PPC Package

INDEX 

Chapter Topic Page No. 

01. Operation of ON-LINE PPC Package 01 

02. Inventory Management Module 05 

03. Purchase Order Planning & Control 11 

04. Vendor Analysis 20 

05. Costing Module 25 

06. User Manual on Database Module 30 

07. Maintenance Management Module 80 

08. Quality Assurance Module 92 

09. Tools Control 93 

10. Work In Progress 97 

11. Shop Order Release Module 100 

12. Details Operation Schedule 116

Chapter – 1 

Operation of On –line PPC Package 

Scope : 

Though computerisation of inventory details is quite old in the ordnance factories this 

write-up is intended to discuss operational details of the ONLINE PPC system. It starts with an 

introduction to the operation of the on-line system in ordnance factories followed by a detailed 

discussion on the various operations involved while using the inventory management and the 

purchase order control modules of the PPC software package. 

To keep the write up within manageable size, certain details like formats of outputs and of 

screen layouts are ommitted since they will vary from factory to factory and are so trivial that one 

can easily absorb it in practice. 

General Information 

Following are the general procedure to be followed in order to get service from PPC Software. 

1. Power on/off 

If the power on indicator is off, then switch on the terminal and wait for around thirty 

seconds to get any response. NEVER switch on the terminal immediately after switching it off; wait 

for a minute before doing it. 

Before putting power off, it should be ensured that the terminal displays the login prompt on 

an otherwise blank screen. This is to ensure that unauthorized persons can not access data through an 

idle connected terminal. 

NB: 

If the terminal at your location is housed inside the airconditioned enclosure or if you have 

additional voltage stabiliser or any other equipment, then first switch them on before 

switching the terminal. While putting off the power, sequence should be reversed; first the 

terminal and then the additional equipments. 

2. Log in/out 

This procedure connects/disconnects the user in the computer system. When the screen 

displays "Login: " message, give your user identification and password. Watch the screen carefully 

after logging in. There may be some message stored for you regarding the computer system. After 

using the computer, switch it off only when the message 

3. Messages and errors 

"Login: " appears on the screen. 

While working with the software, there will be different help messages and error 

messages shown on the screen depending on the situation. These will be appearing at the bottom of 

the screen. General messages will be like 

a) A fixed highlighted line always appearing at the bottom describing the function of 

Ordnance Factories Institute of Learning, Dehradun 1

the dedicated keys. 

b) Depending on the field in which cursor is present now, there may be a one-line help 

message. 

c) After the screen is executed by pressing the escape key finally, system will give a 

message telling whether the operation was successful. 

d) In case of raising a new document carrying a document number generated by the 

computer, that number will be displayed on the screen and the message "Press return 

to continue..." will appear. User may note down the number for future reference 

before pressing the return key; computer will wait till this is done. 

e) In case of a fault while processing, computer will give an error message and wait 

there with the message "Press return to continue...". Before pressing the return key, 

user is to note down the message in exactly the same format as is given by the 

computer and report this to EDP. 

4. Dedicated keys 

The software will be presented in the form of a menu. There will be different options and 

suboptions in order to reach the screen where the user actually gets the service. The following set of 

keys will be generally applicable on any screen. 

Esc : 

^C : 

^B : 

This key is used to tell the computer that all the data corresponding to the screen has 

been entered. 

To be read as "control C". This key is effected by pressing the key "C" while key 

"Ctrl" is kept pressed. This key is used to abort any screen that is running currently. 

This does not work while inside "Inquire" options. 

Depending on the field in which cursor is staying, there may be a message "Press 

control-B for help". Once Control-B is pressed, there will be a secondary window 

appearing on the screen giving the set of valid data required for the field. In order to 

come out of the screen, escape has to be pressed. 

^P : Sometimes data is entered through more than one consecutive screens. IN such cases, 

if it is required to go back to the previous screen, then control-P can be used. Going 

to the next screen in multiscreen input is, however, effected by pressing conventional 

Esc key. 

Arrow keys : Sometimes information will be displayed or input in the form of an array. In 

order to travel from one element of the array to the other, arrow keys 

can be used. 

F1 : 

While entering data through an array, if this key is pressed then the data in the 

current line is erased. 


F2 : 

While entering data through an array, if this key is pressed then a blank line is 

inserted before the current line of data. 

5. Inquire option 

In an inquire option, user has to give the selection criteria in the fields wherever the cursor 

goes. After entering the selection criteria,user has to press Esc key. The computer then searches all 

the data depending on the criteria given and displays them one by one. Using the ring menu 

appearing at the top, user can select first, last, the next or the previous row. The following symbols 

can be used to establish the relationship between the value entered and the rows in the table. 

> Greater than 

< Less than 

>= Greater than or equal to 

=12 entered in a field means that all the rows having the column value greater than or 

equal to 12 will be displayed. 

pre* 

?p? 

entered in a character field means that all the data having the column value starting 

with "pre" will be displayed. 

entered in a character field will mean that all the rows having the corresponding 

column value as: first character any arbitrary single character, second character as 

"p" and third character as another arbitrary single character, will be displayed. 

Length of the selected values will be three characters in this example. 

PPC Software is now available under directory /user/develop/demo. This means that all the software 

which includes program sources, form sources, program definitions and compiled versions of both 

programs and forms are available under directory /user/develop/demo. 

The entire software is divided into 15 modules. A module is collection of logically similar programs. 

For example, all the programs relevant to purchase orders are available under the module 

PURCHASE ORDER AND CONTROL. Sources of each module are kept in a separate directory. 


Module names and their respective 

directories are as follows: 

Databases 

Inventory 

Purchase order 

Vendor Analysis 

Payment Analysis 

Material Requirement Planning 

Forecasting 

Shop order release 

Work in progress 

Quality assurance 

Maintenance Management 

Tools Control 

Costing 

Detailed Operation Schedulling 

db 

im 

po 

va 

pa 

mp 

fc 

wr 

wi 

qa 

mm 

tc 

ct 

ds 


Chapter – 2 

Inventory Management Module 

The primary purpose of this module is to handle the information regrading different 

inventory activities. This includes material receipt, issue to sections for internal consumption and 

issue of finished product to the customers. There will be different reports generated on different 

activities in order to facilitate the management in information handling. 

In addition, there will be mechanism for verification, detection and regularization of stock 

anomalies with proper documents like expense voucher, certified vouchers etc. 

Receipt of material starts with the logging of transport activities. When the information about 

the transport booking etc. for the material is received, they can be logged in the computer so that 

material that has already started for , can be tracked. Once this material arrives at the gate, a 

Summary at Material. 

Inwards Bond is prepared. At that time the person sees the purchase order rate, ordered 

quantity etc on the screen and verifies. This is in order to confirm the accuracy of the purchase 

orders that are transferred from the computer existing earlier. The person raising the Summary also 

sees the description of the material as described in the document. Once satisfied, he raises the 

document for further action. It is not absolutely necessary to enter the transport documents because 

they may not be available in advance before the actual material arrives or there may not be any 

transport document at all. But the next stage of raising the Summary is necessary. 

Once Summary is raised, an MIS can be raised against the Summary. At this stage also, the 

purchase order details are shown alogwith the material description. 

Then the MIS can be printed and forwarded to MID for inspection of the material. A material can 

have its description at different documents. They are like 

i) There is a permanent 35 character long decription corresponding to every item in the stock 

master. whenever a document is being raised or a query is made on the screen, this 

description is picked up and shown to the user. 

ii) 

iii) 

iv) 

For some items this description is found inadequate to give the specification. So there has 

been an option to provide a longer description of 300 characters for such items. In printed 

documents, this longer description is printed whenever details are required. It is not essential 

for all the items to have long description. Then the documents will contain the 35 character 

description which is sufficient for these items. 

While the vendors send their quotations against a tender enquiry, they may offer to supply a 

material which is not exactly what is required by the factory, but something compatible. The 

description/specification of these items may be deviating from the specification we are 

maintaing in our master files. At the time of entering the quotation if there is any deviation 

that can be entered against that item for that tender enquiry. When order is placed or later 

material is received against that order, this deviated specification/description will be printed 

in the documents. 

Sometimes it is found that at the time of raising the purchase order FY wants to give 


specification of the material more precisely than is possible within 300 characters. There is 

provision given to describe the material at the time of raising the purchase order using a 

maximumof 200 lines of 75 characters each. 

At the time of printing the MIS, the 30 character description is always printed.Next, if the 

200 line description is found, this is printed. Otherwise it is 

checked whether there is any deviated description was provided by the vendor at the time of sending 

quotation. If so, this is used in the MIS. If none of them are available then the long description of the 

item, if any, is printed. The MIS thus printed will be sent to MID for inspection. They will determine 

the accepted/rejected/expended in test quantities and forward the MIS to stores for further action. 

The quantity accepted together with the quantity expended in test at FY expenses will be updated in 

the purchase order so that party can be paid for the material. 

The MIS sentenced now arrives at Stores for posting. Once executed, this will update the 

stock value and quantity so that material can be issued to the demanding sections against demand 

notes. 

Demand notes are used to draw materials from stores against warrants. There will be two 

mechanisms available to process demand notes. 

According to one mechanism, Production sections will be raising the demand notes from 

their terminals. Only those items that are authorized against the warrant will be allowed to be drawn. 

Quantity will be limited to the quantity less the quantity already drawn and quantity already 

authorized against other demand notes for the same item. If there is any alternate material given in 

the warrant then that is also taken care of in the calculation of the allowable quantity. If certain 

percentage of one of the alternate materials is drawn then only the remaining proportion can be 

drawn from any of the alternates. 

This demand note now will be going to MCO for authorization. MCO will see the demand 

note and determine whether there is any crisis of the material. seeing the stock situation, demand 

postion and criticality of different demand notes, they authorize the suitable amount to the section on 

the demand note. 

Finally this demand note will be posted in the stores so that stock and warrant are updated. 

Stock quantity and value are reduced by the drawn amount. The same is enhanced in the drawn 

quantity and value in the warrant. 

The above requires that the demand notes are raised only against valid warrants issued 

through the computer. But this situation may take some time to be implemented. So temporarily 

there is a parallel mechanism for raisisng demand notes. In this, only the warrant numbers will be 

available in a file. At the time of raising the demand note this file will be consulted for the existance 

of valid warrant numbers only. MCO raises the demand note. Section produces the demand note to 

MCO. MCO raises the demand note. The two operations of raising and authorizing are clubbed 

together so that no further authotizaion is required. The mechanism of posting the demand note is 

same as before but the warrants are not updated since they do not exist in the computer. 

The mechanism for processing return note is exactly same as that used for the demand notes. 


The same form is used for both the purposes. In case of authorization of return notes, a separate 

option is given so that this option can be executed by inspections department. 

The procedure currently being followed is the second one. 

When material from the factory is to be issued outside te factory an issue voucher is needs to 

be prepared. Issue vouchers can be of several types: 

i) Production issue vouchers are prepared to issue items manufactured in the factory against 

warrants. It reduces the item held in the manufactured item master and increases the issued 

quantity in warrant and order files. 

ii) 

iii) 

iv) 

Nominal issue vouchers are prepared to send material without affecting the stock. Actual 

issue voucher as is appropriate will be issued later. 

Stores issue vouchers are prepared for issue of store from purchase item master. 

COD issues are required to take care of transaction of material outside the factory. 

Sometimes materials will be despatched from the vendor to the indentor directly without any 

involvment of FY in between. But since the order for the material was received by FY and in 

turn FY placed the purchase order to thy vendor, the order masters sre to be updated without 

affecting the store. Store will not be affected since FY is not receiving anything from the 

vendor, nor it is isuueing anything from the store. Only the masters of received orders and 

purchase orders will be updated. 

If there is any anomaly in the physical balance and the documanted balance then that will be 

detected during stock verifications. These and any other anomalies can be rectified using 

discrepancy vouchers. 

Sometimes it may be required to adjust the stock value without altering the stock quantity to 

take care of depreciation or inflation. This can be done through Adjustment vouchers. 

In addition, extensive reports and queries are be available in order to facilitate the monitoring 

of the Store. 


CONTENTS 

main - im000menus 

1. RR/LWB Transaction - im905trtdetails 

Add - im901trt Modi - im901trt Delete - im901trt 

Inquire - im902trt, im903trt RR/LWB Receipt - im904trt 

2. Entry on Receipt of Materials in Bond 

MIB Transactions - im910amib Inquire - im911imib 

3. Material Inward Slip - im110mis 

1. Raise MIS - im001anmis 

2. Print MIS 11 

3. Sentence MIS - im112mis 

4. Post Receive Voucher - im107mis 

5. Print Receive Voucher 

6. Inquire MIS - im104mis, im108mis 

7. Print Discrepancy Report - im001dskr 

8. Print MIS Summary - lb_dates 

4. Demand/Return Notes 

Add - im153enter 

Delete - im155modfy 

Post - im156pass 

Report 

Print Demand Note 

Print Return Note 

Inquire - im155modfy 

5. Issue Vouchers 

Production - im600isvra Nominal - im600isvra Stores - im600sivr 

Report - im600issvr Inquire - im600isvra 

6. Certified Vouchers - im700ncirv 

1. Raise CIV/CRV - im700acirv 2. Inquire CIV/CRV - im700icirv 

7. Discrepancy Vouchers - im200nddvr 

1. Raise a DD Voucher - im200addvr 


2. Authorise a DD Voucher - im200addvr 

3. Delete a DD Voucher - im200addvr 

4. Inquire on DD Voucher - im200addvr 

5. Post a DD Voucher - im200addvr 

6. Print a DD Voucher - im200addvr 

7. Adjustment Vouchers 

Add - im151adjst Inquire - im151adjstz 

8. Stock Verification Vouchers 

Add - im120stver Modify - im120stver Inquire - im120stver 

Delete - im120stver 

9. Reports - im100nrept 

1. Consumption Statement - lb_dates 

2. Fast/Slow/Non moving items 

3. Negative stock balance 

4. Stock of vital items 

5. Stock of scarce items 

6. Stock of critical items 

7. List of Bottlenecks 

8. Nil balance statement 

9. XYZ analysis 

10. ABC analysis 

11. Stock item list 

12. Manufactured item list 

13. Stock statement 

14. Priced Stores ledger - lb_dates 

15. Priced Stores accounts ledger - dateim60 

16. Inward lorry weigh bills - lb_dates 

17. Statement of LWBs booked for despatch - lb_dates 

18. Items below stock level 

19. Items above stock level 

20. Monthly despatches - lb_dates 


21. Loss statement for every DD voucher 

22. Surplus statement - lb_dates 

23. List of scrap items 

24. Monthly incoming wagons - lb_dates 

25. Item nomenclature 

26. RR's Pending actual receipts 

27. LWB's Pending actual receipts - lb_dates 

28. Stock not verified 

29. Daily Collection report - im115mis 

Option: 

Main menu in Inventory module 

im000menus INVENTORY MAINTENANCE IM000MENUS 

1) RR / LWB TRANSCATION 6) DISCREPANCY DEF. VOUCHER 

2) MATERIAL INWARD SLIP (MIS) 7) ADJUSTMENT VOUCHERS 

3) DEMAND / RETURN NOTES 8) STOCK VERIFICATION VOUCHER 

4) ISSUE VOUCHERS 9) REPORTS 

5) CERTIFIED VOUCHERS 10) EXIT 

Enter your option : [ ] 


Chapter – 3 

Purchase Order Planning and Control 

The purpose of this module is to register the information on different procurement activities. 

This includes raising of purchase requisitions by sections, raising and authorizing an SHIS, raising a 

tender, registering quotations recieved from suppliers and finally raising a purchase order. Reports 

are generated on the various activities covered to help in information management. 

Purchase requisitions can be raised from the production sections to indicate their requirement 

of materials. In that information will be available on item code, quantity, approximate date by which 

the material is required and any justification/ authority for the material procurement. This may 

further be processed by MCO to raise the SHIS. 

An SHIS is raised to initiate the procurement action. This document is raised from MCO and 

forwarded to Provisioning office to take procurement action. 

Based on the SHIS one of several actions can be take. Either a purchase order to a trade 

agency or and IFD to a sister factory or an Indent to an allied agency can be raised to get the 

material. 

In case of procurement from the trade, a Tender enquiry will be raised and distributed to the 

vendors. There the item and quantities to supplied will be mentioned. 

Vendors will respond against these Tenders by sending quotations. The selected quotation 

will be entered into the computer for further while raising the purchase order. this quotation will 

contain different rates of the material. A party can supply different alternates for a given item. If the 

specification of the item supplied by the vendor deviates from what is required then that can be 

registered at the time of entering the quotations. This deviated specification will be used in further 

documents like purchase order, MIS etc.. 

There is provision for processing rate contract information also. Rate contract document 

contains rates of different items that will be supplied by the vendor for a fixed interval. If these 

information are registered in the computer then these can be used like quotation information and rate 

and value of an order can 

be obtained. 

Total allowable expenditure is allocated under different budget heads and this is fixed at the 

beginning of the year. This allocated amount can be registered in the computer as soon as they are 

available at the beginning of the year. 

Later, whenever an order is placed against a budget head or payment is done, respective 

fields in the corrsponding budget record will be updated. 

After raising the purchase order, the vendor will start supplying the material. When the full 

quantity is received, the supply order can be closed. In case there is requirement of closing the 

supply order before completion of the order, it can be short-closed. No further material will be 

received against such closed or short-closed purchase order. 


CONTENTS 

main - po000menu 

1. Purchase Requisitions 

1. Raise - po101preq 

2. Modify - po106preq 

3. Inquire - po106preq 

4. Delete - po106preq 

5. Reports - lb_dates 

2. SHIS 

Add - po203sis, po205pusi 

Modify - po203sis, po206sis 

Vett - po203sis 

Inquire - po203sis 

Delete - po203sis 

Print - po203sis 

Reports - lb_dates 

3. Tender Enquiry 

Raise - po121te, po122tept, po124tesis 

Modify - po121te, po122tept, po124tesis 

Inquire - po121te 

TE_items - po125tept 

Delete - po121te 

Reports 

Tcp - tend_scr 

Cst - itend_scr 

Tender printing - po209pte 

4. Quotations 

Add - po131quot 

Modify - po131quot 

Delete - po131quot 

Inquire - po131quot 

P_rating - va100prce 

Ord_qty - va200itent 

5. Vendor Rating 

Vendorwise - po132vitm 

Itemwise - po132vitm 


6. Rate Contract 

Add - po202rc 

Modify - po202rc 

Delete - po202rc 

Inquire - po202rc 

7. Head Budget 

Add - po201hb 

Modify - po201hb 

Delete - po201hb 

Inquire - po201hb 

8. Purchase Order 

1. Raise Purchase Order 

2. Amend Purchase Order 

3. Inquire Purchase Order 

Amendment - po151poam 

4. Delete Purchase Order 

5. Close Purchase Order 

Purchase Order - po111po 

Item - po114pt 

6. Shortclose Purchase Order 

Purchase Order - po111po 

Item - po114pt 

7. Give Purchase Order dates - po210po 

8. Print Purchase Order - po111po 

9. Reports 

Item wise - lb_dates 

Party wise - lb_dates 

Po Number wise - lb_dates 

Purchase Type wise - lb_dates 

10. Add Direct Purchase Order - po111po, po112fpt, 

9. Indents 

Add - po208indt 

Modify - po208indt 

Delete - po208indt 

Inquire - po208indt 

Print - po208indt 

10. Cash Purchase 

Add - po207capu 

Modify - po207capu 

Delete - po207capu 

Inquire - po207capu 

Print - po207capu 


11. Vendor Item 

Add - po132vitm 

Modify - po132vitm 

Inquire - po132vitm 

Delete - po132vitm 

Suspend - po132vitm 

Revoke - po132vitm 

Reports 

Party - vend_scr 

Item - item_scr 

12. Reports 

List of purchase requisitions - lb_dates 

List of SISs - lb_dates 

Tender enquiry reports 

Tpc - tend_scr 

Cst - itend_scr 

Tender Printing - po209pte 

STA-form - po121te 

Purchase Order reports 

Item wise PO list - lb_dates 

Party wise PO list - lb_dates 

PO number wise PO list - lb_dates 

Purchase type wise PO list - lb_dates 

Dues List - dues_frm 

Purchase type wise receipts - lb_dates 

Party-Item listing 

Party wise item list - vend_scr 

Item wise party list - item_scr 

Page 1 

Option: Main menu in purchase order module 

po000menu PURCHASE ORDER PLANNING AND CONTROL 

PO000NMAIN 

1. Purchase Requisitions 2. SHIS 

3. Tender Enquiry 4. Quotations 

5. Vendor rating 6. Rate Contract 

7. Head Budget 8. Purchase Order 

9. Indents 10. Cash Purchase 

11. Vendor Item 12. Reports 

0. Exit 

Enter your option : [ ] 

This menu appears when the user selects the purchase order option in the main menu of the 


ppc package. The user may select any of the options in this menu according to the activity he is to 

perform. Please note that the reports shown in this manual have been generated with test data. 

