Control task

CONTROL TASK

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To go back to the Search screen, click Control Task next to Welcome at the top-right corner of the page.

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This screen is designed to regulate and maintain the optimal functioning of a system or process by monitoring and making necessary adjustments.

Search for a Control Task

Before Step 1, the Search panel is shown:

• controlProcessId [Text Field]: Enter the control process Id to search for.
• machineId [Text Field]: Enter the machine Id to search for.
• runningNumber [Text Field]: Enter the task's running number to search for.
• Click Search to list matching tasks, or click Add Task to skip search and go straight to Step 2 to create a new task.
• Click Clear to reset the search fields.

The results table lists each matching task's S.No, a View/Edit button to open it, and its Task Running Number.

Step 1: Daily Maintenance Check Sheet

• This sheet includes tasks such as inspecting equipment, checking fluid levels, cleaning filters, testing safety features, and ensuring the proper functioning of machinery.
• The Daily Maintenance sheet will prompt for the first time based on the first shift time.
• After the operator completes the maintenance, it won’t prompt again until the end of the day shift.
• Select the machine and check all the listed points.
• Click the "Submit Maintenance Check Sheet" button at the bottom.
• For more details, refer to the documentation of the Daily Maintenance screen in the Maintenance section.

Step 2: Machine And Process Setup

This screen is exclusively designed for operator access, allowing the user to select and input necessary details to retrieve relevant tasks based on the given selections.

Fields Available:

• Machine: The specific machine being used for the task.
• Machine Pallet: Only shown for machines that use pallets. Select the pallet loaded on the selected Machine; this becomes required once shown.
• Part Name - Control Plan: The name of the part along with its associated control plan.
• Machining Process: The specific process or operation performed on the machine.
• All three fields (Machine, Part Name - Control Plan, and Machining Process) must be selected to enable the "Get Tasks" button.
• The "Shift Start" button (green) on the top right corner should be enabled.
• Click the "Shift Start" button to begin the shift, which will then change to "Shift Close" (red).
• The shift time interval options in the dropdown are 15 minutes and 30 minutes, which can be configured in the organizational details.
• Tasks can only be retrieved after clicking the "Shift Start" button.
• Click the green "Get Task" button to proceed to the next step.

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This will only proceed if the cycle time is provided; otherwise, tasks will not be fetched.

• Use the "Clear All Fields" option to reset all fields to empty.
• By clicking the "Shift Details" button, you can view the previous production details in a separate tab within the screen.
• Additionally, you can filter the data based on Control Plan-Process and Status using multiselect dropdowns. This allows you to refine the displayed information according to the specific control plan-process or status.
• You can also add idle items by clicking the buttons below on the screen.
• Click Idle Time Detail to view the idle time already recorded for the current shift on the selected machine (from date/time, to date/time, idle minutes, and reason). This button is disabled while a shift is running.
• Click Setting Piece Details to view the last ten Setting-piece transactions approved for the selected Machine (and Pallet, if applicable). This button is only shown when Setting Piece is restricted, and is disabled if there are no transactions to show.

When the shift is closed, the idle time is recorded for the selected machine. The shift start and close times can be viewed in the operator shift log.

When the shift closes, apart from production time, the remaining idle time will be prompted on the screen for entry. If this is skipped, it will proceed to the "Skip Idle Time" screen.

Step 3: Control Task Screen Subtabs

• Part Validation: Ensures that the parts meet the required quality and specifications.
• Tool Change: Records and tracks any changes made to the tools during the process.
• Pending Validation: Lists items that are awaiting validation before proceeding.
• Rework: Tracks parts that need reprocessing due to defects or errors.
• Work Instruction: Provides specific guidelines or steps for the operator to follow during the task.

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When Restrict Setting Piece is enabled, the setting piece is automatically populated for users with Operator Access if available; otherwise, a notification is displayed indicating that no setting piece is available.

Each subtab will have its unique color-coded validations.

