Microsoft Word - Production Module
Microsoft Word - Production Module
Microsoft Word - Production Module
Packing Master
Accessibility:
Purpose
This is the master form in which user can define the unit of packing bags. This is
basically as per the convenience of customers and their requirement. User can declare the
packing codes and can use them in various forms of bagging.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Packing Code: The user can define the code as per the requirement.
Packing Type: User can define the type either as BAG or SILO.
Units in Pack: User can define in one pack how many such units are there.
Gate Entry Required: This is checkbox type here user can state whether
Gate Entry is required or not.
Status: User can set whether this Packing Code is still in use or not.
Bags Enquiry
Accessibility:
Purpose
This is the form as the name says is to cancel the excess Bag Tags. User usually prints the
Bag Tag prior to Bags actual bagging. It is quite possible that user is left over with
excess tags. These tags have to be cancelled then this menu works in. If the status is open
then these are displayed and can be cancelled.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Item Code: The user can select the type from the list of values provided. This
list can be obtained by pressing Function Key F9 and selecting the same from
this.
From Bags No.: This list can be obtained by pressing Function Key F9 and
selecting the same from this.
To Bags No.: This list can be obtained by pressing Function Key F9 and
selecting the same from this.
User can also press this button to display the list below.
Simplified Business Management System
Page No:
Location Master
Accessibility:
Purpose
This is the master form in which user can define the location of finished and semi
finished goods. It maintains all the database of products and contact persons as well.
Products can be traced back with the help of location and parent location in the time of
need.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Plant: User has to give the location in plant whether it is Yard or Port or SSP
or AMP.
Main Store Code: Main store code can be defined by the user.
Location Type: Now user has to define the location type. It is drop down
External/Internal Transfer: This field user has again to select for what
Packing Type: User has to select here also so as to define the packing type
On/Off Spec Grade: User can define whether this is off spec product or
on spec grade of product.
Status: This is check box option to state whether this field is used or not.
Once all this data entry is done the user has to save the template. He can do this either by
using the Save Button on top left corner
Contact details of person name, address, city, postal code, phone number, email can be
filled and saved here.
One can go back to menu by pressing Previous Button.
Prod Tracing
Accessibility:
Purpose
This is basically a multi entry query form in which if user knows a little bit knowledge
about the product and rest of details are missing then system can help user in tracing back
and get the exact details of the product.
Now once this request form is opened then the screen looks like
Key Fields:
User can trace the product, it means user can open the form and then press F7 to enter
into query mode. Once user is in query mode now data known to user is to be entered in
the right field and then press Function key F8 to execute query. Results corresponding to
that particular field are obtained and displayed on the screen.
For example only SSP Production from date is known to 2007.09.10, user can input this
detail in F7 mode and press F8 query mode to see details as below corresponding to that
date..
Like wise can be done for rest of the fields and data can be traced back with the help of
this form.
Silo Empty
Accessibility:
Purpose
This is the master form in which user can define the type of list values in any type of
form. If some new field is defined then the same has to be added into the masters so as it
is visible for users to select, in that case fields can be appended to one or any number of
tables through this master form.
Now once this request form is opened then the screen looks like
Key Fields:
This is a virtual table inside a form. This is automatically picked up from the master. The
fields shown in left table are the ones which are illustrated in the database table. The
user can navigate from one code to another by down arrow key and corresponding values
are shown in right table, which can be amended as per need.
Status: User can check this box if this code is in use or vice versa.
Description: The user can describe the name of the required field or category
which is to be inserted. These are displayed in the list of value while data
entry.
Values: These are the values which are inserted into the table means database.
Status: User can check this box if this is still in use or vice versa.
Silo Empty
Accessibility:
Purpose
This is the master form in which user can define the number of shifts in which user has to
work or will be working.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Shift: The user can select the code for the type of shift.
Shift Name: The user can describe the name of the shift..
Status: User can check this box if this is still in use or vice versa.
