To get started, make sure you have your username and password ready.
Once you log in, you will land on the welcome screen.
Note: This screen is designed to document, monitor and standardize processes to ensure consistent quality and compliance with standards.
1.1 SEARCH FOR CONTROL PLAN:
Step 1: ACCESS THE CONTROL PLAN SECTION:
1. Navigate to the main menu and click on "Production & Quality"
2. Go to "Masters" and select "Control Plan"
Step 2: UNDERSTANDING THE SEARCH FIELDS:
The Search Screen for the Control Plan is designed to filter and locate specific control plans based on a set of criteria.
Below is an explanation of the fields available on this screen:
Select Company: (Single select dropdown) to choose the company for which the control plan is being created or managed.
Origin Date: Date field to filter control plans based on their original creation date.
Control Plan Number: Unique identifier for each control plan. Allows users to search for a specific control plan directly by its number.
Revision No: Text field to filter control plans by their revision number. Helps in tracking the latest or specific versions of a control plan.
Revision Date: Date field to filter control plans based on the date of their latest revision. Useful for identifying recent updates to control plans.
Select Prepared By: (Single select dropdown) to filter control plans based on the person or team who prepared them.
Prepared Date: Date field to filter control plans by the date they were prepared.
Select Approved By: (Single select dropdown) to filter control plans by the approver's name.
Approved Date: Date field to filter control plans by their approval date.
Select Part: (Single select dropdown) to select specific parts associated with the control plan.
These fields will work as exact search that looks for results which exactly match what you type.
It’s different from "like search" which shows results that are similar or close to what you enter.
These fields collectively allow users to perform precise and efficient searches for control plans based on specific details such as company, dates and associated parts.
STEP 3: START SEARCHING:
Once all necessary inputs are provided, click on Search to generate the results table
Clicking on Search will fetch the control plan table based on the selected filters, enabling users to quickly narrow down data according to their needs.
Clear Functionality: Selecting Clear will reset all the applied filters to their default values, ensuring a clean slate for a new search.
By leveraging these features, users can effortlessly tailor the control plan to their specific needs, enhancing overall compatibility and usability
If you don't have a specific item name or category, just click "Search" to see all Item.
STEP 4: UNDERSTANDING SEARCH RESULTS TABLE:
S.No: Sequential number assigned to each row in the table, helping to quickly identify and reference individual records.
View/Edit: Provides a button to view or edit the selected control plan. Users can open the control plan details and make necessary modifications.
Generate CONTROL PLAN: Action button to generate or download the control plan as an Excel file containing five sheets:
Control Plan: The main plan details.
Control Item: Items requiring specific controls.
Control Processes: Detailed descriptions of processes involved.
Process Cycle Times: Data on time taken for each process cycle.
Sampling Plan: Information on the sampling strategy used.
Customer Name: Displays the name of the customer for whom the control plan is created, helping users identify control plans associated with specific clients.
Part Name: List the name of the part associated with the control plan, enabling filtering and organizing control plans based on the component or part.
Control Plan No: Shows the unique control plan number, useful for identifying and referencing control plans easily.
Date of Origin: Displays the date the control plan was originally created, helping in tracking the plan's lifecycle from its inception.
Plan Revision No: Indicates the current revision number of the control plan, useful for understanding the version history and ensuring the use of the latest revision.
Plan Revision Date: Shows the date when the control plan was last revised, providing insight into the most recent updates or changes made to the plan.
Export as Excel: Provides an option to export the entire table data into a single Excel sheet.
The exported file includes columns such as Customer Name, Part Name, Control Plan No, Date of Origin, Plan Revision No, and Plan Revision Date.
1.2 ADDING NEW CONTROL PLAN:
On the Control Plan Search page, there is an "Add Control Plan" button located on the top-right corner of the screen. Clicking on this button opens a new screen designed specifically for creating a new control plan.
Step 1: UNDERSTANDING THE FIELDS ON THE "CREATE CONTROL PLAN" SCREEN:
Customer: (Single select dropdown) to filter and select the customer from a list of available customers.
Control Plan Category: (Single select dropdown) to choose the category of the control plan. The available options are Prelaunch, Production and Prototype.
Control Plan Number: (Text field) to enter a unique number for the control plan.
Part: (Single select dropdown) to select the specific part related to the control plan.
Drawing No - Rev: This field is automatically populated based on the selected part once the user selects it.
Date of Origin: (Date field) to enter the original creation date of the control plan. It helps track when the plan was first created.
