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Hourly Production Entry

HOURLY PRODUCTION ENTRY​

Add Hourly Production Entry​

This document provides a step-by-step guide to adding an hourly production entry in the system:

Step 1: Reach the Hourly Production Entry Screen​

From the Main Side Menu, navigate to:
Production and Quality -> Operations -> Hourly Production Entry. This opens the Hourly Production Entry page.

Step 2: Fill in Hourly Production Entry Form (Form 1)​

Fields:

  • Machine: Select the machine (Mandatory)
  • Start Date & Time: Specifies the start time of the current hour (Mandatory)
  • End Date & Time: Specifies the end time of the hour (Mandatory)
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End Date & Time Logic:
Start and end times are pre-filled based on the operator's shift end time. By default, the start time is set to one hour before the end time. You can adjust these times if needed. Minutes are rounded off to the nearest half-hour (e.g., 4:15 becomes 4:30). This will be auto-calculated based on the total quantity entered and cycle time of the selected process.

  • Part Name + Control Plan: Combined dropdown; this shows only active control plan data (Mandatory)

  • Process: Based on the selected control plan, the corresponding process is fetched and displayed in a dropdown. The user can then select the desired process (Mandatory)

  • First Process Logic: If the selected process is the first process:

  1. Serial Number Mode - This checkbox will be shown.

    If New is selected, it will show the fields below:

  2. Total Quantity: Based on the entered total quantity, it will be auto-selected and populated in the batch list table.

  3. Heat Code & Serial Number: The user needs to enter the heat number and serial number.

Batch: Select the batch (Mandatory for the first process)

Batch Selection Logic:
By default, the most recent active batch (status = NEW, remainingQty > 0) is auto-selected.
If users need to change or split the batch, they may delete the preselected batch and select the batches of their choice.
Different batches can be added by selecting a batch and entering the quantity, then clicking the ADD button.

  • Shows current selected batches and their split quantities.
  • The system ensures quantity does not exceed each batch's remaining quantity.

If Existing is selected, it will show the fields below:

  1. Total Quantity: It shows the existing serial number count for the selected process as the remaining quantity and users are restricted to entering quantity within that limit.
  • Non-First Process Logic: If the selected process is a non-first process:
  1. Total Quantity: It shows the serial number count from the previously completed process as the remaining quantity and users are restricted to entering quantity within that limit.

Click Submit after filling these fields.

  • After submit, the above fields are editable. If edited, the system asks for confirmation; if you proceed, it clears the dependent data and you can enter data again after editing.
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If the selected process does not have a cycle time or does not have a control item, a warning message will be shown. You can proceed only after adding the missing cycle time or control item.

The system validates:

  • Mandatory fields are filled.

  • Machine's process has a defined cycle time.

  • Total quantity aligns with cycle time and time range.

  • If there are any existing entries for the selected time range, they will be displayed.

  • After clicking Submit, the following option will be shown:

Production Details Box:

  • Total production time is reduced based on:
  • Existing production entries
  • Existing idle time entries (auto-deducted if already recorded for this time range)

This box shows up after the main hourly entry form is submitted (View Production Details).

Selected Process Cycle Time Total Production Time Added (Calculated based on the entered quantity and the process's cycle time) Total idle time yet to add

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Remaining Idle Time: As production time is added, the idle time is reduced. If idle time still remains, it must be recorded using the Validate Production button, as explained in Step 7.

Step 6: Proceed to Control Task Validation​

After all fields are submitted successfully:

  • Select Task Serial Numbers.
  • Heat No Filter - Users can use this Heat No filter to filter task serial numbers.
  • The system fetches eligible serial numbers and shows the validation list (filtered by Is Hourly Entry = Y).
  • By default, the status is set to Approved.
  • Once task validation is completed, you may see the Approved and Rejected quantity count on the screen.

Serial Number Validation Workflow:

  • Approved: All selected serials move to Approved List.

  • Rejected: Selected serials move to Rejected List.

  • Mandatory: Must select a Reason for Rejection from a searchable dropdown.

  • Approved Qty & Rejected Qty are displayed like the Outsource Screen.

    Swipe Logic (Multiple Serials):

    • All selected batches' serials are in the Approved List by default.
    • You can click and move any serial to the Rejected List.
    • Must provide a reason if any rejected serial exists.

Step 7: Idle Time Entry & Validation​

  • After submitting the production details, a Validate Production button will appear.
  • Click this button if idle time needs to be recorded for the same time range.

Steps to Record Idle Time:

  • Select Reason (Mandatory). Reasons are fetched from master data.
  • If the required reason is not listed, you can add it to the master data and then proceed.
  • Enter Idle Time in Minutes (Mandatory)
  • Click Submit to save the idle time entry.
Idle Time Calculation

Idle time is calculated by subtracting the total production time (based on the selected process's cycle time and entered quantity) from the available time range.

If idle time exists:

This idle time section is optional and users can fill it if needed. If a user needs to submit it, a reason must be selected and the idle time must be submitted. If no idle time remains, you can directly click Submit Production Details. Also, if any existing production entries fall within the selected time range, their duration is also deducted during idle time calculation.

Important Notes
  • Idle time must be within allowed limits.
  • Cannot be negative.
  • Combined idle + production time must equal the From-To range.

Step 8: Duplicate Serial Handling​

If duplicate serials are detected:

  • System shows message:

    "These are the duplicate heat serial numbers: AA-1. Total: 10 serial numbers. Clear these duplicates before submitting the production entry."

  • Click "For more details" to open a pop-up showing duplicates.

  • Confirm to clear duplicates.

Step 9: Process Flow & Overrides​

  • Subsequent Processes: Prior processes must be completed for selected serials.

  • Override (Future Enhancement): Only duplicate checks apply.

Step 10: Final Submission & Validation​

Upon clicking Submit Production Details:

Heat Code & Serial Number Validations

  • If duplicates found:

    • Pop-up lists existing entries
    • Filter options available for review before submission

  • On successful submission:

    • Saves the production entry after verifying all validations.
    • After saving the data, you will see an Edit option to proceed with the same process, or you may change the relevant fields if needed.
    • Once the data is saved:
    • The validated serial numbers are saved in Control Task Validation.
    • The approved and rejected serials are saved in the Control Task.
    • All of this saved data is displayed in the Control Task Report for your reference.
    • Updates batch/operator's last operation datetime
    • Sets partStatus:
      • Approved or
      • Rejected

Step 11: After Submission​

After successful submission, the system updates:

  • Master Data: In these three forms, the submitted values are saved into task validation. The serial number is also stored and reflected in reports under the task type 'Hourly Entry'.

  • Last Operation Date & Time: The last operation's date and time are auto-calculated. If you continue editing, this value may be carried forward. However, you can manually adjust it as needed.

  • Start/End Time Adjustment: You can customize the start and end times for the next process entry as required.

  • Batch Quantity Adjustment: The batch quantity is automatically reduced based on the selected time range.

That's it! You've learned how to add an hourly production entry using the DMeX app. If you need help, contact the support team.