Visual EstiTrack - Chapter 9 9 QUALITY CHAPTER

Transcription

1 CHAPTER 9 QUALITY Chapter 9 QUALITY Engineering Change Order Maintenance...4 Action Request (NONCONFORMANCE CONCERN IMPROVEMENT)...10 Action Request Tab...12 Related Corrective Action...20 Corrective Action Maintenance...27 Preventative Action Maintenance...35 Tabulation 1 Initiating Circumstance Tab...37 Tabulations 2 through 4 (Preventative Action, Implementation, Effect Analysis, Common/Similar Opportunities)...40 Deviation Maintenance...41 Deviation Requested Tab...43 Reason for Deviation Tab...46 Approval/Comments Tab...47 Containment Management...49 Placing an Item into Containment...50 Releasing Containment...51 Task Manager...52 Preventative Maintenance...58 Editing Preventative Maintenance Groups...63 Assigning a Preventative Maintenance Task...64 Gage Maintenance...68 Assign Gage Calibration Task...73 Internal Audit Maintenance...76 Audit Definition...78 Audit Questionnaire...81 Audit Results...82 Document Control Manager...85 Assigning an External Document to a Document Number...89 Customer Efficiency Reports...94 Vendor Efficiency Reports...99 Inspection Maintenance Inspection Maintenance Inspection Information Overview Inspection Maintenance Inspection Information Details Inspection Tables Inventory Inspection Maintenance Adding an Inspection Dimension Inspection Method Maintenance AQL Level Maintenance Certification of Compliance Note Inspection Setup Numbers Certification of Compliance

2 Certification of Compliance Details Tab Certification of Compliance Ship Details Tab Certification of Compliance Lot Details Tab General Employee Training Employee Operational Training Adding a New Inspection and Procedure Verification Dock Audit Defining an Audit Interval Monitoring the Dock Audit History

3 Chapter 9 QUALITY Visual EstiTrack s fully integrated quality program ensures reliability and accountability throughout. Figure 9.1 Visual EstiTrack s System 9-3

4 ENGINEERING CHANGE ORDER MAINTENANCE Visual EstiTrack TM provides the capability to capture and track Engineering Change Orders. The Engineering Change Order Maintenance form can be used to evaluate proposed changes, capture the reason for change and manage all revision details for a given item and action type. The form below is split into three distinct sections. Section 1 is used to capture all the key information regarding the source, risk and type of Engineering Change Order. Section 2 is used to capture the actual item and its associated details relating to the Change Order. Section 3 provides three tabulations used to capture the proposed change, the reason for change and the details of the revision. Sect. 1 Sect. 3 Sect. 3 Figure 9.2 Engineering Change Order Maintenance 9-4

5 Menu Selection Left click on the menu heading labeled Select Engineering Change Order Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-5

6 Engineering Change Order Maintenance Field Req. Field Type Description ECO Number YES NUMBER The Engineering Change Order number is automatically assigned for every new added change order. All change orders are tracked by this number. Action Type Box YES RADIO BUTTON Identify the Action Type of Engineering Change Order. The following options are available: - Engineering Change - Concern - Improvement - Nonconformance - New Part Date Defined YES DATE Enter in the Engineering Change Order capture date or select the date from the Visual EstiTrack interactive calendar. The system will default to the current date if left blank. Due Date NO DATE Enter in the date the Engineering Change Order is due for completion. Status YES DROPDOWN Select the status of the Engineering Change Order from the dropdown menu. The system automatically defaults to an Open status if left blank. Status Date YES DATE The date is automatically updated to the current date when a change in status is made. The date may be over-ridden when required. Defined by NO DROPDOWN Select the user defining ECO from the dropdown list. Assigned to NO DROPDOWN Select the employee assigned responsibility of the ECO from the dropdown list. Approved by NO DROPDOWN Select the employee designated to approve the ECO from the dropdown list. Approval Date NO DATE Enter the approval date of the ECO. 9-6

7 Engineering Change Order Maintenance Field Req. Field Type Description Risk NO RADIO BUTTON Identify the ECO risk from the following options: - Critical - Major - Minor - None Source NO RADIO BUTTON Identify the source of the ECO from the following options: - Internal Audit - External Audit - Customer - Vendor - Improvement - Prevention - Employee - Contract Review Relates To Inventory Number NO ALPHANUMERIC Enter in the Inventory Number related to the Engineering Change Order or use the search key for selection. The Inventory Number is validated after entry. Part Number NO ALPHANUMERIC Enter in the Part Number related to the Engineering Change. This field is automatically populated upon inventory number validation if previously defined in the system. Shop Order NO ALPHANUMERIC Enter in the related shop order if applicable. The search key is available for selection. Customer NO TEXT Enter in the customer code if applicable or use the attached search key for selection. This entry is automatically validated after entry. Customer Contact NO TEXT Enter in the customer contact if applicable. Supplier NO TEXT Enter in the supplier code if applicable. The attached search key can also be used for selection. The entry is automatically validated after entry. Supplier Contact NO TEXT Enter in the supplier contact if applicable. 9-7

