| # | Input | Type | Used in step |
|---|---|---|---|
| I-1 | Work Order RELEASED from Master Plan — WO number, Q'ty, P.O (Month) = Plan Month, Style, Model, Base Color, Area (display only), Destination, SPRAY / Logo, Start I/J Date, I/J ETC, Priority | Document — Master Plan flow | Start → Create a Detail Plan for each WO |
| I-2 | Grouping key on the WO — Style · Model · Base Color · P.O Month (= Plan Month); excludes Area, SPRAY / Logo, Destination, Part BOM | Document — Master Plan flow | Is there a NEW / DRAFT Big Plan with the same key? |
| I-3 | WO Q'ty per size — SO allocation + Common Stock, used as the Detail Plan Order Q'ty | Document — Master Plan flow | Sum Order Q'ty per size over WOs |
| I-4 | Confirmed A-grade output (POP of Injection shifts), cumulative per size | Production result — MES | Update Produced · Remaining |
| I-5 | P.O of the Model and Base Color in the month, by size | Document — Sales module | Sum Total Monthly Order Q'ty per size |
| I-6 | INV Mold Q'ty — all molds of the Model per size in Mold Management | Mold stock — Mold Management | Calculate Shortage Mold = INV − Need |
| I-7 | Part BOM of the Model — Part Weight (g) and Gate Weight (g) per size and Compound Type | Master data | Compute Need Compound per size |
| I-8 | Items of group RAWMATERIAL (raw-material Item Codes) | Master data | Pick Item Code · mix ratio |
| Step | Role | Screen · UI button |
|---|---|---|
| Create a Detail Plan for each WO · Create Big Plan NEW per grouping key · Attach Detail Plan to the Big Plan | System (auto) | I/J Plan · tab I/J Plan · I/J Plan List (rows n (Big Plan) / n-m) |
| Open Big Plan | Planner | I/J Plan List · Detail on the Big Plan row → two-step Big Plan page |
| Sum Order Q'ty per size over WOs · Enter Overrun % per size for Big Plan · Compute Planning Q'ty Big Plan · each WO | System (auto) · Planner | Big Plan · Step 1 · Order & Overrun |
| Save Plan · Save plan · Big Plan → DRAFT | Planner · System (auto) | Big Plan · Save Plan → popup Save I/J Detail Plan? |
| View Detail Plan (each WO) | Planner | I/J Plan List · Detail on the Detail Plan row → read-only page (the WO's Order Q'ty, Planning Q'ty per size) |
| Release Big Plan · Big Plan RELEASED · lock Detail Plans | Planner · System (auto) | I/J Plan List · tick the Big Plan row + Release (n) |
| Big Plan already has an SO PR? · Create SO PR from Final Need | System (auto) | On Release Big Plan; shown on the Big Plan page · Step 2 · Compound Calculate · strip Sales Order Purchase Request (SO PR) |
| Update Produced · Remaining · Move Big Plan to COMPLETED | System (auto) | I/J Plan List · column Progress; report I/J Production Plan |
| View report I/J Production Plan | Planner | Report I/J Production Plan (not on the prototype yet) |
| Select P.O (Month) · Model · Base Color · Enter Cycle · Need Mold Q'ty by size · Save Calculation | Planner | I/J Plan · tab Mold Calculate · Save Calculation |
| Open Compound Calculate · Pick Item Code · mix ratio · Enter Material Overrun % · Save Plan | Warehouse Staff | Big Plan · Step 2 · Compound Calculate (BRD: a separate Warehouse Staff tab) |
| Click Revision · Edit Overrun · Save Plan · Release Big Plan again | Planner | Big Plan · Revision (every WO Produced = 0) → Save Plan; I/J Plan List · Release (n) |
| # | Output | Produced when |
|---|---|---|
| O-1 | Save blocked — total Order Q'ty differs from WO Q'ty | The Planner clicks Save Plan on the Big Plan when a WO has Σ Order Q'ty of sizes ≠ the WO's Q'ty (Overrun excluded); the Big Plan keeps its status |
| O-2 | Big Plan RELEASED → Injection Schedule (injection plan) | Planner Release Big Plan NEW / DRAFT; the plan locks, Planning Q'ty per size of each WO goes to Injection Schedule — machine, mold count, injection day / shift and finish date are set in Injection Schedule |
| O-3 | SO PR (Requested) → Purchase makes the Purchase Order → goods are received into the raw-material warehouse (WMS Inbound) → Stock Out to the Mixing area against the WO / WI MOR (Material Issue & Return flow) | Automatic when a Big Plan without an SO PR is released: one Sales Order Purchase Request for the Big Plan, one line per Item Code = Final Need × ratio ÷ Σ ratios (kg), status Requested; a Big Plan that already has an SO PR (re-released after a Revision) gets no other |