Step 4: Understanding Part Validation Tab

The Part Validation screen includes the following fields:

1. Batch No: (Mandatory) An identifier for the batch being processed.

   • If available, select the batch number and proceed.
   • If the previous batch quantity is not completed, further actions will not be allowed.
   • Scenario 1: If the batch number is unavailable, inform your QC team.
   • Scenario 2: Navigate to Production Quality → Operations → Add Inward. Then, go to Production Quality → Operations → Add Inward Inspection.
     Note: If a batch is approved, the remaining quantity will be reduced based on the approval.
     The Child Part concept allows you to handle situations where a larger batch of parts (e.g., 1000) is divided into smaller sub-batches. If these sub-batches (child parts) are made from the same raw material, you can add them in this section.

2. Heat/Month Code: (Mandatory) This is the batch code or serial numbers.

   • Select the Heat/Month Code from the dropdown (e.g., AA).
   • If unavailable, enter the Heat/Month Code as a reference.

3. Serial Number: (Mandatory) This will be generated against the Heat/Month Code for the selected control plan process.

   • This will generate a serial number (e.g., AA-1, AA-2, AA-3).
     Note: In the control plan, if "Autogenerate Serial Number" is set to "Yes," the serial number will be read-only and automatically generated here. If it is set to "No," the serial number will be editable.

4. Reference Number: (Optional) A number used for tracking or referencing the part.

   • Enter the Reference Number if available; otherwise, you can skip this optional field.
   • Click the Submit button.

5. Other Frequency: (Mandatory) Specifies the inspection or maintenance frequency.

   • Select the frequency.
   • The first component will default to "Setting." Once approved, it will change to "Regular."
   • Scenario 1: If the first component is not approved, it will remain as "Setting."
   • You can choose from Regular, Lot, Shift, or Setting as needed.

6. Heat No: (Mandatory) Identifies the specific heat treatment batch of the material.

   • Select the Heat Code from the dropdown (e.g., AA).
   • If unavailable, enter the Heat/Month Code as a reference.

7. Task Serial No: (Mandatory) A unique number assigned to the task for tracking purposes.

   • Click on Task Serial No; the generated serial numbers will show in the dropdown (e.g., AA-1, AA-2, AA-3).
   • Select the appropriate serial number to view Task Validation Results.
   • Validate (Fill) the results as per actual values.
   • After filling in the actual values, scroll down to see the Status field.
   • Go to Part Validation Tab
   • If the currently selected process is the Final Inspection process, this field is replaced by Final Inspection Task Serial No, a multi-select dropdown used the same way to pick the serial number(s) to inspect.
   • Next to Task Serial No is a Swap Serial No checkbox. Enable it if you need to swap the part currently in this task for a different physical part with the same serial number:
     • An Enter Serial Number to Swap field appears — type the serial number of the part to search for.
     • Click Search Part Sl.No to look it up. The Search Result table lists each match's Heat - SerialNo, Part Status, Process Status, and TaskType, with an Action button to select it for the swap.

Task Validation Results table: Once a Task Serial No is selected, this table shows one row per check point defined for the process, with columns for Print Number, Description, Spec Value, Actual Value, Lower Spec Limit, Upper Spec Limit, Lower Control Limit, Upper Control Limit, Measurement Method, and Severity. For a measurable check point, enter the measured value under Actual Value; the row is shaded based on whether it falls within the spec limits. For a go/no-go check point, the Actual Value column instead shows Ok and Not Ok buttons — click Ok if the check point passes, or Not Ok to record a failure. An Auto Save toggle above the table lets you turn automatic saving of entered values on or off.