8 Engineering Change Order Maintenance Field Req. Field Type Description P.O. Number NO ALPHANUMERIC Enter in any applicable Purchase Order Number if necessary. Lot Number NO ALPHANUMERIC Enter in lot number if applicable. Operation NO NUMBER Enter in the operation number pertaining to the Engineering Change Order if applicable. This operation number is assigned during Job Estimating under the Material Requirements tab and is carried out through sales and shop orders. Department NO DROPDOWN Select the corresponding department relating to the Engineering Change Order if applicable. Workcenter NO DROPDOWN Select the corresponding workcenter relating to the identified operation from the dropdown menu when applicable. JC/Rec ID NO ALPHANUMERIC Enter in the Job Card ID pertaining to the Engineering Change Order if applicable. Operator NO DROPDOWN Select the operator involved in the Engineering Change Order from the dropdown list if applicable to the ECO. --- Proposed Change NO TAB A free form text box used to describe the proposed Engineering Change Order. Reason for Change NO TAB A free form text box used to describe the reason for the change. Details of Revision NO TAB A free form text box used to detail all revisions. Search Key N/A PUSHBUTTON Activate search key to retrieve and view previously captured Engineering Change Orders. Add N/A PUSHBUTTON Activate to Add a new Engineering Change Order. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Deletes current Engineering Change Order. After the delete validation is confirmed, the record is permanently removed from the system. 9-8

9 Engineering Change Order Maintenance Field Req. Field Type Description Exit N/A PUSHBUTTON Exits the Engineering Change Order form back to the main Visual EstiTrack system. Scroll to First N/A PUSHBUTTON Scrolls to the first ECO record. Scroll Back N/A PUSHBUTTON Scrolls back one ECO record. Scroll Forward N/A PUSHBUTTON Scrolls forward one ECO record. Scroll to Last N/A PUSHBUTTON Scrolls to the last ECO record. E-Advisory N/A PUSHBUTTON Activates the e-advisory subsystem. Engineering Change Order Report N/A PUSHBUTTON Activate the pushbutton to print the Engineering Change Order. All of the information defined in the form is included in the report. Once activated, the user has the following options to perform on the selected Engineering Change Order Report: Print View PDF Edit Delete Sends Engineering Change Order report to the printer View the Engineering Change Order on the monitor Activates the Visual EstiTrack TM system. Creates a PDF file of the selected Engineering Change Order. Creates a user defined form of the Engineering Change Order report. Deletes the user defined Engineering Change Order report. 9-9

10 ACTION REQUEST (NONCONFORMANCE CONCERN IMPROVEMENT) The Action Request form is used to capture all quality related issues and improvements that are either initiated internally or from the customer. The form is divided into two distinct functions that are separated into two tabulations the Action Request tab and the Related Corrective Actions tab. The Action Request tab is used to capture the issue or improvement. Four distinct types of actions may be identified Nonconformance, Concern, Improvement, and RMA (Return Material Authorization). Each identified request is further detailed outlining the type of issue, parts and shop orders affected as well as any contacts relating to the issue. The Related Corrective Actions tab is used to monitor and maintain all corrective actions taken. The 8-D Concerns Analysis is used as an outline for problem solving. It is an eight step method used to define the problem, contain the problem, select and implement corrective action and prevent any further occurrences. Figure 9.3 Action Request Form 9-10

11 Menu Selection Left click on the menu heading labeled Select Action Request Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-11

12 Action Request Tab The Action Request tab is used to authorize parts for return or refund. An example of an Action Request tab identified with a RMA action type is displayed in figure 9.4. The figure below also displays the RMA tab (section 3) that is used to manage all returns. This tab allows the user to track all related return activities in one central location. This maintains data integrity and ensures proper quality control surrounding the issue. Sect. 1 Sect. 2 Sect. 3 Sect. 4 Figure 9.4 Action Request Tab 9-12

13 Action Request Maintenance Action Request Tab Field Req. Field Type Description Serial Number YES NUMBER An automatically assigned unique number identifying the action request. The serial number may at times be referred to by the assigned action type: For example, if a action request is identified as a RMA, the serial number may be referred as a RMA number. Action Type YES RADIO BUTTON Identify the type of action requested from the following options: Nonconformance Concern Improvement RMA Date Defined YES DATE The initial date the action request is opened. The system automatically defaults to the current date. The date may however be overridden if necessary. Due Date NO DATE Enter in the date the action request is due for completion. The Visual EstiTrack TM s interactive calendar can also be used for date selection. Status YES DROPDOWN Select the status of the action request from the dropdown menu. The status is automatically initiated as Open. Defined by NO DROPDOWN Select the user name of the employee who defined the action request from the dropdown menu. Assigned to NO DROPDOWN Select the user name of the employee responsible for the action request from the dropdown menu. MIR Number NO ALPHANUMERIC Enter in the Material Inspection Release number relating to the action request. Status Date YES DATE The date is automatically updated to the current date when a change in status is made. The date may be over-ridden when required. End Sort Date NO DATE Enter in the last day the non-conformance parts need to be 100 % inspected by (sorted by). 9-13

14 Action Request Maintenance Action Request Tab Field Req. Field Type Description Risk YES RADIO BUTTON Identify the severity of the action request. The following options are available: Source YES RADIO BUTTON Critical Major Minor (Default) None Identify the source of the action request. The following options are available: Internal Audit (Default) External Audit Customer Vendor Improvement Prevention Employee Required Action Step NO RADIO BUTTON Identify the required action necessary. The following options are available: No Action Corrective Action Preventative Action Relates to Inventory Number NO ALPHANUMERIC Enter in the Inventory Number related to the Action Request or use the search key for selection. The Inventory Number is validated after entry. Quantity NO NUMBER Enter in the number of parts involved in identified issue. Part Number NO ALPHANUMERIC Enter in the Part Number related to the Action Request. This field is automatically populated upon inventory number validation if previously defined in the system. Shop Order Number NO ALPHANUMERIC Enter in the related shop order if applicable. The search key is available for selection. 9-14