Silo Empty
Accessibility:
Purpose
This is the entry form in which user can detail the status of silo. User can key in when the
silo got empty and date followed by the reason of the same.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Empty Date: The user can enter the date. Press F9 to get the help in date
menu to select.
Location Name: The user can enter the location name. Press F9 to get the
help in list menu to select.
Empty Time: User can key in the time when silo got empty.
Main Template
Accessibility:
Purpose
This is the master form in which user can define the template of work or process. The
whole idea of using template is to avoid repetitive work. A set pattern of process can be
saved in as template and can be used whenever such process is required. User can define
location, item, code and quantity required in terms of multiples so as tedious calculation
becomes at backhand.
Key Fields:
These are mandatory fields. The user has to enter data in them.
Plant Name: The user has to input the plant name. This field is optional.
From Date: Date can be given from which date this template is used.
Status: When this template is made then it is kept open. Then this is to be
Location: User gives the location of item. Function key F9 can be pressed to
get the list of items and the same can be declared in Location Master.
Item Code: User has to enter the item code involved. Function key F9 can be
pressed to get the list of items.
Entry/Formula: User can select from drop down menu, either as entry or
formula based.
Factor: User has to declare what is the factor of usage declaring how much is
used during a particular process.
Direct Qty Entry: If there is some direct quantity entry then user can state
here.
Status: This is check box option to state whether this field is used or not.
Ref Item Name: This is display field picked from Item Master.
Once all this data entry is done the user has to save the template. He can do this either by
using the Save Button on top left corner
Silo Empty
Accessibility:
Purpose
This is the master form in which user can define the relation between the item code and
the location name. User can segregate the same on the basis of product and in which silo
or line the same has to go.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Item Code: The user can select the same from the list of values provided by
pressing F9 and select the item.
Location Name: The user can describe the location where the item goes to.
Status: User can check this box if this is still in use or vice versa.
This form is designed for defining Quality Parameters for all type of item codes
for the Production departments.
Accessibility:
(MODULE Production SUB MODULE QC Parameter Master LT)
(Action Double Click on QC Parameter Master LT)
Purpose:
The main purpose of QC Parameter Master LT is to define exact parameter
names for each and every item codes, defining the precision level of tests, their minimum
and maximum values, their units and methods of tests. The basic idea behind this form is
to have a detailed value analysis of item codes which are required by the Production
Department.
Key Fields
Item Code: Item codes are the codes defining the category of product. Each and
every product required by the customer has certain fixed specifications, based on
these specifications items are categorized into various item and thus item codes.
Parameter Name: Now every item can be categorized into different type based
on few parameters so Parameter is basis of different item types. So one can define
here what the type of test it is.
Decimal Entry: Tells up to what preciseness results are required for internal use.
Decimal Report: This tells up to what preciseness results are required for
reporting use.
Value: This tells the range of value for this kind of item. Minimum and
Maximum range can be specified.
Sale: This tells the range of sale value for this kind of item, this is as per customer
for selling purpose. Minimum and Maximum range can be specified.
Sq. No.: This tells the sequence of parameters tests for a particular item. This can
also be as number of tests for parameters for any particular item.
Default Value: This value defines what type of item it is if certain default value is
given.
Unit: This defines the Unit of Measurement for that particular parameter name.
This can be different as per parameter.
Test Method: These are the Certificate of Methods of Indorama Polymer Public
Company certified by South East Company.( Please fill in correct name)
Type: The item and parameters and parameter tests can be divided into three
Remarks: User can enter his comments or details of item here if required.
Certain customers also do not want to indulge them selves in rechecking the
quality of product. So these require from us a COA Certificate Of Analysis
stating the quality on each and every bag or lot, it becomes our responsibility to
state the exact parameters. These companies randomly re-check our Print Seals
and if there is any error then our company becomes responsible for the same.
Such types of valued customers are maintained separately. User can click on this
Customer Parameter Master and screen shows as below.
Purpose
This is the entry form in which user can make adjustment entries. This is basically for
PLA that is silo 4, where the results of quality are received later and then these have to be
categorized into the graded quality as per the results. Sometimes it also happens that
production assumes a certain amount of product and later some part of it goes off grade
and has to be re-categorized and then this module works in to do the same by putting
transfer entry.