8. Status: (Mandatory) Indicates the current status of the part or task.By default, the status is set to Approved.
   • If you click, you will see the following fields:
   • Approved: If all items are approved and marked as green. If any rejection is marked, approval is not possible.
   • If all validations are correct, select the Approved option.
   • Click the "Submit Tasks" button to mark the component as approved and proceed to the next operation.
   • Hold for Inspection: Indicates that the part is being held for further inspection before proceeding.
   • Hold for Research: Indicates that the part is being held for further research or analysis before proceeding.
   • Rework: If the part needs rework.
   • If the selected serial number has a rework issue, click the Status button and select Rework.
   • A dropdown menu labelled Rejection Cause In Single Word will appear to choose the specific rejection cause in a single word.
   • If applicable, provide additional reasons for the rework.
   • The Submit button (in green) will be enabled. Click it to mark the serial number as Rework.
   • If applicable, provide additional reasons for the defect. If needed, add it to the master category (REJECTION_SINGLE_WORD).
   • Casting Rejection: If there is a defect in the casting and rejection is confirmed, mark this.
   • If the selected serial number has a casting issue, click the Status button and select Casting Rejection.
   • A dropdown menu will appear to choose the specific casting defect.
   • If applicable, provide additional reasons for the defect.
   • The Submit button (in green) will be enabled. Click it to mark the serial number as Casting Rejection.
   • If applicable, provide additional reasons for the defect. If needed, add it to the master category (CASTING_REJECTION).
   • Machining Defect: If there is a defect in machining and rejection is confirmed, mark this.
   • If the selected serial number has a machining issue, click the Status button and select Machining Defect.
   • A dropdown menu will appear to choose the specific machining defect.
   • If applicable, provide additional reasons for the defect.
   • The Submit button (in green) will be enabled. Click it to mark the serial number as Machining Defect.
   • If applicable, provide additional reasons for the defect. If needed, add it to the master category (REJECTION_SINGLE_WORD).
9. Reason: (Optional) Explains the cause or justification for a specific action or status.
   • If applicable, provide additional reasons for the defect.
   • Select the required fields and click "Submit Task." If you click Submit in this tab, an Idle Time Add tab will open on the same screen to add idle time.
     You can add multiple rows with specific times and reasons for the idle time being recorded. Ensure that Idle Total Time matches the calculated difference across the added rows. Once all entries are completed, you can click "Add Idle Time Reason" to update the idle time.

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If any serial numbers are rejected, they will be reflected in the NCR.

Step 5: Understanding Tool Change Tab

This screen is designed to document and track tool changes, including selecting the tool, recording the task serial number, and providing any relevant reasons for the change.

Fields to Fill:

• Tools: (Mandatory)
  • In this tool field, we have added the Tool Layout for this process; it will appear in the tool field.
  • A list of tools will be displayed. Click the required tool from the dropdown.
• Task Serial No: (Mandatory) The Task Serial No from the Part Validation will be shown in the dropdown. Select the required option.
• Tool Change At: (Mandatory)
  • If the tool change occurs at the beginning, select "Beginning of Process."
  • If the tool change occurs in the middle, select "During the Process."
• Remarks: (Mandatory)
  • Fill in the Remarks field. This field is mandatory, while the Reason field is optional.
  • Click "Change Tool" to submit the details.

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The serial number associated with the tool layout's print number is added to this control item for revalidation purposes.

Step 6: Understanding Pending Validation Tab

Heat No: (Mandatory)

• The Heat numbers added in the Part Validation field will be displayed in the Heat No field.
• Select the required Heat No from the dropdown.

Task Serial No: (Mandatory)

• Select the Task Serial No corresponding to the selected Heat No.
• A Task Validation Sheet will appear; fill in the actual values.

CMM Entry: (Optional)

• Check the box for CMM Entry.
• If you have a CMM Entry Excel Sheet, add it by clicking the Validate & Import CMM Excel button (enabled once the Task Validation table has loaded).
• A separate tab will appear within the screen to choose and upload the CMM Excel file.
• It includes columns such as Print Number, Actual Value, and Geometry Value. Except for the Geometry Value column, other fields are mandatory to validate the file.
• Once the file is validated, the CMM values will be populated below. You can then manually validate the values, confirm all, and submit them.
• Additionally, there are options to reset or remove values if needed.

Status: (Mandatory)

• Select the actual status from the options listed in the Status field.By default, the status is set to Approved.
• Fill in the reason if needed.
• Click "Submit Task" to finalize.

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If the part status is "Hold for Inspection" or "Hold for Research," all details must be filled in before proceeding.