15 Action Request Maintenance Action Request Tab Field Req. Field Type Description Defect NO DROPDOWN Select the defect code from the dropdown list.. The dropdown list for the part defect maintenance is maintained in the table: Tables Defect Codes Customer NO ALPHANUMERIC Enter in the customer code if applicable or use the attached search key for selection. This entry is automatically validated after entry. Contact NO TEXT Enter in the customer contact if applicable. Supplier NO ALPHANUMERIC Enter in the supplier code if applicable. The attached search key can also be used for selection. The entry is automatically validated after entry. Supplier Contact NO TEXT Enter in the supplier contact if applicable. Standard Number NO DROPDOWN Select the document requirement standard relating to the action request from the dropdown menu. A pre-populated list of ISO/TM/QMS document requirement standards is maintained in the table: Tables Other Tables ISO/TS/QMS Document Standards P.O. Number NO ALPHANUMERIC Enter in any applicable Purchase Order Number if necessary. Lot Number NO ALPHANUMERIC Enter in lot number if applicable. Operation NO NUMBER Enter the operation number pertaining to the action request. This operation number is assigned during Job Estimating under the Material Requirements tab and is further referenced throughout sales and shop orders. Department NO DROPDOWN Select the corresponding department relating to the Action Request if necessary. Workcenter NO DROPDOWN Select the corresponding workcenter relating to the identified operation from the dropdown menu if applicable. JC/Rec ID NO ALPHANUMERIC If applicable, enter in the Job Card ID best relating to the 9-15

16 Action Request Maintenance Action Request Tab Field Req. Field Type Description Action Request. Operator NO DROPDOWN If applicable, select the operator involved in the Action Request. IA ID NO ALPHANUMERIC If applicable, enter in the corresponding Internal Audit ID. Problem Description NO TAB A free form text box used to describe the corresponding problem. Special Instructions NO TAB A free form text box used to identify any special instructions relating to the action request. Inspector Comments NO TAB A free form text box used to maintain all inspector comments regarding the action request. RMA NO TAB Return Material Authorization Sales Order Number N/A PUSHBUTTON Activate the pushbutton to retrieve the Sales Order Maintenance subsystem on the entered Sales Order Number. Sales Order Number NO ALPHANUMERIC Enter in the Sales Order Number relating to the Action Request. The search key can be used to select the associated Sales Order Number. Sales Order Line No. NO DROPDOWN Select the Sales Order Line Number relating to the Action Request from the dropdown list. The dropdown is retrieved when the above Sales Order Number is entered. Create a RMA Shop Order N/A PUSHBUTTON Activate the pushbutton to create a Return Material Authorization Shop Order. The Shop Order Maintenance form is retrieved in add mode with a shop order number automatically assigned. The prefix RMA is used to identify the shop order as rework. The shop order is also automatically initialized as non-billable, indirect and as a rework. Shop Order Number N/A PUSHBUTTON Activate pushbutton to review the selected Shop Order number. The Shop Order Maintenance form is automatically 9-16

17 Action Request Maintenance Action Request Tab Field Req. Field Type Description retrieved. Shop Order Number NO ALPHANUMERIC Enter the associated Shop Order Number or use the search key for retrieval. This field needs to be blank if the user wishes to create a RMA shop order. The newly created RMA Shop Order number is then automatically populated into the field. Create a RMA Return Shipment N/A PUSHBUTTON Activate the pushbutton to create a Return Material Authorization Ship Order. The customer information including shipping address is automatically populated along with the item and sales order quantities if the default is selected. Ship Code N/A PUSHBUTTON Activate the pushbutton to review the selected Ship Code. The Shipping Maintenance form is automatically retrieved for the given Ship Code. Ship Code NO ALPHANUMERIC Enter the associated Ship Code or use the associated search key for retrieval. This field needs to be blank if a new RMA shipment is to be created and is automatically populated with the new RMA Ship Code. Disposition NO RADIO BUTTON Identify the disposition of the Action Request. The following options are available. Use as is Rework Scrap Return to Customer Return to Vendor Sort N/A Other Return from Customer Re-inspected by NO DROPDOWN Select the inspector that re-inspected the parts from the dropdown list of inspectors. 9-17

18 Action Request Maintenance Action Request Tab Field Req. Field Type Description An employee is identified as an inspector in the table: Tables Employee Maintenance Date NO DATE Enter in the date of inspection. Approved by NO DROPDOWN Select the employee name from the dropdown list. Date NO DATE Enter in the date of approval. Approved by NO DROPDOWN Select the employee name from the dropdown list. Date NO DATE Enter in the date of approval. Add N/A PUSHBUTTON Activate the pushbutton to add a new Action Request. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Removes the current Action Request. After the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits back to the main Visual EstiTrack system. Scroll to First N/A PUSHBUTTON Scrolls to the first record. Scroll Back N/A PUSHBUTTON Scrolls back one record. Scroll Forward N/A PUSHBUTTON Scrolls forward one record. Scroll to Last N/A PUSHBUTTON Scrolls to the last record. Spell N/A PUSHBUTTON Performs a spell check on all of the memo fields. e-advisory N/A PUSHBUTTON Activates the e-advisory subsystem. Reject Parts Label N/A PUSHBUTTON Activate pushbutton to print a Reject Parts Label used to attach to the lot of rejected parts. The label is bar-coded for 9-18