Scope:- 

Other modules related to 

Material Management 

This write-up is meant for introducing the operational details of the four modules (namely 

Forecasting,Material Requirements Planning, Vendor Rating and Payments analysis) of the online 

PPC system which is currently operational in the ordnance factories. 

Forecasting Module 

Forecasting module calculates the probable consumption of a maerial in a quarter based on past 

consumption of the material. This is done by processing the demand/return notes available in the 

computer. 

There is provision for calculating average consumption of an item over the period of last 18 months. 

It is expected that future consumption can be predicted based on this average consumption. This is 

the monthly requirement of an item. 

In this it is assumed that the consumption history has equal importance irrespective of its age. 

Instead, it is expected that the future consumption will be more close to the consumption in the 

recent past, whereas earlier data will have gradually deminishing effect on the forecasted quantity. 

So instead of taking 1/18th of the consumption of a material over last 18 months and summing them 

up to get the forecast quantity, we take a fraction of the consumption for each of the previous 

quarters, the factor having a decreasing value as we go back in the past. This way we calculate the 

smooth average consumption quantity for an item. 

In addition to the average quantity, looking at the trend of the consumption, it can be predicted 

whether consumption is likely to increase or decrease in the future. If we add this trend to the 

average consumption, prediction can be expected to be more accurate. 

Sometimes consumption may follow a fixed pattern. During a certain period every year there may be 

increase or decrease in the consumption. If we do not consider the seasonality then there may be 

extra provisioning when the material is not needed or there may be prediction of just the average 

consumption whereas expected consumption is more. The seasonality factor in a quarter is 

calculated as the ratio of average consumption in the quarter and the average quarterly consumption. 

If the average consumption of an item in a quarter is low then this factor will be low and the overall 

forecast quantity will also be less. After running the forecasting activity the user will be presented a 

report that will give the estimated consumption quantity in a quarter. 

For running the forecasting module, first the master which will contain one record for each item that 

has been consumed as indirect material in the past, has to built. After that the item history file, which 

will summarize the past consumption from the demand/return note file is to be generated. After 

generating this file, if it is known that some more consumption history is available in addition to the 


data available in the computer, that can be added. Also the consumption history can be modified or 

deleted according to the requirement. Once the forecastin master and history file is generated, 

calculations can be started. Three calculations re involved in the process; Smooth average 

calculation, trend calculation and seasonality calculation. After these calculations are over the report 

can be generated. It is important to note that unless all three calculations are over the report 

generated will not be as is expected. 

The trend component of the forecast quantity gives the expected increase or decrease in the 

consumtion from the average forecast consumption. This is expected to be low in comparison to the 

average. A rigorous process is available to calculate this component also. In this, first the smoothed 

average of all the items in all the quarters in the past are calculated and stored in the forecast master 

table. Then the trend is calculated as follows: 

Trend in consumption of an item for a quarter is the difference of consumption in the previous 

quarter anad the consumption in the previous to previous quarter. This trend is calculated for all the 

quarters for which data is available. Then a mechanism similar to that for finding smmothed average 

consumption is applied to find smoothed average trend. 

The above procedure, though sophisticated by nature, requires abnormally high computation time. 

Considering its effect on the overall forecast quantity, a simpler but much faster mechanism is also 

considered. In this, the average of earliest consumption and latest consumption is taken over the 

period of consumption. 

The monthly requirement computation involves finding the average consumption of and item as 

indirect material over the period of last 18 months. The average quantity is updated as monthly 

requirement in the stock item master. 

Material Requirement Planning Module 

This module accepts the quarterwise production plan. This production plan can be decided based on 

the orders received from different agencies for different end products. Once this plan is entered, this 

module calculates the amount of raw material required at different period of time. Then the net 

quantity for which procurement action has to be initiated, considering all the stock and dues 

quantities, is also calculated. 

Optionwise explanation follows 

MAIN: (mp000menu.4ge) 

1. Plan maintenance (mp001nplan.4ge) 

Add, Inquire, Modify, Delete, Exit 

(mp001nplan, mp001aplan, mp001ipl, mp001mplan, mp001dplan, mp001fdues) 

Data expected for addition: 

EP Code 

Plan year 

Plan quantity 

Action: 

After EP Code, Ep description is displayed 


After plan quantity, it is distributed into 4 quarterly quantities in 20%, 25%, 25%, 

30% proportion. 

In modify option the above quarterly distribution can be altered and plan quantity will be the 

aggregate of the modified quarterly planned quantities. Key for modification (EP Code, Plan 

year) 

2. Gross requirement calculations (mp002ngros.4ge) 

a) Run gross requirement calculation (mp002tgros.4ge),(mp002sgros, 

mp002tgros, mp002gdate, mp002estrv, mp002globl) 

Data expected: 

Starting year 

Starting quarter 

End year 

End quarter 

Action: 

Inserts rows in m_epgros indicating material requirement upto the raw 

material level. Production target is taken from m_plan. 

b) Query on gross calculation (mp002igros.4ge) 

(mp002globl, mp002igros) 

Query on: 

EP Code 

Item code 

Component code 

Qty required 

Year 

QuarterUnit of quantity 

Required date 

Required quantity 

Makes query on m_epgros 

c) Run adhoc requirement calculation (mp004tadhc.4ge) 

(mp004tadhc, mp004sadhc, mp004globl, mp002estrv, mp002gdate) 


EP code 

Year 

Quarter 

Scheduled quantity 

Action: 

Inserts rows in m_adhmp indicating material requirement upto the raw 

material level. Production target is taken on adhoc basis. 

d) Query on adhoc calculation (mp004niadh.4ge) 

(mp004niadh, mp004iadh) 

Query on: 

Item code 

Required year 

Required month 

Unit of quantity 

Adhoc quantity 


3. Net requirement calculations (mp003nnet.4ge) 

a) Net requirement calculation (mp003tnet.4ge) 

(mp003tnet, mp003fldt, mp003globl) 

Calculates net requirement itemwise after considering stock and dues from 

purchase order. 

b) Query on net requirements (mp003ninet.4ge) 

Query on Item code 

Plan year 

Plan month 

Unit of quantity 

Gross quantity required 

Drawable/current stock 

Dues from purchase order 

Net quantity required 

4. Explosion details (mp007nexpl.4ge) 

Options: Single level, Multi_level, Consolidated 


EP Code 

Quantity required 

Displays the items required and respective quantities 

5. Implosion details (mp008nimpl.4ge) 

6. Reports (mp000rmain.4ge) 

a) MRP production program (mp020rsecp.4ge) 

(mp020globl.4gl, mp020gdate.4gl, mp020estrv.4gl, 

mp020expsp.4gl, mp020rsecp.4gl, mp000fconv.4gl) 


Starting year, quarter 

Ending year, quarter 

Action: 

Gives sectionwise production plan for different components. 

b) Gross/Net requirement (mp030rgnrq.4ge) 

(mp030rgnrq.4gl, mp020globl.4gl) 


Starting year, quarter 

Ending year, quarter 

Action: 

Gives the total quantity required of an item between start date and end date. 

c) Procurement program (mp010rproc.4ge) 

(mp010rproc.4gl) 


Year, quarter 


Action: 

Requirement in the year and quarter is printed itemwise 

d) Review sheet (mp050rrevu.4ge) 

(mp050globl.4gl, mp050rrevu.4gl, mp050revst.4gl) 


Item code 

Action: 

Gives Material details, 

End product details which require this material, orders received for these End products, 

Production plan, and pending supply order details for a given item 


Chapter – 4 

Vendor Analysis 

The principal purpose of this module is to calculate the ratings of a vendor. The three 

types of ratings included are price rating, quality rating, and delivery rating. Price rating is 

calculated on receiving a quotation from the vendor on the item mentioned in the tender. Quality and 

Delivery ratings are calculated each time the supplier supplies material against a purchase order, and 

therefore, take into account the past performance of the vendor. 

The options in this module are generally invoked by other modules, namely, the 

purchase order and inventory control modules, though the user may run the "Price rating" and 

"Tentative Order Quantity" options from this module itself. 

VA000 Vendor Analysis - MENU VA000NMAIN 

1. Price Rating 

2. Tentative Order Quantity 

0. Exit 

CHOICE [ ] 

The above menu is displayed when the vendor analysis option is selected by the 

user. It is important to note that the Price Rating and Tentative Order Quantity may also be 

calculated from the Purchase Order module. 

PRICE RATING 

VA100 UPDATE PRICE RATING VA100TPRCE 

Tender Enquiry Number : [ ] 

Party Code : [ ] [ ] 

Item Code : [ ] 

Description : [ ] 

Input : Tender Enquiry Number, Party code, Item code 

Action : 

On pressing the escape key after entering the required information, the system 

calculates the price rating of the vendor for the item. The price rating is 

recorded in the vendor item master. 


CALCULATION OF TENTATIVE ORDER QUANTITY 

VA200 CALCULATION OF TENTATIVE ORDERING QUANTITY VA200ITENT 

Supplier Code : [ ] 


Quotation Date : [ ] 

Input : Supplier code, Item code, Quotation date 

Action : 

The tentative ordering quantity is calculated and displayed on the sreen. 

QUALITY RATING 

The quality rating is calculated during the posting of reciept voucher (please refer to 

the user manual on inventory control). On pressing the escape key after entering the reciept voucher 

details, the user is prompted with the message "Do you want to run Quality rating (y/n)?". If the user 

responds with a "Y/y"then the system calculates the Quality rating for the vendoron the item 

mentioned in the reciept voucher. The quality ratingfor the vendor is recorded in the vendor item 

master. 

DELIVERY RATING 

The delivery rating is also calculated during the posting of reciept voucher (please 

refer to the user manual on inventory control). 

Once the system has calculated the quality rating, the user is prompted with "Do you 

want to run Delivery rating (y/n)?". 

If the user confirms with a "Y/y", then the delivery rating for the vendor on the item 

mentioned in the reciept voucher is calculated. The delivery rating for the vendor is recorded in the 

vendor item master. 

PAYMENT ANALYSIS Module 

The purpose of this module is essentially to track vendor bills from the time that they are raised or 

registered till cheque details are issued for the bill. The activities include linking of bills to receipt 

vouchers on receipt of material, posting the bill and generating payment advice. When a bill is 

received, the person dealing with the registration of the bill has to enter the purchase order number 

against which the bill is being registered. The person may then verify the vendor code that appears 

on the screen. Other particulars like bill type, challan number, inote number etc are then entered. It 

is important to elaborate a little on the bill type that is to be entered. While raising the purchase 

order, the basis on which the payment is to be made and the payment percent are identified. In case 


the payment is to be a part (provisional) payment, then the bill type should be P. When a bill is to be 

registered for the remaining (adjustment) amount, the bill type entered should be A. Whenever a 

single bill is raised for the entire amount in the purchase order, then the bill should be treated as an 

adjustment bill. On entering the amount claimed against each item, the computer cross checks with 

the maximum amount allowable for that item on the basis of the payment percent in the purchase 

order. The computer generates a bill serial number for reference purpose. Any recovery statements 

against a particular vendor are to be registered in the system. The recovery from a particular vendor 

are to made against a purchase order raised against him. The type of recovery and the amount to be 

recovered are required once the vendor code and purchase order number are cross checked by the 

computer. The recoveries registered may be adjusted against a particular vendor bill when the bill is 

being passed. 

If the bill is an adjustment bill, then it has to be linked to receipt vouchers before any further action 

can be taken on it. This activity links the material that has been received against the purchase order 

with the bill. It must be noted that the values on receipt vouchers which are partly linked or not 

linked at all are linked to the adjustment bill. 

Payment may not be made before the bill is passed. A provisional bill may be passed once it has 

been registered whilst an adjustment bill may only be passed after it has been linked to receipt 

vouchers. In case of adjustment bills the amount that is passed cannot exceed the amount against 

which material has been linked. While passing a bill any recoveries that are to be made against the 

vendor are accounted for in the bill. The recoveries in this case are made purchase orderwise. The 

amount that is to be recovered in the bill is therefore deducted from the total bill amount. Once a bill 

has been passed, there is provision to modify the recovery amount. 

Once a bill has been passed, the payment advice is generated. The particulars of the bank of the 

vendor (if payment is to be made through a bank) are to be entered and a printed copy of the 

payment details is obtained. 

In case recoveries are to be made by accounts after a bill has been passed, then they must be 

identified and recorded against the particular bill. These recoveries are distinct from the recoveries 

made against a purchase order. It is for this simple reason tthat the recovery type for such recoveries 

should always begin with the digit 3. A final deduction in the amount that has been passed would 

therefore be nescessary. 

The cheque number, cheque date and the cheque amount are recorded when a cheque is passed 

against a particular bill. The cheque amount should not exceed the amount that has been passed by 

accounts. In case the bill is a provisional bill, it has to be regularised. This activity may be done after 

the part payment has been made and before the adjustment bill is registered. This activity involves 

the linking of the provisional bill to receipt vouchers. The values in the receipt vouchers for an item 

in the bill are either comppletely linked or partly linked to the bill. The partly linked receipt 

vouchers and those receipt vouchers which have not been linked are linked against the item in the 

adjustment bill after it has been registered. Thus regularising the provisional bill and linking the 

coressponding adjustment bill actually links up the entire material received against the purchase 

order. 

CONTENTS 


main - pa000menu 

1. Enter Bill Details 

Add - pa201aabil, pa202aabil 

Modify - pa201aabil 

Delete - pa201iabil 

Inquire - pa201iabil 

2. Enter Recovery Details 

Add - pa103arecy 

Modify - pa103arecy 

Delete - pa103arecy 

Inquire - pa103arecy 

3. Linking RVs 

- pa220ln 

- pa222itmd 

- pa223mis 

4. Bill Passing 

Pass - pa102blpas 

- pa102tblps 

Modify - pa102blpas 

- pa102tblps 

5. Generate payment advice 

Print - pa200adv1 

- pa200adv2 

- pa200adv3 

- pa204adv4 

6. Recoveries by accounts - pa601rcbil 

7. Enter cheque details - pa104paymt 

8. Regularisation of bill 

- pa260re 

- pa222itmd 

- pa223mis 

9. Reports - pa105rmenu 

1. Details of recoveries made - pa105r001 

2. Supplierwise bill status report - pa105r002 

3. Purchase order wise bill status report 

4. Cash outflow statement - pa105r004 

5. Spot payment - pa105r006 


6. Statement of payment - pa105r0071 

7. Bill status report 

8. Details of bills not linked 

pa000menu PAYMENT ANALYSIS PA000MAIN 

1. ENTER BILL DETAILS 6. RECOVERIES BY ACCOUNTS. 

2. ENTER RECOVERY DETAILS. 7. ENTER CHEQUE DETAILS 

3. LINKING RV's 8. REGULARISATION OF BILL. 

4. BILL PASSING 9. REPORTS. 

5. GENERATE PAYMENT ADVICE. 0. EXIT TO MAIN MENU. 

ENTER YOUR OPTION : [ ] 

The above menu displays the different options available to the user in the payment analysis module. 

The user may select a particular option by entering the number and pressing return. 


Chapter – 5 

Costing Module 

MAIN: ct000nmenu.4ge 

(ct001nmenu.4gl) 

1. Master file maintenance (ct100filmt.4ge) 

(ct100filmt.4gl, ct120wotyp.4gl, ct130sectp.4gl, ct140otchg.4gl) 

1. Work order type in ct120wotyp.4gl 


Work order number 

Work order type(0: debit only, 1: Credit Only, 2: KOP only) 

Action: Input wo no and wo type from screen and insert into m_wo_typ 

2. Section type in ct130sectp.4gl 

Data Expected: 

Section code 

Section type (0: Production section, 1: Service section where total indirect cost is distributed 

w.r.t. direct labour 2: Service section where total indirect cost is distributed w.r.t. direct 

material) 3: Production section where portion of cost is to be apportioned w.r.t. direct labour) 

Action: Input section code and type from screen and insert them into m_sectyp. In case of 

type being "3", get ratio from screen and insert them into m_dstrt. 

3. Other charges in ct140otchg.4gl 

Data expected: Month, 

Year, 

Section code, 

Document number, 

Charge type, 

Work order number, 

Warrant number, 

Amount 

Action: Insert all the data accepted from screen into table t_othchg. 

2. DA & Overheads parameter maintenance (ct009ndaoh.4ge) 

(Add, Modify, Inquire) 

(ct009ndaoh.4gl, ct009adaoh.4gl, ct009mdaoh.4gl, ct009idaoh.4gl, ct009fdaoh.4gl) 

Data expected: Section code, 

Percent type, 

Date effective from, 

Percent 

Action: Insert all the data accepted from screen to the file m_pctfil. 


3. Warrant WIP Calculation 

(ct003nwip.4ge) 

(Select, All) 

(ct003fmwip.4gl, ct003flwip.4gl, ct003nwip.4gl, ct003globl.4gl) 

Options: Selective, All 

Actions: 

For single warrant: Call ct_fswip() 

Select the correct warrant from m_wts and check that the warrant is of type 1 

(Manufacturing warrant) and not yet costed. 

Call ct_flwip(wo_no, wt_NO) returning _r_l_wip, error code. Calculates the labour WIP. 

First it calculates the estimated unit rate and then find out the labour value for which there 

has been production. The rest of labour value drawn is WIP value. 

Call ct_fmwip(wo_no, wt_no) returning _r_m_wip 

Find the material value per unit qty using estimated material value. 

Find material value used. 

Call ct_fmtlr(wo_no, wt_no) returning mtl_loss_of_rej 

Total wip = _r_l_wip + _r_m_wip 

4. Punching media file maintenance (ct005npume.4ge) 

(Add, modify, Inquire) 

(ct005npume.4gl, ct005apume.4gl, ct005globl.4gl, ct005mpume.4gl, ct005dpume.4gl, 

ct005ipume.4gl) 

5. Pricing of Standard Estimates (ct800rpest.4ge) 

(ct800rpest.4gl, ct800frpes.4gl, ct801frplb.4gl, ct803rpest.4gl, ct850globl.4gl, 

ct800rests.4gl) 

MAIN in ct800rpest.4gl 

6. Production loss calculation (ct007ipdls.4ge) 

(ct007ipdls.4gl, ct170estrv.4gl) 

7. Unit cost of warrant determination (ct010nucwt.4ge) 

(ct010nucwt.4gl, ct170fpdnl.4gl, ct170estrv.4gl) 

Main in ct010nucwt.4gl 

Calls ct_fpdnl(wo_no, wt_no) in ct170fpdnl.4gl 

8. Budget file maintenance (ct004nbudt.4ge) 

(ct004abudt.4gl, ct004dbudt.4gl, ct004mbudt.4gl, ct004ibudt.4gl, ct004nbudt.4gl, 

ct004globl.4gl) 

(Add, Modify, Delete, Inquire) 

9. Costing of closed warrants (ct008wtact.4ge) 

(ct008factc.4gl, ct170fpdnl.4gl, ct180fucwp.4gl) 


10. Reports (ct009reprt.4ge) 

(ct009reprt.4gl) 

1. Cost card (ct009cstcd.4ge) 

(ct009globl.4gl, ct009cstcd.4gl, ct009rptcd.4gl, 

gen00wtdes.4gl, mp003fldt.4gl, ct003flwip.4gl, ct003fmwip.4gl) 

This report prints the cost details for a main or component warrant. Firstly, all the demand 

note details, return note details (amounts are negative), red demand note details for items 

recieved into the warrant, red demand note details for items drawn from this warrant 

(quantities and amounts are negative), transfer voucher details and other charges for the 

warrant are inserted into a temporary file w_cost. Each type of document in w_cost has a 

document numberand they are processed according to the document number. Prints the 

document number, document type and the details for that document. Prints the monthly totals 

for all the documents of a month. At the end the grand total is printed. The estimated 

labour, material, foh and voh costs are calculated thus, (estimated cost from m_estcst * 

warrant quantity) / quantity per set. 

