Fine Chemical Flow Library ← Flow library

Master Plan — build the plan for a Plan Month, group SO lines into Big Plans (Style + Model + Base Color + SPRAY/Logo + Area), one Work Order per Big Plan, release the Work Orders directly to I/J Plan

Fine Chemical (FC) · MES module · v0.7 · 01/10/2026 · Standard flow — for implementation, testing and development

Process Flow (swimlane)

MES · Master Plan — group SO lines into Big Plans (one WO per Big Plan), pick the Routing, release the WOs directly to I/J PlanPhaseInputPlannerOutputExceptions — delete plan · Update ETDYesNoDRAFTRELEASEDApply RescheduleSave as SimulationCancelSales Order (lines per size,ship-to Country)Internal ProductionRequestMaster data: Country(Area)Master dataMaster data: Item · Routing· Routing MappingMaster dataMaster data: Machine ·Capacity CalendarMaster dataStart▣ Master PlanOpen the Create Plan wizardWeb▣ Master PlanSelect SO size linesWeb▣ Master PlanEnter Plan Qty per lineWeb▣ Master PlanSelect Plan MonthWeb▣ Master PlanGroup SO lines intoBig PlanSystem (auto)▣ Master PlanCalculate Common StockSystem (auto)▣ Master PlanPick a Routing foreach Work OrderWeb▣ Master PlanCalculate Plan From / Tofrom lead timeSystem (auto)Any process overCapacity?▣ Master PlanFlag Over capacitySystem (auto)▣ Master PlanCreate Master PlanWeb▣ Master PlanGenerate Work Orderper Big PlanSystem (auto)▣ Master PlanRelease Work OrderWeb▣ Master PlanSend WOs to I/J PlanSystem (auto)▣ Master PlanCreate NEW plans foreach planned processSystem (auto)EndDrop the planPlan currently inwhich status?▣ Master PlanDelete Master PlanWeb▣ Master PlanRestore SO line RemainingSystem (auto)EndETD needs changing▣ Master PlanEnter new Current ETDWeb▣ Master PlanBuild Reschedule PreviewSystem (auto)Planner pickswhich action?▣ Master PlanApply new scheduleSystem (auto)▣ Master PlanSave SimulationSystem (auto)EndPlan RELEASED · Work OrderRELEASED → I/J Plan (one rowone Detail Plan, grouped intoBig Plan I/J)+ NEW Trimming /Spray Out / Packing+ Common Stock (surplus)SO Remaining restoredNo delete in Master Plan— handled at Work OrderNew Current ETD+ rescheduled process datesSimulation copy· live schedule unchangedKeep ETDand process scheduleThe Planner opens the Master Plan creation wizard from the plan list. Action: Master Plan › Plan List › "Create Plan" button. System: Plan List has an "Area" field outside the grid (All / Europe / Asia / America) to filter plans — a plan shows when at least one SO line ships to a Country in that Area; the "Area" column lists the Areas of the plan's SOs. Result: opens the 3-step wizard "Sales Orders" · "Items" · "Review". Test: - Filter "Area" = Asia → only plans with SO lines shipping to a Country in Asia remain Open: the real Area list in Master Data Country — prototype v0.56 uses sample data by continent. Source: Q-20261001-04 · prototype v0.12 · v0.22 · v0.56The Planner selects the Sales Order lines, per size, to put into the plan. Action: Step 1 "Select SO Lines" › tick lines; each size (W5–W11) is one line ("Each shoe size (W5–W11) is its own item line"). System: each line shows "ORDERED" · "REMAINING" · "PLAN QTY" and the ship-to Country · Area (Area looked up from the Country in Master Data Country); Internal Production Requests can be selected too. Source: BRD §6.1 · Q-20260918-29 · Q-20261001-04 · prototype v0.22 · v0.56The Planner enters the production quantity for each selected