Create Item Process Plan

This page allows you to define a process plan that specifies the sequence of activities that are required to manufacture an item. Tell me more

Select the “Create Item Process Plan” link under the “Process Model” business component.

The “Create Item Process Plan” page appears.

Enter the following fields:

Process Plan No.	The unique number identifying the process plan either generated by the system or entered manually. Mandatory. A Process plan gives information detailing the method of manufacture of a particular item.
	Help facility available.

Click “Get” pushbutton to retrieve the process plan details.
Enter the following fields:

PP Desc.	The description of the process plan.
	Zoom facility available.
Status	Use the drop-down list box to select the status of the process plan. Mandatory. The system displays the default value based on the save template field defined for the login user. However, if the default does not exist for the login user then displays “Active” by default on launch of the page. The options available are
	Active – indicates valid process plan.
	Draft – indicates incomplete process plan.
	Inactive – indicates invalid process plan.

Note: The status can be modified through the “Edit Item Process Plan” screen.

Item Code	The code identifying the item for which process plan is created.
	Press <Enter> key.
	The item code should be valid. If variant is left blank, then the item code should exist and should be in “Active” status. If the variant is not left blank, then the item and variant combination should be valid and should be in “Active” status. In both the cases, the item should have been defined in the warehouse Organization Unit to which Process Model Organization Unit is mapped. The system retrieves the item details for the specified item and variant (if any) combination. If the item does not have a variant, then the system retrieves the item description. If the item has a variant, then the system retrieves the item and variant description (concatenated). If the Item has more than one variant and the variant is not specified, then the system retrieves only the item description.
	Help facility available.
Variant Code	The code or number identifying the variant of the item.

The system displays the following:

Desc.	The description for the combination of item and its variant.
	Zoom facility available.

Note: If help on Item code was taken, the description gets fetched along with the Item code.

PP Type	Use the drop-down list box to select the user-defined types of the process plan. The system retrieves the types from the “Create Types” page of the “Organization Model” business component. The system displays the default value based on the save template field defined for the login user. However, if the default does not exist for the login user then displays “Blank” by default on launch of the page.
PP Usage	Use the drop-down list box to select the process plan usage Mandatory You can select from “Standard”, “Alternate1”, “Alternate2”, “Alternate3”, “Alternate4” or “Alternate5”. The system displays the default value based on the default set through the save template field. Otherwise, the system displays “Standard” by default on launch of the page. The options available are:
	Standard – indicates the standard process plan.
	Alternate 1 – indicates the first alternative process plan for the item.
	Alternate 2 – indicates the second alternative process plan for the item.
	Alternate 3 – indicates the third alternative process plan for the item.
	Alternate 4 – indicates the fourth alternative process plan for the item.
	Alternate 5 – indicates the fifth alternative process plan for the item.

Note: A process plan can be linked automatically to a product structure based on the selection of the process plan usage. The selection has to be made in conjunction with the product structure usage.

PP Category	Use the drop-down list box to select the category of the process plan. Mandatory. The system displays the default value based on the default set through the save template field. Otherwise, the system displays “Production” by default on launch of the page.
	Production – indicates the process plan used for production purpose.
	Costing – indicates the process plan used for costing purpose.
	Engineering – indicates the process plan under engineering change control.
	Subcontract – indicates the process plan used for the item that is sub-contracted.
	Purchase – indicates the process plan used for the item that is purchased.
	Rework – indicates the process plan used for the item that is reworked.

Note: The process plan category must be selected based on the product structure category.

Maintained By	Use the drop-down list box to select the “Maintained By” control units for which the login user has “Transaction” and/or “View” access permissions. Mandatory. The system retrieves the control units from the “Organization Model” business component. The system displays the default value based on the value saved through the save template field. Otherwise, the system displays the “Default Maintained By” defined for the login user. If neither the default “Maintained By” or the default through the save template field exist, then the system displays the first value as the default value.
Prodn. Controller	Use the drop-down list box to select the production controllers control units for which the login user has “Transaction” permission. Mandatory. The system retrieves the control units from the “Organization Model” business component. The system displays the default value based on the value saved through the save template field. Otherwise, the system displays the “Default Production controller” defined for the login user. If neither the default “Prodn Controller” or the default through the save template field exist, then the system displays the first value as the default value.
Prodn. UOM	The production unit of measure in which the output item of the process plan is produced. Mandatory. The UOM should be valid in the UOM administration business component.
	Help facility available.
Plant	Use the drop-down list box to select the valid plants. The system retrieves all the warehouses Organization Unit to which Process Model Organization Unit is mapped. The system displays the “Warehouse OU” by default on launch of the page.
Save Template	Select the check box to save the default fields like Status, PP Usage, PP Type, PP Category, Maintained By, Production Controller, Costing basis, Costing Reqd and Prodn Reqd that can be viewed when the user revisits the screen. If the defaults (if any) exist then the system retrieves the defaults saved earlier. Otherwise, leaves the box “Unchecked” by default on launch of the page.

Enter the following fields in the “Activity Sequence” multiline:

PP Seq.