Now once this request form is opened then the screen looks like
Key Fields:
Template Category: User can select the same by help menu pressing F9 key and
enter the template used.
Location Name: User can select the same by help menu pressing F9 key and
select the location name from the list.
From Date: User can select the same by help menu pressing F9 key and selecting
the date of product.
To Date: User can select the same by help menu pressing F9 key and selecting
the date of product.
Item Code: User can select the same by help menu pressing F9 key and selecting
the item code of product produced.
User can press this button and get the details of daily production of the
required date and template. The list is fetched from the database and displayed with the
actual and target values.
In the list user can view the actual and target production data, suppose there is a
mismatch with the actual then the following steps or actions are to be taken.
User has to press or click this transfer button and then a transfer screen appears as
In this tab user can put the location and actual quantity for which automatic sequence
number is shown. Next entry will be adjustment entry in which the balance quantity is to
be given for which new sequence number is generated and the amount is transferred.
Actual quantity and Target quantity should match in total otherwise system will not allow
user to save and move further.
Now user can click on
button and the corresponding entry will be
passed and adjusted. Now user goes back to original screen and can check the data.
Purpose
This is the form in which user does the daily production job and uses the defined template
in process. The whole idea of using template is to avoid repetitive work. User can define
a particular process and defaults defined in template are exhibited, now quantity and
factors for a lot can be given and calculations becomes at backhand.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Doc Type: The user can select the type from the list of values provided. This
list can be obtained by pressing Function Key F9 and selecting the same from
this. Usually this is type PRD, specifying that it is Production Daily.
Doc Date: This refers to the date of origination of PRD. Press F9 to get the
selection of dates.
Doc Series: This field gets selected from Document type set. This can be any
desired format YYYY, MMYY as specified.
Doc No.: This is non enterable field and it is auto generated once we save the
PRD.
Status: At first when the Daily Production is being done the status is always
kept open.
The status can be Open, Approve, Reversal and Cancel.
Reversal is like Virtual deletion.
Shift: User has to select from drop down menu as which shift user is working. It
can be Day and Night.
No. Transition: This shows number of daily transition, this data is used for
MIS department.
Plan Shutdown Hrs: User can state if shutdown hours are required for the
process.
Unplan Shutdown Hrs: User can state if shutdown hours are required all of
sudden.
Template: User has to select the required template from the list provided for
doing a particular type of process. Press F9 to get the list help. New templates
can be defined in Template Master.
Target: Plant runs on some target, this target can be given here so as to have an
idea of how much production is being done.
User can now click on this button to get the list of defined and
being used template below. Here user can now enter the Flow where ever it is
Production and when ever it is consumed and no factor then actual entry is to be
given. If it is consumed and factor then calculate button does the job.
User can now press this button to get the actual consumption or
usage as per the data given. Tedious calculations are done backend and results are
shown.
Simplified Business Management System
Page No:
This button can be pressed by the user to enter another form. Many a
times a process is running but user notices some problem in some point of place, such
abnormality can be noted down by one shift user for another user and also for reporting
purpose. This can be done by clicking this form.
Purpose
This is the form from which the daily Production item is bagged into Bags and Labels are
printed for each bag. In this user has to define the item code and from which parent
location bagging is done. It also specifies the number of bags, the net content of bag and
quality of bag.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Doc Type: The user can select the type from the list of values provided. This
list can be obtained by pressing Function Key F9 and selecting the same from
this. Usually this is type PDT, specifying that it is Production Daily Transfer.
Doc Date: This refers to the date of origination of PDT. Press F9 to get the
selection of dates.
Doc Series: This field gets selected from Document type set. This can be any
desired format YYYY, MMYY as specified.
Doc No.: This is non enterable field and it is auto generated once we save the
PDT.
Status: At first when the Daily Production Transfer is being done the status is
Shift: User has to select from drop down menu as which shift user is working.
It can be Day and Night.