The difference between actual value drawn (labour, material) and the estimated value for 

producing the accepted quantity is also printed. The difference between actual cost and 

estimated costis printed. The actual and estimated units are obtained by dividing the actual 

and estimated costs respectively by warrant quantity. 

The difference in percentage is calculated thus, ((estimated cost from m_estcst - actual 

value) / (estimated cost from m_estcst)) * 100 

2. Production ledger card (ct009rplcd.4ge) 

(ct009rplcd.4gl) 

Prints the production details for a particular item. Print the warrant quantity, quantity 

accepted,quantity still unfinished (warrant quantity - quantity accepted), quantity still 

remaining to be drawn(quantity accepted - cumulative quantity issued) and total cost of 

production. Also generates the extract details for the warrant. Generates inspection note 

details (both material andinspection) and red demand note details for material drawn from 

the warrant. PIV and transfer voucher details are also printed if such has been raised against 

the warrant. 

3. Labour abstract (sacego ct721rlaba.arc) 

This report generates the section wise and within section work order wise total of group 

value obtained from m_pwcs and labour amount obtained from m_punmed. 

4. Material abstract (ct009mtabs.4ge) 

(ct009mtabs.4gl) 

This report prints the amount of material consumed section wise for each work order series 

(all work orders which have the first two characters the same are classified as one series) in a 

month. The amount of material consumed for the two cost classes 20, 21 and the total 

material consumed is printed for each work order. 

A section wise total is generated for the total material consumed in the section. 


5. Trransfer voucher abstract (ct009trvab.4ge) 

(ct009trvab.4gl) 

This report prints section wise and within a section cost class wise labour amount details for 

all warrants which are not of the type 1, 2, or 3. The data is obtained from the punching 

media file for all documents of type 0 (allocation sheet). Prints the cost class wise total and 

the section wise total. Cost classes in this case can have values 11, 43, 44. 

Codes followed: 

Work order type: 

0: Debit only 

1: Credit only 

2: KOP only 

Section type: 

0: Production section. 

1: Service section where total indirect cost is distributed w.r.t. direct labour. 

2: Service section where total indirect cost is distributed w.r.t. direct material. 

3: Production section where portion of cost is to be apportioned w.r.t. direct 

labour. 

USER MANUAL ON COSTING MODULE 

main - ct000nmenu 

CONTENTS 

1. DA & Overheads Parameter maintenance 

Add - ct009ndaoh 

Modify - ct009ndaoh 

Inquire - ct009ndaoh 

2. Warrant WIP calculation 

Select - ct003nwips 

All - ct003nwipa 

3. Punching Media file maintenance 

Add - ct005npume 

Modify - ct005npume 

Inquire - ct005npume 

4. Pricing of standard estimates - ct800rpest 

5. Production loss calculation - ct007ipdls 

6. Unit cost of warrant determination - ct010nucwt 

7. Budget file maintenance 

Add - ct004budf 

Modify - ct004budf 


Delete - ct004budf 

Inquire - ct004budf 

8. Costing of closed warrants - wr950rwprt 

9. Reports 

Cost Card - ct710cstcd 

Production ledger card - wr950rwprt 

Labour abstract 

Material abstract - ctmtabs 

Transfer voucher abstract - ct730trvab 

Option: Main menu 

ct000nmenu 

C O S T I N G M O D U L E 

------------- ----------- 

1. DA & Overheads Parameter Maintenance 

2. Warrant WIP Calculation 

3. Punching Media File Maintenance 

4. Pricing of Standard Estimates 

5. Production Loss Calculation 

6. Unit Cost of Warrant Determination 

7. Budget File Maintenance 

8. Costing of Closed Warrants 

9. Reports 

0. Exit 

Enter your Option ( 0 - 9 ) : [ ] 

This is the main menu in the costing module. On entering the number of the option the user wishes 

to select and pressing return, the activity that is to be performed may be done. 


Chapter – 6 

User Manual on Database Module 

main - db000menus 

1 Party Master 

Add - db010apty 

Modify - db010party 

Inquire - db010party 

Delete - db010party 

Suspend - db010party 

Revoke - db010party 

2. Machine Master 

Machines 

Add - db020machn 

Modify - db020machn 

Inquire - db023machn 

Delete - db020machn 

Book value 



Maintenance statistics 



3. Machine Spares master 

Add - db030mcspr 

Modify - db030mcspr 

Inquire - db030mcspr 

Delete - db030mcspr 

4. Tools Master 

Add - db040tools 

Modify - db040tools 

Inquire - db040tools 

Delete - db040tools 

5. Estimate header file 

Add - db050est 

Modify - db050est 

Inquire - db050est 

Delete - db050est 

Print - db050est 

Recalculate - db050est 

SMH - db061smh 


6. Material estimates 

Add - db060estmt 

Modify - db060estmt 

Inquire - db060estmt 

Delete - db060estmt 

Print - db060estmt 

7. Labour estimates serial 

Add - db070elb 

Modify - db070elb 

Inquire - db070elb 

Delete - db007destl 

8. Order file 

Add - db090order 

- db091order 

- db092order 

Modify - db094order 

Inquire - db093order 

Delete - db094order 

Suborders - db009rsub 

9. Inspection authority/officer 

Add - db016insp 

Modify - db016insp 

Delete - db016insp 

Inquire - db016insp 

10. Stores item master 

Add - db110stitm 

- db111stitm 

- db112stitm 

- db113stitm 

- db117stitm 

- db115specf 

Modify - db110stitm 

- db111stitm 

- db112stitm 

- db113stitm 

- db114stitm 

- db115specf 

Delete - db110stitm 

Inquire - db114stitm 


11. Manufactured item master 

Add - db120mfitm 

- db121mfitm 

- db122mfitm 

Modify - db120mfitm 

- db121mfitm 

- db122mfitm 

Delete - db120mfitm 

Inquire - db123mfitm 

Print - db120mfitm 

12. Parameter file 

Add - db131param 

Modify - db131param 

Inquire - db131param 

Delete - db131param 

13. Last number file 

Add - db140lstno 

Modify - db140lstno 

Inquire - db140lstno 

Delete - db140lstno 

14. Long description file 

Add - db015long 

Modify - db015long 

Delete - db015long 

Option: Main menu 

db000menus DATABASES DB000MENUS 

1. Party master 2. Machine master 

3. Machine spares master 4. Tools master 

5. Estimate header file 6. Material estimates 

7. Labour estimates serial 8. Order file 

9. Inspection authority/officer 10. Stores item master 

11. Manufactured item master 12. Parameter file 

13. Last number file 14. Long description file 

Enter your option and press return: [ ] 

0. Exit 


Option: Add a party record in party master 

db010party PARTY MASTER MAINTENANCE DB001NPRTY 

Party code :[ ] Party name :[ ] 

Party type :[ ] Sister factory flag & code :[ ] [ ] 

Party address :[ ] 



Party state :[ ] Pin code :[ ] 

Telex no :[ ] Phone no :[ ] 

Telegram no :[ ] Sales tax no :[ ] 

Income tax no :[ ] IT clearence date :[ ] 

Contact person & dsgn :[ ] [ ] 

Country :[ ] Currency :[ ] 

Party regn code :[ ] Party regn date :[] 

Ext Regn with(1) [ ] Regn Code [ ] Date :[ Ext Regn with(2) [ ] Regn 

Code :[ ] Date:[] 

Party bank :[ ] No of items :[ ] 

Input: Party code, party name, party type, sister factory flag, sister factory code, party address (three 

fields 1, 2 and 3), state, pin code, telex number, phone number, telegram number, sales tax number, 

income tax number, income tax clearance date, contact persons, contact person's designation, 

country, currency, party registration code, party registration date, first external registration agency, 

external agency code, date, second external registration agency, code, date, party's bank, number of 

items 

Action: The details of an organisation with which the factory's deals with is registered through this 

option. If the organisation happens to be a sister factory then the sister factory code is to be entered. 


Option: Modify a party record in party master 



Party type :[ ] Sister factory flag & code:[ ] [ ] 






Telegram no :[ ] Sales tax no :[ ] Income tax no :[ ] 

IT clearence date :[ ] 

Contact person & dsgn:[ ] [ ] 


Agent code :[ ] Agent comm % :[ ] 


Party regn code :[ ] Party regn date :[ ] 

Suspense cd :[d] Due date :[ ] Suspn.reason :[ ] 

Input: Party code 

Second input: Party name, party type, sister factory flag, sister factory code, party address (1, 2 and 

3), state, pin code, telex number, phone number, telegram code, sales tax number, income tax 

number, income tax clearance date, contact person, designation of contact person, country of origin, 

currency, agent code, commision percent of agent, party bank, number of items, party registration 

code,party registration date . 

Action: On entering the party code and pressing escape, the party details are displayed on the screen 

for modification if the party exists. When modification has been done the escape key comes in use 

again to register the modification in the system. 


Option: Inquire about a party in party master 

















Action: The procedures to be followed while inquiring on existing data have 

the manual on general procedures. 

been described in 

Option: Delete a record from party master 















Party regn code :[ ] Party regn date :[] 



Action: The party cannot be deleted if material is due from the party. The party details are displayed 

and the user is asked to confirm deletion. On receiving confirmation, the party is deleted from the 

system. 


Option: Suspend a party 















Party regn code :[ ] Party regn date :[ 

expense cd :[d] Due date :[ ] Suspn.reason :[ ] 


Second input: Suspension code, due date, reason of suspension 

Action: Once the suspension details are entered for the party, the escape key 

register the suspension in the computer. 

may be used to 

Option: Revoke suspension on a party 


















Second input: Suspension code 

Action: The user may revoke the suspension on a party through this option. 


Option: Add machines in machine master 

db020machn MACHINE MASTER DB002MACHN 1 OF 3 

Machine No [ ] Desc [ ]ection Code [ ] Location [ ] 

Machine Type [ ] Shift Type [ ] Model [ ] 

Grant Type [ ] RV_No [ ] 

Receipt Dt. [ ] Install. Dt. [ ] 

Commission Dt [ ] 

Supplier. Code [ ] Name [ ] 

Supp. Machine No [ ] Country Of Origin [ ] 

Criticality [ ] Machine Status [ ] Termination Date [ ] 

Description [ ] 

Input: Machine number, machine description, section code, location, machine type, shift type, 

model, grant type, receipt voucher number, receipt date,installation date, commision date, supplier 

code, supplier machine number, country of origin, criticality, machine status, termination date 

Action: The machine details are entered through this option and registered into the computer. The 

keys Ctrl and B are to be typed in that order to view the section codes, machine types and location 

codes available in the computer. Once the escape key has been used to commit the data entered, the 

user is asked if Book value details are to be entered. 

The maintenance details may also be entered if the user wishes to do so. The book value details and 

maintenance details may also be entered from separate options and the details about them are 

available later in this documentation. 

Option: Modify machines in machine master 


Machine No [ ] Desc [ ] 

Section Code [ ] Location [ ] 










Input: Machine number 

Second input: Machine description, section code, location, machine type, shift type, model, grant 

type, receipt voucher number, receipt date, installation date, commission date, party code, supplier 

machine number, country of origin 

Action: On entering the machine number and pressing the escape key, rest of the information are 

displayed and the second input details may be modified if required. The escape key must be used 

again, on which the system allows the user to modify the book value details and the maintenance 

details. 

Option: Inquire about machines in machines master 

db023machn MACHINE MASTER INQUIRY DB002MACHN 1 OF 1 

Machine No [ ] Description [ ] 

Section Code [ ] Location [ ] Machine Type [ ] 


Commissioning Dt. [ ] 

Supplier Code [ ] Supp. Machine No [ ] 

Country Of Origin [ ] Criticality [ ] Machine Status [ ] 

Machine Price [ ] Depreciation % [ ] 

Current Book Value [ ] Shifts Last Month [ ] 

Deprn Last Month [ ] Deprn. Updation dt. [ 

Mnt. Updation dt [ ] Maintenance Status [ ] 

Action: The query may be made on a single field or on a combination of fields. The procedure to be 

followed in the inquire mode has been described in the manual on general procedures. 

Option: Delete machines from machine master 


Machine No [ ] Desc [ ] 

Section Code [ ] Location [ ] 










Action: The escape key must be used after the machine number has been entered on which the 


ecord to be deleted is displayed. The user is asked to confirm deletion of the record. On receiving 

confirmation, the record is deleted from the system. 

Option: Update book value and depreciation 

db021machn MACHINE BOOK VALUE DB002MACHN 2 OF 3 


Section [ ] Machine Type [ ] 


Residual Percent [ ] Salvage Value [ ] 

Book Value At Current 

Year Beginning [ ] Book Value [ ] 

Shifts Worked Depreciation for 

Last Month [ ] Last Month [ ] 

Date of Updation [ ] 


Second input: Machine price, depreciation, residual percent, book value at the beginning of the year, 

current book value, shifts worked last month, depreciation for last month, date of updation 

Action: On entering the machine number and pressing the escape key, the second input details are 

displayed and may be modified accordingly. 

The salvage value is calculated by the system and displayed. On pressing the escape key 

again, the modifications are registered into the system. 

Option: Inquire on book value and depreciation 

db021machn MACHINE BOOK VALUE DB002MACHN 2 OF 3 


Section [ ] Machine Type [ ] 


Residual Percent [ ] Salvage Value [ ] 

Book Value At Current 

Year Beginning [ ] Book Value [ ] 

Shifts Worked Depreciation for 

Last Month [ ] Last Month [ ] 

Date of Updation [ ] 

Action: A single field or a combination of fields may be part of the selection criterion based on 

which selection of records is made. The records retrieved are displayed with the help of a ring menu. 

Option: Modify maintenance statistics 


db022machn MACHINE MAINTENANCE RECORD DB002MACHN 3 OF 3 


Section [ ] Machine type [ ] 

Cum. Hours worked [ ] Cum. Breakdown Hrs [ ] 

YTD Breakdown Hours [ ] Cum. No of Breakdowns [ ] 

Shifts Under Maintenance Maintenance Costs 

YTD MTD YTD CUM 

[ ] [ ] [ ] [ ] 

Cost Of Spares Consumed Maintenance Status 

Cumulative YTD Maint-Stat Date 

[ ] [ ] [ ] [ ] 


Second input: Cumulative hours worked, cumulative hours of breakdown, year to date breakdown 

hours, cumulative number of breakdowns, year to date shifts under maintenance, month to date shifts 

under maintenance, year to date maintenance cost, month to date maintenance cost, cumulative cost 

of spares, year to date cost of spares consumed, maintenance status, last maintenance date Action: 

On entering the machine number and pressing escape, the maintenance details are displayed and may 

be modified if required. The escape key comes good again to register the modifications. 

Option: Inquire on maintenance statistics 

db022machn MACHINE MAINTENANCE RECORD DB002MACHN 3 OF 3 


Section [ ] Machine type [ ] 

Cum. Hours worked [ ] Cum. Breakdown Hrs [ ] 

YTD Breakdown Hours [ ] Cum. No of Breakdowns [ ] 

Shifts Under Maintenance 

Maintenance Costs 

YTD MTD YTD CUM 

[ ] [ ] [ ] [ ] 

Cost Of Spares Consumed 

Maintenance Status 

Cumulative YTD Maint-Stat Date 

[ ] [ ] [ ] [ ] 

Action: The cursor moves around in all the fields on the screen and the selection of records is based 

on the value(s) of a single field or a combination of fields. The escape key must be used to activate 

the search for the specific records, which may be viewed with the help of a ring menu. 

Option: Add records to machine spares master 


db030mcspr MACHINE SPARES MASTER DB003MCSPR 1 OF 1 

Spare No [ ] Description [ ] 


Machine Group Code [ ] 

Spare Qty [ ] No Replaced [ ] 

Last Replacement Dt. [ ] 

Last Purchase Dt. [ ] 

Last Purchase Price [ ] 

Alternate Spare No. [ ] Description [ ] 

Supplier's Spare No [ ] 

Input: Spare number, machine number, machine group code, spare quantity, number replaced, last 

replacement date, last purchase date, last purchase price, alternate spare number, supplier's spare 

number 

Action: On pressing escape after entering the required information, the machine spares details are 

recorded in the computer. 

Option: Modify records in machine spares master 











Input: Spare number, machine number 

Second input: Machine group code, spare quantity, number replaced, last replacement date, last 

purchase date, last purchase price, alternate spare number, supplier's spare number 

Action: The spare details for a particular machine may be modified in this option. Once the spares 

data has been modified the escape key comes good to register the modifications in the system. 

Option: Inquire about records in machine spares master 












Action: The records that satisfy the selection criteriion may be viewed with the help of a ring menu. 

Option: Delete records from machine spares master 











Input: Spare number, machine number 

Action: On entering the spare number and machine number, the record details are displayed on the 

screen and the user is asked whether the record is to be deleted. On receiving confirmation the 

record is deleted from the system. 

Option: Add a record to tools master 

db040tools TOOLS MASTER DB004TOOLS 1 OF 1 

Tool No [ ] 



Tool Sl. No [ ] Tool Value [ ] 

Party Code [ ] 


Introduction Dt. [ ] Last Rework Date [ ] 

EP Code [ ] 


Opn. No [ ] Hrs/Pieces Indicator [ ] Cum. No of Reworks [ ] 

Max. Pieces Handlable [ ] Max. Hours Workable [ ] 

Cumulative Pieces [ ] Cumulative Hours [ ] 

Section Issued to [ ] Due Return Date [ ] 

Tool life [ ] 

Tool status [ ] Discard reason [ ] 

Input: Tool number, tool serial number, tool value, party code, introduction date, last rework date, 

end product code, operation number, hours /pieces indicator, cumulative number of reworks, 

maximum pieces handlable/maximum hours workable before rework, cumulative pieces/cumulative 

hours, section issued to, due return date, tool life, tool status, discard reason 

Action: The tool details are recorded in this option. Each piece of a certain tool is identified by the 

serial number. 

Option: Modify a record in tools master 


Tool No [ ] 






EP Code [ ] 






Tool life [ ] 


Input: Tool number, tool serial number 

Second input: Tool value, party code, introduction date, last rework date, end product code, 

operation number, hours/pieces indicator, cumulative number of reworks, maximum pieces 

handlable/maximum hours workable before rework, cumulative pieces handled/cumulative hours 

worked, section issued to, due return date, tool life, tool status, discard reason 

Action: On entering the tool number, tool serial number and pressing the escape key, the rest of the 

information is displayed on the screen. The second input details may then be modified if required. 

On pressing the escape key again after the required modifications have been done, the updated tool 

details are registered in the computer. 

Option: Inquire about tools in tools master 



Tool No [ ] 






EP Code [ ] 






Tool life [ ] 


Action: The procedures to be followed in the inquire option have been explained in the manual on 

general procedures. 

Option: Delete a record from tools master 


Tool No [ ] 






EP Code [ ] 






Tool life [ ] 


Input: Tool number, tool serial number 

Action: The tool details are displayed and the user is asked to confirm whether the record is to be 

deleted. On receiving confirmation, the record is deleted from the computer. 

