setup for this inheritance is explained in Inheriting Specifications. As a pre-requisite to auto-attaching specs to the output of an MO, there is a system check to see if there is an item from which specifications have to be inherited.

Another function program (QMS800Fnc) handles the output reporting of both lot controlled and non-lot controlled items.

Based on the MO type and other QMS-related settings including the Quality plan, in the event of incremental quantities being reported of the by-product output, or in the event of newly added output being reported, a new QI request will be created or an existing QI request will be updated with new sequences for the quality tests in question.

The system refers to the setting of the 'QI request timing' (QIRT) field on the MO type to determine when to generate the QI request (either on release of the order or on reporting output).

Logic for creation of QI requests added upon MO creation

The QI request timing is handled the same regardless of whether the MO has a single primary output or has a primary output, co-products and/or by-products. Since the primary product, co-product and by-product can all be quality controlled and have their own specifications, the QI requests must be made for each output. The system checks through all outputs for a given MO to make sure that the QI requests are generated properly.

A QI request is created for any lot coming from an MO regardless of the assigned MO type. There may be cases where a new lot number is created for an MO which previously had been reported under a different lot number. As such, when any balance ID record is created for a new lot number from an MO, a corresponding QI request is created. If a QI request already exists as a result of an MO release, it will not be replaced.

In 'Manufacturing Order. Open' (PMS100/B), select Related > QI Requests to view the QI requests that have been created for the given MO.

Logic for creation of QI requests added upon MO report receipt

After the product and MO number are specified in 'Manufacturing Order. Report Receipt' (PMS050), the Received quantity value is specified on the E panel. After specifying the lot, received quantity, and location, the system calls the QMS800Fnc function program to create the QI request for the primary output. Upon clicking the Next button, the system validates each test based on its frequency to generate the test sequence.

The system refers to the Quality Plan (QMS009) program, specifically the setting of 'Replace MO QI request' (QIPF) field, to determine how to process any subsequent inventory receipts of a quality-inspected item for a MO. The default selection in the 'Replace MO QI request' field is '2 - Use different location' where each receipt is processed in a different location with a new QI request until such time that the balance identities of the receipts allow the lots to be reclassified into the same location. Refer to Quality Approval Rules and Process for an explanation of each setting option for the 'Replace MO QI request' field on the Quality plan.

Note: For items that are not lot-controlled, a new QI request will be created in every instance.

In addition, these scenarios describe the processing of QI requests for MO inventory receipts based on the Replace MO QI Request (QIPF) setting:

The Replace MO QI Request (QIPF) field is set to '0- Use the last QI request created' and the QI request is approved

The Replace MO QI Request (QIPF) field is set to '0- Use the last QI request created' and the QI request is rejected

The Replace MO QI Request (QIPF) field is set to '1- Manually reclassify lot' and the QI request is approved

The Replace MO QI Request (QIPF) field is set to '1- Manually reclassify lot' and the QI request is rejected

The Replace MO QI Request (QIPF) field is set to '2- Use different location' and the QI request is approved

The Replace MO QI Request (QIPF) field is set to '2- Use different location' and the QI request is rejected

Note: If the Quality Plan (QMS009) does not have the Maximum Quantity and corresponding Unit of Measure (U/M) defined, the QMS800Fnc program will use the Reported Quantity and U/M as the maximum quantity. This quantity value is used to determine whether the creation of a new QI request is required.

Logic for creation of QI requests for output reporting of co-products

Output reporting of co-products requires that the product structure is set up to include a co-product. Based on the MO type and other settings including the Quality plan, if incremental quantities are reported for the co-product output, either a new QI request will be created or an existing QI request will be updated with new sequences for the quality tests in question.

Aging setup for manufactured items

Many manufactured items, regardless of whether they have quality specifications, need to age before they can be used or sold. Depending on the type of item, the aging can be measured in days, hours, or minutes. These values are set in the (MMS002) record as AGDY, AGHO, and AGMI, respectively.

To allow for scenarios where the default aging time must be changed during manufacturing, the MO must be created with a type that has the Aging parameter (AGIG) in the MO type (hyperlink to (PMS120)) set to 2-‘Dynamic aging’.

For such an MO, a manual reclass date (MREC) and time (MRCT) can be specified upon MO creation. A default of either now (if item has no aging parameters) or an aging date and time based the aging parameters in the warehouse where the MO is received will be populated. This date and time can be updated on the MO until the first receipt of a lot for that MO.

Upon MO receipt, the manual reclass date and time will be saved on the corresponding Lot master record (MILOMA) as the planned reclass date and time. Through the putaway program (PMS130), the reclass date and time can be extended or changed to a value before 'now' for an item-lot manufactured through an MO that is created with an MO type with dynamic aging. If the reclass date and time are changed, the status of the balance ID must remain as 1.

To continuously monitor the aging status of balance identities, there is an autojob mechanism with the purpose of polling the items' reclassification dates and updating their status as the items complete the aging process. In 'Subsystem Job. Open' (MMS975), the Subsystem is 'ASJ' with the Job name of 'MMS975'. The default delay for this job is 180 seconds.

It is important to note that, depending on the Inspection code as well as whether Aging parameters have been defined for a particular manufactured item, the balance identity status of the item will be impacted when the item is reported through 'Manufacturing Order. Report Receipt' (PMS050).

Aging functionality's impact on QMS logic

As part of the MO processing, if an item has one or more QI requests created, the auto-approval rules will dictate the status of the balance identity as the quality test results are specified in 'QI Test Results. Open' (QMS400) for this item and lot combination.

Before you start

The setup conditions outlined in Managing Quality Control must be met.

Note: There is the assumption that the MO is already created in a facility whose division has the switch 407 set to enable the Quality Management System (QMS).

Process for adding/updating a QI request

The QMS800Fnc function program has this operation:

Process for deleting QI requests upon deletion of manufacturing orders

Manufacturing orders (MO) can be deleted when no transactions are associated with them. The MO can also be created for an output that is set up as a quality inspected item in a facility that has QMS enabled. If such an MO is created with an MO type where the QI requests are created on release, then upon deletion of the MO, the corresponding QI requests will be deleted also.

As an MO can be created with a co-product and by-product both of which can be set up as QMS items, it is possible that there are QI requests generated for all of these products. If no transactions have occurred for this MO and the MO is deleted, all such QI requests also will be deleted.

The DeleteQIReq operation of the QMS300Fnc program is called from the Lot master to delete all the tables associated with a QI request.

MI transactions

QI requests related to MO creation and reporting include these MI transactions:

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