line. Action: the "PLAN QTY" cell of each line. System: defaults to the line's "REMAINING"; entering more than Remaining is allowed, the excess becomes Common Stock. Test: - Remaining 100, enter 120 → saved, Common Stock = 20 Source: BRD §6.1 · Q-20260923-03The Planner picks the production month (Plan Month) for the whole Master Plan. Action: Step 2 "Item Lines" › "Plan Month" field ("Master plan is built for production month <yyyy.mm>"). System: a Master Plan has exactly one Plan Month; on Release every WO of the plan gets "P.O (Month)" = Plan Month; changing the Plan Month while the plan is DRAFT changes the P.O Month, after Release it does not change. Blocked when: no Plan Month selected → the plan cannot be created. Test: - Plan Month 2026.10 → every WO of the plan has "P.O (Month)" 2026.10 - SO lines needed for month 2026.11 → build another Master Plan Open: the message when no Plan Month is selected does not exist yet; prototype v0.56 does not yet save the Plan Month to the plan / WO. Source: Q-20261001-03 · prototype v0.51 · v0.56The system groups the selected size lines into Master Plan Big Plans; each Big Plan becomes one Work Order. System: grouping key = Style + Model + Base Color + SPRAY/Logo + Area. Style, Model, Base Color, SPRAY/Logo are Item attributes of the line; Area is the Area of the ship-to Country on the SO line, looked up in Master Data Country. The Plan Month is shared by the whole plan, so every Big Plan has the same month. Result: Step 2 "Item Lines" shows one row per Big Plan, one column per size, with chips Style · Color · SPRAY/Logo · Area (Country); text "Selected SO lines are consolidated into n Big Plan(s) by Style + Model + Base Color + SPRAY/Logo + Area". Test: - Same Sandal Black, one SO shipping to DE (Europe), one to JP (Asia) → 2 Big Plans - Same Style, Model, Base Color, SPRAY/Logo, Area; different SOs or different Countries in the same Area → 1 Big Plan - Same Style, Model, Base Color, Area; one SPRAY line, one Logo line → 2 Big Plans Open: block ticking an SO line whose Country has no Area — proposal, not confirmed; within one Area, does the WO show Destination "Mixed" or split by Country (OQ-12). Source: Q-20261001-04 · Q-20261001-02 (D1) · prototype v0.56The system calculates the surplus quantity not tied to any order. System: Common Stock = Plan qty − total allocated to SO lines. Result: the surplus goes with the Work Order created with the plan. Test: - Plan qty 500, SO allocation 480 → Common Stock = 20 Source: BRD §6.1 · BRD §9The Planner picks the Routing (process sequence) for each Work Order to be created. Action: Step 3 "Review & Create" › Work Order card (WO-NEW-nn) › "Routing" field. System: defaults to the item's default routing from Routing Mapping; can be changed to another routing. Process table: "Seq" · "Code" · "Process" · "Lead" · "Plan From" · "Plan To" · "Source". Open: the routing picked in Step 3 is not yet carried to the Work Order screen on the prototype (OQ-49). Source: prototype v0.16The system calculates each process start / end date from its lead time. System: Plan To = Plan From + Lead Time − 1; next process Plan From = Plan To + Buffer Days. Changing the Routing rebuilds and recalculates the process table. Test: - Plan From 01/10, Lead Time 3 → Plan To 03/10 Source: BRD §6.1 · prototype v0.16The system compares each process load with the machine / work center capacity. Yes: load