19 Action Request Maintenance Action Request Tab Field Req. Field Type Description identification purposes. Suspect Material Label N/A PUSHBUTTON Activate pushbutton to print a Suspect Material Label used to attach to the lot of suspected material. This bar-coded label can be attached to the material for further investigation. Action Request Report N/A PUSHBUTTON Activate the pushbutton to print the Action Request Report. The report is automatically generated using the information captured in the form. The title of the report changes according to the type of action request selected. Once activated, the user has the following options to perform on the selected Action Request Report: Print View PDF Edit Delete Sends report to the printer View report on the monitor Activates the Visual EstiTrack TM system. Creates a PDF file of the selected Action Request. Creates a user defined form of the Action Request. User may edit the format of the report according to company standard. Deletes the user defined Action Request report. 9-19

20 Related Corrective Action The Related Corrective Actions tab is used as a central location to maintain all corrective actions taken on the defined issue. Multiple corrective actions can be added per each Action Request defined. The serial number found in the figure below is carried over from the Action Request tab. Each added action is provided the eight step analysis guiding the user through a consistent problem solving routine. Figure 9.5 Related Corrective Action Tab Adding a New Corrective Action To add a new corrective action to the given Serial Number, activate the ADD pushbutton located on the bottom of the screen. The Corrective Action Maintenance form is retrieved with the 8-D Concerns Analysis for entry. 9-20

21 Corrective Action Maintenance (8D Concerns Analysis) The form is divided into eight tabulations. Each tabulation represents one of the eight disciplines in team oriented problem solving. Although each discipline is unique and distinct, the module will be described viewing three distinct tabs. The first tab defines the problem at hand, the second form is used to build the team responsible for the corrective action and the third represents an example of the remaining six disciplines. It includes a text field containing the description of the discipline, the responsible team member and status. Figure 9.6 Corrective Action Maintenance 9-21

22 Discipline 1 Problem Description Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description CAR (Corrective Action Reporting) Number YES NUMBER An automatically assigned unique number identifying the corrective action. Date Defined YES DATE The initial date the corrective action request is opened. The system automatically defaults to the current date however, the date maybe overridden if necessary. Due Date NO DATE Enter in the date the corrective action is due for completion. The Visual EstiTrack TM s interactive calendar is available for date selection. Status YES DROPDOWN Select the status of the corrective action from the dropdown menu. The status is automatically initiated as Open. Status Date YES DATE The date is automatically updated to the current date when a change in status is made. The date may be over-ridden when required. Defined by NO DROPDOWN Select the user name of the employee who defined the corrective action from the dropdown menu. Standard Number NO DROPDOWN Select the document requirement standard relating to the action request from the dropdown menu. A pre-populated list of ISO/TM/QMS document requirement standard is maintained in the table: Tables Other Tables ISO/TS/QMS Document Standards Serial Number (Nonconformance) YES NUMBER The serial number generated in the Action Request Tab. Short Problem Description NO TEXT A short description used in the subject of the Corrective Action list. Detailed Problem Description NO TEXT A free form text box used to detail the problem. 9-22

23 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Relates To Inventory Number NO ALPHANUMERIC Enter in the Inventory Number related to the Corrective Action or use the search key for selection. The Inventory Number is validated after entry. Part Number NO ALPHANUMERIC Enter in the Part Number related to the Corrective Action. This field is automatically populated upon inventory number validation if previously defined in the system. Shop Order Number NO ALPHANUMERIC Enter in the related shop order if applicable. The search key is available for selection. Customer NO ALPHANUMERIC Enter in the customer code if applicable or use the attached search key for selection. This entry is automatically validated after entry. Supplier NO ALPHANUMERIC Enter in the supplier code if applicable. The attached search key can also be used for selection. The entry is automatically validated after entry. P.O. Number NO ALPHANUMERIC Enter in the Supplier Purchase Order number used to purchase the item in question. Operation NO NUMBER Enter the Operation Number pertaining to the corrective action. This operation number is assigned during Job Estimating under the Material Requirements tab and is carried out through sales and shop orders. Department NO DROPDOWN Select the corresponding department relating to the corrective action if applicable. Workcenter NO DROPDOWN Select the corresponding workcenter relating to the identified operation from the dropdown menu if applicable. Search Key N/A PUSHBUTTON Activate search key to retrieve and view previously captured Corrective Actions. Add N/A PUSHBUTTON Activate the pushbutton to add a new Corrective Action. 9-23

24 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Removes the current Corrective Action. After the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Corrective Action Maintenance back to the Action Request list. Scroll First N/A PUSHBUTTON Scrolls to the first record. Scroll Back N/A PUSHBUTTON Scrolls back one record. Scroll Forward N/A PUSHBUTTON Scrolls forward one record. Scroll Last N/A PUSHBUTTON Scrolls to the last record. Spell Check N/A PUSHBUTTON Performs a spell check on all text fields. E-Advisor N/A PUSHBUTTON Activates the e-advisory subsystem. Positive Recall Status N/A PUSHBUTTON Activate pushbutton to print a positive recall corrective action label. 8-D Concerns Analysis Report N/A PUSHBUTTON Activate pushbutton to print an overall summary of the corrective action report including each of the outlined disciplines, responsible team members and status. 9-24

25 Discipline 2 Team Members Figure 9.7 Discipline 2 Team Members Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Team Description NO TEXT Enter in a description regarding the assembled team. Team Members NO DROPDOWN List of added team members. The dropdown list can be used to select the team members. Add N/A PUSHBUTTON Activate the Add pushbutton to add each team member. Delete N/A PUSHBUTTON Removes the highlighted team member. Notify Members N/A PUSHBUTTON Activate pushbuttons to notify members added to the list. Responsible Team Member NO DROPDOWN Select the responsible team member from the dropdown list. Date Completed NO DATE Enter in the date the corrective action is completed. Status YES DROPDOWN Select the status of the corrective action discipline. The status is automatically initiated as Open. 9-25