Option: Add an estimate 


db050est ESTIMATE HEADER MAINTENANCE DB005ESTHD 

EP code :[ ] Drawing number :[ ] 

Estimate num :[ ] Revision num :[ ] 

Estimate date :[ ] Last revision date :[ ] 

Date effective :[ ] Last operation num :[ ] 

Unit quantity :[ ] Section code :[ ] 

Per Quantity :[ ] Labour cost :[ ] 

Estimate cost :[ ] Material cost :[ ] 

Input: End product code, estimate number, revision number, estimate date, last revision date, date 

effective, per quantity 

Action: The estimate header details are registered on pressing the escape key 

required data. 

after entering the 

Option: Modify an estimate 









Input: End product code 

Second input: Estimate date, last revision date, date effective, last operation number, section code, 

per quantity, labour cost, estimate cost,material cost 

Action: On entering the end product code and pressing escape, the rest of the record details are 

displayed and the second input details may be modified if required. The escape key has to be used to 

record the modifications in the system. 

Option: Inquire an estimate 










Action: The procedures to be followed in the inquire option has been explained in the manual on 

general procedures. 


Option: Delete an estimate 










Action: The record details are displayed and the record is deleted after getting confirmation from the 

user. 

Option: Print an estimate 










Action: Prints an estimate. 

Option: Recalculate labour and material value 









Input: End product 

Action: Updates estimate cost, material cost and labour cost in estimates header file for all the 

components for this end product. 


Option: Query on standard man hour 

db061smh 

STANDARD MAN HOUR 

Estimate Number : [ ] 

Labour Type Class Hours 

[ ] [ ] [ ] [ ] 

[ ] [ ] [ ] [ ] 

[ ] [ ] [ ] [ ] 

Input: Estimate number 

Action: Calculates the standard man hours required for each labour code and labour class. 

Option: Add a material estimate 

db060estmt 

MATERIAL ESTIMATE MAINTENANCE 

Estimate number :[ ] EP code :[ ] 

Revision number :[ ] 

Item code :[ ] [ ] 

Rate Form No :[ ] 

Material serial no. :[ ] Alternate Serial No :[ ] 

Secondary alternate :[ ] 

Qty. required :[ ] Unit of qty :[ ] 

Rej allowance :[ ] 

Section Code :[ ] [ ] [ ] 

Comp. item type :[ ] 

Input: Estimate number, revision number, end product code, item code, rate form number, material 

serial number, alternate serial number, secondary alternate, quantity required, rejection allowance, 

section code, section code1, section code2, section code3, component item type 

Action: The material estimates for an estimate in the header is added through this option. The 

material estimates have been categorised into Regular material estimates, where the material 

authorized is proportional to the warrant quantity, and Constant material estimates, where the 

material authoried is independent of the warrant quantity. 

Every material will be assigned a serial number by the computer. This serial number will be 

caculated by looking at the serial number of the materials already entered. For all the original items 

this number will be different from one another. In case of alternate materials, alternates will have 

same serial number. Computer will assign a serial number once a material is identified by forcible 

assignment of existing material serial number. This second serial number, which will be different for 

the alternate items under the same serial number, is called alternate serial number. 

Some times a group of items together may be alternate to a material or even to another set of 


materials. This situation can be indicated by using the field "secondary alternate". A group of 

materials which are to be considered together for substitution, will have same material serial number 

and alternate serial number. In such case their secondary alternate number will change. 

For example, if in a situation Items A, B, C can be used instead of using D, E, F and G then 

the serial numbers may be like 

Mtl Sl No. Alt Sl No. Secondary Alt.Itm Code 

7 0 0 A 

7 0 1 B 

7 0 2 C 

7 1 0 D 

7 1 1 E 

7 1 2 F 

7 1 3 G 

We assume that in the estimate in the example, 6 materials have already been included and 

now the seventh material is being considered which happens to be a group of materials. 

On pressing the escape key after entering the required information, the material estimate is 

recorded in the system. 

Option: Modify a material estimate 

db060estmt 












Input: Estimate number, revision number, item code, serial number, alternate serial number, 

secondary alternate 

Second input: Quantity required, rejection allowance, section code1, section code2, section code3, 

component item type 

Action: On entering the values of the fields required for selecting the record to be modified and 

pressing the escape key, the rest of the information is displayed on the screen. The second input 

details may then bemodified if required. The escape key must be used again to register the 

modifications in the computer. 

Option: Inquire about material estimates 


db060estmt 












Action: The cursor moves around in all the fields and the query may be based on a single field or a 

combination of fields. The escape key activates the search for the specific records which are 

displayed one at a time with the help of a ring menu. 

Option: Delete a material estimate 

db060estmt 












Input: Estimate number, revision number, item code 

Action: Selects all the records for the item and displays them one by one. The user is asked to 

confirm deletion of the record on which the record is deleted from the system. If the user does not 

wish to delete the record, the next record is then displayed. The user may also exit to the menu 

without seeing the next record. 

Option: Print a material estimate 


db060estmt 












Input: Item code 

Action: Prints a material estimate. 

db070elb LABOUR ESTIMATE MAINTENANCE DB007ESTLB 


End prod code :[ ] [ ] 

Rate form num :[ ] Drawing Number :[ ] 

Opn num :[ ] Alt Opn num : [ ] Secondary Alternate :[ ] 

Section code :[ ][ ][ ] Machine type :[ ] 

Next section :[ ] Operation type :[ ] 

Oprn Description :[ ] 

Machine hour :[ ] Set up time :[ ] 

Delay :[ ] Reference item :[ ] 

Criticality ind :[ ] Tgt opn num :[ ] 

WIP ind :[ ] Reject Percent :[ ] 

Comment required :[ ] Price qty :[ ] 

Operation Rate :[ ] Cumulative rt :[ ] 

Input: Estimate number,revision number, rate form number, 

operation number,alternate operation number, secondary alternate,section code,section 

code2,section code3,machine type,next section, operation type, operation description,machine hour, 

set up time, delay, reference item, criticality indicator, target opn number, work in progress 

indicator, rejection percent, whether comments are to be added. 

Sl no Trade Grade Labour Hr No. of Rate 

code code people 


[f002 ][a ] [b ] [f004 ] [f005 ][f006 ] 

[f002 ][a ] [b ] [f004 ] [f005 ][f006 ] 

[f002 ][a ] [b ] [f004 ] [f005 ][f006 ] 

[f002 ][a ] [b ] [f004 ] [f005 ][f006 ] 

[f002 ][a ] [b ] [f004 ] [f005 ][f006 ] 

Second input: Trade code, Grade Code, Labour hour and number of persons. 

Action: Every operation is given a unique combination of operation number,alternate operation 

number and secondary alternate number. For the explanation of these three serials, material addition 

option may be referred. 

Price quantity is the quantity for which labour will be authorized in the warrant. This 

includes the rejection allowance. 

When the first set of input is entered, the second screen is displayed and second set set of 

input is taken. Amount authorized for a certain trade code is the product of hourly rate, number of 

persons and number of hours mentioned in the screen. 

Total labour amount authorized for an operation is the sum total of labour authorized for each 

trade code. 

After pressing the escape key, one new record is created in the labour details of the estimate, 

one trade detail is created for each of the trade codes entered and the total labour amount for the 

operation is updated in the header of the estimate. 

Option: Modify a labour estimate 

db070elb LABOUR ESTIMATE MAINTENANCE DB007ESTLB 




Opn num :[ ] Alt Opn num :[ ] Secondary Alternate :[ ] 


Next section :[ ] peration type :[ ] 



Delay :[ ] Reference item :[ ] 

Criticality ind :[ ] Tgt opn num :[ ] 





Input: Estimate number, operation number, alternate operation number, secondary alternate 

Second input: Rate form number, section code, section code2, section code3, machine type, next 

section,operation type,opn description,machine hour,set up time, delay, reference item, 

criticality indicator,target opn number,work in progress ind rejection percent, price quantity 

Action: On entering the first set of inputs, the record to be modified is displayed and the second 

input details may be modified if required. 

Option: Inquire about labour estimates 

db070elb LABOUR ESTIMATE MAINTENANCE B007ESTLB 




Opn num :[ ] Alt Opn num : [ ] Secondary Alternate : [ ] 


Next section :[ ] Operation type :[ ] 



Delay :[ ] Reference item :[ ]icality ind :[ ] 

Tgt opn num :[ ] 




Action: The cursor moves around in all the fields and the query may be based on a single field or a 

combination of fields. The escape key activates the search for the specific records which are 


Option: Delete a labour estimate 

db007destl 

Estimate No :[ ] [ ] 

Operation No :[ ] [ ] 

Alternate Operation No : [ ] 

Secondary Alternate : [ ] 

Input: Estimate number,operation number, alternate operation number secondary alternate number 

Action: Deletes the labour estimate record after getting confirmation from the user. 

Option: Add records to order master 

db090order ORDERS MASTER DB009ORDER 1 OF 3 


Sl. Order No [ ] Order Type [ ] 

ORD/EXT No [ ] Item Code [ ] 

Description [ ] UQ [ ] 

Estimate No [ ] Revision No [ ] 

Order Qty [ ] Order Dt. [ ] 

Order Due Dt [ ] Indent No [ ] 

Indent Date [ ] Customer Cd. [ ] 

Cust. Name [ ] Order Status [ ] 

Unit Rate [ ] EMD Amount [ ] 

Input: Order type, extract number, item code, order quantity, order date, order due date, indent 

number, indent date, indentor code, unit rate, EMD amount 


SL Ord No [ ] Order Type [ ] ORD/EXT No [ ] 

Item Code [ ] Order Quantity [ ] 

Scheduled Quantity 1 [ ] Scheduled Quantity 2 [ ] 


Last Dely Date [ ] 

Issue Qty 1 [ ] Issue Qty 2 [ ] 


Cumulative Issues [ ] Month To Date Issues [ ] 

Week To Date Issues [ ] Warrant Pending Qty [ ] 

Cum. Warrant Qty [ ] Second Year Qty [ ] 

Third Year Qty [ ] Fourth Year Qty [ ] 

Second input: Scheduled quantity for the first quarter, scheduled quantity for the second quarter, 

scheduled quantity for the third quarter scheduled quantity for the fourth quarter, last delivery date, 

quantity issued for the first quarter, quantity issued for the second quarter, quantity issued for the 

third quarter, quantity issued for the fourth quarter, cumulative quantity issued, month to date 

quantity issued, week to date issued, warrant quantity, cumulative warrant quantity, quantity 

required in the second year, quantity required in the third year, quantity required in the fourth year 




Part No [ ] Cat. Part No. [ ] COD Part No [ ] 


Alt. Item [ ] Description [ ] UQ [ ] 

Indendor's E.P. Code [ ] Consignee Code [ ] 

Inspection Authority [ ] DGOF Reference [ ] P & AO Code [ ] 

Spare Indicator [ ] Cost Debit [ ] 

Material Mgmt Code [ ] Remarks [ ] 

Third input: Part number, catalog part number, COD part number, alternate item code, EP code for 

which the order is received, consignee code, inspection authority, DGOF reference number, P & AO 

code spare indicator, cost debit, remarks 

Action: When an order is received for the manufacture of a certain item, the order details are 

entered. The escape key is to be used to traverse from one screen to the next when the required data 

is entered in one particular screen. Finally, the escape key is to be used again after the data has been 

entered in the third screen to register the order details. The order serial number is generated by the 

system and is displayed for reference. 

Option: Modify records in Orders master 










Unit Rate [ ] EMD Amount [ ] 

Input: Extract number, item code, 

Second input: Order type, order quantity, order date, order due 

date, indent number, indent date, indentor code, unit rate, EMD 

amount 







Last Dely Date [ ] 




Week To Date Issues [ ] Warrant Pending Qty [ ] 

Cum. Warrant Qty [ ] Second Year Qty [ ] 


Third input: Scheduled quantity for the first quarter, scheduled 

quantity for the second quarter, scheduled quantity for the third 

quarter scheduled quantity for the fourth quarter, last delivery 

date,quantity issued for the first quarter, quantity issued for the 

second quarter, quantity issued for the third quarter, quantity 

issued for the fourth quarter, cumulative quantity issued, month to 

date quantity issued, week to date issued, warrant quantity, 

cumulative warrant quantity, quantity required in the second year, 

quantity required in the third year, quantity required in the 

fourth year 




Part No [ ] Cat. Part No. [ ] COD Part No [ ] 

Alt. Item [ ] Description [ ] UQ [ ] 

Indendor's E.P. Code [ ] Consignee Code [ ] 

Inspection Authority [ ] DGOF Reference [ ] 

P & AO Code [ ] 

Spare Indicator [ ] Cost Debit [ ] 

Material Mgmt Code [ ] Remarks [ ] 

Fourth input: Part number, catalog part number, COD part number, 

alternate item code, EP code for which the order is received, 

consignee code, inspection authority, DGOF reference number, P & AO 

code spare indicator, cost debit, remarks 

Action: On entering the key fields, extract number and item code, 

the order details in the first screen are displayed. The user may 

then modify the order screen wise with the escape key coming in use 

to commit the data in the first screen and move on to the next 

screen. Once ,the required data has been modified, the 

modifications are updated in the computer. 


Option: Inquire about records in Orders master 

db093order 

ORDERS INQUIRY 

SL Ord No. [ ] Order Type [ ] ORD/EXT NO [ ] 

Est. No [ ] Est. Revision No. [ ] Item Code [ ] 

Order Qty [ ] Order Dt. [ ] Order due Dt. [ ] 

Indent No [ ] Indent Dt. [ ] Indentor [ ] 

Scheduled Qty 1 [ ] Scheduled Qty 2 [ ] 

Scheduled Qty 3 [ ] Scheduled Qty 4 [ ] 




Week To Date Issues [ ] Pending Warrant Qty [ ] 

Cum Warrant Qty [ ] Second Year Qty [ ] 


Order Status [ ] Last Dely Dt. [ ] 

Unit Rate [ ] Earn. Mon. Dep. [ ] 

Action: The cursor moves around in all the fields and the query may 

be based on a single field or a combination of fields. The escape 

key activates the search for the specific records which are 


Option: Delete records from Orders master 










Input: Extract number, item code 

Action: The details of the order may be viewed screen wise with the 

help of a ring menu. The ring menu also has a delete option which 

when selected deletes the order after getting confirmation from the 

user. 


Option: Print a list giving the requirement of different components 

for an order 

db009rsub 

Extract Number: [ ] End Product Code: [ ] 

Input: Extract number, End product code 

Action: This option prints a list giving the requirement of 

different components for an order. 

Option: Add a record for an inspection officer/authority 

db200insp 

Inspection office/authority 

Code : [ ] 

Name : [ ] 

Address : [ ] 

[ ] 

Input: Inspecting officer/authority's code, name, address 

Action: The details about an inspecting officer/authority is 

recorded in the computer. 

Option: Modify a record for an inspection officer/authority 

db200insp 


Code : [ ] 

Name : [ ] 

Address : [ ] 

[ ] 

Input: Inspection officer/authority's code 

Second input: Name (description), address 

Action: On entering the code and pressing escape, the description 

of the code and address are displayed for modification. The escape 

key is to be used again for registering the modifications in the 

computer. 


Option: Delete a record for an inspecting officer/authority 

db200insp 


Code : [ ] 

Name : [ ] 

Address : [ ] 

[ ] 

Input: Inspection officer/authority code 

Action: The record is displayed and the user is asked to confirm 

deletion. On receiving confirmation, the record is deleted from the 

system. 

Option: Inquire about inspecting officer/authority records 

db200insp 


Code : [ ] 

Name : [ ] 

Address : [ ] 

[ ] 

Action: The cursor moves about in all the fields and the inquiry 

may be based on one or more fields. The records retrieved may be 

viewed with the help of a ring menu. 

Option: Add a record in stock master 

db110stitm STOCK ITEM MASTER Screen 1 DB011STITM 

Item Code :[ ] 

Description :[ ] 

Unit of Quantity :[ ] 

Estimate Number :[ ] 

Revision Number :[ ] 

Part Number :[ ] 

Drawing Number :[ ] 

Manufactured / Purchased :[ ] 

Item Class Technical :[ ] Commercial:[ ] 

Item type :[ ] 

Alternate Item Exists :[ ] 

Procurement Lead Time :[ ] days 

Monthly_requirements :[ ] 

Input: Item code, item description, unit of quantity, estimate 

number, revision number, part number, drawing number, whether 

manufactured or purchased, item technical class, item commercial 

class, item type, whether alternate item exists, procurement lead 

time 





Quantity on Stock :[ ] 

Moving Average Rate :[ ] 

Value of Stock :[ ] 

Danger Qty ( Explosives ) :[ ] 

Drawable Quantity :[ ] 

Godown Code :[ ] 

Bin No :[ ] 

Purchase Type :[ ] 

If Stockpile Item :[ ] 

ABC Analysis Code :[ ] FSN Analysis Code :[ ] 

VED Analysis Code :[ ] XYZ Analysis Code :[ ] 

Second input: Stock quantity, moving average rate, danger quantity, 

drawable quantity, godown code, bin number, purchase type, whether 

stock pile item, abc code, fsn code, ved code, xyz code 




Economic Order Qty :[ ] 

Reorder Quantity :[ ] 

Stock verified on :[ ] 

Verification Tally :[ ] 

Month Opening Balance :[ ] Value :[ ] 

Year Opening Balance :[ ] Value :[ ] 

Quantity on MIS :[ ] 

Maximum Stock Quantity :[ ] 

Minimum Stock Quantity :[ ] 

Third input: Economic order quantity, reorder quantity, stock 

verified on, whether stock tallies with verified quantity, month 

opening balance, month opening value, year opening balance, year 

opening value, quantity on mis, maximum stock quantity, minimum 

stock quantity 

db113stitm STOCK ITEM MASTER Screen 4 

DB011STITM 



Year Todate Received Qty :[ ] Value:[ ] 

Year Todate Drawn Qty :[ ] Value:[ ] 

Month Todate Recvd Qty :[ ] Value:[ ] 

Month Todate Drawn Qty :[ ] Value:[ ] 

Dues Quantity :[ ] Dues Value :[ ] User 

Section :[ ] AHSP :[ ] 


Qty for which SIS raised :[ ] 

Last Receipt Date :[ ] 

Last Drawn Date :[ ] 

Last Issue Date :[ ] 

Fourth input: Year to date received quantity, year to date received 

value, year to date drawn quantity, year to date drawn value, month 

to date received quantity, month to date received value, month to 

date drawn quantity, month to date drawn value, dues quantity,dues 

value, user section, AHSP, quantity for which SHIS raised, last 

receipt date, last drawn date, last issue date 


Item code: [ ] 

Description: [ ] 

SDE code [ ] 

Godown keeper [ ] 

Purchase responsibility [ ] 

Danger code [ ] 

Valuation code [ ] 

Inspection responsibility [ ] 

Packing code [ ] 

Perish code [ ] 

Introduction date [ ] 

2nd verification date [ ] 

2nd verification tally [ ] 

Fifth input: SDE code, godown keeper, purchase responsibility, 

danger code, valuation code, inspection responsibility, packing 

code, perish code, introduction date, second verification date, 

second verification tally 

db115specf ITEM SPECIFICATIONS DB011AMSPC 

Item code:[ ] 

[ ] 

[ ] 

[ ] 

[ ] 

[ ] 

Sixth input: Item specifications (long description) 

Action: The stock item details are registered in the system. The 

required information for a stock item has to be entered through six 

screens as shown above. Once the data has been entered in one 

screen, the escape key must be used to enter data in the next 

screen. Finally,after the fifth screen, the user is asked if the 

specifications are to be added for the item. If there are no 

specifications for the item then the data entered is recorded in 


the computer. If the specifications are required, then the sixth 

screen appears. The entire data on the stock item is recorded only 

if the escape key is used in the sixth screen. 

