Red Highlighted:

  • For Treated type Work order if the difference between book date and today's date is greater than 16 weeks
    and Work Order is not closed Company in Summary Page is shown in red
  • For Untreated type work order if the difference between book date and today's date is greater than 12 weeks
    and Work Order is not closed Company in Summary page is shown in red.

1. Cust PO

Based on the PRN entered by the user in the line item

  • Part Number and Part Name details are taken from Master Data (Active).
  • The remaining details i.e. RM Type, RM Spec, Condition, uom, length, width, thickness, grain flow, maxruling, altspec and unit RM cost details are taken from RM Master.
  • All spec types of RM Master i.e. Primary Spec, Alt Spec1, and Alt Spec2 are shown.
  • No comparison of the data.

2. Assembly Review

  • The PRN, Part Number, Description, BOM ref, BOM Issue (BOM rev #) fields are populated with data from BOM master.
  • Along with the parent details the child details i.e. manufactured, sub assembly, bought out items and consumables are also populated in the line items after the parent details.
  • The user should enter the line number and qty before selecting a parent PRN and BOM details.The quantity for the child is calculated based on the quantity entered for the parent i.e. parent quantity * qpa of the child. The line numbers for the child is based on the line number of the parent.
  • No comparison of the data.

3. RM PO

  • Data from RM Master (Active) is taken based on the supplier, spec type and PRN entered for Regular type PO .If there are no data matching for the given specification an error message is shown indicating the same.
  • For Bought Out and Consumable type PO's the instead of PRN part number is entered and data fetch happens from Part Master based on the supplier and part number given. If there are no data matching for the given specification an error message is shown indicating the same.
  • The fields material type and material spec is populated with type and manufacture part number respectively. The no of lengths is calculated based on the order quantity entered.
  • Once the data is selected for regular type PO's fields i.e. Dia, length, width, thickness, rmtype, rmspec,grainflow, maxruling, uom of RM Master (Primary Spec Only) is compared with data in the cust po line items(Active) for the entered PRN.
  • After the comparison the non matching data are shown in red. No action is taken. If Special Characters are present an alert is shown indicating the same.
  • (f) After the PO is entered the quantity received is auto populated as and when a GRN is created for the PO along with the accepted date i.e. received date of the GRN. If the quantity coming from GRN is same as or 10 % more than PO quantity i.e. either no of lengths or no. of meterages the status of the respective line item is set to closed.
  • If more than one GRN is created for the same PRN and line number new line with same details as the parent PRN line is auto created. The new line number is based on the parent line number. The respective GRN number, accepted date and quantity received are entered.

4. GRN

  • If the GRN is RM by Company based on the PO# and RMPO line number entered the respective PRN is populated into PO PRN field.
  • After the GRN line item(s) are entered and submitted the entered length, width and thickness along with raw material spec , type and quantity is compared with RMPO data for the PRN and line number. No special character Check .
  • After the comparison if validation fails GRN is stored in pending state. If validation is complete GRN is stored in Open state. The pending GRN will go to open state once the pending GRN is approved by the Director or Purchasing Department.
  • (The GRN can be amended by entering a new line item with the required specification along with parent line number in the amend line number column. This line will not be considered to calculate the total qty of the GRN.
  • A child GRN can be created for open GRN's with amended line with the same specifications as the parent GRN except for line items. The parent GRN # will be stored in the child GRN.
  • After submit the child GRN data is validated with RM type and RM spec of RM master (it should match with at least one spec type of the PRN) and Length, width &thickness are compared with dim1, dim2 & dim3 of Master Data.
  • When a GRN is created a new record for the consumption is auto entered with details like invoice number, invoice date,GRN#,GRN date, RM type, RM spec, length, width , thickness, GRN type, parentGRN # quantity and quantity to make. If GRN is edited the respective fields are updated.

