XXX INDIA PRIVATE LIMITED Page : 1 of 9

Quality Procedure Manual Issue : 1

DM/2/FDY/P11 Date : May’17
Production Scheduling & Planning Process
1.0 Objective:
To ensure supply of castings as per customer demand.
2.0 Input
Customer purchase order, Customer delivery schedule, and Preventive Maintenance
schedule, Inventory details.
3.0 Output
Dispatch schedule / Production Planning / delivery performance
4.0 Scope:
This procedure is applicable to all production scheduling and Production Planning process
in FIPL.
5.0 Process Owner(s):
PPC / Marketing In charge
6.0 Work Instruction / Shop operation procedure reference:
Customer specific requirements manual DM/3/CSR
Production Planning and Control Procedure DM/3/PPC
7.0 Documents generated:

Document Name Responsible for release

Dispatch schedule Marketing
Production schedule Production, Planning & Control
Work in progress (WIP) Finishing
Contract review Marketing
8.0 Records:
Storage / Indexing /
Retention Disposition Disposition
Record Name Preservation Retrieval
Time Method Responsibility
Method Method
Customer Marketing in-
Warehouse stock File 6 months Tearing off
wise charge
Customer Marketing in-
Customer schedule File 2 years Tearing off
wise charge
Customer As per Marketing in-
Customer purchase order File Tearing off
wise DM/3/CSR charge
Marketing in-
Dispatch schedule File Month wise 2 years Tearing off
charge
Capacity Verification
File Month wise 1 Year Tearing off PPC In Charge
Report
Monthly Dispatch
File Monthly 3 years Tearing off Marketing
Statement

Weekly Production Plan File Weekly 3 years Tearing off PPC

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 2 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17

Daily Works Management File Daily 3 years Tearing off PPC

Weekly Review File Weekly 3 years Tearing off PPC

Monthly Review File Monthly 3 years Tearing off PPC

Customer Marketing in-

ASN File 1 month Tearing off
wise charge
Delivery Customer Marketing in-
File 2 years Tearing off
Performance wise charge
9.0 Linkage with other business process:
a. Control of documented information DM/2/FDY/P02
b. SF manufacturing process DM/2/FDY/P12
c. Tooling Management DM/2/FDY/P14
10.0 Business Management system control plan:

Control Method Review / Analyze / Evaluation

Sl. Data group /
Measurable Graph Plotting
No. Responsibilit Type Frequency Responsibility
parameters Frequency
y

Effectiveness
Adherence to X Axis -
schedule Product wise / Month Marketing In-
1 Monthly Chart Monthly
(Delivery Marketing Y Axis – DSA Charge
performance) %
X Axis -
Adherence to Product wise /
Month
2 Production PPC In Monthly Chart Monthly PPC In charge
Y Axis – PSA
schedule Charge
%
Efficiency
X Axis -
Foundry
Finished goods Month Marketing In-
1 wise / Monthly Chart Quarterly
inventory Y Axis - No of Charge
Marketing
tons
Customer line Overall / X Axis - Marketing In-
2 Monthly Chart Quarterly
stoppages marketing Month Charge

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 3 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
Y Axis - No of
occurrences
X Axis -
Every Chart PPC / Fettling In
3 WIP inventory Overall / PPC Month Monthly
Month charge
Y Axis - Tons

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 4 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
11.0 Turtle diagram:
Turtle Diagram - Scheduling & Planning process

With what? With Who?

Ramco ERP system, DWM board, PC Printer.E-Mail Marketing in charge / PPC In charge /
Manufacturing head

Input Output

Customer purchase order,

Customer schedule, Marketing Scheduling Despatch schedule / Production
Schedule, Preventive process Planning / delivery performance
Maintenance Schedule,
Inventory, Risk Analysis Result

Adherence to schedule (delivery performance), FG

DM/2/FDY/ P03, P11 , P 12 , P15 and DM/3/CSR
inventory, Line stoppages, WIP Inventory

How Many? How?

Control of Sand Foundry Tooling

Process of Utilities
documented Manufacturing management
and Maintenance
Information Process Process

Support Processes

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 5 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
12.0Process Flow Diagram:

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 6 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
Scheduling & Pla nning process
Reference
Documents /
document /
Input Job Position Activity Records
Details of
generated
activity

Customer Receive / review schedule with Schedule

RL Marketing
schedule / order previous schedule/norms norms

Confirm acceptance and advise Email / Letter,

RL Marketing
on revised commitment Verbal

Customer
RL Marketing Review of schedules
schedule / order

Customer
schedule,
Previous Convert customer schedule into Despatch
RL Marketing consolidated despatch schedule COD
schedules and schedule
and release schedule to planning
Despatch
statement
Despatch
Che ck for Yes Lead time f or
schedules, Capacity
PPC In charge capacity manuf acture,
Preventive availability transportation verification report
Maintenance
Capacity
E-Mail / Internal
verification PPC In charge No
Inform m arketing on
modifications required (If Any) Communication
report
Relevant
Delivery Monthly
Process Production Planning DM/3/PPC
Schedule Production Plan
Owner

Monthly Weekly
PPC In charge Weekly Production plan DM/3/PPC
Production Plan production plan

Monthly
Core Production
Production Plan Core shop In Core Production
Plan
/ Weekly Charge plan
production plan

Customer
Urgent
Communication Updated Weekly
Marketing Customer
for Urgent requirement Production Plan
Requirement

