Before You Begin

Note: This screen is designed to regulate and maintain the optimal functioning of a system or process by monitoring and making necessary adjustments.

Step 1: DAILY MAINTENANCE CHECK SHEET

Step 2: MACHINE AND PROCESS SETUP

This screen is exclusively designed for operator access, allowing the user to select and input necessary details to retrieve relevant tasks based on the given selections.

Fields Available:

• Machine: The specific machine being used for the task.
• Part Name - Control Plan: The name of the part along with its associated control plan.
• Machining Process: The specific process or operation performed on the machine.

When the shift is closed, the idle time is recorded for the selected machine. The shift start and close times can be viewed in the operator shift log.

When the shift closes, apart from production time, the remaining idle time will be prompted on the screen for entry. If this is skipped, it will proceed to the "Skip Idle Time" screen.

Step 3: CONTROL TASK SCREEN SUBTABS

• Part Validation: Ensures that the parts meet the required quality and specifications.
• Tool Change: Records and tracks any changes made to the tools during the process.
• Pending Validation: Lists items that are awaiting validation before proceeding.
• Rework: Tracks parts that need reprocessing due to defects or errors.
• Operator Instructions: Provides specific guidelines or steps for the operator to follow during the task.

Each subtab will have its unique color-coded validations.

Step 4: UNDERSTANDING PART VALIDATION TAB

The Part Validation screen includes the following fields:

1. Batch No: (Mandatory) An identifier for the batch being processed.
   • If available, select the batch number and proceed.
   • If the previous batch quantity is not completed, further actions will not be allowed.
   • Scenario 1: If the batch number is unavailable, inform your QC team.
   • Scenario 2: Navigate to Production Quality → Operations → Add Inward. Then, go to Production Quality → Operations → Add Inward Inspection.

   Note: If a batch is approved, the remaining quantity will be reduced based on the approval.

   The Child Part concept allows you to handle situations where a larger batch of parts (e.g., 1000) is divided into smaller sub-batches. If these sub-batches (child parts) are made from the same raw material, you can add them in this section.

2. Heat/Month Code: (Mandatory) This is the batch code or serial numbers.
   • Select the Heat/Month Code from the dropdown (e.g., AA).
   • If unavailable, enter the Heat/Month Code as a reference.
3. Serial Number: (Mandatory) This will be generated against the Heat/Month Code for the selected control plan process.
   • This will generate a serial number (e.g., AA-1, AA-2, AA-3).

   Note: In the control plan, if "Autogenerate Serial Number" is set to "Yes," the serial number will be read-only and automatically generated here. If it is set to "No," the serial number will be editable.

4. Reference Number: (Optional) A number used for tracking or referencing the part.
   • Enter the Reference Number if available; otherwise, you can skip this optional field.
   • Click the Submit button.
5. Other Frequency: (Mandatory) Specifies the inspection or maintenance frequency.
   • Select the frequency.
   • The first component will default to "Setting." Once approved, it will change to "Regular."
   • Scenario 1: If the first component is not approved, it will remain as "Setting."
   • You can choose from Regular, Lot, Shift, or Setting as needed.
6. Heat No: (Mandatory) Identifies the specific heat treatment batch of the material.
   • Select the Heat Code from the dropdown (e.g., AA).
   • If unavailable, enter the Heat/Month Code as a reference.
7. Task Serial No: (Mandatory) A unique number assigned to the task for tracking purposes.
   • Click on Task Serial No; the generated serial numbers will show in the dropdown (e.g., AA-1, AA-2, AA-3).
   • Select the appropriate serial number to view Task Validation Results.
   • Validate (Fill) the results as per actual values.
   • After filling in the actual values, scroll down to see the Status field.
8. Status: (Mandatory) Indicates the current status of the part or task.
   • If you click, you will see the following fields:
   • Approved: If all items are approved and marked as green. If any rejection is marked, approval is not possible.
   • If all validations are correct, select the Approved option.
   • Click the "Submit Tasks" button to mark the component as approved and proceed to the next operation.
   • Hold for Inspection: Indicates that the part is being held for further inspection before proceeding.
   • Hold for Research: Indicates that the part is being held for further research or analysis before proceeding.
   • Rework: If the part needs rework.
   • If the selected serial number has a rework issue, click the Status button and select Rework.
   • A dropdown menu will appear to choose the specific rejection cause in a single word.
   • If applicable, provide additional reasons for the rework.
   • The Submit button (in green) will be enabled. Click it to mark the serial number as Rework.
   • If applicable, provide additional reasons for the defect. If needed, add it to the master category (REJECTION_SINGLE_WORD).
   • Casting Rejection: If there is a defect in the casting and rejection is confirmed, mark this.
   • If the selected serial number has a casting issue, click the Status button and select Casting Rejection.
   • A dropdown menu will appear to choose the specific casting defect.
   • If applicable, provide additional reasons for the defect.
   • The Submit button (in green) will be enabled. Click it to mark the serial number as Casting Rejection.
   • If applicable, provide additional reasons for the defect. If needed, add it to the master category (CASTING_REJECTION).
   • Machining Defect: If there is a defect in machining and rejection is confirmed, mark this.
   • If the selected serial number has a machining issue, click the Status button and select Machining Defect.
   • A dropdown menu will appear to choose the specific machining defect.
   • If applicable, provide additional reasons for the defect.
   • The Submit button (in green) will be enabled. Click it to mark the serial number as Machining Defect.
   • If applicable, provide additional reasons for the defect. If needed, add it to the master category (REJECTION_SINGLE_WORD).
9. Reason: (Optional) Explains the cause or justification for a specific action or status.
   • If applicable, provide additional reasons for the defect.
   • Select the required fields and click "Submit Task." If you click Submit in this tab, an Idle Time Add tab will open on the same screen to add idle time.