Type: User has to select from drop down menu as which type it is. It can be
Item Code: The user can select the type from the list of values provided. This
list can be obtained by pressing Function Key F9 and selecting the same from
this.
UOM: This is Unit of Measurement and it is picked from Master on its own.
Line Name: User has to select from the list as to is it AMP-BAG means
amorphous Bag or is it SSP-BAG means SSP Bag.
User now has to click this Tab to get the six different parent locations from
which the bagging can be done. Now user has to select the parent location from
where bagging is to be done and specify the Quantity which is required.
Once user has input the quantity Bags button is to be clicked and we get to
see a different screen.
Sub Stores: This field is also usually type FGS Finished Goods Store.
Bag Series: This field gets selected from Bag type set. This can be any
desired format YYYY, MMYY as specified.
Bagging Quantity: User has to specify the bagging quantity, normally it is same
as what user entered in quantity.
Bags Category: User has to specify the category of Bags. Press F9 to get the list.
Gross Weight: This comes automatically from the two fields above and master.
Packing Type: User has to specify what the packing type is. User can press F9 to
Repacking: This is drop down field, where user can select Yes or NO.
User now can click on this button to generate Bag Label for amount of
bags entered. Once this button is generated then below list is populated and user can find
the required number of entries.
So this form helps user to generate Bag Tags which are to be tagged while bagging.
User can click on this button to get the print of labels. On pressing this
button screen which shows is
Here Bags from and to can be selected and Print Label button can be pressed to get the
desired labels.
Once all this data entry is done the user has to save the entry. He can do this either by
using the Save Button on top left corner
Bag Cancellation
Accessibility:
Purpose
This is the form as the name says is to cancel the excess Bag Tags. User usually prints the
Bag Tag prior to Bags actual bagging. It is quite possible that user is left over with
excess tags. These tags have to be cancelled then this menu works in. If the status is open
then these are displayed and can be cancelled.
Now once this request form is opened then the screen looks like
Key Fields:
These are mandatory fields. The user has to enter data in them.
Item Code: The user can select the type from the list of values provided. This
list can be obtained by pressing Function Key F9 and selecting the same from
this.
From Bags No.: This list can be obtained by pressing Function Key F9 and
selecting the same from this.
To Bags No.: This list can be obtained by pressing Function Key F9 and
selecting the same from this.
User can also press this button to display the list below.
Production Reports
This form is designed for generating the reports related to Production
Functions.
Accessibility:
(MODULE Report SUB MODULE Production Reports)
(Action Double Click on Production Reports)
Purpose:
Reports are the most required and most useful tool for the user. The whole
purpose of doing detail entry is to get the output in viewable form or printed form for
studying or analyzing the data, the functions and the requirement. The name of sub
modules is the name of module of which reports are available. Production Reports is
for Reports of Production modules. Like wise all departments can get the required reports
from the respective sub modules.
Key Fields:
These are mandatory fields. The user has to enter data in them.
Dates: Press Function key F9 and select the dates for which the user desires to
run the reports. From date and To date indicates the duration of the period for
which the report is to be Run or Executed.
Item Code. : Press Function key F9 to select the required list of item for which
the user desires to run the reports. From Item Code and To Item Code once
indicated, the reports can be generated on basis of these.
Location: The user can select the required location for which the reports are to
be generated. From Location and To Location once indicated, the reports can
be generated on basis of these.
Print Criteria: User can select the print criteria from the options given.
Shift: User can select the criteria of print for which user wants the report,
Bag No: The user can select the required bag number for which the reports are
to be generated. From Bag No and To Bag No once indicated, the reports can
be generated on basis of these.
Is Generate XL: User has the facility to select whether the report generates in
excel sheet listing or not. It is drop down menu option, whether Yes or No can
be selected.
Template Name: The user can select the required template name for which the
reports are to be generated.
Template Category: The user can select the required template category for
which the reports are to be generated. From Template Category and To
Template Category once indicated, the reports can be generated on basis of
these.
Line Name: The user can select the required line number for which the reports
are to be generated. From Line Name and To Line Name once indicated, the
reports can be generated on basis of these.
