Sales Forecast depend upon sales demand

Sales Operation Planning

Material Requirement Planning(MRP)

Monthly Process Order

BOM

Resource

Receipe

Materials to Be used to produceFG(Finish goods) or SFG (Semi finish goods)

Various Activities and Cost center

Process formation andIndividual rates of

activities

Purchase Requisition(PR)

Purchase Order(PO)

Goods Receipt(GR)

Quality Recording

Unrestricted Stock

updation

Quality configured

Quality StockUpdated

Yes

No

Release of Process Order

Updation of Costing sheet forPlanned activity

and Material Reservation

Will Generate accordingTo Order

Daily Confirmation ofProcess Order

Updation of Costing sheet

for Actual activity and

Material Consumption Will book as

per confirmation

Finish Goods/Semi finish Goods

Unrestricted Stock updation

Quality Recording

Quality configured

Quality StockUpdated Yes

No

Finish goods is madeAvailable for

Despatch And SFG isAvailable for next process

Process of PP/QM module

JK LAKSHMI DURG RESOURCES

Sl No Resource Total No Capacity Unit Full Unit

1 Crusher 1 850 TPH Ton per hour

2 Coal Mill 1 50 TPH Ton per hour

3 Raw Mill 1 400 TPH Ton per hour

4 Kiln 1 4500 TPD Ton per Day

5 Slag Mill 1 100 TPH Ton per hour

6 Paddel Mixture 1 225 TPH Ton per hour

7 Cement Mill 2 80 TPH (Each) Ton per hour

BOM Has Created for Following Materials in Quality Server

SL No Description Code Material Type

1 Crusher Feed A1301010006 Crusher Feed

2 Crushed Lime Stone A1301010002 Raw Material

3 Raw Meal A1301010003 Semi Finish Goods

4 Clinker A1301010001 Semi Finish Goods

5 Fine Coal A1301010004 Fuel

6 Grounded Slag A1000050014 Raw Material

7 Loose Cement OPC-53 Grade A1401010003 FG

8 Loose Cement OPC-43 Grade A1401010002 FG

9 Loose Cement PPC A1401010004 FG

10 Loose Cement PSC A1401010024 FG

SLNO

RESOURCE NAME COST CENTER

NAME ACTIVITIES

1 DUMC01 CEMENT MILL -1 DURG

1120020602 CEMENT MILL NO1 DURG

MACHINE,LABOR,POWER

2 DUMC02 CEMENT MILL -2 DURG

1120020603 CEMENT MILL NO2 DURG

MACHINE,LABOR,POWER

3 DUCOLMIL COAL MILL 1120020401 COAL MILL DURG

MACHINE,LABOR,POWER

4 DUCRUSH1 CRUSHER DURG 1

1120020201 CRUSHER DURG MACHINE,LABOR,POWER

5 DUKILN1 KILN DURG 1120020501 KILN DURG MACHINE,LABOR,POWER

6 DUMINES LAKSHMI CEMENT LS

MINES

1120020107 MINES PRODUCTION

OIL&LUB,LABOR,POWER,EXPLOSIVE,ROYALTY&HEALTH CESS,HANDLING COST

7 DURM01 RAW MILL 1120030101 RAW MILL NO. 1 -DURG

MACHINE,LABOR,POWER

8 DUPKU01 PACKING PLANT UNIT 1

1120020702 PKG PLANT UNIT1-DURG

MACHINE,LABOR,POWER

9 DUSLG SLAG-DURG 1120020901 SLAG GRINDING MACHINE,LABOR,POWER

Resources Has Created for Following in Quality Server

Recipe Has Created for Following in Quality Server

SLNO RECIPE NO NAME

1 50000485 LOOSE CEMENT OPC-53 GRADE

2 50000486 CLINKER

3 50000487 RAW MEAL

4 50000488 FINE COAL

5 50000489 CRUSHER FEED

6 50000490 CRUSHED LIME STONE

7 50000491 GROUNDED SLAG

8 50000492 LOOSE CEMENT PSC (SLAG MILL)

9 50000493 LOOSE CEMENT PSC (PADDEL MIXTURE)

10 50000494 GROUNDED SLAG (SEMIFINSH)

11 50000495 LOOSE CEMENT OPC-43 GRADE

12 50000496 LOOSE CEMENT PPC GRADE

Storage Locations for material storage Has Created for Following in Quality Server

SLNO STORAGE LOCATION NAME

1 5015 CLINKER SILO

2 5016 OPC43 CEMENT SIL

3 5017 OPC53 CEMENT SIL

4 5018 PPC CEMENT SILO

5 5019 PSC CEMENT SILO

6 5021 SLAG SILO

7 5031 LIME STONE YARD

8 5032 SLAG YARD

9 5049 CRUSHER FEED YAR

10 5050 FACE REJECT

11 5051 SCREEN REJECT

12 5052 C F SILO

13 5053 IRON ORE YARD

SLNO STORAGE LOCATION NAME

14 5054 BAUXITE ORE YARD

15 5055 SAND STORAGE YARD

16 5060 ALTERNATIVE FUEL

17 5061 COAL YARD IND

18 5062 COAL YARD IMP

19 5063 PET COKE YARD

20 5064 HIGH ASH COAL

21 5065 GYPSUM YARD

22 5066 FLY ASH BUNKER

23 5067 FLY ASH YARD

24 UNT1 PACKED CEMENT

Some key practices followed by JKPURAM Plant

1. Process order created monthly at each production stage for all SFG and FG.

2. Seperate process order has to created for each SFG/FG combination of Line/Resource Used For Example : We have two no of cement mills and our FG are 3 than we have To create 3X2=6 process orders for month.

3. During process order creation, masters like Recipe, BOM etc. are copied automatically to the order as per selection of master recipe and production version provided they are maintained for that SFG/FG correctly before creation of the Process order.

4. Process order to be released when the production as to be executed.

5. On order confirmation BOM components will reserved automatically against The process order.

6. After all transaction are complete the order will be closed at end of month and Above cycle will start for new month/plan

Sl No Resource Total No No of Process Orders for month

1 Crusher Feed 1 1

2 Crusher 1 1

3 Coal Mill 1 1

4 Raw Mill 1 1

5 Kiln 1 1

6 Slag Mill 1 1

7 Paddel Mixture 1 1

8 Cement Mill 2 * 2X3=6

Monthly process order will created as resources are

* Assuming 3 nos of Finish Goods