Option: Modify an item in stock master 
















Second input: Item description, unit of quantity, estimate number, 

revision number, part number, drawing number, whether manufactured 

or purchased, item technical class, item commercial class, item 

type, whether alternate item exists, procurement lead time 


DB011STITM 



Quantity on Stock :[ ] 

Moving Average Rate :[ ] 

Value of Stock :[ ] 

Danger Qty ( Explosives ) :[ ] 

Drawable Quantity :[ ] 

Godown Code :[ ] 

Bin No :[ ] 

Purchase Type :[ ] 

If Stockpile Item :[ ] 

ABC Analysis Code :[ ] FSN Analysis Code :[ ] 


Third input: Stock quantity, moving average rate, danger quantity, 

drawable quantity, godown code, bin number, purchase type, whether 

stock pile item, abc code, fsn code, ved code, xyz code 


DB011STITM 




Economic Order Qty :[ ] 

Reorder Quantity :[ ] 

Stock verified on :[ ] 

Verification Tally :[ ] 

Month Opening Balance :[ ] Value :[ ] 

Year Opening Balance :[ ] Value :[ ] 

Quantity on MIS :[ ] 

Maximum Stock Quantity :[ ] 

Minimum Stock Quantity :[ ] 

Fourth input: Economic order quantity, reorder quantity, stock 

verified on, whether stock tallies with verified quantity, month 

opening balance, month opening value, year opening balance, year 

opening value, quantity on mis, maximum stock quantity, minimum 

stock quantity 


DB011STITM 



Year Todate Received Qty :[ ] Value:[ ] 

Year Todate Drawn Qty :[ ] Value:[ ] 

Month Todate Recvd Qty :[ ] Value:[ ] 

Month Todate Drawn Qty :[ ] Value:[ ] 

Dues Quantity :[ ] Dues Value :[ ] 

User Section :[ ] AHSP :[ ] 

Qty for which SIS raised :[ ] 

Last Receipt Date :[ ] 

Last Drawn Date :[ ] 

Last Issue Date :[ ] 

Fifth input: Year to date received quantity, year to date received 

value, year to date drawn quantity, year to date drawn value, month 

to date received quantity, month to date received value, month to 

date drawn quantity, month to date drawn value, dues quantity, dues 

value, user section, AHSP, quantity for which SHIS raised, last 

receipt date, last drawn date, last issue date 


Item code: [ ] 

Description: [ ] 

SDE code [ ] 

Godown keeper [ ] 

Purchase responsibility [ ] 

Danger code [ ] 

Valuation code [ ] 


Inspection responsibility [ ] 

Packing code [ ] 

Perish code [ ] 

Introduction date [ ] 

2nd verification date [ ] 

2nd verification tally [ ] 

Sixth input: SDE code, godown keeper, purchase responsibility, 

danger code, valuation code, inspection responsibility, packing 

code, perish code, introduction date, second verification date, 

second verification tally 

db115specf ITEM SPECIFICATIONS 

DB011AMSPC 

Item code:[ ] 

[ ] 

[ ] 

[ ] 

[ ] 

[ ] 

Seventh input: Item specifications 

Action: On entering the item code and pressing escape, the details 

are displayed screenwise for modification. The procedure in moving 

from one screen to another is similar to the previous option, but 

in this option the user may also skip the remaining screens if the 

required modifications have been completed. 

Option: Delete an item from stock master 

















Action: Once the escape key is pressed after entering the item 

code, the record details are displayed and the user is asked for 

confirmation. If the user confirms deletion of the record, the 

system deletes the record. 

Option: Inquire about items in stock master 

db114stitm STOCK ITEM MASTER DB011ISTKI 


Item Descrition :[ ] 


Estimate Number :[ ] Revision Number :[ ] 

Part Number :[ ] Drawing Number :[ ] 

Mfd / Purchased :[ ] 

Item Class Technical :[ ] Commercial :[ ] 

Item Type :[ ] If Alternate Item exists:[ ] 

Procurement Lead Time:[ ] BIN Number :[ ] 

Purchase Type :[ ] If Stockpile Item :[ ] 

ABC Analysis Code :[ ] Critcality Code :[ ] 


Action: The manual on general procedures contains a detailed 

description on how to proceeed while inquiring on existing data. 

Option: Add an end product to manufacturing master 

db120mfitm MANUFACTURING ITEM MASTER 1 OF 3 DB012MFITM 

EP Code :[ ] 

Description:[ ] 

Unit Of Qty :[ ] 

Estimate No :[ ] 

Revision No :[ ] 

Part No :[ ] 

Drawing No :[ ] 


Item Class Technical:[ ] Commercial:[ ] 

Item Type :[ ] 


Manufacture Lead Time (Days):[ ] 

Input: End product code, end product description, unit of quantity, 

estimate number, revision number, part number, drawing number, 

manufactured/purchase indicator, item technical class, item 

commercial class,item type, whether alternate exists, manufacturing 

lead time 



EP Code :[ ] 


Qty on hand :[ ] Value :[ ] 

Danger code: [ ] Danger Qty (Explosive Items) :[ ] 

Manufacture Lot Qty :[ ] 

Value Cd : [ ] Perish Code: [ ] Packing Code: [ ] 

Cumulative Yearly Wrnted Qty :[ ] Value:[ ] 

Cumulative Mnthly Wrnted Qty :[ ] Value:[ ] 

Cumulative Yrly Produced Qty :[ ] Value:[ ] 

Cumulative Monthly Prod Qty :[ ] Value:[ ] 

Cumulative Weekly Produced Qty :[ ] Value:[ ] 

Second input: On hand quantity, on hand value, danger code, danger 

quantity, manufacturing lot size, value code, perish code, packing 

code, cumulative warrant quantity in this year, cumulative warrant 

value in this year, cumulative warrant quantity in this month, 

cumulative warrant value in this month, cumulative produced 

quantity in this year, cumulative produced value in this year, 

cumulative produced quantity in this month, cumulative produced 

value in this month, cumulative produced quantity in this week, 

cumulative produced value in this week 


EP Code :[ ] 


Godown keeper: [ ] Inspection responsibility: [ ] 

Year Todate Issues Qty :[ ] Value: [ ] 

Month Todate Issues Qty :[ ] Value: [ ] 

Week Todate Issues Qty :[ ] Value: [ ] 

Date of : Introduction :[ ] Last Manufacture:[ ] 

Last Withdrawal:[ ] Last Issue :[ ] 

Date of 1st Issue: [ ] Moving average rate: [ ] 

VDE Code: [ ] FSN Code: [ ] Bin Page Bin Line: [ ] 

Third input: Godown keeper, inspection responsibility, year to date 

issued quantity, year to date issued value, month to date issued 

quantity,month to date issued value, week to date issued quantity, 

week to date issued value, date of introduction, date of last 

manufacture,date of last drawal, date of last issue, date of first 

issue, moving average rate, VDE code, FSN code, bin number 

Action: The details of a manufactured item is recorded in this 

option. The user has traverse through three screens before the 

entire data for a manufactured item is entered. Once the required 

data has been entered in one screen, the next screen screen appears 

as soon as the escape key is used. Finally, after entering data in 

the last screenthe escape has to be used once again to register the 

data in the computer. 

Option: Modify an end product in manufacturing master 



EP Code :[ ] 





Part No :[ ] 








Second input: End product code, end product description, unit of 

quantity, estimate number, revision number, part number, drawing 

number, manufactured/purchase indicator, item technical class, item 

commercial class, item type, whether alternate exists, 

manufacturing lead time 


EP Code :[ ] 


Qty on hand :[ ] Value :[ ] 

Danger code: [ ] Danger Qty (Explosive Items) :[ ] 

Manufacture Lot Qty :[ ] 

Value Cd : [ ] Perish Code: [ ] Packing Code: [ ] 

Cumulative Yearly Wrnted Qty :[ ] Value:[ ] 

Cumulative Mnthly Wrnted Qty :[ ] Value:[ ] 

Cumulative Yrly Produced Qty :[ ] Value:[ ] 

Cumulative Monthly Prod Qty :[ ] Value:[ ] 

Cumulative Weekly Produced Qty :[ ] Value:[ ] 

Third input: On hand quantity, on hand value, danger code, danger 

quantity, manufacturing lot size, value code, perish code,packing 

code, cumulative warrant quantity in this year, cumulative warrant 

value in this year, cumulative warrant quantity in this month, 

cumulative warrant value in this month, cumulative produced 

quantity in this year, cumulative produced value in this year, 

cumulative produced quantity in this month, cumulative produced 

value in this month, cumulative produced quantity in this week, 

cumulative produced value in this week 


EP Code :[ ] 



Godown keeper: [ ] Inspection responsibility: [ ] 

Year Todate Issues Qty :[ ] Value: [ ] 

Month Todate Issues Qty :[ ] Value: [ ] 

Week Todate Issues Qty :[ ] Value: [ ] 

Date of : Introduction :[ ] Last Manufacture:[ ] 

Last Withdrawal:[ ] Last Issue :[ ] 

Date of 1st Issue: [ ] Moving average rate: [ ] 

VDE Code: [ ] FSN Code: [ ] Bin Page Bin Line: [ ] 

Third input: Godown keeper, inspection responsibility, year to date 

issued quantity, year to date issued value, month to date issued 

quantity,month to date issued value, week to date issued quantity, 

week to date issued value, date of introduction, date of last 

manufacture, date of last drawal, date of last issue, date of first 

issue, moving average rate, VDE code, FSN code, bin number 

Action: On entering the end product code and pressing the escape 

key, the rest of the details are displayed screenwise for 

modification. The escape is to be used to traverse from one screen 

to another and finally to register the modifications. 

Option: Delete an end product from manufacturing matser 


EP Code :[ ] 





Part No :[ ] 



Item Class Technical:[ ] Commercial:[c ] 





Action: The system does not allow deletion if there are active 

warrants against the end product code. If deletion of the record is 

possible then the details may be viewed screenwise with the help of 

a ring menu. 

The ring menu also has a delete option which when 

activated asks for confirmation from the user. If the user confirms 

deletion, then the record is deleted from the system. 

Option: Inquire about manufactured items 

db123mfitm MANUFACTURING ITEM MASTER DB012IMANI 


EP Code :[ ] 


Part No:[ ] Unit of Qty :[ ] 

Mfd/Purchased:[a] 

Item Class: Technical:[ ] Commercial:[ ] Item 

Type:[d] 

Alternate Item Exists:[ ] 

(Days) :[ ] 

Manufacture Lead Time 

Quantity On Hand :[ ] Value: [ ] 

Cumulative Yrly Warranted Qty :[ ] Value: [ ] 

Cumulative Mthly Warrnted Qty :[ ] Value: [ ] 

Cumulative Yrly Produced Qty :[ ] Value: [ ] 

Cumulative Mthly Produced Qty :[ ] Value: [ ] 


description on on how to proceed while querying on existing data. 

Option: Print the details of a manufactured item 


EP Code :[ ] 





Part No :[ ] 








Action: Prints the details of a manufactured item 

Option: Add a parameter record 

db131param PARAMETER FILE MAINTENANCE 

DB013PARAM 

Parameter Type : [ ] 

Parameter Code : [ ] 

Short Description: [ ] 


Input: Parameter type, parameter code, short description, 


description 

Action: The set of values for a parameter are recorded through this 

option. Each value of a parameter (parameter type) is coded and 

description of the code is added for easy reference. The escape key 

must be used to record the data in the computer. 

Option: Modify a parameter record 

db131param PARAMETER FILE MAINTENANCE DB013PARAM 

________________________________________ 





________________________________________________________ 

Input: Parameter type, parameter code 

Second input: Parameter code, short description, description 

Action: The record details are displayed and the second input 

details may be modified if required. The escape key comes in use to 

register the modifications in the computer. 

Option: Inquire about parameter records 

db131param PARAMETER FILE MAINTENANCE 013PARAM 





_________________________________________________ 

Action: The procedure to be followed while querying on existing 

data has been explained in the manual on genaral procedures. 

Option: Delete a parameter record 

db131param PARAMETER FILE MAINTENANCE 

DB013PARAM 

_________________________________________________________________ 





_________________________________________________________________ 

Input: Parameter type, parameter code 

Action: The parameter record is deleted after receiving 

confirmation from the user. 


Option: Add a last number record 

db140lstno LASTNO. FILE MAINTENANCE DB014LSTNO 

___________________________________________________________ 

Lastno. Type : [ ] 

Lastno. : [ ] 


____________________________________________________ 

Input: Last number type, last number, description 

Action: This option records the last number of each document 

generated through the ppc package. The last number type is the code 

for a particular document whose last number is to be recorded. The 

last number is initialized in the beginning, and is updated by the 

system as and when a document of that type is generated. 

Option: Modify a last number record 


______________________________________________________________ 


Lastno. : [ ] 


_____________________________________________________________ 

Input: Last number type, last number 

Second input: Last number, description 

Action: On entering the key fields and pressing the escape key, the 

last number and description for that type are displayed for 

modification. The escape key registers the mdifications in the 

computer. 

Option: Inquire about last number records 


_______________________________________________________________ 


Lastno. : [ ] 


________________________________________________________________ 


description how to proceed while inquiring on data. 

Option: Delete a last number record 

db140lstno 

DB014LSTNO 

LASTNO. FILE MAINTENANCE 


_________________________________________________________________ 


Lastno. : [ ] 


_________________________________________________________________ 

Input: Last number type, last number 

Action: The system deletes the record on receiving confirmation 

from the user. 

Option: Add long description for a code 

db015long LONG DESCRIPTION OF CODES DB015LONG 

Type: [ ] Code: [ ] 

Description 

[ ] 

[ ] 

[ ] 

[ ] 

Input: Type, code 

Second input: Description 

Action: This option records the long description for the codes 

existing in the parameter file (The type and the code must be the 

same as that existing in the parameter file). 

Option: Modify long description of a code 



Description 

[ ] 

[ ] 

[ ] 

[ ] 


Second input: Description 

Action: On entering the type, code and pressing the escape key, the 

descrption may be modified. 

Option: Delete long description of a code 




Description 

[ ] 

[ ] 

[ ] 

[ ] 


Action: The record is displayed and is deleted on receiving 

confirmation from the user. 

NOTES ON ESTIMATES 

ESTIMATE HEADER 

est_no char(10) Estimate number 

rev_no smallint Revision number 

est_dt date Estimate date 

l_rev_dt date Last revision date 

dt_efct date Date from which this is effective 

l_opn_no char(4) Last operation number 

wo_no char(10) Work order number 

itm_cd char(10) Item code that will be manufactured 

drg_no char(10) Drawing number 

uq char(3) Unit of quantity 

qty_set integer Qty for which the entire estimate is 

prepared 

lab_cost money(11,2) Estimated labour cost 

est_cost money(12,2) Estimated total cost 

mtl_cost money(11,2) Estimated material cost 

ep_rej 

decimal(5,2) 

rej_all 

decimal(4,2) 

sec_cd char(3) Section code in which operation starts 

man_l_tm integer Manufacturing lead time 

1. Estimate Number: Validated for nonexistance. 

2. Last Operation No: Programmatically updated whenever a new operation number is entered in 

the labour estimate. 

3. Item Code: Validated for existance in the manufactured item master. 

4. Labour Cost: Updated through program whenever a new operation is entered in the 

labour estimate. 

5. Estimated Total Cost: Updated through program whenever a new material or labour is 

added in the material or labour estimate. 

6. Material Cost: Updated through program whenever a detailed record is entered in 

the material estimate. 

Material Estimate 

ep_cd char(10) End product code 


itm_cd char(10) Item code 

est_sl smallint Serial number 



alt_mtl smallint Alternate material 

secondary_alt smallint Secondary alternate 

ln_sl_no 

smallint 

ln_alt_no 

smallint 

uq 

char(3) 

qty_req decimal(12,4) Quantity required 

rej_all decimal(5,2) Rejection allowance 

shr_all 

decimal(4,2) 

crm_all 

decimal(4,2) 

iss_stor 

char(3) 

src char(2) Source 

cmp_itm_typ char(3) Component/Item type 

sec_cd1 char(3) Section code 

rt_frm_no char(6) Rate form number 

1. Estimate serial: Consecutive numbers given to the operations. 

2. Alternate material: This is zero for the original material, 1 for the first alternate, 2 

for the second alternate and so on. 

3. Secondary alternate: For a set of materialsu, this increments by one, keeping 

alternate material and estimate serial constant. 

4. Quantity required: Quantity required for producing the quantity per set 

mentioned in the estimate header. 

5. Section code: Validated for existance in the parameter file. 

6. Component/Item type: Validated to be one of five different types; 

1 - Raw material purchased from trade 

2 - Component manufactured in the factory 

3 - Tool 

4 - Gauge 

5 - Returnable item 

7. Item code: Validated for existance in the stock item master. 

Labour estimate 


rat_fm_no char(10) Rate form number 


ep_cd char(10) EP code 

opn_no char(4) Operation number 

alt_opn_no char(3) Alternate operation number 

secondary_alt smallint Secondary alternate operation number 

sec_cd char(3) Section code 


mc_typ char(6) Machine type 

nxt_sec char(3) Next section code 

opn_typ char(1) Operation type 

opn_des char(60) Operation description 

lab_cd char(3) Labour code 

lab_cl char(3) Labour class 

lab_hr decimal(6,3) Labour hour required 

rat_100 money(13,4) Rate per set 

cum_rat money(13,4) Cummulative rate upto this operation 

mc_hr decimal(5,2) Machine hour required 

set_up_tm decimal(4,2) Setup time 

delay 

decimal(4,2) 

ref_itm char(10) Referrence item 

crit 

char(1) 

tgt_opn_no char(3) Target operation number 

wip_ind char(1) WIP indicator 

price_qty decimal(11,3) Priced quantity(to indicate how much labour 

has to be authorized for 

producing the required qty. It is excess 

to nthe required qty by the rejection 

percentage) 

multiply_ind char(1) Whether required qty is to be multiplied by 

the warrant qty 

rej_pct decimal(4,2) Rejection percent 

1. Operation Number: Consecutive numbers for operations. 

2. Alternate operation number: 0 for the original operation number, 1 for the first operation, 

2 for the second operation and so on. 

3. Secondary alternate: For set of operations to be considered togehter, this 

increments by one while operation number and 

alternate operation number remains same. 

4. Rate per set: Rate for producing the qty per set mentioned in the 

header. 

5. Cummulative rate: Cumulative rate upto this operation. If a new 

operation is inserted before this operation, then this 

field in this record and all the subsequent records gets 

updated. 

6. Priced quantity: If the estimated quantity is to be produced then labour 

has to be allowed for some more quantity considering 

the rejection. That is called price quantity. 

7. Section code: Validated for being a valid a section code. 

Operation detail 



ev_no 

smallint 

rat_fm_no char(10) Rate form number 

opn_no char(4) Operation number 

alt_opn_no char(3) Alternate operation number 

secondary_alt smallint Secondary alternate 

sl_no smallint Serial number 

lab_cd char(3) Labour code 

lab_cl char(3) Labour class 

lab_hr decimal(7,3) Labour hour required for this labour 

class and labour code 

strength smallint How many persons are required for 

this operation 

rat money(13,4) Rate per person 

This gives the details of labour required for each of the operations mentioned in the labour estimate 

file. There will be one record for each of the labour classes required. 

1. Serial number: Generated sequentially for each of the labour class record. 

2. Labour code: Validated for being available in parameter file. 

3. Labour class: Validated for being one of the possible labour classes. 

GENERAL CONCEPT: For any product (Either final assembly or component), there will be an 

estimate. In case of the final assembly, there will be mention about the subassemblies or raw 

materials puchased from trade. Type of material, whether puchased or manufactured as a 

subassembly or a tool or scrap to generated in the process of manufacturing, will be indicated by the 

Component/Item type field in the material estimate. So there will be mention of subassemblies in the 

estimate of the final assembly. In turn, each of the subassemblies will have their own estimates in 

which there may be mention about further sub-subassemblies. That way, the one single big estimate 

is converted into a number of small subestimates. 

