SPLITTING QUANITITES OF DEFECTIVE MATERIAL …documents.dmetrain.com/custom/1542/courses/Z90f1087/90f1087_revfi… · Work In-Process(WIP) – The status of material identified as

ZOLL Document Number: 90F1087 Page 3 of 18 MES/ERP Nonconforming Material Transaction Instructions REV FI ________________________________________________________________________________________

Proprietary of ZOLL ®

1. INTRODUCTION

The purpose of this document is to provide instruction for when and how to perform the ERP and MES transactions required to process nonconforming material. Execution of transactions per the instructions contained in this document ensure that nonconforming material can be properly identified and quantities in the system of record are accurately maintained. All defective material shall be processed per 90F0030, flowchart 90F1087-A01 and 90E1263.

2. APPLICABLE DOCUMENTS

90E1263 Camstar Visual Aid for QA Inspection 90F0030 Nonconforming Material 90F0072 Product Service 90F0112 Safe Handling and Cleaning Procedures for LifeVest System Hardware

3. DEFINITIONS

Container – Camstar’s primary method for identifying what is being processed in the system. System generated container names may be a lot number, serial number, inspection request parent identifier, inspection request child identifier, or a rework identifier. Other manually assigned container naming conventions are identified in this document. Work In-Process(WIP) – The status of material identified as the part being built on an open manufacturing order, serviced on a service order, or reworked on a rework order. Split Qty – The Camstar transaction used to divide a portion of an existing container into a new identical container that is named by the user. Naming conventions are defined in the instructions in this procedure Remove – The Camstar transaction used to un-issue material from the container it was issued to. By default, the material is returned to the container that it was issued from. Rework Transaction – The rework transaction is the Camstar transaction used to move defective material to a predefined step that has been configured to process nonconforming material.

4. SPLITTING QUANITITES OF DEFECTIVE MATERIAL IN CAMSTAR

4.1 Lot Controlled and Non-Serial/Non-Lot Controlled Material

4.1.1 Material Status: WIP

In order to send accepted material to inventory and defective material to the MRB for disposition, the defective quantity must be split into a new container. When performing the Split QTY transaction, the UCR or II number (e.g. UC-12345, II-12345) shall be used as the container name for the defective material.

If the full quantity associated with the order is defective, the container should not be split.



4.1.2 Material Status: In-Stock, Point of Use

Defective lot controlled or non-serial/non-lot controlled material that is not associated with an order in Camstar shall have a rework order generated in Epicor prior to MRB processing. Any quantity specified on the rework order that is available in Camstar will be automatically split by the system into a rework container using the rework numbering rule (RWxxxxxxxx).

Note: Any point of use material that has been issued to another container should be removed from that container before the rework order is generated in Epicor.

4.1.3 Multiple Dispositions for Lot Controlled Material on a Single UCR or II

4.1.3.1 Camstar requires that each disposition for lot controlled material is processed individually. When splitting material into a new container for this purpose, the following naming conventions should be used:

Disposition Container Name Return to Supplier (UCR# or II#)_RTV Scrap (UCR# or II#)_Scrap Use As Is (UCR# or II#)_UAI Use For (a special purpose) Only (UCR# or II#)_SPO Rework to Specification (UCR# or II#)_RW Other (UCR# or II#)_Other Multiple (UCR# or II#)_Mult

4.1.3.2 Any single piece of material can only exist in a single MES container at once. If any single piece of lot controlled material has multiple failure modes with different dispositions for each, use the naming convention for multiple dispositions.

4.2 Serial Controlled Material

Serial Controlled items shall never be split into a new container to process a nonconformance. Reference flowchart 90F1097-A01 for the appropriate transactions.

5. REPLACEMENT OF SUBASSEMBLY COMPONENTS

All components issued to subassemblies on a manufacturing order must be removed from that subassembly in order to be processed. In order to accomplish this, the subassembly must first be removed from any upper level assembly it is issued to. Once the defective component has been replaced, the subassembly must be reissued to the upper level assembly. Reference flowchart 90F1087-A01 for all required transactions.