The sequence number identifying the activity position in the process plan. Mandatory. The process plan sequence should not be zero.

Note: The default initial value is 0 and the incremental value is 10are retrieved from control unit for the given “Maintained By” i.e., for each row it is increased by 10 as defined by the control unit in the “Create Control Unit” screen.. The value is displayed when you click the “Create Process Plan” pushbutton. The user can modify the default values for the control unit selected in the "Create Control Unit" screen.

Activity Code	The code identifying the standard or non-standard activity entered manually or generated by the system. Mandatory. If a non-standard activity is specified and the Standard field is changed to “Yes”, then the system displays an error message. Standard activities cannot be created from non-standard activities.
	Press <Enter> key.
	The activity code should not be left blank. The activity should be valid and should be in “Active” status. For all the selected rows, the system retrieves the activity details mapped to the specified process plan and primary resource mapped to the activity.
	Help facility available.
Desc.	The description of the activity.
Std.	Use the drop-down list box to specify an activity as a standard activity or non-standard activity. You can select from “Yes” or “No. The system displays “Yes” by default on launch of the page.
Resource No.	The number identifying the resource that is required during the activity.
	Press <Enter> key.
	The resource should not be left blank. The resource should be valid and should be “Active” status. If the activity is “Standard”, then the resource should already have been mapped to the activity. This validation need not be done if the activity is a “Non-Standard” activity. For the specified activity code, the system retrieves the primary resource attached to the activity.
	Help facility available.

Note: Setting the standard field to “No” creates a non-standard activity from a standard activity.

Overlap %	The percentage of completion of an activity after which the subsequent activity can start. If the overlap percentage is specified, it should be greater than or equal to zero. Overlap percentage cannot exceed 100%.
Transfer Lotsize	The quantity of an item moved between sequential resources during production. If the transfer lot size is specified, then it should be greater than zero.
Yield %	The ratio of usable output from a process to its input in terms of percentage is Yield %. If yield percentage is specified, it should be greater than or equal to zero and cannot exceed 100%.
Run Time	The time duration required for the run sub-activity for the activity selected.

Note: This is defaulted from "Create Activity" screen.

Time UOM	Use the drop-down list box to select the time unit of measure of the run time field. You can select from “Hrs”, “Mins”, “Secs”, “Days” or “Blank”. The system displays “Blank” by default on launch of the page.
Run Timetype	The activity time type defined for the run sub-activity of the selected activity.
	Help facility available.

Note: The activity time type refers to the one defined in the "Create Activity Cost Details" screen. This field should not be blank if Run Time exists for the activity.

Run Qty.

The quantity of the output item during the run time of activity.

Note: The value is displayed from the "Create Activity" screen. You can modify run quantity for non-standard activities. If Run Time is non-zero, the value in this field should be non-zero.

Qty. UOM	The quantity unit of measure of the output item of the activity.
	Help facility available.
Setup Time	The time required for the setup sub-activity of an activity selected.

Note: This is defaulted from "Create Activity" screen.

Time UOM	Use the drop-down list box to select the time unit of measure of the setup time field. You can select from “Hrs”, “Mins”, “Secs”, “Days” or “Blank”. The system displays “Blank” by default on launch of the page.
Setup Timetype	The activity time type defined for the setup sub-activity of the selected activity.
	Help facility available.

Note: The activity time type refers to the one defined in the "Create Activity Cost Details" screen. This field should not be blank if Setup Time exists for the activity.

Batch Time

The time required for the batch sub-activity of an activity selected.

Note: This is defaulted from "Create Activity" screen.

Time UOM	Use the drop-down list box to select the time unit of measure of the setup time field. You can select from “Hrs”, “Mins”, “Secs”, “Days” or “Blank”. The system displays “Mins” by default on launch of the page.
Batch Timetype	The activity time type defined for the batch sub-activity of the selected activity.
	Help facility available.

Note: The activity time type refers to the one defined in the "Create Activity Cost Details" screen. This field should not be blank if Batch Time exists for the activity.

The system displays the following details in the “Activity Sequence” multiline.

Inspection Required (QC)

Indicates whether inspection is required or not for the activity.

Enter the following details in the “Activity Sequence” multiline.