In case of orders received from agencies, virtual orders will be created for all the 

components required to produce the final assembly, and this will be done automatically while 

entering the order received. 

At the time of releasing the warrants, this will be done first for the lowest level of 

components. When these are over, warrants will be released for assembling these into the higher 

level of subassembly. This procedure will be repeated till the warrant is released for assembling the 

final product. Every time a warrant is released, it will be checked whether warrant qty is exceeding 

the qty required in the order. 


Chapter – 7 

Maintenance Management Module 

The primary purpose of this module is to record the different maintenance activities performed on a 

machine and thereby generate information on the performance of a machine. Other related actvities 

like recording the usage of spares in different sections and tracking the movement of spares from one 

section to another may also be done. 

When maintenance work is required on a machine, a person from the particular section where the 

machine is installed has to enter the machine handover details. On entering the machine number, the 

computer cross checks the validity of the machine number and the machine description and section 

are automatically displayed. The type of maintenance (electrical, electronic, mechanical etc) 

involved must be entered. Maintenance transactions are to be registered for breakdown as well as 

preventive maintenance. 

Once the machine has been handed over for maintenace, the maintenance section should register the 

planned date of completion of the maintenance activity. 

When the maintenance work is over, the restoration details are to be recorded. The number of 

persons involved in each grade and the number of hours worked has to be entered for each grade of 

labour involved in the maintenance activity. The labour cost is calculated and recorded. 

Once the preventive maintenance activities on each machine have been identified,the preventive 

maintenace schedule should be planned for a given period. The period for which the preventive 

maintenance activities have been planned should be entered. Then for each machine scheduled date 

of the preventive maintenance should be entered. The scheduled date should not exceed the plan 

period. This actvity needs to be done after every plan period. 

The different preventive maintenance activities that are to be done on each machine are identified 

and registered. The interval after which the activity needs to be done again and the expected duration 

in hours is to be entered. 

Once a preventive maintenance has been done on a machine, the date when the same activity is to be 

done again is to be recorded. 

The available stock of spares in a section must be initialized. Whenever a certain quantity of a spare 

is required in a section, it may either be drawn from the main stores against a demand note or it may 

be obtained from another section where it is available. The sectional stock of that spare is then 

updated. 

Whenever a spare is transferred from one section to another, the transfer details must be recorded. 

The quantity is then reduced from the sending section whilst the quantity of that spare is increased in 

the receiving section. 

The quantity of spare material used in a maintenance activity must be recorded before the machine is 

restored back in the section. The material cost is calculated and recorded by the system. This may be 

used to generate the total maintenance cost for a particular machine. 


Machine utilisation is to be recorded at the end of every month. The actual number of shifts worked 

by the machine in that month is to be entered. In case of machines for which the actual number of 

shifts is not available, the computer generates the machine utilisation taking into consideration the 

normal number of shifts in the section and the total number of shifts idle due 

to maintenance. 

The number of shifts worked in a month obtained after executing the machine utilisation option, is 

converted into hours with the help of a standard conversion factor. 

The monthly depreciation of the machine may be generated after the machine utilisation has been 

registered. The monthly depreciated value is recorded. The book value may be calculated for new 

machines. 

main - mm000nmain 

CONTENTS 

1. Maintenance Transactions - mm100nmenu 

1. Machine Breakdown - mm100ahdor 

2. Machine PDC - mm101ppdc 

3. Machine Restoration - mm100placm 

2. Preventive Maintenance - mm200nmenu 

1. Add Planned PM schedule date - mm200aplpm 

2. Add PM activity - mm200apmdt 

3. Update scheduled PM date - mm200apmsc 

3. Spares Management - mm300nmenu 

1. Initialize opening balance of stock - mm300aspre 

2. Recording intersection transfer of spares - mm300asptr 

3. Update usage of spares - mm300aspug 

4. Machine Utilisation and Depreciation - mm400nmenu 

1. Add monthly machine utilisation - mm400umutl 

2. Machine hours updation - mm400umhrs 

3. Machine depreciation calculation - mm400udepc 

4. Book value calculation for new machines - mm400ubkvl 

5. Reports - mm600rpmen 

1. Daily Breakdown Report - mm600bkd 

2. Weekly Breakdown Report - mm600bkw 

3. Preventive Maintenance Chart - mm600pmchk 

4. Preventive Maintenance Report - mm600bkw 

5. Machine Utilisation Report 

6. Depreciation For Idle Machines 

7. Report On Periodic Maintenance Cost - mm600mnt 

8. Depreciation For Machines 

9. Machine History - mm600hist 


Option: Menu for Maintenance management 

mm000nmain 

MM000NMENU 

MAINTENANCE MANAGEMENT MAIN MENU 

1. Maintenance Transactions 

2. Preventive Maintenance 

3. Spares Management 

4. Machine Utilisation & Depreciation 

5. Reports 

0. Exit 

Enter Your Choice : [ ] 

These are the options available to the user in the maintenance management module. The user may 

select any option by entering the number and pressing the return key. 

Option: Maintenance Transactions 

mm100nmenu 

MM100NMENU 

MAINTENANCE TRANSACTIONS 

1. Machine Breakdown 

2. Machine PDC 

3. Machine Restoration 

0. Exit 


This is the menu displayed on screen when the option on Maintenance Transactions is selected by 

the user. The user may select any one of the above options in maintenance transactions. 


Option: Machine breakdown 

mm100ahdor 

MM001AHDOR 

HANDOVER OF MACHINE FOR MAINTENANCE 

Machine number [ ] 

Machine Des [ ] 

Machine location [ ] Section [ ][ ] 

Maintenance type [ ] [ ] 

Breakdown date [ ] 

Breakdown time [ ] 

Complaint book serial number [ ] 

Input: 

Action: 

Machine number, maintenance type, breakdown date, breakdown time,complaint 

serial number 

When a machine has to be handed over to the maintenance department for some 

maintenance activity, the machine handover details are entered into the computer. 

Control B may be used to view the types of maintenance jobs that may be done. 

Various maintenance types are Electrical, Mechanical, Electronic etc. On entering 

the required information and pressing escape, the handover details are registered into 

the computer. If the user gives any details about the nature of breakdown then that 

also will be registered. Later this will be available to the maintenance personnel. 

Option: Machine PDC 

mm101ppdc 

MM100PPDC 

PLANNED DATE OF COMPLETION 

Machine number [ ] [ ] 

Planned date of completion [ ] 

Maintenance Category [ ] [ ] 

Maintenance Type [ ] [ ] 

Machine location [ ] 

Input: 

Action: 

Machine number, planned date of completion, maintenance category 

Once a machine has been handed over to the maintenance department for some 

maintenance activity, the maintenance department has to enter the planned date of 


Option: Machine restoration 

completion of the maintenance activity that requires to be done on the machine. The 

different categories of maintenance may be viewed in an array for selection. They 

may be Breakdown, Conditional, Preventive etc. The selection requires the use of the 

escape key. The escape key is to be used to register the planned date of completion 

into the computer. The nature of fault can be added or altered by the maintenance 

personnel. 

mm100placm 

MM001AMARD 

RESTORATION/LABOUR COST OF MAINTENANCE 

Machine number [ ] [ ] 

Machine Location [ ] 

PDC [ ] 

Handover date [ ] 

Handover time [ ] 

Maintenance type [ ] [ ] 

Maintenance category [ ] [ ] 

Labour code 1 Labour code 2 Labour code 3 

[ ] [ ] [ ] 

Repairs Carried out 

[ ] 

Restoration date [ ] Restoration time [ ] 

Labour cost [ ] Idle shifts [ ] 

Input: 

Action: 

Machine number, labour code 1, labour code 2, labour 3, repairs carried out, 

restoration date, restoration time, labour class, number of persons, labour hour (to be 

input in an array), labour cost,idle shifts 

Once the maintenance activity is completed, the machine is restored back in the 

section and the restoration details are registered in the computer. On entering the 

machine number and pressing the return key, the machine handover details are 

displayed. After entering the restoration time and pressing the return key, the labour 

classes, the number of persons of each class and the number of hours put in by each 

class of labour is to be entered in an array to calculate the labour cost. The labour 

cost for each class and the total labour cost are displayed on screen. The user comes 

back to the original screen by pressing the escape key. The escape key comes good 

again to record the restoration details in the computer. 


Option: Preventive Maintenance 

mm200nmenu 

MM200NMENU 

PREVENTIVE MAINTENANCE 

1. ADD PLANNED PM SCHEDULE DATE 

2. ADD PM ACTIVITY 

3. UPDATE SCHEDULED PM DATE 

0. EXIT 

ENTER YOUR CHOICE : [ ] 

The above menu appears on the screen when the user selects the option on Preventive Maintenance. 

The above options are available on Preventive Maintenance and the user may select one of the 

options according to the information that needs to be recorded. 

Option: Add planned PM schedule date 

mm200aplpm 

MM200APLPM 

PLANNED PM SCHEDULE 

Section code [ ] 


Approximated working hours [ ] 

Planning horizon [ ] 

Machine number [ ] 


PM check code [ ] 

PM interval in hour [ ] 

PM interval in mnth [ ] 

Cumulative hour [ ] 

Last date of PM [ ] 

Scheduled date of PM [ ] 

Input: Section code, Approximate working hours, Planning horizon 

Second input: Scheduled date of PM 

Action: Once the preventive maintenance activity to be performed on a machine has been 

registered (please refer to next option), the date planned for performing the activity 

should be recorded. 

The planning horizon is the duration in terms of days in which the entire PM activity in the section 

is being planned to be completed. On entering the first input details and pressing the escape key the 

scheduled dates for all the PM activities in that section may be entered one by one. The escape key 

must be used once the date planned for a PM activity has been entered. The PM date planned should 

not exceed the planning horizon. 


Option: Add PM activity 

mm200apmdt 

MM200APMDT 

ENTER MACHINE/PM ACTIVITY 

Machine Number [ ] PM check code [ ] 

Machine Des [ ] Machine locat. [ ] 

PM description [ ] Interval Hr. [ ] 

Interval Mnth. [ ] Cum Hours 

wrkd since [ ] 

Last PM date [ ] last PM 

Number of PM done [ ] Exp duration [ ] 

(in hours) 

for PM 

Input: 

Action: 

Option: 

Machine number, PM check code (type of PM that needs to be done), interval in 

hours or month , cumulative hours worked since last PM,last PM date, number of PM 

done, expected duration of PM activity 

The different preventive maintenance activities that are to be performed on a 

machine are recorded in this option. Each activity may be identified by the PM check 

code. Preventive maintenance is done periodically to keep the machine in running 

condition and therefore the periodic interval (hours/months) after which the activity 

is to be done again is to be entered. On pressing the escape key after entering the 

required information, the PM activity details are recorded into the system. 

Update scheduled PM date 

mm200apmsc Enter PM Schedules for Specific Machines 

MM200EPMSC 

Machine Number : [ ] 

Machine Description : [ ] 

Preventive Maintenance 

Check Code : [ ] 

PM Check Description : [ ] 

Scheduled Date : [ ] 

Input: Machine number, PM check code, Scheduled PM date 

Action: The PM schedule for specific machines is registered in this option. 

On pressing the escape key, the information entered is recorded in the computer. 

Option: Spares management 


mm300nmenu 

MM300NMENU 

SPARES MANAGEMENT 

1. INITIALIZE OPENING BALANCE OF STOCK 

2. RECORDING INTERSECTION TRANSFER OF SPARES 

3. UPDATE USAGE OF SPARES 

0. EXIT 


The above options are available to the user in the spares management option. 

Option: Initialize opening balance of sectional stock of a spare 

mm300aspre 

MM300ASPAR 

ENTER SPARES RECORD 

Item code [ ] 




Spare qty [ ] 

Spare value [ ] 

Last use date [ ] 

Input: 

Action: 

Item code, section code, spare quantity, spare value, last use date 

When a new machine spare is issued to a section, the sectional stock for that spare is 

initialized through this option. The spare value is calculated and displayed once the 

spare quantity is entered and return key is pressed. The escape key must be used to 

register the sectional spare details into the system. 


Option: Recording intersection transfer of spares 

mm300asptr TRANSFER OF SPARES MM300ASPTR 

Item code [ ] 


From section[ ] [ ] 

To section [ ] [ ] 

Spare quantity [ ] 

Input: 

Action: 

Item code, section from which spare is being transferred, section to which spare is 

being transferred, spare quantity being transferred 

When a spare is transferred from one section to another, the transfer details are 

recorded through this option. The spare quantity that is being transferred should not 

exceed the quantity existing in the section from which the transfer takes place. The 

item description and the names of both sections are displayed on the screen. 

Option: Update usage of spares 

mm300aspug 

MM300ASPUG 

CONSUMPTION OF SPARES 

Item code [ ] 




Machine code [ ] 


Used quantity [ ] 

Value of quantity used [ ] 

Usage date [ ] 

Input: 

Action: 

Item code, section code, machine code, used quantity, usage date 

Updates the spare quantity that is used when repairs are done on a machine. This 

activity must be done before the machine is restored back in the section. The value of 

the spare consumed is calculated by the system and displayed. The escape key 

registers the information into the system. 


Option: Machine utilisation and depreciation 

mm400nmenu 

MM400NMENU 

MACHINE UTILISATION & DEPRECIATION 

1. ADD MONTHLY MACHINE UTILISATION 

2. MACHINE HOURS UPDATION 

3. MACHINE DEPRECIATION CALCULATION 

4. BOOK VALUE CALCULATION FOR NEW MACHINES 

0. EXIT 


This menu is displayed when the machine utilisation and depreciation option is selected by the user. 

He may select any one of the above options according to his requirement. 

Option: Add monthly machine utilisation 

mm400umutl 

MM400UMUTL 

Monthly Machine Utilisation 

Current Date : [ ] 

Previous Month (MM) : [ ] 

Year (YYYY) : [ ] 

Section Code : [ ] 

Section Description : [ ] 

Normal No of Shifts : [ ] 

Machine Number : [ ] Actual No of Shifts : [ ] 

Machine Description : [ ] 

Input: Section code, normal number of shifts 

Second input: Machine number, Actual number of shifts 


Action: 

The details of monthly machine utilisation in a section are registered in this option. 

On entering the section code, normal number of shifts (default number) and pressing 

the escape key, the user may enter the actual number of shifts utilised by the 

machine. On pressing the escape key the actual number of shifts for the next machine 

in the section may be entered. When the data entry is completed, Control C should be 

used to register the data entered. The user is then asked whether monthly utilisation 

details are to be registered, based on the default number of shifts, for all the machines 

in the section for which the data on the actual number of shifts worked is not present. 

The normal number of shifts is the number of shifts the machine should work without 

considering the shifts wasted due to maintenance work. 

The user is then asked whether he would like to enter the utilisation details for 

another section. If he so desires then the system allows the user to go through the 

entire process again. 

Option: Update machine hours 

mm400umhrs 

MM400UMHRS 

Update Machine Hours 

Month (MM) : [ ] 


Note : This Program Updates Machine Hours in Machine Master for all the Machines. It 

Also updates the Machine Hours in Preventive Maintenance Master, for the given 

month & year. 

Action: 

There are no user inputs in this option. Once the user selects this option, the month 

and the year for which the machine hours is being calculated is displayed. The 

machine hours is updated for all those machines for which the monthly machine 

utilisation has been added. Also updates the cumulative hours worked by the 

machine after the last PM activity. 

Option: Machine depreciation calculation 

mm400udepc 

Machine Depreciation Calculation 

Previous Month (MM) : [ ] 


Note : 

Action: 

This Program Calculates the Machine Depreciation For all the Machines in Machine 

Master. This Program Updates Depreciation for all machines having Depreciation 

Multiplication Factor. If Updation Fails it Displays the Machine Number and does 

not Update the Machine Master for that Machine 

Calculates the machine depreciation for all the machines for which the monthly 


utilisation has been added and which are not uninstalled or commisssioned. 

Option: Book value calculation 

mm400ubkvl 

MM400bvc 

Book Value Calculation 

This Program Calculates the Book Value for all Machines which have the Residual Value 

Greater Than Zero. 

Press 'Y' to Continue Calculation or 'N' to Exit : [ ] 

Action: Calculates the book value for all machines. 

Option: Reports 

mm600rpmen 

MM600RPMEN 

MAINTENANCE REPORTS 

1. Daily Breakdown Report 

2. Weekly Breakdown Report 

3. Preventive Maintenance Chart 

4. Preventive Maintenance Report 

5. Machine Utilisation Report 

6. Depreciation for idle machines 

7. Report on periodic Maintenance Cost 

8. Depreciation of machines 

9. Machine history 

0. Exit 


This is the menu for the reports that are generated in the maintenance management module. The 

purpose of each of the reports have been described option wise in the following pages. 

Please note that the reports shown in the following pages have been generated with test data. 

Option: Daily Breakdown Report 

mm600bkd 

MM600BKD 

DAILY BREAKDOWN REPORT 

RUN REPORT [ ] 

Input: 

Action: 

Choice (whether yes or no) 

The breakdown details entered on the current date are printed in the order of machine 

number, breakdown date and breakdown time. 


Chapter – 8 

Quality Assurance Module 

This module is used to raise and authorize inspection notes once the production is started. Daya to 

day production data will be entered operationwise. Some of the operations will be identified as 

inspection stages. Inspection notes will be prepared for these stages. 

Options: Add, Modify, Inquire, Delete, Authorize, Print 

Add: Used to enter an inspection note into the system. Inspection notes can be of two types: 

Material and Production. In case of material I-Note, Bond No along with other details has to 

be given at the time of raising an Inspection Note. In case of production type inspection note, 

Previous Inspection Note no has to be given. In case of first time manufacturing, we have to 

enter the material inspection note number. 

Data expected: Inote date, 

Work order number, Warrant number 

Operation number (in case of produced items) 

Item code (In case of Material Inote) 

Section code 

Submitted quantity 

Material I-note in case of first time 

production, otherwise previous I-note. 

In case of material inspection note, Bond number of the material has to be 

given. 

Action taken: An Inspection note record will be registered in the system which will be 

sentenced later by inspection authority. 

Authorize: 

Data expected: Inote number, Accepted/rejected quantities 

Action taken : Inspection note status will be changed and inspection quantities will be plotted in 

warrant. In case this is the final operation, then accepted quantity in the 

warrant will also be enhanced so that EP can be isuued. 

In case of rejection, rejection reason is also captured from the screen. This 

will be printed in the inspection note. 

Print: 

Either a particular Inspection note or the summary report giving the list of all 

the pending Inspection notes can be printed. 


Chapter – 9 

Tools Control 

Activity of this module can be divided into two parts. 

1. Tool requirement planning. 

This is applicable to all types of tools. Options 1 & 2 capture the information relevant for 

this activity. Once the requirement is planned and decision about manufacture/purchase is 

taken, it can be processed further through either warrant release or purchase order control 

module. 

2. Tool life tracking. 

This is applicable for special purpose tools where it is required to capture information about 

each individual piece of a certain type. At first the tool master will be prepared for these 

tools and day to day usage and movement will be captured by options 3 through 6. 

Following are the different options through which data management is 

to be done. 

main (tc000nmain.4gl/tc000nmain.4ge) 

1. TOOL REQUISITION (tc300ntlre.4ge) 

A) Add 

Adds requisition details into t_tlreqsn.The requisition no is generated by incrementing last 

no in m_last_no by 1. The requisition status is made "P". 

Data expected 

section no 

tool no 

requisition qty 

requisition date 

requisition type(Manufactured / Purchased) 

required on 

planner 

remarks 

B) Modify 

Modifies tool requisition details 

C) Inquire 

Query on tool requisition details 


D) Delete 

Deletes tool requisition details 

E) Authorize 

Authorizes a pending requisition. Updates requisition-status, authorized-qty, remarks in 

t_tlrqsn. 

Data expected 

requisition no 

accept(A/R) 

authorized qty 

remarks 

2. TOOL REQUIREMENT 

(tc100ntlrq.4ge) 

A) Add Requirements 

Adds the quantity of each tool required for a period i.e. a particular year and quarter in 

w_tlreqd. If the tool exists in 

m_stkitm then it has been purchased else if it exists in 

m_manitm it has been manufactured. 