26 Disciplines 3 through 8 The forms maintaining the remaining six disciplines retain the same format with only the title varying according to the tabulation selected. Figure 9.8 Formats of Disciplines 3 through 8 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Discipline Description NO TEXT A free form text box used to outline and describe all actions taken for the corrective action discipline. Responsible Team Member NO DROPDOWN Select the responsible team member from the member dropdown list. Date Completed NO DATE Enter in the completion date of the discipline at hand. Status YES DROPDOWN Select the status of the corrective action discipline. The status is automatically initiated as Open. 9-26

27 CORRECTIVE ACTION MAINTENANCE Corrective Action Maintenance is used to monitor and maintain all corrective actions taken for a given action type serial number: Nonconformance, Concern, Improvement or RMA. The 8D Concerns Analysis is the method used throughout the corrective action maintenance. The 8-D Concerns Analysis is a team oriented approach to single problem solving. Eight disciplines are used to define the problem, contain the problem, aid in selecting and implementing corrective actions and prevent any further occurrences. This form can also be accessed using the Related Corrective Actions Tab of the Action Request form. Figure D Concerns Analysis: Problem Description Tab 9-27

28 Menu Selection Left click on the menu heading labeled Select Corrective Action Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-28

29 Corrective Action Maintenance (8D Concerns Analysis) The form is divided into eight tabulations. Each of the eight tabulations represents one of the eight disciplines in team oriented problem solving. Although each discipline is unique and distinct, the module will be described viewing three distinct tabs. The first tab defines the problem at hand, the second form is used to build the team responsible for the corrective action and the third represents an example of the remaining six disciplines a text field containing the description of the discipline, the responsible team member and status. Discipline 1 Problem Description Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description CAR (Corrective Action Reporting) Number YES NUMBER An automatically assigned unique number identifying the corrective action. Date Defined YES DATE The initial date the corrective action request is opened. The system automatically defaults to the current date however, the date maybe overridden if necessary. Due Date NO DATE Enter in the date the corrective action is due for completion. The Visual EstiTrack TM s interactive calendar is available for date selection. Status YES DROPDOWN Select the status of the corrective action from the dropdown menu. The status is automatically initiated as Open. Status Date YES DATE The date is automatically updated to the current date when a change in status is made. The date may be over-ridden when required. Defined by NO DROPDOWN Select the user name of the employee who defined the corrective action from the dropdown menu. 9-29

30 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Standard Number NO DROPDOWN Select the document requirement standard relating to the action request from the dropdown menu. A pre-populated list of ISO/TM/QMS document requirement standard is maintained in the table: Tables Other Tables ISO/TS/QMS Document Standards Serial Number (Nonconformance) YES NUMBER The serial number generated in the Action Request Tab. Short Problem Description NO TEXT A short description used in the subject of the Corrective Action list. Detailed Problem Description NO TEXT A free form text box used to detail the problem. Relates To Inventory Number NO ALPHANUMERIC Enter in the Inventory Number related to the Corrective Action or use the search key for selection. The Inventory Number is validated after entry. Part Number NO ALPHANUMERIC Enter in the Part Number related to the Corrective Action. This field is automatically populated upon inventory number validation if it was previously defined in the system. Shop Order Number NO ALPHANUMERIC Enter in the related shop order if applicable. The search key is available for selection. Customer NO ALPHANUMERIC Enter in the customer code if applicable or use the attached search key for selection. This entry is automatically validated after entry. Supplier NO ALPHANUMERIC Enter in the supplier code if applicable. The attached search key can also be used for selection. The entry is automatically validated after entry. P.O. Number NO ALPHANUMERIC Enter in the supplier purchase order number used to purchase the item in question. 9-30

31 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Operation NO NUMBER Enter the operation number pertaining to the corrective action. This operation number is assigned during Job Estimating under the Material Requirements tab and is carried out through sales and shop orders. Department NO DROPDOWN Select the corresponding department relating to the corrective action if necessary. Workcenter NO DROPDOWN Select the corresponding workcenter relating to the identified operation from the dropdown menu if applicable. Search Key N/A PUSHBUTTON Activate search key to retrieve and view previously captured Corrective Actions. Add N/A PUSHBUTTON Activate the pushbutton to add a new Corrective Action. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Removes the current Corrective Action. After the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Corrective Action Maintenance back to the Action Request list. Scroll First N/A PUSHBUTTON Scrolls to the first record. Scroll Back N/A PUSHBUTTON Scrolls back one record. Scroll Forward N/A PUSHBUTTON Scrolls forward one record. Scroll Last N/A PUSHBUTTON Scrolls to the last record. Spell Check N/A PUSHBUTTON Performs a spell check on all text fields. E-Advisor N/A PUSHBUTTON Activates the e-advisory subsystem. 9-31

32 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Positive Recall Status N/A PUSHBUTTON Activate pushbutton to print a Positive Recall Corrective Action label. 8-D Concerns Analysis Report N/A PUSHBUTTON Activate pushbutton to print an overall summary of the corrective action report including each of the outlined disciplines, responsible team members and status. 9-32

33 Discipline 2 Team Members Figure 9.10 Discipline 2: Team Members Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Team Description NO TEXT Enter in a description regarding the assembled team. Team Members NO DROPDOWN List of added team members. The dropdown list can be used to select the team members. Add N/A PUSHBUTTON Activate the Add pushbutton to add each team member. Delete N/A PUSHBUTTON Removes the highlighted team member. Notify Members N/A PUSHBUTTON Activate pushbuttons to notify members added to the list. Responsible Team Member NO DROPDOWN Select the responsible team member from the dropdown list. Date Completed NO DATE Enter in the date the corrective action is completed. Status YES DROPDOWN Select the status of the corrective action discipline. The status is automatically initiated as Open. 9-33