Appendix A

Split Qty Transactions



Instructions for Executing the Split Qty Transaction

1. Generate an Unsatisfactory Condition Report (UCR) or add a nonconformance to the

Incoming Inspection (II) report per 90F0030. 2. Log into Camstar and enter the station ID.

3. Select the “Split Qty” transaction from the container menu. 4. Enter the name of the container being processed into the “Container” field. 5. In the “To Container” field, enter the container name using the instructions in the

“Splitting Defective Quantities in Camstar” section of this document. 6. Enter the quantity to be split into the “Quantity” field. 7. Click the Split button to complete the transaction. 8. Once the container has been split, generate a container label following the instructions

in Appendix C so the material can be identified. 9. For manufacturing, service, or rework order types, perform a rework transaction per

Appendix B. For incoming inspection containers, process per 90E1263.



Appendix B

Rework Transactions



Instructions for Executing a Rework Transaction 1. Create an UCR or record a nonconformance on the Service Report(SR). 2. Log into Camstar and enter the workstation.

3. Open the “Rework” screen. 4. Enter the name of the container identified on the container label for the defective

material. 5. Select the applicable “Rework Reason” from the drop down. 6. Enter the UCR or SR number/SR nonconformance item number in the “UCR/SR-

Number” field. 7. Click “Rework” to complete the transaction. 8. If required by 90F1087-A01, generate a reject label per Appendix C. 9. Forward the defective material to MRB for manufacturing (W) or rework (RW) order

types. Forward defective material to production control for service (SW) order types.



Appendix C

Label Printing



Appendix C

Instructions for Printing Labels

1. Log into Camstar and enter the workstation ID. 2. Open the “Print Container Labels” menu object.

3. Enter the container name of the material being processed. 4. Select the desired label template from the “Printer Label Definition”

dropdown menu. 5. Select the desired printer name from the “Print Queue” dropdown menu. 6. Enter the desired quantity of labels. 7. Click Print Label.

Note: Container labels and manufacturing labels may be applied directly to a finished good. All other labels will leave a residue when removed and contact with material surfaces should be avoided. If any other label is applied to a finished good, clean the area thoroughly using a method approved in 90F0112.



Appendix D

Generating a Rework Order



Instructions for generating a rework order in Epicor

1. Log into Epicor and open the Job Entry Screen

2. Select new job from the drop down menu.

3. Select next job.

4. Select ok.



5. Enter part number in the field next to the “Part…” button. 6. Select the Revision from the “Rev:” dropdown menu. Ensure that the revision selected

matches the revision of the material to be reworked.



WARNING: If the incorrect revision is selected the revision of the material will be changed in Camstar and when returned to inventory. This is not an approved method for converting revisions. All revision changes will take place in Camstar.

7. Select Rework Order from the “Job Type:” dropdown menu. 8. Enter the serial or lot number to be reworked. 9. Select today’s date as the requested date.

10. Select the arrow next to the “New” icon. 11. Select New Demand Link from drop down. 12. Select Make to Stock.

13. Enter the quantity to be placed on the order. All serialized items must be 1. 14. Click Save. Operations and Materials will appear in “Job Details” window. By default,

this is located on the left of the Job Entry screen.



15. Right click on Operation and select “Add Operation”.

16. Select Service from the drop down menu.

17. Right click on Materials



18. Enter part number and select revision from the dropdown menu. Ensure that the

revision matches the revision of the material being reworked.

WARNING: If the revision does not match the revision of the material in inventory, it will not be removed from inventory when the order is generated.

19. Check the Released box. 20. Click Save.

WARNING: Clicking Save will automatically send the rework order to Camstar. Any errors identified after an order is received by Camstar shall be treated as a nonconformance and processed per 90F0030 and the rework order section of 90F1087-A01 to ensure system accuracy.



21. Enter comments and select ok. The order will automatically be sent to Camstar at this

point.

90F1087‐A01 ‐ Nonconforming Materials MES/ERP Transaction FlowIncoming

Inspectio

nStock

Rework Order

Service

POU M

aterials

Manufacturin

g

Return to VendorIdentification of Nonconformance MRB Scrap Rework Use As Is Engineering Investigation

Record Defects on II Report

Record defective Qty in Camstar

Perform Split Qty to move defective material to a new

container.

Move defective container(s) to MRB

pathLotLot or Serial

Controlled?

