Defect and rejection management (DMR)Defect and rejection management (DMR)

Business challenge

A rejected part or batch started a paper discrepant material report. It travelled between production, quality, engineering and purchasing, was photocopied, lost and re-created, and the decision, rework, use-as-is, scrap or return to vendor, was made without the history of similar events. Corrective actions were promised in meetings and forgotten.

Solution

Futera built a defect management application on SAP quality notifications. An operator, an inspector or a receiver records the event on a tablet or desktop: material, batch or serial, order, defect code, quantity, photos. The affected stock is blocked in SAP at once. The notification moves to the material review board with the full history of that material and supplier, and the board records its disposition. Each disposition triggers the right SAP follow-up automatically: a rework order with the extra operations, a scrap posting with the cost object, a return delivery to the vendor, or a release with a deviation record. Corrective and preventive actions are assigned with owners and due dates, and the event closes only when they are done. A management view shows open events, cost of poor quality and repeat offenders by supplier, material and machine.

Results

• Every quality event has one record, one owner and one status
• Rework orders, scrap postings and vendor returns are created from the decision, not typed afterwards
• Corrective actions are tracked to closure, not to the next meeting
• Repeat defects by supplier, material and machine are visible

Technologies