exceeds the Capacity Calendar → flag Over capacity. No: create the plan as normal. System: Plan List has a "Capacity" column and an "Over Capacity" quick filter. Source: BRD §6 step 4 · BRD §9The system flags the plan as Over capacity. Result: warning only — does not block creating or releasing the plan; the Planner decides to reduce load or release anyway. Test: - Plan over capacity → "Create Plan" and "Release Work Order" still allowed, with a warning Source: Q-20260923-02 · Q-20260924-04The Planner creates the Master Plan as a draft. Action: Step 3 › button "Create Plan". Result: plan → DRAFT, editable until Release; the system immediately creates one Work Order per Big Plan in the next step. System: Master Plan does not check materials — this is done in I/J Plan · Compound Calculate. Test: - Click "Create Plan" → plan DRAFT, toast "created as Draft — review it, then Release Work Order (no approval step)" Source: prototype v0.22 · v0.28 · Q-20260923-19 (E) · Q-20260924-04 · Q-20261001-04The system creates one Work Order per Big Plan as soon as the Master Plan is created. Result: one WO per Big Plan (running WO number), status NOT RELEASED, carrying the Routing and process schedule chosen in Step 3; Common Stock goes with the WO. System: the WO carries the Big Plan key ("Style", "Model", "Base Color", SPRAY/Logo, Area) so each field has a single value; "P.O (Month)" = the Master Plan's Plan Month; "Destination" takes the SO line Country, shown as "Mixed" when several Countries of one Area are combined; "Start I/J Date" / "I/J ETC" = Plan From / Plan To of the Injection process. Result: a NOT RELEASED WO is not yet in I/J Plan; it is visible in Plan List (expand icon in the "WO" column) and Plan Details › tab "Work Orders". Test: - Selected SO lines group into 7 Big Plans → "Create Plan" → Plan List expands to 7 NOT RELEASED WOs; I/J Plan has no row yet Open: when a DRAFT plan is edited, are the WOs recreated or updated — no source yet; prototype v0.56 does not yet write the Plan Month to the WO. Source: Q-20260924-08 · Q-20261001-03 · Q-20261001-04 · prototype v0.30 · v0.56The Planner releases the plan's Work Orders directly — there is no approval step. When: plan is DRAFT. Action: "Release Work Order" button. Result: plan → RELEASED; every WO of the plan NOT RELEASED → RELEASED; the WO "P.O (Month)" is fixed to the Plan Month and does not change after Release; from now on the plan cannot be edited or deleted in Master Plan. Open: BRD §7 has the Production Supervisor "Approve" "Create / revise Work Order" and "Release WO / Generate WI" — to be confirmed with the customer or the BRD updated. Test: - DRAFT plan → "Release Work Order" works immediately, with no waiting-for-approval status - RELEASED plan → no "Release Work Order" button Source: Q-20260924-04 · Q-20261001-03 · BRD §6.1 Step 5The system sends the newly released Work Orders to I/J Plan for injection planning. Result: each WO becomes one Detail Plan in I/J Plan, with the Master Plan number (Injection is the first process of the Routing); toast "n Work Order(s) sent to I/J Plan". System: I/J Plan groups Detail Plans into I/J Big Plans by Style + Model + Base Color + Plan Month + Area, not by SPRAY/Logo — a SPRAY WO and a Logo WO with the same key share one I/J Big Plan; a Detail Plan's Order Q'ty = the WO Q'ty per size, SO allocation plus Common Stock. Test: - 2 WOs with the same Style, Model, Base