PPC Package

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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 <strong>PPC</strong> 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 Ordnance Factories Institute of Learning, Dehradun 15
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 Ordnance Factories Institute of Learning, Dehradun 16
Page 1 and 2: INDEX Chapter Topic Page No. 01. Op
Page 3 and 4: the dedicated keys. b) Depending on
Page 5 and 6: Module names and their respective d
Page 7 and 8: specification of the material more
Page 9 and 10: CONTENTS main - im000menus 1. RR/LW
Page 11 and 12: 21. Loss statement for every DD vou
Page 13 and 14: CONTENTS main - po000menu 1. Purcha
Page 15: 11. Vendor Item Add - po132vitm Mod
Page 19 and 20: 3. Net requirement calculations (mp
Page 21 and 22: Chapter - 4 Vendor Analysis The pri
Page 23 and 24: the payment is to be a part (provis
Page 25 and 26: 6. Statement of payment - pa105r007
Page 27 and 28: 3. Warrant WIP Calculation (ct003nw
Page 29 and 30: 5. Trransfer voucher abstract (ct00
Page 31 and 32: Chapter - 6 User Manual on Database
Page 33 and 34: 11. Manufactured item master Add -
Page 35 and 36: Option: Modify a party record in pa
Page 37 and 38: Option: Suspend a party db010party
Page 39 and 40: Input: Machine number Second input:
Page 41 and 42: db022machn MACHINE MAINTENANCE RECO
Page 43 and 44: db030mcspr MACHINE SPARES MASTER DB
Page 45 and 46: db040tools TOOLS MASTER DB004TOOLS
Page 47 and 48: EP code :[ ] Drawing number :[ ] Es
Page 49 and 50: Option: Query on standard man hour
Page 51 and 52: db060estmt MATERIAL ESTIMATE MAINTE
Page 53 and 54: [f002 ][a ] [b ] [f004 ] [f005 ][f0
Page 55 and 56: Sl. Order No [ ] Order Type [ ] ORD
Page 57 and 58: db091order ORDERS MASTER DB009ORDER
Page 59 and 60: Option: Print a list giving the req
Page 61 and 62: db111stitm STOCK ITEM MASTER Screen
Page 63 and 64: the computer. If the specifications
Page 65 and 66: Inspection responsibility [ ] Packi
Page 67 and 68:
db121mfitm MANUFACTURING ITEM MASTE
Page 69 and 70:
Description :[ ] Godown keeper: [ ]
Page 71 and 72:
description Action: The set of valu
Page 73 and 74:
___________________________________
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itm_cd char(10) Item code est_sl sm
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ev_no smallint rat_fm_no char(10) R
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Machine utilisation is to be record
Page 81 and 82:
Option: Machine breakdown mm100ahdo
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Option: Preventive Maintenance mm20
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mm300nmenu MM300NMENU SPARES MANAGE
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Option: Machine utilisation and dep
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utilisation has been added and whic
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Chapter - 9 Tools Control Activity
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A) Tool transfer This option record
Page 95 and 96:
Chapter - 10 Work in Progress MAIN:
Page 97 and 98:
(wi100r010.4gl, wi100rmen.4gl) 1. D
Page 99 and 100:
d. Warrant issue date e. Planned da
Page 101 and 102:
Data expected: a. Work order number
Page 103 and 104:
Action: Input: Extract Number, Work
Page 105 and 106:
Action: Operation Code, Authorized
Page 107 and 108:
[ ] [ ] [ ] [ ] [ ] [ ] Input: Work
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With the above data material is tra
Page 111 and 112:
Item Code : [ ] [ ] Warrant Quantit
Page 113 and 114:
material or labour has been drawn i
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5. CONSTRAINTS MAINTENANCE (ds006nc
Page 117 and 118:
time_batch = set_tm + proc_tm where
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