Disa loading
Weekly Disa
PPC In charge Daily Plan DWM Report sheet
loading sheet
FIPL/PPC/01
Disa loading Manufacturing Relevant
sheet supervisors / production as per plan Procedures / Production log
FIPL/PPC/01 operators WI's
Production
Daily works management Board / DWM
Plan, Previous meeting
PPC In charge DM/3/PPC report -
day
FIPL/PPC/02
performance

Board / DW M Board / DWM

report - PPC In charge No Gap Compare DM/3/PPC report -
Daily plan Vs
FIPL/PPC/02 Actual FIPL/PPC/02

Gap
Board / DW M Manufacturing Board / DWM
report - supervisors / Gap Analysis And report -
Implementation of the
FIPL/PPC/02 operators FIPL/PPC/02
corrective Action

PPC &
Weekly Weekly Review
Marketing In W eekly Review DM/3/PPC
schedule Minutes
charge

Finishing In
Daily warehouse
charge/marketi Movement to warehouse
stock statement
ng
Customer Advance
Despatch to customer and DM/3/CSR /
schedule/ Marketing inform them if required shipment
precontract
Warehouse Rep. notification /
review
statement inspection reports

No Review plan vs Delivery

Dispatch Marketing actuals f or Performance
Schedule Rep. failures
report
Yes f ailures
Delivery
Marketing
Performance Intimation to customer if Email
Rep.
report required

Delivery
Marketing Update weekly despatch
performance Weekly Schedule
Rep. schedules and adjust the
report arrears in the next week

Delivery Delivery
Marketing
performance Prepare delivery Performance
Rep.
report performance report report

13.0 Process Flow Chart – DWM

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 7 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
DAILY WORK MANAGEMENT
Reference
Documents /
document /
Input Job Position Activity Records
Details of
generated
activity
Monthly
Daily plan Previous day
Production PPC In charge Production Plan
performance
Schedule

Manufacturing Relevant Records as per

Production Plan supervisors / Plan implementation Procedures / Manufacturing
operators SOP's Process
Production Plan, Board / DWM
Daily work management
Previous day PPC In charge meeting DM/3/PPC report -
performance FIPL/PPC/02
Board / DWM Board / DWM
Review of plan Vs actual &
report - PPC In charge previous action DM/3/PPC report -
FIPL/PPC/02 FIPL/PPC/02

Production Plan, Yes Board / DWM

Is plan
Previous day PPC In charge achieved DM/3/PPC report -
performance FIPL/PPC/02

No
Board / DWM Manufacturing Board / DWM
report - supervisors / Identify the gap and analyse DM/3/PPC report -
FIPL/PPC/02 operators FIPL/PPC/02
Board / DWM Manufacturing Board / DWM
report - supervisors / Identify the corrective action DM/3/PPC report -
FIPL/PPC/02 operators FIPL/PPC/02
Board / DWM Manufacturing
report - supervisors / Implement the corrective action DM/3/PPC
FIPL/PPC/02 operators
* DWM is only followed at manufacturing functions

Notes:

 Every Purchase Order / amendment received from customer, after the development
of castings is to be reviewed by Marketing Department, for the requirements against the
agreed customer requirements as documented in COD. If there are any differences,
marketing is to resolve the same with the customer and after resolving / ascertaining
that internal capability exists to meet the differences. COD to be amended if required.

 Similarly for regular schedules received from customers, Marketing is to review the
schedule for internal capability to meet the requirements and against the current COD
and if acceptable, the same is to be incorporated in the dispatch schedule as required
by reviewing authority in marketing. COD to be amended if required. If discrepancy is
noticed, the same is to be informed to customer suitably and agreed upon.

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 8 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
 Monthly dispatch schedule is to have foundry code issue no. Reference for each
foundry code.

 The number of shots made in each pattern plate is to be monitored through history
card and recorded in the number of shots monitoring register on a monthly basis.

 Whenever the number of shots reaches the number of shots specified, inspection is to
be intimated for carrying out layout inspection.

 A copy of the Preventive Maintenance schedule is handed over to PPC in charge by

concern department, PPC in charge has to consider Preventive maintenance schedule
before Production Planning.

 When the deviation of actual from the plan is within + 5% / - 10% the deviation is
accepted. No actions will be initiated generally. If it exceeds this norm the corrective
actions are initiated. Wherever required actions and follow up will be carried out by the
Department heads.

 Castings are to be dispatched as per the current COD till the validity, as mentioned in
the COD to be amended if required

 Marketing is to prepare and forward dispatch schedules to foundry.

 Dispatch statement is to be prepared on a monthly basis furnishing scheduled quantity;

dispatched quantity and copies of it are to be sent to Vice President – Marketing - RL

 Marketing department is to inform the customers about the changes from the
scheduled quantity and is to take care of the previous month's changes in the
subsequent month's dispatch schedules.

 Customer purchase order & amendments are to be acknowledged to customer if

specified by them.

LOGISTICS PROCESS:

 Container is to be booked from approved shipping lines once sufficient stock available
in warehouse. This is ensured with the information from warehouse & finishing.

 Monthly approval for shipping liner is to be done by marketing

 Container capacity, packing list will be ensured for its statutory requirements by
marketing.

Authorized By:

Mr. S. Chandramouli
 XXX INDIA PRIVATE LIMITED Page : 9 of 9
Quality Procedure Manual Issue : 1
DM/2/FDY/P11 Date : May’17
 Packing method, packaging control will be carried out by warehouse as per DM/3/WHP

 Shipping liner will be tracked by their reports.

Authorized By:

Mr. S. Chandramouli