   You can add multiple rows with specific times and reasons for the idle time being recorded. Ensure that Idle Total Time matches the calculated difference across the added rows. Once all entries are completed, you can click "Add Idle Time Reason" to update the idle time.

   Note: If any serial numbers are rejected, they will be reflected in the NCR.

Step 5: UNDERSTANDING TOOL CHANGE TAB

This screen is designed to document and track tool changes, including selecting the tool, recording the task serial number, and providing any relevant reasons for the change.

Fields to Fill:

• Tools: (Mandatory)
  • In this tool field, we have added the Tool Layout for this process; it will appear in the tool field.
  • A list of tools will be displayed. Click the required tool from the dropdown.
• Task Serial No: (Mandatory) The Task Serial No from the Part Validation will be shown in the dropdown. Select the required option.
• Tool Change At: (Mandatory)
  • If the tool change occurs at the beginning, select "Beginning of Process."
  • If the tool change occurs in the middle, select "During the Process."
• Remarks: (Mandatory)
  • Fill in the Remarks field. This field is mandatory, while the Reason field is optional.
  • Click "Change Tool" to submit the details.

Important Notes: The serial number associated with the tool layout's print number is added to this control item for revalidation purposes.

Step 6: UNDERSTANDING PENDING VALIDATION TAB

Heat No: (Mandatory)

• The Heat numbers added in the Part Validation field will be displayed in the Heat No field.
• Select the required Heat No from the dropdown.

Task Serial No: (Mandatory)

• Select the Task Serial No corresponding to the selected Heat No.
• A Task Validation Sheet will appear; fill in the actual values.

CMM Entry: (Optional)

• Check the box for CMM Entry.
• If you have a CMM Entry Excel Sheet, add it by clicking the "CMM Excel Import" button.
• A separate tab will appear within the screen to choose and upload the CMM Excel file.
• It includes columns such as Print Number, Actual Value, and Geometry Value. Except for the Geometry Value column, other fields are mandatory to validate the file.
• Once the file is validated, the CMM values will be populated below. You can then manually validate the values, confirm all, and submit them.
• Additionally, there are options to reset or remove values if needed.

Status: (Mandatory)

• Select the actual status from the options listed in the Status field.
• Fill in the reason if needed.
• Click "Submit Task" to finalize.

Note: If the part status is "Hold for Inspection" or "Hold for Research," all details must be filled in before proceeding.

Step 7: UNDERSTANDING REWORK TAB

Step 8: UNDERSTANDING OPERATOR INSTRUCTIONS TAB

That's It! You’ve successfully learned how to search and edit control tasks using the DMeX app.

For further assistance, please contact the Support Team.