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Bulk Production Entry

BULK PRODUCTION ENTRY​

1.1 Add Bulk Production Entry​

Add a Production Entry Step-by-Step

Step 1: Reach the Bulk Production Entry Screen

  • From the main Side menu, click on "Production and Quality", then go to "Operations", and finally choose "Bulk Production Entry". This will directly open the Bulk Production Entry page.

Step 2: Fill the Production Details

  • Machine: (Mandatory) Select the Machine. Process cycle time will be fetched only after the machine is selected.

  • Operator: (Mandatory) Select the Operator.

  • Process Start Date and Time (labelled Start Date / Time on screen): (Mandatory) The user can also set any required time period manually. A copy/paste icon next to the field lets you copy this date & time and paste it into the End Date / Time field (or vice versa).

  • Process End Date and Time (labelled End Date / Time on screen): (Mandatory) This is auto-calculated based on process cycle time.

  • For first process, it is calculated using total quantity x process cycle time.

  • For non-first process, it is calculated using selected task serial numbers count x process cycle time.

  • The user can also manually extend the end time if needed and add idle time accordingly.

  • It also has the same copy/paste icon as Start Date / Time.

  • Part Name - Control Plan: (Mandatory) Selecting it automatically fetches the linked processes. If changed or removed after validation, the dependent data is cleared automatically.

  • Process: (Mandatory) Once a process is selected, the system automatically loads the required batch details or task serial numbers based on whether it is the first or non-first process.

  • First Process Logic:

  • Batch: Batch dropdown is displayed if serial number mode (Generate) is selected and the remaining quantity of the selected batch is shown.

  • Next to the Batch field is a Child Part toggle — switch it on when this entry is for a child part rather than the main part; this changes the batch list offered.

  • If no batch is available, an error message is shown.

  • Total Quantity: Entered quantity must be within the remaining batch quantity.

  • Serial Number Mode: Two modes are available.

  • Generate: Enter the Heat Code and starting Serial Number. Task serial numbers are generated automatically and pre-selected based on the entered quantity. If needed, the selection can still be changed manually.

  • Existing: Already created serial numbers are fetched and auto-selected based on the entered quantity.

  • Non-First Process Logic:

  • Total Quantity: Remaining quantity is based on the serial numbers available from the previous process.

  • Entered quantity cannot exceed the available remaining serial number count.

  • Task serial numbers are fetched automatically from the previous process and pre-selected based on the entered quantity. If needed, the selection can still be changed manually.

  • Heat No Filter: An optional filter is available to narrow the task serial number list by Heat No.

  • Part Status: User must select the part status.

  • Reason: If the part status is Rework, Machining Rejection, Machining Defect, Casting Rejection or Casting Defect, the reason dropdown becomes mandatory.

  • Remarks: Remarks can be added optionally.

Locking the Production Details

Once the Machine, Operator, Part - Control Plan, Process, Batch/quantity and date/time fields above are filled in, click Apply Details to lock them and reveal the Status Entry section described below. The button is replaced with Edit Details — click it if you need to unlock and change the production detail fields again.

Status Entry — Adding Part Status Rows

With the production details locked, use the Status Entry section to record one or more part-status splits for the quantity:

  • Select Part Status, enter the Reason (when applicable) and Quantity, and pick the Task Serial No (filtered by Heat No Filter if shown, or auto-picked with the Auto select toggle) and any Remarks.
  • Click Add to List to add this status split as a row to the Entries Added table below.
  • The table lists every row added so far, with its Part Status, Reason, Remarks, Qty and the chips of Serial Numbers included; each row can be removed individually.
  • Click Edit Serial Numbers to switch the table into edit mode (the button then reads Done) — in this mode you can search for a serial number, click Select all/Unselect all on a row to select or clear all its serials, and click individual serial chips to select them, then click Remove from List to move the selected serials back out of that row.

Fill in the required fields and click "Validate Production".

  • The system validates whether process cycle time is available for the selected machine and process.
  • If all validations pass, the production details can be reviewed and submitted.
  • Upon clicking "Validate Production", the system verifies that the production entry fits within the available time range.
  • Existing production entries and existing idle time in the selected range are also considered.
  • Any field can be edited at any time. If a field is changed after validation, a confirmation popup appears.
  • On confirmation, idle time details and other dependent validated data are cleared.
  • The user must click "Validate Production" again before submitting.

Step 3: Understanding Existing Production Details

  • Once "Validate Production" is clicked, a "View Existing Production List" button is displayed.
  • Clicking it opens a dialog showing the existing production records for the selected time range.
  • The dialog also shows existing idle time details.
  • The user can refer to this information any time before submitting the current production details.

Step 4: Understanding the Production Details

  • The dialog shows a quick summary of:
  • Selected Time: Total time between the selected process start time and process end time.
  • Existing Production: Total production already recorded in the selected time range.
  • Existing Idle Time: Total idle time already recorded in the selected time range.
  • Available Time Left: Remaining time after deducting existing production and existing idle time from the selected time.
  • It also shows:
  • Selected Process Cycle Time: The cycle time for the selected machine and process.
  • Production Added Now: Time calculated for the current production entry based on the selected task serial numbers.
  • Idle Time Yet To Add: The balance time after considering existing production, existing idle time and the current production entry. This may be zero, positive or negative based on the selected time range.
  • A status-wise table is shown below with:
  • SL.NO
  • Part Status
  • Quantity
  • Cycle Time
  • If production records are already present in the selected time range, they are displayed in the table.
  • If no production records are found, the dialog shows a message saying that no existing production records are available in the selected time range.
  • Based on the available balance time, the dialog also shows whether time is available for the current production entry or whether the selected production exceeds the available time.

Step 7: Idle Time Details

  • If idle time is available, the user can optionally enter:
  • Reason: Select the idle reason.
  • Idle Time Minutes: Enter the idle time in minutes.
  • Adding idle time is not mandatory.
  • If no idle time is needed, the system shows the message: "No idle time to add. Please submit to proceed production details".
  • If production already exists in the selected time range, the system shows the message: "Production entries found in this time range. Review the details before proceeding".
  • Added idle time can be deleted before submission if needed.

Step 8: Submit Production Details

  • Upon clicking "Submit Production Details", the system validates the production details and idle time details.
  • If the entry is valid, the data is saved and the database is updated.
  • Idle time can be skipped and the user can directly submit if no idle time needs to be added.

Heat Code & Serial Number Validation

  • The system will validate the heat code and serial number before submission.
  • If a duplicate heat code and start serial number are entered, the system will display an alert message with a link.
  • Clicking the link will open a popup containing a list of duplicate heat serial numbers, with a filter option to search for verification.

Process Validation

  • If the selected process is not an initial process, the system will not allow submission unless the previous process is completed.
  • If the previous process is incomplete, a link will be provided. Clicking the link will open a popup showing the incomplete heat serial numbers, with a filter option for verification.

Override Option

  • If the selected process has the override option enabled (Yes), the system will only validate duplicate serial numbers and will not check whether the previous process is completed.
  • The user must resolve all validation errors before submitting the production entry.
note

We can view the added production entry in the Control Task Report, where the task type is marked as Bulk Entry.

That's it!! You've successfully learned how to Add Bulk Production Entry using the DMeX Pro app. For further assistance, please contact the Support Team