Revision No: (Text field) to enter the revision number of the control plan. This allows tracking different versions of the plan.
Revision Date: (Text field) to specify the date when the control plan was last revised. This helps in tracking updates and changes over time.
Prepared By: (Single select dropdown) to select the person or team responsible for preparing the control plan.
Prepared Date: (Date field) to enter the date when the control plan was prepared or created.
Approved By: (Single select dropdown) to select the person or team who approved the control plan.
Approved Date: A date field to enter the date when the control plan was approved.
Mandatory Fields: All the fields mentioned above are mandatory to ensure complete information is provided for creating the control plan.
Clear: The clear button clears all the fields, allowing the user to start fresh without any previously entered data.
Cancel: The cancel button redirects the user back to the search page, discarding any entered data without saving it.
Submit: Once all fields are filled, this button opens a new tab below the fields with 5 sub-tabs. Each sub-tab corresponds to a different section of the control plan.
Step 2: UNDERSTANDING THE SUB TABS OF CONTROL PLAN:
Control Plan Process: This subtab defines the overall process steps and workflows for the control plan. It typically includes details such as the process name, description, inputs, outputs, and associated risks to ensure a structured and comprehensive approach.
Control Plan Item: This section specifies the individual items or components that are part of the control plan. It includes details such as the item name or ID, specifications, and critical characteristics that are essential for maintaining quality.
Process Cycle Time: This subtab focuses on the timing and efficiency of the process and other key performance indicators to optimize productivity.
Sampling Plan: This section outlines the sampling frequency and criteria, ensuring that quality standards are met consistently. It defines how and when samples should be taken during the process.
This sampling plan will be used in both the Inward Inspection and Outsourcing screens to maintain consistent quality checks.
Operator Instructions: This subtab provides step-by-step guidelines or procedures for operators to follow. It ensures that all tasks are performed correctly and consistently, minimizing errors and improving overall efficiency.
CONTROL PLAN PROCESS:
Process Number: Text Field to enter the unique identifier for the process.
Process Name: Input box to provide the name or title of the process.
Process Type: Dropdown or selection field to specify the type of process (e.g., initial, machining, final, inward inspection) dropdown or selection field used to specify the type of process. Initial, Inward, Inward Inspection processes must be completed sequentially.
Only the Initial Process can be marked as the first process, with a Yes or No selection.
Process Order: Field to define the sequence or order of this process in the workflow. Initial, Inward, Inward inspection process will set values to 0 and 1 in default
If initial process is selected as the process type the process is populated as 1.
Is First Process (Y or N Only): Field to indicate if this process is the first in the workflow, allowing only "Y" or "N" inputs.
Machine Type: Dropdown or selection field to specify the type of machine used for this process ( eg., HMC, VMC, Assembly).
Reaction Plan: Field to define the actions to be taken if the process deviates from its expected outcome.
Over Ride Process: Field to specify any processes that may override the current process in exceptional cases.
Description: Field to provide additional details about the process.
Completion %: Field to specify the percentage of process completion as a measure of progress or compliance.
Auto Generate Serial No: This field is used to determine whether the serial number for the process should be automatically generated by the system.
All the fields except description are mandatory to ensure complete information is provided for adding the control plan process.
CONTROL PLAN ITEM:
Process: Dropdown field to select the relevant process associated with the control plan item.
Print Number: Field to input a unique print or reference number for the item (Balloon number)
Product Description: Input field for describing the product associated with this control plan item.
Item Order: Field to define the order or sequence of the item within the control plan.
Severity: Dropdown to select the severity type, indicating the criticality of the item in the process.
Spec Type: Dropdown to specify the type of specification (e.g., length, weight, volume, temparature).
Spec Value Type: Dropdown to define the type of value for the specification (e.g., number, angle, file, standard).
Number: Values for LSL, USL, LCL, and UCL must be in numerical format, with LCL ≤ LSL and UCL ≥ USL.
Angle: Values must represent angular measurements in degrees, with LCL ≤ LSL and UCL ≥ USL.
Standard/File: Values will be in text format for spec value.
Spec Value: Field to specify the exact value required for the specification.
Lower Spec Limit (LSL): Input field for the lower boundary or minimum acceptable value for the specification.
Upper Spec Limit (USL): Input field for the upper boundary or maximum acceptable value for the specification.
Lower Control Limit (LCL): Field to define the lower threshold for process control limits.
Upper Control Limit (UCL): Field to define the upper threshold for process control limits.
Sample Size: Input field to define the number of samples to inspect or test, based on the specific control plan's measurements and values.