34 Disciplines 3 through 8 The forms maintaining the remaining six disciplines retain the same format with only the title varying according to the tabulation selected. Figure 9.11 Formats of Disciplines 3 through 8 Action Request Maintenance Related Corrective Actions Tab Corrective Actions Maintenance Field Req. Field Type Description Discipline Description NO TEXT A free form text box used to outline and describe all actions taken for the corrective action discipline. Responsible Team Member NO DROPDOWN Select the responsible team member from the member dropdown list. Date Completed NO DATE Enter in the completion date of the discipline at hand. Status YES DROPDOWN Select the status of the corrective action discipline. The status is automatically initiated as Open. 9-34

35 PREVENTATIVE ACTION MAINTENANCE The Preventative Action Maintenance subsystem is used to maintain all preventative actions taken for a given Corrective Action and Nonconformance. This also ensures that adequate steps are taken in order to prevent other items from being affected by the same problem. The form is comprised of the following five distinct tabulations: Initiating Circumstance Preventative Action Implementation Effect Analysis Common/Similar Opportunities The definition of the initiating circumstance is captured within this form. A PAR number is defined for the preventative action taken. A free form text box used to define the exact preventative action taken. A free form text box used to describe all defined implementation steps A free form text box used to describe the effect analysis taken. A free form text box used to identify all other common or similar opportunities where the preventative action can be implemented for improvement. Figure 9.12 Preventative Action Maintenance: Initiating Circumstance 9-35

36 Menu Selection Left click on the menu heading labeled Select Preventative Action Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-36

37 Tabulation 1 Initiating Circumstance Tab Preventative Action Maintenance Initiating Circumstance Tab Field Req. Field Type Description PAR Number YES NUMBER The Preventative Action Report number is a unique automatically generated number that is assigned when a new Preventative Action is opened. Date Defined YES DATE The initial date the Preventative Action is opened. The system automatically defaults to the current date. It however, maybe overridden if necessary. Status YES DROPDOWN Select the status of the preventative action from the dropdown menu. The status is automatically initiated as Open. Status Date NO DATE The date is automatically updated to the current date when a change in status is made. The date may be over-ridden when required. Defined By NO DROPDOWN Select the user name of the employee who defined the preventative action from the dropdown menu. Standard Number NO DROPDOWN Select the document requirement standard relating to the Preventative Action from the dropdown menu. A pre-populated list of ISO/TM/QMS document requirement standard is maintained in the table: Tables Other Tables ISO/TS/QMS Document Standards CAR No. (Corrective Action) NO NUMBER Enter in the Corrective Action tied to the Preventative Action taken. The search key can be used to aid in retrieval. Serial Number (Nonconformance) NO NUMBER Enter in the Serial Number of the nonconformance previously defined. This Serial Number is directly related to the Preventative Action taken. Short Description NO TEXT A short description used as a title for the defined Preventative Action and initiating circumstance. Initiating Circumstance NO TEXT A detailed description outlining the initiating circumstance of the preventative action. 9-37

38 Preventative Action Maintenance Initiating Circumstance Tab Field Req. Field Type Description Relates to Inventory Number NO ALPHANUMERIC Enter in the Inventory Number related to the Preventative Action or use the search key for selection. The Inventory Number is validated after entry. Part Number NO ALPHANUMERIC Enter in the Part Number related to the Preventative Action. This field is automatically populated upon inventory number validation if previously defined in the system. Description NO TEXT Enter in the description of the part related to the Preventative Action. Customer NO ALPHANUMERIC Enter in the customer code if applicable or use the attached search key for selection. This entry is automatically validated after entry. Supplier NO ALPHANUMERIC Enter in the supplier code if applicable or used the attached search key for selection. Operation NO NUMBER Enter the Operation Number pertaining to the Preventative Action. This Operation Number is assigned during Job Estimating under the Material Requirements tab and is further referenced throughout sales and shop orders. Department NO DROPDOWN Select the corresponding department relating to the preventative action if necessary. Workcenter NO DROPDOWN Select the corresponding workcenter relating to the identified operation from the dropdown menu if applicable. Search Key N/A PUSHBUTTON Activate search key to retrieve and view previously captured Preventative Actions. Add N/A PUSHBUTTON Activate the pushbutton to add a new Preventative Action. Save N/A PUSHBUTTON Saves any changes made to the form. 9-38

39 Preventative Action Maintenance Initiating Circumstance Tab Field Req. Field Type Description Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Removes the current Preventative Action. After the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Preventative Action Maintenance subsystem. Scrolls to First N/A PUSHBUTTON Scrolls back to first record Scrolls Back N/A PUSHBUTTON Scrolls back one record. Scrolls Forward N/A PUSHBUTTON Scrolls forward one record. Scrolls to Last N/A PUSHBUTTON Scrolls to last record. E-Advisory N/A PUSHBUTTON Activates the E-Advisory subsystem. Preventative Actions Report N/A PUSHBUTTON Activate pushbutton to print the Preventative Actions Report. The generated report includes the details outlined in the initiating circumstance tab as well as each of the defined remaining tabulations (Preventative Action, Implementation, Effect Analysis, and Common/Similar Opportunities). 9-39

