| # | Input | Type | Used in step |
|---|---|---|---|
| I-1 | Per-shift Injection WI — WO × machine × date × shift, SHIFT REQUIRED per size (generated when the Planner Releases the injection schedule in Injection Schedule, one WI per shift) | Document — MES (Injection Schedule) | Open the shift WI list |
| I-2 | Mold · Cavity · Machine (Mold / Cavity Master, BRD §6.2) | Master data | Assign molds to machine positions |
| I-3 | Raw-material lots issued to the Mixing area for the WI's WO (MOR ISSUED) — list used to check the lots the Operator scans | Material — MRP & Material Ready / WMS | Declare the material lots used |
| I-6 | Material Lot Assignment CONFIRMED — issued raw-material lots assigned to a date · shift · machine · WI | Document — MES (Material Lot Assignment) | Material Lot Assignment for the WI? |
| I-4 | Defect Reason · Downtime Reason | Master data | Enter grade C defect reasons · Enter times · downtime |
| I-5 | ILOT lot status at Curing — confirmed in Curing Confirmation or not | Production result — Curing Confirmation | Lot already Curing-confirmed? |
| Step | Role | Screen · UI button |
|---|---|---|
| Open the shift WI list | Operator | Daily Injection by Shift |
| Open shift POP entry · Assign molds to machine positions · Declare the material lots used · Enter output by size and grade · Enter grade C defect reasons · Enter times · downtime | Operator | Injection Shift POP Entry (Enter Shift POP, Fill A = Required, Add Lot, Add Defect Line) |
| Save shift POP draft · Validate POP data · Confirm shift POP · Transfer POP to Curing | Operator | Save Draft, Validate, Confirm Shift POP, Save POP & Transfer to Curing |
| Prefill lots from Material Lot Assignment | System (auto) | Injection Shift POP Entry › block Material Lot |
| Create batch and Curing lot · Post grade C Defect Records · Post material lot consumption · Post downtime · mold · cavity · Update Produced · Shift Remaining · Raise replanning alert | System (auto) | Injection Batch POP Confirmation |
| Request shift POP reopen | Operator | Request POP Reopen |
| Review reopen request · Reopen shift POP · Post reversal entries | Production Supervisor (System (auto) steps sit in this lane) | Daily Injection by Shift |
| # | Output | Produced when |
|---|---|---|
| O-2 | POP = DRAFT — no batch / lot created | The Operator presses Save Draft |
| O-3 | Batch IB + ILOT lot waiting for Curing — shift output by machine · size | The Operator presses Save POP & Transfer to Curing; POP = CONFIRMED, the shift's Injection WI → COMPLETED |
| O-4 | Defect Records grade C (scrap) — reason · WI · machine · shift; creates no Repair / Rework record | The POP has grade C when confirmed |
| O-5 | Material lot consumption ([Injection] Stock Out (Used Compound)) | POP confirmed — Used Qty per lot |
| O-6 | Downtime · mold · cavity to Machine Maintenance / Mold Management | POP confirmed |
| O-7 | Produced (A + A-) added to the I/J Plan Detail Plan (= WO) — Remaining on I/J Inquiry | POP confirmed |
| O-8 | Remaining → the Planner reschedules on the Injection Schedule (Replanning alert) | Shift Remaining > 0 — not converted to shortage |
| O-9 | Shift complete — Shift plan fully produced | Shift Remaining = 0 |
| O-10 | POP stays CONFIRMED | The Production Supervisor rejects the reopen |
| O-11 | POP back to WAITING — Operator re-enters the shift; ILOT lot withdrawn from the Curing queue; Injection WI COMPLETED → RELEASED | Production Supervisor approves the reopen, lot not yet Curing-confirmed |
| O-12 | Reopen blocked — lot already in Curing | The shift's ILOT lot already confirmed in Curing Confirmation |
| O-13 | Reversal entries: Produced · material lot consumption · Defect Records · downtime / mold | Shift POP reopened — old transactions kept, audited reversal transactions posted (BRD §6.3) |
| Glossary | Meaning in this flow |
|---|---|
WI | Work Instruction — the work order for one injection shift (WO × machine × day × shift), created when the schedule is released in Injection Schedule |
WO | Work Order — production order; one I/J Plan Detail Plan maps to one WO |
POP | Point of Production — output reported at the process, per shift and per size |
Grade A / A- / C | A: first grade · A-: first grade, minor defect · C: defective (Reject) |
Shift Required | The shift's planned quantity per size |
Shift Remaining | Shift Required − A − A-; stays a planned quantity, never a shortage |
Produced | A + A- accumulated on the I/J Plan Detail Plan |
IB batch / ILOT lot | Each shift POP creates one injection batch (IB-…) and one lot waiting for curing (ILOT-…) |
Downtime | Machine stop time during the shift, in minutes, with a reason |
Material Lot Assignment | Record assigning raw-material lots issued to the Mixing area to a date · shift · machine · WI; once CONFIRMED, the POP entry screen prefills the lots |
Mixing area | Mixing area: shop-floor area where raw materials issued against the MOR are mixed; not a Routing process and creates no new lot |
Reversal entry | A transaction that reverses recorded figures when a POP is reopened; the old transaction is not deleted |