Sample Frequency: This field is aligned with the specific control plan's measurements and values.
Measurement Method: Single select dropdown to define the method used for measuring the item or product specification (eg., vernier caliper, micrometer).
If user needs to add a new measurement method, it can be added to the codes table under (CP_CALIBRATION) category. Refer Master Category Documentation.
Control Method: Single select dropdown to define how the item or process will be controlled based on the specifications.
Response For Controls: Field to define the actions or responses required when control measures deviate from specifications (eg.,store keeper, operator)
Spec Value (Go / No Go): Single select dropdown to indicate whether the specification value is auto, manual, file based on testing
Auto: The control task screen's operator's status will be filled automatically.
Manual: Provides OK and Not OK buttons for the operator to select the status.
File: Displays an option to upload a file for the specification.
Outsourcing: Field to specify whether the item or process is outsourced ("Yes" entried control plan in Outsourcing screen, "No" entries only in Control Task screen).
All the fields except spec type, severity and outsourcing are mandatory to ensure complete information is provided for adding the control plan item.
PROCESS CYCLE TIME:
Process: Dropdown to choose the specific process associated with the cycle time configuration.
Machine: Multiselect dropdown to select the machine relevant to the process cycle time. If multiple machines are selected, process cycle time tabs will be displayed for each machine below.
Cycle Time Type: Dropdown to specify the type of cycle time (e.g., hours, minutes, seconds).
Cycle Time: Field to input the actual cycle time for the selected process and machine.
Handle Time: Input field to define the handling time required for the process.
Digital Entry Time Limit: Field to specify the time limit for digital entries (default is 0). This is used in Control Task for the system-generated idle time. For more reference, refer to the Control Task Documentation
Effective Date: Field to set the date from which the cycle time configuration becomes effective.
Expiry Date: Field to set the date until which the cycle time configuration remains valid.
All the fields except expiry date are mandatory to ensure complete information is provided for adding process cycle time.
SAMPLING PLAN:
Process: Dropdown to choose the specific process for which the sampling plan is being created.
Min Range: Input field to specify the minimum range of values applicable for the sampling plan.
Max Range: Input field to specify the maximum range of values applicable for the sampling plan.
Acceptance Qty: Field to input the quantity that is acceptable within the specified range.
Rejection Qty: Field to input the quantity that will be rejected if it falls outside the specified range.
Effective Date: Field to set the date when the sampling plan becomes effective (default will be current date).
Expiry Date: Field to set the date when the sampling plan expires or is no longer valid.
All the fields except expiry date and rejection qty are mandatory to ensure complete information is provided for adding sampling plan.
OPERATOR INSTRUCTIONS:
Process: Dropdown to choose the specific process for the operator instructions.
File type to Upload: Dropdown to select the type of file that needs to be uploaded.(eg., process flow chart, process layout)
Remarks: Field to enter any additional comments or notes related to the operator instructions.
Choose File: Button or input field to select and upload the required file.
After submission, the submitted file is displayed for Download, Edit, and View by clicking the file link on same screen.
All the fields except process are mandatory to ensure complete information is provided for adding operator instructions.
Every sub-tab has Submit and Cancel buttons.
After filling all the mandatory fields, an Edit Screen is displayed for all the sub-tabs.
Users can edit the details of any submitted tab through the Edit Screen.
In the Control Process, after completing the Initial Process, the Inward Process and other processes need to be filled sequentially.
Only the Initial Process can be marked as the first process, with a Yes or No selection.
1.3 EDIT CONTROL PLAN
Start searching control plan in search plan with search filters.
Click "View/Edit" next to that Customer Name to reach the Edit Control Plan page.
When you're ready, click "Submit" to save the updates.
There is an option called Clone located in the top right of the Edit and Add screen, where you can clone a created control plan, make minor changes to it, and submit it as a revised version of the original.
When you click "Clone", a confirmation box appears in the center of the screen with the message: "Are you sure? Would you like to clone the existing control plan?"
In the confirmation box, you will have the options to Proceed or Discard.
If you click Proceed, it will then show another box with the message: "Would you like to switch to the new cloned control plan?"
In this second box, you will have the options to either Switch to the new cloned control plan or Cancel the action.
After the control plan is cloned, in the Edit option after searching, the file will show an Activate button on top right to confirm the file.
The file will not be considered as main file until it is activated.
Until the file is activated, you can still delete control items and subtab entries.
That's It !! You’ve successfully learned how to Search, Add and Edit Control plans using the DMeX app
For further assistance, please contact the Support Team