Color, Plan Month, Area, one SPRAY and one Logo → I/J Plan has 2 Detail Plans in one Big Plan - WO of 1,100 pairs (SO allocation 1,000 + Common Stock 100) → Detail Plan Order Q'ty 1,100 Source: BRD §6.1 Step 5 · Q-20260924-04 · Q-20261001-02 (D3) · Q-20261001-04 · prototype v0.30The system pre-creates NEW plans for the processes that have a Plan screen in the WO Routing. Result: each Trimming · Spray Out · Packing process in the Routing gets one NEW plan (customer note: generated automatically from the WO and routing). System: no Injection WI at this step — Injection WIs are created only when scheduling in Injection Schedule. Test: - Routing without Spray → no NEW Spray Out plan Source: OQ-46 · Q-20260923-19 (G) · Q-20260924-04Only a plan that has not been released can be deleted. DRAFT: delete the plan. RELEASED: no delete in Master Plan — handled in Work Order. Source: Q-20260923-03 · Q-20260924-04The Planner deletes a draft plan that is no longer needed. When: plan is DRAFT. Action: Delete. Result: the plan is deleted. Test: - RELEASED plan → no Delete Open: the NOT RELEASED WOs of the deleted plan are deleted with it — proposed, not yet confirmed. Source: Q-20260923-03 · Q-20260924-04The system gives back the remaining-to-produce quantity to the SO lines of the deleted plan. Result: each SO line's "REMAINING" is increased by exactly the Plan qty taken; the SO line can be picked again in another plan. Test: - SO line Remaining 0 (plan took 100) → delete plan → Remaining 100 Source: Q-20260923-03The Planner enters a new expected delivery date (Current ETD) for the plan. When: plan is RELEASED. Action: Plan Details › "Update ETD" button › "NEW CURRENT ETD *" · "RESCHEDULE SOURCE *" › "Preview Reschedule". Open: whether a DRAFT plan uses "Update ETD" or is edited directly in Plan Details; keeping Frozen processes unchanged is a proposal, not yet confirmed. Source: Q-20260923-05 · prototype v0.22The system builds a preview of the process schedule after moving the ETD. System: process table with "Has Qty?" · "Frozen" · Old / New From–To · "Change Status"; Frozen processes keep their actuals and are not moved ("Frozen processes keep their actuals and are never auto-rescheduled."). Test: - A process with quantities (Frozen) → new From–To = old From–To Source: prototype v0.22The Planner chooses to apply, save as a trial, or cancel. Apply Reschedule: move the ETD and the real schedule. Save as Simulation: save the scenario only, the real schedule stays. Cancel: discard, ETD and schedule unchanged. Source: prototype v0.22The system applies the new schedule to the plan. Action: "Apply Reschedule" button. Result: Current ETD changes; Plan From / To of non-Frozen processes move accordingly. Open: no Supervisor approval step for rescheduling yet — differs from BRD §7. Source: Q-20260923-05 · BRD §7The system saves the rescheduling scenario for review without changing the real schedule. Action: "Save as Simulation" button. Result: a Simulation copy exists; the real Current ETD and process schedule stay unchanged. Source: prototype v0.22
Startwhere the flow begins
Endevery Start reaches at least one End
Process steptop strip = screen used, colored tag = platform
Decisionevery outgoing branch carries its condition
Data / documentinputs in the Input lane, results in the Output lane
Main flowthe required order of steps
Tags on a boxMaster dataWebSystem (auto)

