Feature Overview: Manufacturing Quality Control

The manufacturing quantity control (QC) feature tracks component failures and repairs during the manufacturing process. When operations are reported (typically test operations), the operator can enter or scan the serial numbers that have been through a quality check.

Requirements

The manufacturing QC feature requires that:

  • The item to be tracked must be serial controlled and have pre-assigned serial numbers. You must have a process in place to associate units with a pre-assigned serial number. This can be as simple producing a label when the order is released. Bar coding serial numbers simplifies data entry.

  • Work-in-process tracking is enabled.

  • Failed serial numbers are repaired before they can be received to stock.

Manufacturing Quality Control Programs

Codes and descriptions are maintained in tables to streamline entry and validate data as it is entered:

  • Component Codes (TQCCC)
    Component codes describe the type of component that failed. In an electronics environment, for example, you might set up codes for resistors, fuses, relays, etc.

  • Component Tech Codes (TQCCT)
    Component technology codes describe the type of technology used with a failed component; e.g., surface-mount or through-hole.

  • Functional Areas (TQCFA)
    Functional area codes describe the type of test the component failed, such as visual or in-circuit.

  • Failure Codes (TQCFC)
    Failure codes describe the types of failures that can be reported. In an electronics assembly, bad solder or flux residue could be reasons for failure.

  • Test Stations (TQCTS)
    Test station codes define the physical location or specific test equipment used on the component.

Several programs are included for failure & repair entry, maintenance and reporting:

  • QC Failure (MOQC)
    Typically run from within WIP Movement (WIPM) when you click the QC tracking button to record a failure. See Failure Reporting.

  • QC Repair (MOQCM)
    Records repairs to previously-entered failures by manufacturing order and work center.

  • QC Maintenance by Manufacturing Order (MOQM)
    Displays operations for a specified manufacturing order and provides access to failure and repair data for each operation.

  • QC Failure to Rework (MQWK)
    Receives the failed unit to stock for the original order (picking any components if needed) and creates a new rework order for the failed unit.

  • Failure & Repair Inquiry (MOQCQ)
    Provides a summary of failure and repair data.

  • QC Defect Report (MQCDF)
    Lists failures including the item number, manufacturing order, failure description, operator, component designator and the date the failure record was added.

  • Manufacturing QC Detail Report (MQCDR)
    Reports failure and repair details, including serial numbers and the operator's remarks about the failure as well as the evaluator's remarks about repair.

  • First Pass Yield Report (MQCDP)
    Reports the number and percentage of units that pass the quality check at the time of the first test. Based on your sort and selection criteria, the report can show trends over time so that you can take corrective action.

Failure Reporting

The operator reports the number of tests completed as good pieces in WIP Movement (WIPM); failures can be recorded at the same time by clicking the QC tracking button.

The failed serial number is scanned or entered and following information is reported:

  • The testing operator's ID

  • The operation at which the item failed

  • The test type that failed

  • The test station where the failure was identified

  • Operator remarks (Notes can also be entered)

When multiple units fail for the same reason, failure data can be copied to other serial numbers.

Repair Reporting

When a failed unit is repaired, the serial number is entered in QC Failure & Repair (MOQC). It displays the failure and allows an evaluator to provide additional information. Entered data can aid in trend analysis for the product produced and/or the components consumed in production.

Data can include:

  • Component that failed (a lookup based on the manufacturing order component list is available)

  • Component type that failed

  • Component technology that failed

  • A specific component designator

  • A failure type

  • The ID of the evaluator completing the repair

  • Evaluator remarks (can be expanded by Notes entry)

The final step is the indication that the repair of the unit was completed, at which point the unit can be received to stock.

Note
Failure data can be entered as the unit is being repaired and does not have to wait until the unit is fully repaired.

When applicable, the same repair can be applied to other failed serial numbers. This can be a great time saver!