Subcontract	Use the drop-down list box to indicate whether the activity has to be subcontracted. You can select from “Yes” or “No. The system displays “No” by default on launch of the page.
Supplier Code	The code identifying the supplier of the activity that is sub-contracted.
Queue Time	The time buffer that is to be given at the beginning of an activity, which uses this resource. This is useful when the actual start time of an activity differs from the planned time. If the actual start time is within the buffer time, no rescheduling is done.
Wait Time	The time buffer that is to be given at the end of an activity which uses the resource being defined. This is useful when the actual end time of an activity is different from the planned time. If the actual end time is within the buffer time, no rescheduling is done.
Transport Time	The time required for the job on this resource to move to the next resource.
Time UOM	Use the drop-down list box to select the unit of measure of the queue, wait and transport time defined. You can select from “Hrs”, “Mins”, “Secs”, “Days” or “Blank”. The system displays “Blank” by default on launch of the page.
Costing Reqd.	Use the drop-down list box to specify whether the activity requires costing. You can select from “Yes” or “No”. The system displays “Yes” by default on launch of the page.
Costing Basis	Use the drop down list box to select the type of costing. You can select from "Standard", "Actual Time" or "None". The system displays "Actual Time" by default on launch of the page.
Prodn. Reqd.	Use the drop-down list box to specify whether the activity is used for production purpose. You can select from “Yes” or “No”. The system displays “Yes” by default on launch of the page.
Lot No. Gen.	Use the drop-down list box to select whether the activity requires lot number generation. You can select from “Yes” or “No”. The system displays “No” by default on launch of the page. Only one activity should be lot controlled.
Serial No. Gen.	Use the drop-down list box to select the serial generation number. You can select from “Yes” or “No”. The system displays “No” by default on launch of the page. Only one activity should be serial controlled.
Setup Cap Units	Use the drop-down list box to select whether the activity requires serial number generation number. You can select from “Yes” or “No”. The system displays “No” by default on launch of the page. Only one activity should be serial controlled.
Batch Cap Units	The capacity of resource that is used during batch sub-activity. If the batch capacity for the resource has been specified and if the resource is a “Discrete” resource, then the batch capacity should be a whole number.
Run Cap Units	The capacity of resource that is used during actual processing of the activity. If the run capacity for the resource has been specified and if the resource is a “Discrete” resource, then the run capacity should be a whole number.
Valid From	The date from which an activity is valid. If the date is specified, then the system checks if it is in the correct date format. If both valid from and valid to date is specified, then the system ensures that the valid from is lesser than valid to date. If the date is not specified, then the system displays “Low Date” as the default date.
Valid To	The date till which an activity is valid. If the date is specified, then the system checks if it is in the correct date format. If the date is not specified, then the system displays “High Date” as the default date.
Min. Qty.	The minimum quantity of the activity. If the minimum quantity is specified, then it should be greater than zero. If the minimum and maximum quantity is specified, then the minimum quantity should be lesser than maximum quantity. If the quantity is not specified then the system displays “Low Quantity” as the default quantity.
Max. Qty.	The maximum quantity of the activity. If the maximum quantity is specified, then it should be greater than zero. If the quantity is not specified then the system displays “High Quantity” as the default quantity.
Checklist Code	Use the drop-down list box to select the checklist code for creating the item process plan. The combo is loaded with all checklist codes as defined in the “Master Checklist” activity. The system displays “Blank” by default on launch of the page.

Click the “Get” pushbutton to retrieve the activity and resource details for the selected rows in the “Resource Sequence” multiline.

Click the “Create Process Plan” pushbutton to create item process plans.

The login user should have “All” access permission for the "Maintained by" CU of the process plan. The system checks the status of the item process plan. If the status is set to “Draft”, then the system links the product structure and item specific process plan in “Draft” status and saves the details with status as “Draft”. The system ensures that at least one row in the multiline should be present. The system saves the process plan details.

The login user ID and the system date are updated in the “Created By” and “Created Date” fields.

To proceed, carry out the following

Select the “Edit Item Process Plan” link at the bottom of the page to modify the item process plan details.

Select the “Edit Resource Requirements” link at the bottom of the page to modify the resource requirement details.

Select the “Edit Activity Options” link at the bottom of the page to modify the activity option details.

Select the “Create Types” link at the bottom of the page to create the type details.

Select the “Create Activity Cost Details” link at the bottom of the page to create activity cost details.

Select the “Create Activity” link at the bottom of the page to create the activity details.

Select the “Create Resource” link at the bottom of the page to create activity cost details.

Select the “Attach Notes” link at the bottom of the page to modify the notes.

The system displays the following:

Created By	The login user ID of the person who has created the item process plan.
Created Date	The date on which the item process plan was created.

Create Item Process Plan – An overview

In case of an item specific process plan, the process plan is defined for the specific item. In case of a generic process plan, you can define a process plan excluding the item.

In the multiline, you can select the standard and non-standard activities. On selecting the standard and non-standard activity, the corresponding resources, activities and their sub-activities time and capacity unit details are displayed. Position sequence numbers are determined for all the activities selected in the multiline. These position sequence numbers refers to the position of the activities in the process plan.

You can also create new non-standard activity to be defined using the existing standard activity using this screen. You can also define the quantity required during actual processing and the quantity unit of measure in the multiline. You can make use of the help facility to search and fetch the process plan, item, production unit of measure, activity, resource and sub-activity time type details. On entering the necessary details, you can generate the process plan.

Prerequisites

Mandatory

Maintained By should have been defined in the “Create Control Unit” activity of the “Organization Model” business component.

Production Controller should have been defined in the “Create Control Unit” activity of the “Organization Model” business component.

Production UOM should have been defined in the “Create UOM” activity of the “UOM Administration” business component.

Activity Code should have been defined in the “Create Activity” activity of the “Process Model” business component.

Optional

Item Code should have been defined in the “Maintain Item – Basic Information”activity of the “Item Administration” business component.

PP Type should have been defined in the “Create Types” activity of the “Organization Model” business component.