Status lifecycle

Master PlanDRAFTRELEASEDRelease Work OrderDeleteDeleted
◻ DRAFT ◻ RELEASED

Input

#InputTypeUsed in step
I-1Sales Order (lines per size, carrying the ship-to Country) — Plan qty may exceed Remaining, the excess becomes Common StockDocument — Sales moduleStart → Create Plan: select SO lines
I-2Internal Production RequestInternal documentCreate Plan: select SO lines
I-5Country — Area field (Area of the ship-to Country on the SO line)Master dataStep 2: group SO lines into Big Plans (Area is part of the grouping key)
I-3Item · Routing · Routing Mapping (the item's default routing + alternative routings)Master dataStep 3 Review: pick a Routing for each Work Order
I-4Machine · Capacity CalendarMaster dataCalculate Plan From / To from lead time, check Capacity

Step ↔ screen

StepRoleScreen · UI button
Open the Create Plan wizardPlannerMaster Plan · Plan List · Create Plan
Filter plans by Area (view only, not a business step)PlannerMaster Plan · Plan List · field Area outside the grid (All / Europe / Asia / America) · column Area
Select SO size lines · Enter Plan Qty per linePlannerMaster Plan · Step 1 · Select SO Lines
Select Plan MonthPlannerMaster Plan · Step 2 · Item Lines · field Plan Month
Group SO lines into Big Plans · Calculate Common StockSystem (auto)Master Plan · Step 2 · Item Lines (one row per Big Plan)
Pick a Routing for each Work OrderPlannerMaster Plan · Step 3 · Review & Create (the Routing field of each WO)
Calculate Plan From / To from lead time · Flag Over capacity (warning only)System (auto)Master Plan · Step 3 · Review & Create
Create Master PlanPlannerMaster Plan · Step 3 · Create Plan
View the plan's Work Orders (view only, not a business step)PlannerMaster Plan · Plan List · column WO with an expand icon (1 plan → n WOs, with Process · Progress · Status); Plan Details › tab Work Orders › Process view (tree WO → processes, status and quantity of each process)
Release Work Order · Delete Master Plan · Enter new Current ETDPlannerMaster Plan · Plan Details (Release Work Order, Update ETD)
Create Work Orders per Big Plan · Send WOs to I/J Plan · Create NEW plans for processes with a Plan · Restore SO line Remaining · Build Reschedule Preview · Apply new schedule · Save SimulationSystem (auto)Master Plan (Preview Reschedule, Apply Reschedule, Save as Simulation)

Output

#OutputProduced when
O-2Plan = RELEASED; Work Orders (one WO per Big Plan, created at Create Plan, NOT RELEASED; P.O Month = Plan Month) carrying the chosen Routing turn RELEASED → I/J Plan, each WO one Detail Plan with the Master Plan number, grouped by I/J into an I/J Big Plan by Style + Model + Base Color + Plan Month + Area; Order Q'ty = WO Q'ty incl. Common Stock — + plan NEW for Trimming / Spray Out / Packing (per the WO's Routing) + Common Stock (the surplus). The Injection WI is not created here — it is created when scheduled on Injection SchedulePlan DRAFT, the Planner clicks Release Work Order (no approval step)
O-3SO line Remaining given backDelete plan DRAFT
O-4No delete in Master Plan — handled in Work OrderPlan already RELEASED
O-5New Current ETD + rescheduled process dates (Frozen processes unchanged)Planner clicks Apply Reschedule
O-6Simulation copy, live schedule unchangedPlanner clicks Save as Simulation
O-7Keep ETD and process schedulePlanner clicks Cancel in Reschedule Preview

Glossary

GlossaryMeaning in this flow
SOSales Order — each size is one line
Internal Production RequestInternal request to produce, not tied to a customer order
Plan qtyQuantity the Planner decides to produce for a line
REMAININGQuantity of the SO line still to be planned
Big Plan (Master Plan)Group of SO lines with the same Style + Model + Base Color + SPRAY/Logo + Area in one Master Plan; each Big Plan becomes one Work Order
AreaField of Master Data Country; the SO line carries the ship-to Country and the system derives the Area
Plan Month · P.O MonthProduction month the Planner picks for the whole Master Plan · month recorded on the WO, equal to the Plan Month, unchanged after Release
SPRAY / LogoItem attribute telling whether goods go to Spray or Logo printing — two different Routings, so it is part of the Master Plan grouping key
Master PlanOverall plan for one Plan Month; one Master Plan → n Big Plans → n Work Orders
Work Order (WO)Production order, created for each Big Plan when the Master Plan is created (NOT RELEASED), released when the Master Plan is released; its status in Master Plan follows the whole Routing: NOT RELEASED → RELEASED → IN PROGRESS → COMPLETED
RoutingThe item's process sequence; defaults from Routing Mapping
Lead Time · Buffer DaysDays per process · buffer days before the next process
Common StockSurplus not tied to any SO line = Plan qty − total SO allocation
Capacity CalendarDaily machine / work center capacity, used for Over capacity warnings
Current ETDThe plan's current estimated delivery date
FrozenA process with actuals, never rescheduled automatically
SimulationA saved trial reschedule that does not change the real schedule