Serial

Print and Attach Reject Label

Process MRB in QA Database/Docuclass Quarantine? Yes Perform Hold

Transaction

Perform Release when Quarantine Release

form is signed

Assign move path based on disposition in

Camstar

Epicor automatically performs transactions based on disposition

No

Generate Rework Order in Epicor

MRB indicates that a possible defect is

associated with the RW order


Process MRB in QA Database/Docuclass

Device/Sub Assy or Component

Component

LotLot or Serial Controlled?

Transfer to MES Warehouse in Epicor

Serial

Perform Rework transaction to send

to MRB


Is the item associated with an

order?

Is the order already complete (in the FGI workflow)?

Yes No

No Perform Scrap transaction in Epicor

YesYes

Perform Hold Transaction

Perform Release after Quarantine Release

form is signedNo

Perform Change Qty to trigger order

completion in Camstar

Device or Component?

Device

Was the component issued during this service cycle? (new)

Component No Discard Component (No Transactions)

Add Nonconformance to Service Report

Perform Rework Transaction to Send to Production Control

Scrap?

No

Yes

Financial Scrap Identified

Scrap

Rework

Return to Vendor

Move to Production Control for Routing

Is the item associated with an

order?

Is the order already complete (in the FGI workflow)?

Yes

No

Yes

Generate Rework Order in Epicor

MRB indicates that a possible defect is

associated with the RW order

No Forward to RMA processor

Enter the vendor in Camstar and move to holding step using

Procedure

POPO or Rework Order?

RW

Select appropriate path to move to inventory or production control

for routing.

Use As Is

Answer Routing Questions and route

for service

Item associated with RW or

component issued to it?

Component

Perform split qty per from original

container

Perform Rework transaction to send

to MRBLot

Serial


Item associated with RW

Lot or Serial Controlled?

Has the component been issued?

Perform Component Remove

(removes to the container it came

from)*

No

Can the component be reworked or RTV

offline?

Yes

Yes Print and Attach Reject Label

Device/Sub Assy

Perform Split qty for the defective qty

Lot or Serial Controlled? Serial

Lot

Defective

Click move to send accepted material to

inventory.

Accepted

Perform Hold Transaction for hold reason “Eng_Inv”

Engineering Investigation

What was the disposition?

Perform Release transaction for release reason “Inv_Comp”

Move to production control for routing.

DRAWING NO.

REVISION C.O.CAD FILE

SHEET OF

Nonconforming Materials Transaction Flow Chart

90F1087‐A01

FI90F1087‐A01_revfi.vsd NA

ZOLL MANUFACTURING CORPORATION121 GAMMA DRIVE

PITTSBURGH, PA 15238‐2919

11

What level has the component been

issued to?1 (current container)

Perform Component Remove to remove

subassembly*

* Replacement components must be issued to the subassembly and the subassembly must be reissued to the top level. 2 or higher (issued to a subasembly)

Does Engineering recommend scrapping?

No

Yes

Process MRB and indicate disposition and move in Camstar

No

Were multiple dispositions assigned?

Perform Split Qty per 90F0030 for each

disposition

Quarantine/Engineering Hold?

No

Yes

KeyCamstar Transaction

Epicor Transaction

Defect Identified

Defect Identified – Generate UCR

Incoming Inspection Database/Docuclass

UCR Database/Docuclass

Service Database/Docuclass

QA Database/Docuclass




Defect Identified

Lot Controlled or Serial Controlled

Lot

Serial

System Responsibility

QA – QualityMfg – Manufacturing/ServiceMat – Material Control

QA

QA, Mfg

QA QA QA QA QA QA QA

QA

QA

QAMatMat

QA or MFGQA or MFGQA

QA or MFG QA or MFG

QA

QA

QA QA

QA QA

QA

QA QA

QA

QA, Mfg or Mat

QA

QA

QA

Mat

QA

Mfg

Mfg

Mfg

QA or MfgQA or Mfg

Mfg

Documents

SPLITTING QUANITITES OF DEFECTIVE MATERIAL …documents.dmetrain.com/custom/1542/courses/Z90f1087/90f1087_revfi… · Work In-Process(WIP) – The status of material identified as