40 Tabulations 2 through 4 (Preventative Action, Implementation, Effect Analysis, Common/Similar Opportunities) Tabulations two through four are free form text boxes provided to the user for maintaining any related information. The purpose of each tab is to provide the user a medium to record any and all activity regarding its corresponding tabulation title. The added information is included on the Preventative Action Report available via the printer icon. All four tabs have the same format. An example of the Preventative Action tab is displayed below. Figure 9.13 Preventative Maintenance Tabulations 2 through

41 DEVIATION MAINTENANCE The Deviation Maintenance subsystem is used to maintain any requests for deviations, their reasons for the request as well as the corresponding required approvals. Deviation requests are at times needed when there is a change in a pre-approved process or there is a slight noncritical dimensional change in a part. The Deviation Maintenance form provides the user the opportunity to circumvent the standard Engineering Change Order process in order to allow temporary deviations in a controlled environment. The Deviation Maintenance form is divided into three tabulations. The Deviation Requested tab is used to capture the pertinent information regarding the request; the Reason for Deviation tab is used to outline the reason for the request (new supplier, etc.) and the Approval/Comments tab is used to maintain the authorization, quantities, and any additional comments regarding the Deviation Request. The tabulations are further outlined in the chapter below. Figure 9.14 Deviation Maintenance 9-41

42 Menu Selection Left click on the menu heading labeled Select Deviation Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-42

43 Deviation Requested Tab The Deviation Requested tab is used to capture the pertinent information regarding the request. Some items included are: the related inventory number, any associated CAR or Nonconformance serial numbers, as well as a description of the deviation requested. Deviation Request Deviation Requested Tab Field Req. Field Type Description DEV Number YES NUMBER The Deviation Number is a unique automatically generated number that is assigned when a new deviation request is opened. This number is used internally within Visual EstiTrack TM Date Defined YES DATE The initial date the Deviation Request is opened. The system automatically defaults to the current date. This date however maybe overridden if necessary. Status YES DROPDOWN Select the status of the Deviation Request from the dropdown menu. The status is automatically initiated as Open. Defined By NO DROPDOWN Select the user name of the employee who defined the Deviation Request from the dropdown menu. Employees are maintained in the table: Tables Employees Corrective Action Required NO CHECKBOX Activate check box if a Corrective Action is required for this Deviation request. CAR No. (Corrective Action) NO NUMBER Enter in the Corrective Action associated with the Deviation Request. The search key can be used to aid in retrieval. Serial Number (Nonconformance) NO NUMBER Enter in the Serial Number if a Nonconformance was defined. The search key may be used to aid in selection. Short Description NO TEXT Enter in a short description summarizing the Deviation Request. Deviation Requested NO TEXT Enter in a detailed description of the Deviation Requested. 9-43

44 Deviation Request Deviation Requested Tab Field Req. Field Type Description Relates to Inventory Number NO ALPHANUMERIC Enter in the Inventory Number related to the Deviation Request or use the search key for selection. The Inventory Number is validated after entry. Part Number NO ALPHANUMERIC Enter in the Part Number related to the Deviation Request. This field is automatically populated upon Inventory Number validation if previously defined in the system. Description NO TEXT Enter in the description of the part related to the Deviation Request. Customer NO ALPHANUMERIC Enter in the Customer Code if applicable or use the attached search key for selection. This code is automatically validated after entry. Supplier NO ALPHANUMERIC Enter in the Supplier Code if applicable or used the attached search key for selection. Operation NO NUMBER Enter the Operation Number pertaining to the Deviation Request. This operation number is assigned during Job Estimating under the Material Requirements tab and is further referenced throughout Sales and Shop Orders. Department NO DROPDOWN Select the corresponding department relating to the Deviation Request if necessary. Workcenter NO DROPDOWN Select the corresponding workcenter relating to the identified operation from the dropdown menu if applicable. Search Key N/A PUSHBUTTON Activate search key to retrieve and view previously captured Deviation Requests. Add N/A PUSHBUTTON Activate the pushbutton to add a new Deviation Request. Save N/A PUSHBUTTON Saves any changes made to the form. 9-44

45 Deviation Request Deviation Requested Tab Field Req. Field Type Description Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Removes the current Deviation Request. After the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Deviation Request subsystem. Scrolls to First N/A PUSHBUTTON Scrolls back to first record Scrolls Back N/A PUSHBUTTON Scrolls back one record. Scrolls Forward N/A PUSHBUTTON Scrolls forward one record. Scrolls to Last N/A PUSHBUTTON Scrolls to last record. E-Advisory N/A PUSHBUTTON Activates the E-Advisory subsystem. Deviation Listing Report N/A PUSHBUTTON Activate pushbutton to retrieve the Report Criteria form for Deviation Listings. A report can be generated according to the criteria. If left blank, a report listing all Deviation Requests can be generated to either the printer or monitor. Deviation Request Report N/A PUSHBUTTON Activate pushbutton to print a Detailed Deviation Report. The Deviation Request number can be entered or selected using the search key within the report criteria popup. A detailed report including the information entered in both tabs 1 and 2 can be generated to either the printer, monitor or to an account. 9-45

46 Reason for Deviation Tab The Reason for Deviation tab is a free form text box used to capture the exact reason the Request for Deviation was initiated. The information entered within this tab will be printed on the Deviation Request Report. An example of the tab is displayed below: Figure 9.15 Reason for Deviation Tab 9-46

47 Approval/Comments Tab The Approval/Comments tab is used to maintain the authorization, quantities, and any additional comments regarding the Deviation Request. Figure 9.16 Deviation Request Approval / Comments 9-47