| O-4 | Report I/J Production Plan (Remaining) → schedule more shifts | Big Plan RELEASED still has a Detail Plan with Remaining = Order Q'ty − Produced > 0; columns Produced · Remaining · Progress (no MIC, Cycle, Estimated Date) |
| O-5 | Big Plan COMPLETED (Order Q'ty reached) | Automatic when every Detail Plan has Produced ≥ Order Q'ty in every size (Overrun is a buffer) |
| O-6 | Shortage Mold per size — warning only | Shortage Mold = INV Mold Q'ty − Need Mold Q'ty < 0 in at least one size of the Model and Base Color in the month (red; ≥ 0 blue) |
| O-7 | Save Calculation blocked | Cycle is 0 / empty, or the P.O (Month) / Model / Base Color set has no P.O |
| O-8 | Compound not saved — no raw material | No raw-material row or Σ ratios = 0 |
| O-9 | Revision blocked — a WO already has output | The Planner clicks Revision when a WO of the Big Plan has Produced > 0; the rest is handled through Remaining |
| O-10 | Big Plan DRAFT — Injection Schedule keeps booked shifts, blocks new shifts | Planner Save Plan on the Revision; the old version is archived |
| O-11 | New injection plan → Injection Schedule | The Planner re-releases the Big Plan after a Revision; no new SO PR is created |
| Glossary | Meaning in this flow |
|---|---|
Big Plan | Group of Detail Plans with the same grouping key Style + Model + Base Color + Plan Month (not by Area, SPRAY / Logo), showing P.O (Month) · Style · Model · Base Color; where the Planner plans (Overrun, Save Plan, Compound, Revision), at most one SO PR per Big Plan, and the only place carrying the status NEW → DRAFT → RELEASED → COMPLETED |
Detail Plan | Injection plan of one Work Order, read-only; Planning Q'ty uses the parent Big Plan's Overrun % and follows the parent Big Plan status |
Grouping key | Style + Model + Base Color + P.O Month (= Plan Month) of the WO — Detail Plans with the same key join one NEW / DRAFT Big Plan, including WOs from two Master Plans of different Areas |
Area · P.O Month | Area of the Master Plan (delivery Country → Area), copied to the WO, display only in I/J Plan, not part of the grouping key · production month, equal to the Master Plan's Plan Month |
Order Q'ty | Work Order quantity per size, including SO allocation and Common Stock |
Common Stock | The part of the WO produced above the SO allocation, decided by the Planner in Master Plan; counted in Order Q'ty |
Overrun % | Safety overrun rate per size, entered once for the Big Plan, default 3% |
Planning Q'ty | Quantity to inject = Order Q'ty × (1 + Overrun %), rounded to nearest |
I/J ETC | Injection due date of the WO, copied from Master Plan; the expected finish date is computed in Injection Schedule, not in I/J Plan |
Total Monthly Order Q'ty | Total quantity of all P.Os of the Model in the month per size, all colors |
Need Mold · INV Mold · Shortage Mold | Molds needed (entered by the Planner per size) · mold inventory from Mold Management (view only) · Shortage Mold = INV − Need, negative means short |
Mold Management | Where molds are managed — source of INV Mold Q'ty |
Compound · Part BOM · BOM | Mixed material for injection · injected-part norm per Model: Part Weight (g), Gate Weight (g) per size · BOM = (Part Weight + Gate Weight) ÷ 1000 kg / pair |
Need Compound · Final Need | Planning Q'ty × BOM per size · Total Need × (1 + Material Overrun %) |
Material Overrun % | Raw-material loss rate, default 5% |
SO PR | Sales Order Purchase Request — raw-material purchase request the system creates on Release Big Plan, from the Final Need of each Item Code; initial status Requested |
Purchase Order | Purchase order made by Purchase from the SO PR, outside I/J Plan; goods are received against the PO in WMS Inbound |
Produced · Remaining | Cumulative confirmed A-grade output · Remaining = max(0, Order Q'ty − Produced) |
POP | Point of Production — output reported per shift |
Revision | Reopen the plan of a RELEASED Big Plan for editing when every WO has Produced = 0; Save Plan archives the old version and returns the Big Plan to DRAFT |