Data expected 

tool no 

year 

quarter no 

required quantity 

B) Modify Requirements 

In case the quantity required for a period and/or the status (whether purchased or 

manufactured) of the tool needs to be modified then this option is used. 

Data expected 

year 

quarter no 

make or buy status 

required quantity 

3. TOOL TRANSFER/RETURN (tc400ntsts.4ge) 


A) Tool transfer 

This option records the transfer details of a tool when it is transferred from one section to 

another. The transfer details are entered into t_tlxfer. The section issued to and the due date of return 

are updated in m_tool. 

Data expected 

tool no 

tool serial no 

transfer date 

to section 

due return date 

B) Tool return 

When a tool is returned back to the previous section, the return details are entered through 

this option. The t_tlxfr is updated with the return date. In m_tool the section to which the tool is 

returned is recorded and due date of return is made null. 

Data expected 

tool no 

tool serial no 

return date 

4. TOOL USAGE (tc700ttlug.4ge) 

Updates tool usage in a section based on hours worked/pieces handled. The cumulative 

hours worked/cumulative items handled is updated in m_tool. 

Data expected 

section code 

hours worked/no of items 

to be updated(Y/N) 

5. TOOL REWORKING (tc800arwgd.4ge) 

This option accepts information on the reworking of a tool. 

Updates last-rewok-date with current-date, cumulative-no-of-rework section-issued-to, 

max-ep/max-hrs-before-rework in m_tool. Also creates a record in t_tlhsty with status="R". 


Data expected 

tool no 

serial no 

reworking date 

section issued to 

max end products to be handled/max hours before rework 

6. TOOL SCRAPPAGE (tc900asotl.4ge) 

Used to register scrappage details of a tool. Creates a record in t_tlhsty with status="S". Also 

changes status to "S" in m_tool. 

7. REPORTS 

Data expected 

tool no 

serial no 

scrapped(Y/N) 

scrappage date 

A) Report of gauges due for calibration. (tc850rgacl.4ge) 

B) Report on tool life (tc851rtllf.4ge) 

C) Report on quality assurance (tool & guages) (tc100r001.4ge) 

D) List of tool on ep code for an operation (tc100r002.4ge) 

E) List of guages on ep code for an operation (tc100r003.4ge) 


Chapter – 10 

Work in Progress 

MAIN: wi000main.4ge 

1. Daily production maintenance 

(wi001nprod.4ge) 

(wi001globl.4gl, wi001iprod.4gl, wi001nprod.4gl, 

wi001mprod.4gl, wi001aprod.4gl, wi001dprod.4gl) 

Options: Add, Modify, Inquire, Delete 


a) Production date 

b) Shift 

c) Work order number 

d) Warrant number 

e) Operation number 

f) Section code 

g) Produced quantity 

h) Accepted quantity in case this is not an inspection stage 

i) Rejected quantity in case this is not an inspection stage 

j) Rectified quantity in case this is not an inspection stage 

Daily production details will be captured using this option. If an operation is identified as 

bookkeeping stage then all the details of Accepted, rejected quantities will be captured through 

option. In case the operation is identified as inspection stage then, only the produced qty will be 

captured here. Inspection details regarding accepted, rejected quantities will be captured through 

inspection note raising operation in QA module. 

Adds a record in t_dayprd 

Updates m_labwts(qty_prd, qty_act, qty_rfr, qty_rej) 

for given wo_no, wt_no, opn_no 

2. Red demand notes (wi003nrdns.4ge) 

(wi003fchld.4gl, 

/user1/DEMO/mp/mp007globl.4gl, 

wi003mrdns.4gl, 

wi003hrdns.4gl, 

wi003irdns.4gl, 

wi003drdns.4gl, 

wi003ardns.4gl, 

wi003nrdns.4gl, 

wi003globl.4gl, 

/user1/DEMO/ct/ct203frdxa.o, 

/user1/DEMO/ct/ct170fpdnl.o, 

/user1/DEMO/ct/ct103frdrx.o, 

CALLS ct_frdxe or ct_frdxa depending on estimated or actual cost 

/user1/DEMO/ct/ct180fucwp.o, 

/user1/DEMO/ct/ct303frdxe.o, 

/user1/DEMO/ct/ct403fpval.o 


Input expected: 

a) Date 

b) From Work order number, warrant number 

c) To work order number, warrant number 

d) Transfer quantity 

e) Inspection note number 

This is used to capture data regarding drawal of component from one warrant to the assembly 

warrant. The end product of the feeding warrant is mentioned as a darwable material in the parent 

warrant. After this is executed, Drawn quantity and value is enhanced in the parent warrant. 

Options: Add, Modify, Inquire, Delete, Authorise 

(wi_ardns, wi_mrdns, wi_irdns, wi_drdns, wi_hrdns......) 

Add option adds a record in t_rdnrrn and updates m_lastno. 

Authorize option updates m_wts, m_mtlwts, m_cosec, m_manitm, t_rdnrrn Act_qty in 

m_wts for the from warrant has to be updated beforehand. Also, the inspection note has to generated 

earlier in t_inspnt. 

3. Piecework cards 

(wi005npwcs.4ge) 

(wi005globl.4gl, 

wi005rgang.4gl, 

wi005hpwcs.4gl, 

wi005dpwcs.4gl, 

wi005apwcs.4gl, 

wi005ipwcs.4gl, 

wi005npwcs.4gl, 

/user1/DEMO/ct/ct111fdacl.o, 

/user1/DEMO/ct/ct112fohcl.o, 

/user1/DEMO/ct/ct110tppwc.o, 

/user1/DEMO/wr/wr004fbsrt.o 

) 

Suboptions: Add, Authorize, Delete, Inquire, Print 


year 

month 

Whether individual ticket number or gang number 

Work order number, Warrant number 

Range of operation numbers which will be covered by this pw card 

Piecework quantity 

This option is used to capture data about Piecework card preparation. In add option it creates 

a record in m_pwcs and in authorization option these are ploted in m_labwts (labour warrant record) 

for the quantity and cost. 

4. Reports (wi100rmen.4ge) 


(wi100r010.4gl, wi100rmen.4gl) 

1. Daily production report (call wi_100r1() in wi100r010.4gl) 


Production date 

Section code 

Action: Gives daywise, sectionwise production report 

2. Store, component & labour booking report (wi200rwipm.4ge) 

(wi200rwipm.4gl) 

Data expected 

Work order number 

Warrant number 

Action: Gives the current consumed amount of raw materials, components and value 

of labour drawn 



Shop Order Release Module 

MAIN: wr900main.4gl/wr000main.4ge 

1. Warrant requisitions: (wr001reqn.4ge) 

(wr000globl.4gl, wr001figde.4gl, wr001fgdes.4gl, wr001nrqn.4gl, wr001irqn.4gl, 

wr001mrqn.4gl, wr001drqn.4gl, wr000fwtst.4gl, wr001arqn.4gl, wr000fwtdi.4gl) 

Production Section will be raising requisition for warrants when there is spare capacity with 

them. 

Data expected are: 

a. Requisition type C - Component warrant 

M - Main warrant 

b. Requisition Date 

c. Section Code 

d. EP Code 

e. Requisition Qty 

f. Planned Date of Completion 

2. Authorization of requisitions: (wr002auth.4ge) 

(wr000fwtdi.4gl, wr002fauth.4gl, wr000fwtst.4gl, wr002nauth.4gl, wr001figde.4gl, 

wr000globl.4gl, wr001irqn.4gl, wr002hauth.4gl) 

P & P will be authorizing this requisition. 


a. Requisition No 

b. Whether to be accepted pr rejected 

c. Rejection reason in case of rejection 

d. Orders for which warrants are to released 

e. Authorized Qty 

3. Quot WO No: (wr003quot.4ge) 

(wr000fwtst.4gl, wr000globl.4gl, wr000fwtdi.4gl, wr003nquot.4gl, wr001irqn.4gl, 

wr001figde.4gl) 

Works office will quote the work order number. Warrant number will be assigned here. 


a. Work order number 

4. Release warrants: (wr004manwt.4ge) 

(wr004indpr.4gl, wr000fwtst.4gl, wr000fwtdi.4gl, wr000cddes.4gl, wr020iwthd.4gl, 

wr004rwprt.4gl, wr004nmwre.4gl, wr004fwsht.4gl, wr004wtprt.4gl, wr004fwmtl.4gl, 

wr004fwlab.4gl, wr004awhd.4gl, wr004fmwck.4gl, wr004wtrel.4gl, wr004globl.4gl) 

Used for releasing warrants : 


a. Warrant type 

b. Warrant requisition No 

c. Estimate Number & revision number (Default will 

be shown from Manufactured item master) 


d. Warrant issue date 

e. Planned date of completion 

f. Inspection Type 

After entering these details, shotage list of material required will be calculated and 

present status for them will be displayed User may still release the warrants based on expected 

arrival of material or abort the operation. 

5. Indirect warrant release: (wr007opnwt.4ge) 

(wr000cddes.4gl, wr000fwtst.4gl, wr000fwtdi.4gl, wr020iwt.4gl, wr007nowre.4gl, 

wr007mowmt.4gl, wr007mowlb.4gl, wr007fmcmt.4gl, wr007dowre.4gl, wr007aowre.4gl, 

wr007aowmt.4gl, wr007aowlb.4gl, wr007globl.4gl) 

This is used for both indirect warrants and SWODs. 


a. Warrant type (Whether SWOD or Open warrant) 

b. Work order no 

c. Activity code (Machine No in case of 

maintenance activity or 

ep_cd in case of new item to be developed) 

d. Warrant issue date 

e. Planned date of completion 

f. Inspection type to be performed on the warrant 

g. Section code 

h. Estimated labour and material value 

i. Material and labour details 

6. Release Nonrecurring materials (wr009nrmwt.4ge) 

(wr009pvnrm.4gl, wr009amnrm.4gl, wr000fwtst.4gl, wr000fwtdi.4gl, wr_clear.4gl, 

wr_prompt.4gl, wr009nrmmn.4gl, wr009inrmm.4gl, wr009ahnrm.4gl, wr009globl.4gl) 

Data required: 

a. Work order number 

b. Warrant Number 

c. Item code to be replaced 

d. Replacement item 

e. Qty required 

7. Release nonrecurring rate (wr010nrrwt.4ge) 

(wr000fwtdi.4gl, wr_prompt.4gl, wr_clear.4gl, wr010pvnrr.4gl, wr010globl.4gl, 

wr010ahnrr.4gl, wr010arnrr.4gl, wr010inrrr.4gl, wr010nrrmn.4gl) 


a. Work order no 

b. WArrant no 

c. Operation no to be replaced 

d. Replacement operation number 

e. Total value authorized 

8. Transfer End product from one warrant to another (wr070epxfr.4ge) 

(wr000fwtdi.4gl, wr011globl.4gl, wr011nepxv.4gl, ct160fexfr.o, ct161fxfra.o, ct162fxfre.o, 


ct180fucwp.o, ct170fpdnl.o) 


a. Transfer date 

b. From work order number and warrant number 

c. To work order number and warrant number 

d. Item code 

d. Source and destination section codes 

e. Transfer quantity 

f. Inspection note number 

9. Transfer Material from one warrant to another (wr071mtxfr.4ge) 

(wr000fwtdi.4gl, wr011globl.4gl, wr012nmtxv.4gl, ct160fmxfr.o) 


a. Source and destination work order no and warrant no 

b. Item code and transfer qty 

10. Transfer labour from one warrant to another (wr072lbxfr.4ge) 

(wr000fwtdi.4gl, wr013nlbxv.4gl, wr011globl.4gl, ct160flxfr.o) 


a. Transfer date 

b. Source and destination work order and warrant numbers 

c. Source and destination section numbers 

d. Labour amount transferred 

11. Replacement warrant (wr014repwt.4ge) 

(wr000fwtdi.4gl, wr004fwprt.4gl, wr004rwprt.4gl, wr004fwlab.4gl, wr004fwmtl.4gl, 

wr004fmwhd.4gl, wr004fwsht.4gl, wr004globl.4gl, wr014nrwre.4gl, wr014arwre.4gl) 

Issued when one warranat is short closed before completing the whole authorized qty. 

Can be issued for the remaining qty. 


a. Parent work order and warrant no. 

b. EP Code 

c. Estimate and revision number 

d. Warrant qty 

e. Issue date and planned date of completion 

12. Close a warrant (wr008wtclo.4ge) 

(wr020iwt.4gl, wr000fwtdi.4gl, wr000fwtst.4gl, wr004globl.4gl, wr008fwclo.4gl, 

wr008twclo.4gl, wr000cddes.4gl, wr008nwlco.4gl) 

Main is in wr008nwclo.4gl 

Calls function wr_twclo() in wr008twclo.4gl 

Inputs wo_no, wt_no, wt_adc, validates and displays warrant details. 

calls function wr_fwclo(wo_no, wt_no) in wr008fwclo.4gl afetr input 

updates m_order cum_wt_qty by the short qty 

updates m_stkitm drawablw qty by unused qty 

updates m_wts wt_stat(closed or shortclosed) and wt_adc 



a. Work order number and warrant number 

b. Warrant closure date 

13. Inquire options (wr020inqwt.4ge) 

(wr020niwts.4gl, wr020iwt.4gl, wr000fwtdi.4gl, wr000cddes.4gl, wr000fwtst.4gl) 

14. Warrant discrepancies (wr008iwtdi.4ge) 

( wr000fwtdi.4gl, 

wr000fwtst.4gl, 

wr008iwdis.4gl(contains main, calls wr_fiwdi() in wr008fiwdi.4gl) 

wr008fiwdi.4gl, 

wr008globl.4gl ) 

15. Queries (wr001qrqn.4ge) 

(wr000fwtst.4gl, wr000query.4gl, wr001qrqn.4gl, wr000fwtdi.4gl, wr001figde.4gl, 

wr000globl.4gl) 

16. Reports (wr700rmain.4ge) 

(wr700rmain.4gl, wr700globl.4gl, wr702rwtis.4gl, wr702rwtcm.4gl, wr701rrqns.4gl, 

wr700figde.4gl, wr700frdts.4gl, wr703fnrmr.4gl, wr704splrp.4gl, wr702pndwt.4gl, 

wr000fwtst.4gl, wr705fnrrr.4gl) 

17. Print warrant (wr025prtwt.4ge) 

(wr004wtprt.4gl, wr004rwprt.4gl, wr025nwprt.4gl, wr004globl.4gl, wr004indpr.4gl) 

18. Inquire on transfer vouchers (wr600nxfrq.4ge) 

(wr600nxfrq.4gl) 


GENERAL CONCEPT: 

For any product (Either final assembly or component), there will be an estimate. In case of 

the final assembly, there will be mention about the subassemblies or raw materials puchased from 

trade. Type of material, whether purchased or manufactured as a subassembly or a tool or scrap to 

generated in the process of manufacturing, will be indicated by the Component/Item type field in the 

material estimate. So there will be mention of subassemblies in the estimate of the final assembly. In 

turn, each of the subassemblies will have their own estimates in which there may be mention about 

further sub-subassemblies. That way, the one single big estimate is converted into a number of small 

sub-estimates. 

In case of orders received from agencies, virtual orders will be created for all the components 

required to produce the final assembly, and this will be done automatically while entering the order 

received. At the time of releasing the warrants, this will be done first for the lowest level of 

components. When these are over, warrants will be released for assembling these into the higher 

level of subassembly. This procedure will be repeated till the warrant is released for assembling the 

final product. Every time a warrant is released, it will be checked whether warrant qty is exceeding 

the qty required in the order. 

Option: Release warrants 

wr027wtrel 

Extract No : [ ] 

WO No : [ ] Warrant No: [ ] 

EP Code : [ ] [ ] 

Estimate No : [ ] 

Pending Qty : [ ] 

Warrant Qty : [ ] PDC : [ ] 

This option is executed before warrants are to be issued to the production sections. There are 

two different sub-options through which the screen can be executed. One is single level and the other 

is Multi-level. 

In single level warrant generations, records are created only for the EP code entered. Before 

releasing the warrant it is verified whether that much quantity is yet to manufactured against the 

extract. If not then the user is given a 

warning. 

For multi-level warrant generation option, all the subassemblies required to manufacture the 

required qty of the mentioned EP, is calculated. Then the calculated quantity is verified against the 

pending ordered quantity for that assembly or subassemly and if required warrant is issued for that 

quantity. If some quantity of the item is already is already manufactured and the remaining quantity 

to be manufactured is less than the calculated quantity then warrant is released for the remaining 

quantity only. 


Action: 

Input: Extract Number, 

Work Order Number, 

EP Code, 

Estimate Number, 

Warrant Quantity, 

Planned Date of Completion 

After extract number is entered, it is verified whether the Extract is existing in the order file. 

After Work Order number, this is verified for having entry in the parameter file. 

After EP code corresponding to the material to be manufactured is entered, its existance in 

the manufactured item master is verified. Default estimate number is taken to be the one mentioned 

in the manufactured item master. It is also verified whether the given item has been ordered against 

the extract number entered earlier. 

After estimate number, it is verified whether the estimate is existing and the given estimate 

number manufactures the required EP. After Warrant qty, it is seen whether the warranted quantity is 

exceeding the required quantity against the order. After all the validations are done, warrant records 

are created which include header, labour and material. 

Option: 

Indirect warrants 

wr700owre SWOD / INDIRECT WARRANT RELEASE 

WR007 

AOWRE 

Warrant type : [ ] Type Desc : [ ] 

Work Order No. : [ ] Warrant No. : [ ] 

Activity Code : [ ] 

Activity Desc : [ ] 

Warrant Issue Date : [ ] Warrant PDC : [ ] 

Inspn. Type : [ ] Section code : [ ] 

Desc. : [ ] 

Est. Material Val : [ ] Est. Labour Val : [ ] 

Est. Total Val : [ ] Warrant status : [ ] 

Input: Warrant type, Valid values are 4 (Open warrant) and 5 (SWOD) 


Activity Code - EP CODE, 

Warrant Issue Date, 

Planned date of completion, 

Inspection type - 


Section Code 

Estimated material value, 

Estimated labour value, 

Estimated total value 

1: No inspection, 

2: DA Note, 

3: Insp Note 

wr701owmt 

MATERIAL WARRANT CREATION 


Component Item type : [ ] Component Item No. : [ ] 

Item Description : [ ] 

Unit of Quantity : [ ] 

Qty authorised : [ ] 

Section Code : [ ] 

Input : 

Component Type, 

1: Raw material, 3: Tool, 4: Gauge, 5: Returnable 

Item Code, 

Qty authorized, 

Section Code 

wr702owlb2 

LABOUR DETAILS FOR INDIRECT WARRANTS/ SWOD 


Opn No : [ ] Opn Cd : [ ] [ ] 

Authorized qty : [ ] 

Sec Cd : [ ] Trade Cd : [ ] 

Grade Cd : [ ] 

Rate : [ ] No Hrs : [ ] 

Lab Auth : [ ] 

WIP Ind : [ ] Tgt Opn No : [ ] 

Opn No : [ ] Opn Cd : [ ] [ ] 

Authorized qty : [ ] 

Sec Cd : [ ] Trade Cd : [ ] 

Grade Cd : [ ] 

Rate : [ ] No Hrs : [ ] 

Lab Auth : [ ] 

WIP Ind : [ ] Tgt Opn No : [ ] 

Input : 

Operation number, 


Action: 

Operation Code, 

Authorized Quantity, 

Section Code, 

Trade Code, 

Grade Code, 

No of Hours, 

WIP Indicator, 

Target Operation number 

Open warrant/SWOD are warrants against which indefinite amount of any material can be 

drawn. After the input data is entered, it adds a new record into warrant header table and asks from 

the user whether any specific material or labour to be provided immediately. Then accordingly it 

accepts labour data or material data from the relevant screen. Data entered for material or labour is 

recorded in the corresponding table. 

