Calibration process mapping in SAP
Hi,I want to share my experience of implementing calibration process in SAP.we have use SAP MM,SAP QM and SAP PM module for mapping required scenario.
Business Scenario :Business has to do calibration of test equipments on periodic basis,calibration of few equipment is inhouse and for few equipment it will be done by external vendor.after calibration test equipment location details,calibration date are updated in document called history card.history card consist of unique serial number which is also label on test equipments.schedule of test equipment calibration is maintain manually.Quality control team has to review documents regularly to know Test equipments pending for Calibration.
Challenges during SAP Implementation :
1.Uploading of existing Test Equipments in SAP system
2.Capturing history of each and every Test Equipment with Calibration status,Last Calibration date,Procurement details,Location details.
3.Automatic reminder for Test Equipment Calibration.
4.Capturing Calibration Certificate.
5.Identify Test Equipments at Vendor Locations.
Steps we followed for mapping calibration process in SAP are as below :
Master data creation:
1.Identified Test equipments with common attributes and created unique material code for same with serial number profile.
2.serial number profile profile is created in such way that Equipment number and Serial number will be same
3.Physical stock of Test Equipment are noted in excel sheet.
4.Test Equipment stock upload done in SAP using initial stock movement 561.
5.Test Equipment at vendor location uploaded in system using initial stock movement 561-O.
6.Attributes required for Calibration check are created in SAP as Master Inspection Characteristics (MIC).
7.Test Equipment with common check list are identified and group task prepared for such equipment with Master Inspection Characteristics
8.For special equipments Equipment task list is prepared with MIC.
9.Maintenance Plan/Calibration Plan created with frequency of calibration period ie.monthly,half yearly or yearly.
10.Scheduling of maintenance plan (IP24) as background job.
Calibration order execution :
1.Calibration order get generated in system automatically base of calibration(IW39).
2.Calibration order are review and release for Calibration operation.
3.On release of order,In case of Inhouse Calibration,Inspection lot will get generated,Quality Inspector can perform calibration and update result in system against Inspection lot ( QA32 ).after completion of operation,operation confirmation was done.Calibration order status updated as completed.
4.In case of external calibration,Purchase requisition generated is converted into Purchase order buy purchasing,Test equipment issue (541) to vendor against PO and during good receipt Inspection lot will get generated,Inspection can be done before taking calibrated instrument into unrestricted stock, confirmation of external calibration operation and closing of calibration order will be done.
5.Calibration certificate are scanned and attached in equipment master using document Management system.
1.History of Test Equipment Captured from Equipment Master,Serial number history option (IE03).
2.Calibration orders list with status ( IW39 ).
Advantages of SAP Implementation:
1.No need to maintain history card,equipment history captured through Equipment master
2.Test Equipment pending for Calibration easily available (IW39)
3.Repeatation of work reduced
4.Tracebility of equipment is become easy.
5.Real time data available for Quality Control team.
6.Cost of Calibration can be captured.
I hoped above mention scenario will help you.