Status: User can select the status of report whether ALL/Open or Approve or as
For Item: The user can select the required item name for which the reports are
to be generated. User can press F9 function key and select the desired item.
Location Pack Type: The user can select the location pack type for which the
Production/ Consumed: The user can select the type for which report is
desired.
Sample No.: The user can select the required sample number for which the
reports are to be generated. From Sample No and To Sample No once
indicated, the reports can be generated on basis of these.
Now we can elaborate on what all reports we can get from this menu.
Silo Stock
Daily Production Lith
Daily Production FG
QC Report-2
Bagging Details
QA Register
Daily Production Report
Production Status
Bagging Status
Silo Stock Summary
Packing wise Bag Stock
Daily Production FG Waste
Location Master
Quality Results
QC Report-1
Production Tracing Not Entered
Bag Label
Bag Stock Report
RM Stock Report
Daily Production
Prod trace Details
This Button can be pressed corresponding to the desired report to get report in
desired format from the given list of values.
Output Displayed:
This report informs the user of the actual consumption of the various raw materials and
what is the product out for a particular Template and dates as desired by the user.
The report shows values of consumption in form of negative values and positive values
are shown as production of product.
Initials of operator and remarks are also displayed in the report. A total of production and
consumption is also shown in the summarized form.
Output Displayed:
This report shows user a concise report in tabularized manner of production and the
product categorization on the particular day. In one glance user can find the summarized
amount of production and how much required product was made and how much product
was classified as PLA and how much goes as waste.
Output Displayed:
This report tells user the details of quality analysis done for particular item code, sample
number and time of sample. User can get the details of parameters tested the range of
values and actual value of parametric test performed for that item on that particular day.
Output Displayed:
This report categorizes and shows the daily production date wise of Amorphous and SSP.
It also shows the Total Power consumption categorized again into CP power consumption
and SSP power consumption. These reports also show us the total gas consumption per
day for the specified dates as per the need of user. This is a very useful report to have a
summary of total production in a plant for that particular day.
Output Displayed:
User can get a bifurcated result of SSP Production and Amorphous Production item code
wise as on date and monthly and yearly.
The code Mtd stands for Monthly till date and code Ytd stands for Yearly till date.
Monthly till date production is from month starting to as on date specified by the user.
Yearly till date production is from1st January to as on date as specified by the user.
Raw Material consumption is also shown categorized as amount of MEG, PTA, IPA,
DEG are consumed till date.
Output Displayed:
This report gives the detailed item wise and packing wise bags in stock. Closing quantity
can be obtained from opening quantity plus the bagged quantity minus the dispatch
quantity.
Output Displayed:
User gets the finished goods production status along with waste production in tons
segregated date wise for the required template and category. Raw material and power
consumptions are also displayed. Minus sign indicates that these are consumption goods
not the production goods.
Output Displayed:
As the report says this is quality control internal report for sample number from specified
date to required date.
Output Displayed:
User has to link the days loading/packing from each silo for each and every item
separately with the dates of production so that the product is easily traced back if
required. Now many a times if entries are missed then this report helps the user to
reconcile again. This report indicates that so and so item from so and so silo /location
loaded on particular date is not linked with production date.
Output Displayed:
User can print the Bag No and Net weight of Bag no. for item codes from location can be
printed using this report.
Output Displayed:
User can find bag stock for a particular period for item code from required date to
specified date. It is calculated on the basis of opening quantity plus bagged quantity
minus the dispatched quantity to get the closing balance of bag stock. A summarized total
for duration of period can also be calculated.
Output Displayed:
User can get the stock report for raw material in the stock. The output displays item code,
item name and the closing balance of stock of raw material which is calculated from
opening
quantity
plus
received
quantity
minus
consumed
quantity.
Output Displayed:
Output Displayed:
User has to link the days loading/packing from each silo for each and every item
separately with the dates of production so that the product is easily traced back if
required. This report indicates that so and so item from so and so silo /location loaded on
particular date have so and so production date.