5. WO

  • When creating a Work Order on getPRN all the active PRN's from master data are shown on submit fields part number, part name, project, mps#,mps rev#,drawing #,Rm by customer,Rm by Comp, part iss , cos, drg iss,dim1,dim2 and dim3 are populated.
  • Cust PO#,Customer,Cust PO qty and Cust PO date fields are populated with data from Cust Po and Cust PO line items.
  • Before the set of data part Iss, Drg Iss and Cos Iss of Cust PO line items are compared with PartIss/Attachments, Drg Iss and Cos Iss of Master data. In case of mismatch of data alert is shown to the user indicating the same and submit of PO details is aborted.
  • If a Work Order is being created for a PRN with treatment type Manufacture/With Treatment and there exists a Work Order which is 84/112 weeks old then an alert is shown as Red highlighted WO exists for the PRN and get PO is aborted similarly if Fair status is not entered for the previous Work Order for the PRN an alert is shown as Fair Status not entered and get PO aborted.
  • RM Type and RM Spec fields are taken from GRN along with GRN number and batch number. WO quantity cannot be greater than the selected GRN quantity.
  • When a WO is cancelled the parts are returned to the GRN and the same is reflected in the GRN balance shown in details and summary.
  • To split a Work Order amendment qty has to be entered in the parent WO and stage changed to 'split' The child WO will have the same qty as parent WO amendment qty and parent wonum as Worefnum.
  • For treatment type DN entry can be created when DN stage is entered in the line items. After the DN is created and line item is entered by respective departments the WO line item is updated with the data entered in DN.If the DN is cancelled the respective line item from WO are deleted and qty's are updated.

6. BOM

  • A BOM is created for Assembly/Kit type PRN. Relevant data PRN# , cos iss, drg iss, drg no, assy part number are taken from Master Data (Active).
  • For Manufactured Line Items both manufactured and assembly type PRN's and related Fields part# , part name ,part iss, mps rev, mps # ,drg iss are taken from Master Data based on the type select. For Bought out Items Part Number, description, part iss, drg iss ,make ,supplier details are taken from Vend Part Master.
  • After the BOM is created it is stored in pending state and all the details can be edited until It is approved by QA department. Once approved BOM goes to active state.
  • Two BOM's with same revision number cannot be in active state. Edit of inactive BOM's is not allowed.

7. Assembly Work Order

  • All the details i.e. manufactured, Sub Assembly, Bought Out, consumables from BOM based on the BOM selected while creating the Assembly WO is populated. The qty for WO is the product of assembly qty and qpa for the respective PRN's and part number.
  • Cust PO#,Customer and Cust PO qty fields are populated with data from Assembly Review Assembly Review line items.
  • Two types of Assembly WO's can be created i.e. Assembly type or Kit type.

8. SP PO

  • For 'regular' cust po type PRN, RM type, item description, cos iss, drg iss, RM spec and part iss details are taken from Cust PO Line Item (Active), part number and secondary number are taken from Master data (active) and price from SP Master.
  • For cust po type other than 'regular' PRN, drg iss and part iss are taken from BOM Manufactured Items. Part number and secondary number are taken from Master data (active). No price Fetch. Cust Po Number is taken from Assembly Review.

9. RM Master

  • A PRN with different spec types i.e. primary spec, alt spec1,alt spec2 and alt specP can be created. Two active PRN's with same spec type cannot be created.
  • For a PRN to become Active it has to be approved by both Directors and Engineering Departments.

10. Reports

  • All the reports for stock, efficiency and discrepancy are shown.
  • The PRN stock report shows the total available quantity for a particular PRN entered.
    • The Work in progress (WIP) is the total quantity that is still in open state and under progress. For Treatment type WO's the WIP is the total WO qty (open) excluding the quantity that has been sent for treatment.
    • The Delivery Note (DN) balance is the total DN Qty sent subtracted by total DN qty received. This qty is present only for treatment type Work Orders.
    • The Finished Goods (FG) Qty is the total qty that need to be dispatched. The FG qty is difference between total WO Comp Qty (closed WO) and total dispatched qty.
    • The GRN stock is the total available GRN stock i.e. GRN Qty- WO qty + WO rework.
    • The RMPO qty is the Order Qty for that PRN (Latest Due date and PO is considered).
    • If the delivery of PO is done by air then an additional 20 days is added to the due date and an additional 60 days if it is by sea.It also shows details of these stocks.

11. StrokesCalc

  • Strokes Calculation based on how many shifts per day and avail capacity hours and per month how many working days.
    • Here We did 24 working day per month.
    • Perday Hours = Mc Avail Hrs/(24 * shifts)
    • Strokes per Hours = ff hrs/Perday Hours
    • Days = Strokes per Hours/Shift Hours
    • Hours = Strokes per Hours%Shift Hours

12. Master Data

  • Create a new PRN(Product Reference Number) for the particular customer based on customer requirements.
  • Enter the details like PRN, Customer, Part #, Part Name, RM by customer or RM by host, select treatment, select type whether it is Assembly/non-Assembly/Kit and Dimensions.
  • MPS line items should be entered which will be reflected in MPS Page.
  • Once a New Master is sumbitted, the New PRN will be in Pending status, respective engineer should approve it and then make the status Active.