Option: Release NRMs 

wr0551nrm 

NRM DETAILS 

Work order no. : [ ] Warrant no. : [ ] 

Issue date : [ ] NRM date : [ ] 

Itemcode to replace New itemcode Quantity 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

Drawable quantity : [ ] 

Input: Work Order Number, 

Warrant Number, 

NRM Date 

Second Input: Item Code to replace, 

New Item Code, 

Quantity 

Action: 

Work order is validated for existance in the parameter table. Combintion of work order 

number and warrant number is checked for availability in the warrant header table. It is checked 


whether there is already any NRM issued against the warrant. Second NRM is not permitted against 

the same warrant. However, at a single occassion any number of new materials can be allowed. 

When an Item code is entered in the to-be-replaced column, that item is marked in the existing 

warrant so that no further material can be drawn against that warrant. If a new item is to be 

authorized, then this column is left blank. 

After new item code is entered, a new record is created in the material warrant table. 

Option: Inquire on NRMs 

wr0552nrm 

NRM DETAILS 

Work order : [ ] Warrant no. : [ ] 

Issue date : [ ] NRM date : [ ] 

EP code : [ ] Description : [ ] 

Quantity : [ ] Unit : [ ] 

Warrant status : [ ] 

Item Code Unit Qty Authorised Qty Drawn Value Drawn 

[ ] [ ] [ ] [ ] [ ] 

[ ] [ ] [ ] [ ] [ ] 

[ ] [ ] [ ] [ ] [ ] 

Action: 

Item Description : [ ] 

Press Control-b to view item description 

Accepts Work Order Number, Warrant Number, EP Code as per standard inquire option and 

displays data corresponding to the NRM. Item Details are shown in the array. 

Option: Add NRRs 

wr0562nrr 

NRR DETAILS 


Issue date : [ ] NRR date : [ ] 




Operation no Labour Authorised 

Labour Drawn 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

[ ] [ ] [ ] 


[ ] [ ] [ ] 

[ ] [ ] [ ] 


warrant number, 

NRR Date 

Secon Input: Operation Number to replace, 

New Operation Number, 

Value 

Action: 

After work order number it is verified whether this is appearing in the Parameter table. After 

warrant number is entered, it is seen whether there is any warrant available in the computer that is open 

and against which there is not any NRR issued already. Additional operations are entered into the 

labour warrant details table so that additional labour can be drawn against the warrant. 

Option: 

wr0562nrr 

Inquire on NRR 

NRR DETAILS 


Issue date : [ ] NRR date : [ ] 




Operation no Labour Authorised 

Labour Drawn 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

[ ] [ ] [ ] 

Action: 

Accepts Work Order Number, Warrant Number, anad EP Code as per standard Inquire 

procedure and displays the relevant data on the screen. 

Option: 

Raise Transfer Vouchers for EP 

wr500epxfr TRANSFER VOUCHER ( END PRODUCT ) 

Transfer voucher no. : [ ] Transfer Dt. : [ ] 

From wo no. : [ ] From wt. no. : [ ] 


Accepted qty. : [ ] [ ] 

Item Code : [ ] Item Desc : [ ] 

To wo no. : [ ] To wt. no. : [ ] 

Qty. to produce : [ ] From sec. no. : [ ] 

To sec. no. : [ ] 

I Note No : [ ] Remaining INote qty.: [ ] 

Transfer qty. : [ ] Value of Transfer : [ ] 

Input: Work Order No, Warrant No from which EP is to be transfered, Work Order No, Warrant No to 

which EP is to be transfered, From and to section codes, Quantity to be transferred. 

Action: 

After all the data is entered, the mentioned quantity of the EP is transferred from the source 

warrant to the destination warrant. 

Option: Raise Transfer Vouchers (For Material) 

wr505mtxfr TRANSFER VOUCHER ( MATERIAL ) 

Transfer voucher no.: [ ] Date of transfer : [ ] 

From wo no : [ ] From wt. no. : [ ] 

Code : [ ] Desc. : [ ] 

To wo no. : [ ] To wt. no. : [ ] 

Code : [ ] Desc. : [ ] 

From sec. code : [ ] To sec. code : [ ] 

Value of Xfer : [ ] 

---------------------------------------------------------------- 

Document Type [ ] Document No [ ] 

Itemcode [ ] [ ] 

Qty. to Transfer [ ] Qty. Drawn on [ ] 

From Wt. 

Qty. Drawable [ ] Value of Xfer [ ] 

For To Wt. 

----------------------------------------------------------------- 

Input: From Work Order Number, 

From Warrant Number, 

To Work Order Number, 

To Warrant Number, 

From Section Number, 

To Section Number 

Second Input: Document Number, 

Document Number, Quantity to transfer 

Action: 


With the above data material is transferred from one warrant to another. The receiving warrant 

is updated as if it has drawn that much material from stores. Its authority for drawal of material reduces. 

Option: Transfer voucher for labour 

wr507lbxfr TRANSFER VOUCHER ( LABOUR ) 

Transfer voucher no. : [ ] Transfer Dt. : [ ] 

From wo no. : [ ] From wt. no. : [ ] 

Warrant qty. : [ ] Qty. Acpted : [ ] 

Labour Value Drawn : [ ] Estd. Lab Val : [ ] 


Item Desc : [ ] 

To wo no. : [ ] To wt. no. : [ ] 

Warrant qty. : [ ] Qty. Acpted : [ ] 

Labour Value Drawn : [ ] Estd. Lab Val : [ ] 


Item Desc : [ ] 

From sec. no. : [ ] To sec. no. : [ ] 

Value of Transfer : [ ] 

Input: From work order number, 

From warrant number, 

To work order number, 

To warrant number, 

From Section number, 

To section number, 

Transfer date 

Action: 

When the above set of data is entered, the second window pops up and PWC no and value are 

accepted from that window. with these, the labour value is updated in the appropriate warrants. 

Option: Raise replacement warrants 


wr160rwtre 

REPLACEMENT WARRANT RELEASE 

Work Order No. : [ ] Main Warrant No. : [ ] 

Item Code : [ ] [ ] 

Extract No : [ ] Warrant Rqn. No : [ ] 

Section Code : [ ] Inspn. Type : [ ] 

Desc. : [ ] Desc. : [ ] 

Estimate No : [ ] Revision No : [ ] 

Max Replace qty. : [ ] Warrant Quantity : [ ] 

Warrant Issue Date : [ ] Warrant PDC : [ ] 

1. Est. Material Val : [ ] Est. Labour Val : [ ] 

2. Total Val : [ ] Repl. Warrant No: [ ] 

Input: 



Second input: Estimate number, 

Revision number, 

Warrant Quantity, 

Warrant issue date, 

Planned date of completion 

Action: 

This option is to be used when a warrant is short closed and for 

the remaining remaining quantity another warrant is to be released. 

After the first set of input, the user is shown the relevant details 

on the screen. He notices the remaining quantity yet to be 

manufactured. 

Then warrant can be released only upto the maximum of remaining 

quantity. 

Option: 

wr200wtclo 

Close / Short close a warrant 

WARRANT CLOSURE 


Warrant Status : [ ] Warrant Closure Dt: [ ] 

Warrant Type : [ ] 



Warrant Quantity : [ ] Qty. Produced : [ ] 

Qty. Accepted : [ ] 

Section Code : [ ] Inspn. Typ : [ ] 

Warrant Issue Date: [ ] Warrant PDC : [ ] 

Est. Material Val : [ ] Material Val Drawn: [ ] 

Est. Labour Val : [ ] Labour Val Drawn : [ ] 

Est. Total Val : [ ] 

Input: 


Warrant number, 

Warrant closure date, 

Action: 

Once this option is executed, No more material or labour can be 

drawn against this warrant. In case the warrant is closed after all 

the warranted quantity is produced and accepted against it then the 

warrant is normally closed. Otherwise this is short closed. 

After entering these details, the user is shown details of 

material or labour drawal anomaly and asked if the process is to be 

continued. After confirmation, the warrant is marked closed / Short 

closed so that no more labour or material can be drawn against this 

warrant. 


Option: Inquire on a warrant 

wr900iwt WARRANTS INQUIRY (HEADER) 1/1 WR020NIWTS 

WO No : [ ] Warrant No : [ ] 

EP Cd : [ ] Sec cd : [ ] 

Wt typ : [ ] Wt Qty : [ ] 

Est No : [ ] Rev No : [ ] 

Wt Iss dt : [ ] Wt PDC : [ ] 

Wt Insp typ : [ ] Qty Prod : [ ] 

Qty accepted: [ ] Qty Rej : [ ] 

Est Mtl Val : [ ] Est Lab val : [ ] 

Est Tot Val : [ ] Mtl Val drn : [ ] 

Lab val drn : [ ] Wt status : [ ] 

Wt ADC : [ ] Wt xfr cd : [ ] 

NR cd : [ ] Cum Iss : [ ] 

FOH amt : [ ] VOH amt : [ ] 

DA amt : [ ] Rej Val : [ ] 

XFR frm val : [ ] XFR to val : [ ] 

NRM dt : [ ] NRR dt : [ ] 

Action: 

The selection criteria is taken from the screen as per standard 

inquiry procedure and all the records matching the selection criteria 

is shown on the screen one at a time. 

Option: 

Warrant discrepancy 

wr210wthdr HEADER DETAILS OF WARRANT WR210WTHDR 


Warrant Status : [ ] Warrant Closure Dt: [ ] 


Warrant Quantity : [ ] Qty. Produced : [ ] 

Qty. Accepted : [ ] 

Warrant Type : [ ] 

Inspn. Type : [ ] esc. : [ ] 

Warrant Issue Date: [ ] Warrant PDC : [ ] 

Est. Material Val : [ ] Material Val Drawn: [ ] 

Est. Labour Val : [ ] Labour Val Drawn : [ ] 

Est. Total Val : [ ] 

Input: 

Work Order Number, 


Action: 

After the two input are given, it is calculated how much excess 


material or labour has been drawn in excess of the manufactured 

amount. The calculated amount is shown against the material codes and 

the operation numbers. 

Option: 

Print a warrant 

wr026prtwt 

WARRANTS PRINTING 

Work Order Number : [f000 ] Warrant Number : [f001 ] 

Warrant Issue Date : [g001 ] Warrant PDC : [g002 ] 


Warrant Number, 

Issue Date, 

Planned Date of Completion 

Action: 

After the work order and warrant numbers are given it is 

verified whether the warrant has been printed beforehand. Warrant 

issue date and Planned date of completion overwrites the two dates 

given earlier at the time of creating the warrant records. 



Details Operations Schedule 

1. FACTORY CALENDAR CREATION ds007tfacl.4ge) 

(ds007tfacl.4gl) 

Adds the number of full holidays in a month other than weekly 

holidays and the start time and end time in m_faccal. Also 

generates the dates of weekly holidays(full/half) in each month 

and records it in m_faccal. Also records the period for which a 

full day's work has not been done. 

Data expected 

year 

month 

day 

2. FACTORY CALENDAR MAINTENANCE (ds005nfacl.4ge) 

(ds005nfacl.4gl,ds005afacl.4gl,ds005mfacl,ds005dfacl) 

Add, Modify, Delete 

Adds the date of a holiday/half day and the type 

(full day/half day) in m_faccal. 

3. CAPABILITIES MAINTENANCE (ds002ncapb.4ge) 

(ds002ncapb.4gl,ds002acapb.4gl,ds002mcapb,ds002icapb,ds002dcapb) 

Add, Modify, Inquire, Delete 

Registers the capabilities of a machine for a particular 

operation in the production of an end product. 

Data expected 

machine no 

itm_cd 

operation no 

alternate machine no 

batch qty 

set up time 

process time 

available from 

available to 

4. CONSTRAINTS CREATION (ds008tcont.4ge) 

(ds008tcont.4gl) 

Registers the constraint period of a machine i.e. the period 

during which the machine is under some maintenance activity. If 

two maintenance activities fall on the same date then the 

greater period is considered(/updated). Record created in 

m_mccont. 


5. CONSTRAINTS MAINTENANCE (ds006ncont.4ge) 

(ds006acont.4gl,ds006mcont.4gl,ds006icont.4gl,ds006dcont.4gl) 


Data expected 

Machine Number 

Description 

Start date 

Start time 

End date 

End time 

PRIORITY MAINTENANCE 

(ds004nprio.4ge) 

(ds004nprio.4gl,ds004aprio.4gl,ds004mprio.4gl,ds004iprio.4gl, 

ds004dprio.4gl) 

Add,Modify,Inquire,Delete 

Accepts the priority status of the warrant depending on the 

number of jobs pending. Warrant status must be between red 

priority and green priority. A record is added in m_wtprio. 

Data expected 

work order number 

warrant number 

warrant priority status 

scheduled qty 

7. INITIAL LOAD MAINTENANCE (ds001ninit.4ge) 

(ds001dinit.4gl, ds001ainit.4gl, ds001iinit.4gl, 

ds001minit.4gl, ds001ninit.4gl) 

Record added in m_init. 

Data expected 

machine no 

work order no 

warrant no 

operation no 

qty pending 

8. OPERATION'S STOCK MAINTENANCE (ds012nostk.4ge) 

(ds012nostk.4gl,ds012aostk.4gl,ds012mostk.4gl,ds012iostk.4gl, 

ds012dostk.4gl) 


Registers dependant operation's stock quantity 

Record added in m_opnstk. 

Data expected 

work order no 

warrant no 

operation no 

quantity 

9. PENDING JOBS MAINTENANCE (ds003npend.4ge) 

(ds003npend.4gl,ds003apend.4gl,ds003mpend.4gl,ds003ipend.4gl, 

ds003dpend.4gl) 



Registers the pending job details for a warrant whose wip_ind = 

'3' into m_pndjob. Warrant status must be 1 or 2. 

Data expected 

work order number 

warrant number 

operation number 

inter stage stock 

10. OPERATIONS SCHEDULING (ds009tschd.4ge) 

(ds009fsstk.4gl,ds009fslot.4gl,ds009facnt.4gl,ds009faval.4gl, 

(ds009finit.4gl, ds009fprio.4gl, ds009fpred.4gl, ds009fpgrn.4gl. 

ds009fschd.4gl,ds009fdstk.4gl,ds009fdepn.4gl,ds009fconv.4gl, 

ds009tschd.4gl) 

Dummy schedule creation (ds009fsstk.4gl) 

Adds a record in m_schfle for each record in m_opnstk. 

Initially enters bal_qty in m_schfle as stock qty. 

The machine number is added as "DUMMY" and est_slot 

is -1 and eft_slot is -1. 

Time slot creation 

(ds009fslot.4gl) 

Creates time slots for each day of the scheduling period 

taking into consideration the slot size (fixed). The slots 

are alloted taking into consideration full holidays,half 

days, and break periods. The slots for each day are 

inserted into m_timslt. 

Additional constraints creation 

(ds009facnt.4gl) 

Generates additonal constraints(apart from constraints due 

to maintenance activity) by considering the availability 

time of the machine. 

Machine availibility creation (ds009faval.4gl). In this option 

machine availability slots are created taking into consideration 

the periods of nonavailability of the machine. Initially, for 

each machine a record is created in m_mcaval for all the slots 

available in m_timslt. Then, if a slot start time falls within 

the constraint period or vice- versa, then the record 

coressponding to that slot is deleted from w_mcaval. The slot 

numbers generated can then be checked up with m_timslt to obtain 

the start date and end date and start time and end time . 

Machine initial load processing (ds009finit.4gl) 

Allocates the quantity pending for each operation (wip_ind = 3) 

to slots available on the machine which is to be used for that 

operation. Mc_no,opn_no and qty pending are obtained from m_init 

and the slots required is calculated in the following way: 

if bch_or_pc = 'B' then 

no_of_batches = (_m_init.qty_pend / 

batch_qty) 

where _m_init.qty_pend is the qty pending and batch_qty is the 

quantity to be processed in one batch. The value is converted to 

next highest integer in case it is a fractional value. 


time_batch = set_tm + proc_tm 

where set_tm is the set up time and 

proc_tm is the time to process on batch. 

slot_reqd = (time_batch * no_of_batches) / 

slot_size 

if bch_or_pc = 'P' then 

time_for_qty = set_tm + ((proc_tm / batch_qty) 

* _m_init.qty_pend) 

slot_reqd = time_for_qty / slot_size 

While slots are available for the machine and qty still 

pending,successive slots are alloted until no successive slot is 

available or slots alloted equals the slots required. If slots 

alloted exceeds or equals the slots required then a record is 

inserted into m_schfle. Otherwise, the quantity to be allocated 

in these slots is calculated : 

if bch_or_pc = 'B' then 

ivalue = ((1 / time_batch) * (slot_size * 

no_of_slot)) 

qty = batch_qty * no_of_slot * slot_size 

slot_end = slot_start + ( no_of_slot - 1) 

if bch_or_pc = 'P' then 

time_avail = no_of_slot * slot_size 

qty = (time_avail - set_tm) * ( batch_qty / 

proc_tm) 

Thus a record is created in m_schfle for the number of slots 

alloted and the quantity allocated. If quantity is pending then 

the dependant operations of the current operation are selected. 

Of these dependant operations those which have wip_ind not equal 

to 3 are further processed to obtain their dependant operations 

which have wip_ind = 3. Then for each of the accumulated 

operations with wip_ind = 3 if there is a schedule in m_schfle, 

the minimum bal_qty is taken of all the dependant operations and 

subtracted from bal_qty of each record coressponding to the 

dependant operations. A record is inserted in either w_rpend or 

w_gpend depending on whether is red priority or green priority 

for the target of the initial operation. If qty pending = qty 

pending - min qty is less or equal to zero then the next record 

in m_init is processed. 

The slots alloted are deleted from w_mcaval. Generating 

interstage stock for first operations For each work order 

number, warrant number in m_wtprio, the first operations are 

selected 

(i.e.non target operations) from m_labwts whose wip_ind = 3 and 

a record is written in w_fstopn. 

Those operations, for the same work order and warrant, whose 

wip_ind is not 3 are further processed. The target operations 

for each of these operations is 

obtained where wip_ind is 3. 


If this target operation has no dependant operation with wip_ 

ind = 3 then that operation is recorded as first operation in 

w_fstopn. 

If there are dependant operations, then the dependant operation 

is processed in a similar way. This process is repeated until 

there are no more target operations 

and coressponding dependant operations. 

Then for all the first operations the interstage stock(scheduled 

qty in m_wtprio) is added in m_pndjob. Red Warrant priority 

processing. All work order and warrants in m_pndjob which have a 

red priority status are selected. Then for each of the work 

order and warrants of the same priority the number of jobs 

pending is obtained from m_pndjob. These operations are then 

scheduled on capable machines in the best possible way. The 

finishing slot is calculated as First Free Slot After EST + 

Number Of Slots Required. To Schedule the Full Qty On That 

Machine.If that machine is not available then its alternate is 

considered. If alternate is also not available then next machine 

is considered for scheduling. This process is repeated until 

entire qty is scheduled or no more machines are available. After 

that if there is still some balance qty not scheduled then it is 

written in m_unschd. The pending job is deleted from m_pndjob. 

Similarly, the w_rpend file is processed. Green Warrant 

priority processing. The processing of green priority warrants 

is exactly similar to red warrants. 

Deletion of dummy schedules:- 

All dummy schedules in m_schfle are deleted. 

OPERATIONS SCHEDULING REPORT 

(ds010rsprt.4gl) 

Data expected 

start date 

start time 

end date 

end time 

Generates the operation schedule details workorder,warrant, 

operation wise. The start date should be the same as or after 

first available schedule date and end date should be on or 

earlier than last available schedule date. 

12. MACHINE LOADING REPORT 

(ds011rmprt.4gl) 

Data expected 

start date 

start time 

end date 

end time 

Generates the operation schedule details machine number wise. 

The start date should be on or after the first available 

schedule date and end date should be on or earlier than last 

available schedule date.

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