2480 Johns Manvilles (JM) 8D CAPA Solution Within SAP Quality Issue Management (QIM)

JM’s 8D/CAPA solution within SAP QIM Ginny Wilson – Johns Manville Carl Dunlap – QMS

SESSION CODE: PLM2480

Johns Manville (JM), a Berkshire Hathaway Company, is a leading manufacturer and marketer of premium-quality products for building insulation, mechanical insulation, commercial roofing, and roof insulation, as well as fibers and nonwovens for commercial, industrial, and residential applications. JM serves markets that include aerospace, automotive and transportation, air handling, appliance, HVAC, pipe and equipment, filtration, waterproofing, building, flooring, interiors, and wind energy. In business since 1858, the Denver-based company provides products to more than 85 countries and operates 44 manufacturing facilities in North America, Europe and China.

About QMS QMS: The SAP Consulting Experts QMS is the SAP Consulting Services Partner focused on the Manufacturing Sector. As the recognized global industry leader in SAP Manufacturing and Quality Management, our practical industry experience and expert SAP skills can be leveraged to assist with SAP business and IT consulting to help you achieve your business goals.

 Global Leaders in SAP with unparalleled experience in SAP Manufacturing Solutions, SAP Quality Management and SAP Extended Supply Chain

 Deep industry experience: Automotive, Chemicals, Consumer Products, Durable Goods, High Tech, Industrial Machinery & Components, Life Sciences, Oil & Gas, Retail, Telecommunications, Utilities, and Wholesale Distribution

 Focused on delivering results using SAP to meet complex regulatory, quality and unique business requirements while creating Best Practices throughout the SAP Ecosystem.

 QMS – 2012, 2013, 2014 Winner of the Inc. 5000 “Fastest Growing Companies Award” 3 Years running- a remarkable achievement.

Our Mission is to set a new standard of excellence for SAP Consulting, worldwide .

Learning Points  How the SAP QIM solution enabled the Corrective Action / Preventative Action (CAPA) business process at JM.  User involvement and ownership throughout the design/development cycle was key to implementing the correct solution.  Conducting continuous global reviews utilizing Agile methodology to ensure a timely response to changes.  The system must be easy to use for successful user adoption.

Challenges Current root cause and corrective action processes and tracking was decentralized and maintained in offline systems MS Excel and/or SharePoint. No consistent process between like manufacturing plants let alone across business units. There is no workflow for these Excel based solutions; therefore, tracking and metrics are difficult to measure and efficiency to resolve complaints was lacking. No knowledge management with Excel based solution nor were they linked to the complaint within SAP.

Why QIM? Integrated SAP product Web Based Solution with a flexible user interface Single Sign On Embedded business logic (automatic determination of partners, codes, activities) Workflow notifications & escalations Search capabilities (including within attached documents) Real time Analytics Built in 8D methodology (Global standard)

Best Practices  Maintain one Global system and process but allow for individual business differences.  Global agreement on master data extracted from the existing complaint systems and validated by the businesses which streamlined the implementation.  Realization that a CAPA system is only a tool to enable business processes.  Ability to share similar issues and solutions across all business units.

What is an 8D?  Closed-loop method used to approach and to resolve problems via the deployment of the Eight Disciplines (8D)  Typically employed by quality engineers or other professionals

 Purpose is to identify, correct and eliminate recurring problems  Commonly used in product and process improvement.

 Establishes a permanent corrective action based on statistical analysis of the problem (when appropriate) and focuses on the origin of the problem by determining its root causes

D1

•Team

D2

•Problem Description

D3

•Containment Action(s)

D4

•Root Cause(s)

D5

D6 D7 D8

•Chosen Permanent Corrective Action(s) •Implemented Permanent Corrective Action(s) •Action(s) to Prevent Recurrence

•Congratulate Your Team

CAPA Creation via Quality Notification



Action Box for Creation and Display of QIM Issue

CAPA Creation via Quality Notification 

Store QIM Issue number within Quality Notification



Pull Quality Notification list into QIM Work list

CAPA Overview 

Reference objects used to hold objects from the Quality Notification 



Drill down capabilities launching master data transactions in Web GUI

Additional fields copied include QN short and long text, defects and quantity

CAPA Overview



8D steps with the addition of a Defects tab

D1 - Team

In the step D1 – Team, you enter the members of the problem-solving team by specifying the partner roles and business partners.  Partner roles provided by delivery customizing 

D2 - Problem Description



In the step D2 – Problem Description, the system copies the data (for the codes and description, for example) from the defect. You can overwrite this copied data.

D3 – Containment Actions

 In the step D3 - Containments Action(s), you can create immediate containment actions for the 8D problem analysis via a quick entry function. The activities are ad hoc in nature to allow a dynamic response to the problem.

D4 – Root Causes

If you have performed a defect analysis, you can enter the root causes in the step D4 – Root Causes. For each cause, you can specify under % Contribution which proportion each cause contributed to the defect.

D5 - Chosen Permanent Corrective Action (cause level)

 In the step D5 – Chosen Permanent Corrective Action, you can create a plan of corrective actions for the 8D problem analysis. The system uses the activity type or activity template that you stored in Customizing for the respective step.

D6 - Implemented Permanent Corrective Action(s) (at cause level)

 In the step D6 – Implemented Permanent Corrective Action, you can capture the corrective actions actually performed for the 8D problem analysis. The system uses the activity type or activity template that you stored in Customizing for the respective step.

D7 - Action(s) to Prevent Recurrence (at header level)

 In the step D7 – Action(s) to Prevent Recurrence, you can capture the preventative actions usedh for the 8D problem analysis. The system uses the activity type or activity template that you stored in Customizing for the respective step.

D8 - Congratulate Your Team (at header level)

 In the step D8 – Congratulate Your Team, one can categorize the overall process, findings or result of the Issue.

Key Learnings / Wins Keep the system simple and easy to use!  Deploy out of the box functionality; enhance after the users are in the production system.  Have a cross-functional team to design a centralized global close looped CAPA system while allowing for individual business processes.  Small core work group / larger review group using Agile methodology  Enables the business to align and execute on actions to prevent a root cause from reoccurring.

Key Learnings / Wins (Cont’d)  Ability for system notifications (workflow) and escalations.  Searchable document repository which enhances collaboration via Global Enterprise Search.  Standardized all forms i.e. 5Y, Deviation, and 8D across all of JM.  Ability to print or email 8D reports directly out of QIM at any stage of the process including attachments / images.

STAY INFORMED Follow the ASUGNews team: Tom Wailgum: @twailgum Chris Kanaracus: @chriskanaracus

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