Impact Of Line Inspection On The Pending Validation Tab

• When Line Inspection records Hold for Inspection or Hold for Research on a serial number, that serial appears in the Pending Validation tab at the inspected process, ready to be released.
• Only serials that are currently held are listed. Earlier holds that were already released are history and are not shown.
• Later processes that the hold reverted are not listed in this tab. They stay blocked until the held process is resolved.
• While the serial is held, it is not offered to the next process, and its stock sits in the Hold bucket of the Stock Ledger.
• Submitting the held serial as Approved or Conditionally Approved releases the hold:
  • a new entry is added to the Control Task history (the held entry is kept as it was);
  • the later processes that were reverted return to Approved;
  • the serial is active again at its furthest completed process, and its stock moves back from the Hold bucket to that process.
• Submitting it with another status (for example a rejection) keeps the serial out of the next process and the later processes follow that status.

Step 7: Understanding Rework Tab

• The Rework tab displays only part serial numbers from the past 6 months that are currently in Rework status.
• A single-select dropdown is provided to choose the new status for the selected serial number.

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🛈 Tooltip: "This list shows data from the past 6 months.Use search to find an exact serial number."

• By default, the status is set to Approved.
• If a required serial number is not listed, use the search field to enter the exact serial number. This will search beyond the 6-month limit and include older records.
• Once a serial number’s status is changed to Approved, it will no longer appear in the Rework dropdown list.
• Optionally, you may provide a reason for the rework if needed.
• If a serial number has been reworked multiple times, its previous rework entries will be shown and are editable.
• The Submit button will be enabled after a valid selection is made.
• Click Submit to confirm and save the rework status for the selected serial number.

Impact Of Line Inspection On The Rework Tab

• When Line Inspection (or a Non-Conformance Review) sets a serial number to Rework, it appears in the Rework tab and is not offered to the next process. Its stock moves from approved stock into the Rework bucket.
• Later processes that were already completed are marked Rework as well, with their earlier records kept for history.
• Submitting the serial as Approved or Conditionally Approved in the Rework tab:
  • returns the later processes to Approved;
  • returns the serial to its furthest completed process and moves its stock back from the Rework bucket;
  • removes it from the Rework dropdown list.
• If the rework ends in a Rejection, a Defect or a Hold, the later processes follow the new status. No NCR is raised automatically; the Non Confirmation Review screen lists the defect itself.
• Each rework entry is added to the history. Previous rework entries stay visible and can be viewed in the Control Task Report.

Step 8: Understanding Work Instruction Tab

• To add Work Instruction, navigate to Production/Quality → Control Plan → Work Instruction. To add work instruction, contact the QC team.
• The added instruction files will be visible under Work Instruction here.
• Part documents and Part images are also displayed in this tab when Visible To Operator is set to Yes in Part Image.
• You can click the file link to open a popup and view both PDF and image files on the same screen.

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Part Validation Tab

1. Task Serial Number Dropdown (Default Behavior)

• When the screen loads, the Task Serial No dropdown initially displays only 20 serial numbers.
• This is done to improve loading performance and avoid fetching large datasets unnecessarily.

2. Fetching Task Serial Numbers by Heat Number

• The Heat No dropdown allows users to filter task serial numbers by a specific heat.
• When a user selects a Heat No:
  • The system retrieves all task serial numbers associated with that Heat No.
  • The Task Serial No dropdown then shows the full list with no limit.

3. Search Function (No Limit)

• The Task Serial No dropdown includes a search option.
• When the user enters a minimum of 4 characters, the system:
  • Performs a full search on the available data.
  • Returns all serial numbers that match the entered text.
• There is no limit on the number of results returned through search.

4. Auto-Selection Logic (Control Task Validation)

• When the Task Serial No list loads, the first available serial number is auto-selected.
• The user can still manually change the selection after auto-selection.
• Auto-selection does not override an existing user selection.
• Auto-selection is not triggered while typing in the search filter (to avoid disruptive changes).
• Auto-selection does trigger after a Heat No change if the list refreshes.

Summary

Feature	Behavior
Default Task Serial No list	Shows only 20 serial numbers initially
Heat No selection	Fetches all related serial numbers (no limit)
Search feature	Requires minimum 4 characters, returns all matching serial numbers (no limit)

That's It! You’ve successfully learned how to search and edit control tasks using the DMeX app.For further assistance, please contact the Support Team.