13. MPS(Master Process Sheet)

  • Here we get all the necessary details from the Master Data, and we enter the process sheet details like customer supplied model reference, engineering, control and remarks.
  • We need to enter line items for the new master process sheet, the details are like operation, description, work center, Alternative work center, Jig/fix Value, DC, Sealant/paint then submit
  • On submit of New MPS, MPS will be displayed on Details page, we can delete the NEW MPS created if not required; To proceed further change the status from pending to Active.

14. CRM

  • In CRM we have su-divisions like Enquiry, Risk, Quote, Sales Order, Assy SO, Cust Feedback, which play a very important roles for the customers from enquiry to Sales Order
  • Enquiry: Select the PRN, that displays its details which is accessed from the master data, then enter the quantity and remarks accordingly.
  • Risk: Risk Assesment will be done for the customer enquiry. Select the customer and required enquiry id, make the risk assesments accordingly from the risk line items, which will be reflected in the enquiry details, quote details and in the sales order page.
  • Quote: Create a quote for the enquiry, generate quote ID, quote revision, quote date, enter quote description, select the customer, RFQ ID, delivery date, sales person and enter line items by selecting the Part # and enter the quantity and unit price then submit. Once the quote is finalized change the locked status to locked, so that no further changes can be done.
  • Sales Order: Enter the Customer PO number, select the customer, order date, quote reference, special instructions, contact information, enter line items : select the PRN, enter quantity and unit price.

15. Purchasing

  • Whenever we get an order and we don't have a required raw materials, then the Purchasing will come into picture.
  • RFQ (Request For Quotation) : Here we select the supplier, customer, status and enter ID, approval and then enter line items where you will be selecting the prn and entering the required quantity.
  • Supp Quote : Here supplier quote will be created enter quote ID and fetch RFQ ID, supplier, customer, quote date, deliver date and quote description. Enter the quote line items, fetch the PRN, enter the quantity and unit price. Once the quote is finalized change the locked status from Not locked to locked.
  • PO : Here we fetch the Supplier, Shipping to host, PO date, Quote ID, Customer, type; enter description, remarks and line items, in line items we fetch Cust PO if we have a sales order that matches the customer, other wise will fetch the PRN which will be fetched from the RM Master where supplier is matched.
  • Assy SO : Assembly Sales Order comes into a picture if the PRN is of type Assembly, enter Assembly Review #, select Customer, PO Date, Special Instructions; Next at line items select the PRN and enter the qty, unit price.
  • Supp Eval : Supplier Evaluation is all about Rating the the supplier based on service provided by the supplier, which helps to select the right supplier. Select the supplier and Rate accordingly.

16. WO

  • Reg WO : We create a new Work Order here, select Work Order Type, if Work order type is 'Regular' then get WO Date, quantity, get PRN which will be from Master, get Cust PO which will be from Sales Order, get GRN which is from stores. In Time Line & Owner, get schedule due date then submit.
    • In Details page, Specific departments concerned person has to have to approve the milestones. Then go to Edit.
    • In Edit WO, Approve the MPS details, enter the Part Status details like, squence number, stage, Sl. Number from and to, Sampling Serial Number, Accept Qty, Rework Qty if any, Reject Qty if any, NC Qty if any, Return if any, Hold if any, Date, Final Inspection Number, signoff and remarks. Change the WO status to closed and enter the Actual completion date then submit. Now the work order is closed.

17. QA

  • Final Inspection: Get PRN, WO #, enter bill # and date, issue, report #, page, Qty; Enter final inspection line item deatils like drawing sheet, Dimension Map, dismensions main view, Actual dimensions and accept/reject. Enter the details like inspected by, inspected date, approved by and approved date, then submit; This will be sent to FAIR, where it needs to be approved.
  • FAIR : Here we approve the entry then we can proceed further in WO to close it.

18. Dispatch

  • Enter details to dispatch the work order that is closed. Enter the details like type, dispatch date, company name, PRN, schedule date, pending schedule qty; Enter line items that gets the WO #, enter qty and packing slip number.

19. Invoice

  • Invoice : Generate Invoice for the dispatch, get Customer name, shipping Address, Invoice date, due date, DC Num, description, currency, FOB/C&F/DAP, mention remarks and terms. Based on qty and pricing the total amount will be calculated along with taxes and the Invoice is complete.
  • Pricing : Here we set the price for the particular PRN, hence enter the details like customer, PRN, Part Num, Part Name, Price, Type, Status, Validity of price, remarks.

20. DC Cust

  • Once the product is ready for dispatch, the stores will generate DC Cust, Where details like From and To addresses, DC date, HSN/SAC code, Transport by land/sea/air, Vehicle No., select PRN, Number of Box, Net Weight and Gross Weight need to be entered to generate Delivery Challan.