48 Deviation Request Approval Comments Tab Field Req. Field Type Description Deviation Acceptance: Accepted - Rejected Quantity YES RADIOBUTTON Select whether the Deviation Request is accepted or rejected. Identify the quantity of the deviation request. Annual Volumes YES RADIOBUTTON Select if the quantity approved is an annual amount. Fixed Quantity YES RADIOBUTTON FIELD Select if the quantity approved is a fixed quantity. If selected, enter in the amount approved. Date Cutoff YES RADIOBUTTON Select if the deviation requested has a cut off date. If selected, the cut-off /expiration date field is required. Cut-off/Expiration Date NO DATE Enter in the Cut-off date of the accepted Deviation Request. The Cut-off date must be defined in order to include the deviation numbers entered into the Deviation Numbers field, on the customer s packing slip. Deviation Numbers NO ALPHANUMERIC Enter in the Customer s deviation tracking number. This number will be displayed on the customer s packing slip during shipping. The customer may then use the number for reference and tracking during their receiving process. Date Accepted/Signed NO DATE Enter in the date the Deviation is approved. Drawing Change Required NO CHECKBOX Activate checkbox if a drawing change is required for the Deviation Acceptance. Comments NO TEXT Enter in any additional comments regarding the Deviation Request/Acceptance. 9-48

49 CONTAINMENT MANAGEMENT Visual EstiTrack TM provides the user the capability to contain an inventory number in the system. Once an item is contained, Visual EstiTrack TM locks theitem from shipment by preventing the item s packing slip from printing. Consequently, a red warning screen is retrieved displaying to the user the reason the parts are under containment. The parts will remain under containment until they are released by using the originally defined containment password or the Containment date is met. Figure 9.17 Containment Management Menu Selection Left click on the menu heading labeled Select Containment Management from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-49

50 Placing an Item into Containment To place an item into containment, retrieve the item number from the Containment Management form displayed in figure Once the item is selected, enter in a containment password and if desired, a contained until date. The following table further outlines the Containment Management form including field usage and descriptions. Containment Management Field Req. Field Type Description Inventory Number YES ALPHANUMERIC Activate the attached search key to retrieve an inventory number for containment. Containment Password NO ALPHANUMERIC Enter in a Containment Password used to lock any further shipment of the item. If the user would like to circumvent the containment (parts on hand may meet spec), the password can be entered during shipment in order to continue the shipping process. Contained Until Date NO DATE Enter in an end of containment date for the selected item. The items are made available for shipping after the containment date is met. Containment Reason NO TEXT A free form text box used to enter the reason for containment. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form Clear N/A PUSHBUTTON Clears the containment from the system. The containment is removed when the pushbutton is activated. Exit N/A PUSHBUTTON Exits the form. 9-50

51 Releasing Containment The following screen is retrieved when a packing slip is printed during the shipping process. This pop-up prevents the user from completing the shipping process due to the containment. The containment can be lifted by the following process: The containment can be released for the shipping items by entering the containment password into the corresponding field below. This releases only the current items for shipment; the item number is still under containment for all other shipments. The containment can be permanently released by using the Clear pushbutton on the Containment Management form displayed in figure Figure 9.18 Containment Password pop-up during Shipping 9-51

52 QUALITY TASK MANAGER The Task Manager is a utility used to manage all captured Tasks. The following Actions are included in the Task Manager: Engineering Change Orders Action Requests Corrective Actions Preventative Actions An elaborate search criterion is made available for either narrow results or wide listings. Once a record is selected, the Task manager can be used to open the selected task for update. All captured quality tasks can be conveniently managed from one central location. Figure 9.19 Task Manager 9-52

53 Menu Selection Left click on the menu heading labeled Select Task Manager from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-53

54 Task Manager Field Req. Field Type Description Serial Number NO ALPHANUMERIC Enter a Nonconformance Serial Number generated in the Action Request tab to retrieve all records sharing the same serial number. CAR Number NO ALPHANUMERIC Enter in a CAR number to retrieve the corresponding Corrective Action. Inventory Number NO ALPHANUMERIC Enter in an inventory number to retrieve all records pertaining to the identified number. Defined Inventory numbers can retrieve the following quality applications: - Engineering Change Orders - Action Requests - Corrective Actions - Preventative Action Maintenance - Deviation Maintenance Description NO ALPHANUMERIC Enter in a Part Description to retrieve all records containing the identified description. Defined Part Descriptions can retrieve the following quality applications: - Engineering Change Orders - Action Requests - Corrective Actions - Preventative Action Maintenance - Deviation Maintenance Part Number NO ALPHANUMERIC Enter in a Part Number to retrieve all records containing the identified part number. Defined Part Numbers can retrieve the following quality applications: - Engineering Change Orders - Action Requests - Corrective Actions - Preventative Action Maintenance - Deviation Maintenance 9-54

55 Task Manager Field Req. Field Type Description Shop Order Number NO ALPHANUMERIC Enter in a Shop Order Number to retrieve all records containing the identified shop order. Defined Shop Orders can retrieve the following quality applications: - Engineering Change Orders - Action Requests - Corrective Actions - Preventative Action Maintenance - Deviation Maintenance Customer NO ALPHANUMERIC Enter in a Customer Code to retrieve all records containing the identified customer. Defined customers can retrieve the following quality applications: - Engineering Change Orders - Action Requests - Corrective Actions - Preventative Action Maintenance - Deviation Maintenance Supplier NO ALPHANUMERIC Enter the supplier code to retrieve all records containing the identified Supplier. Defined suppliers can retrieve the following quality applications: - Engineering Change Orders - Action Requests - Corrective Actions - Preventative Action Maintenance ECO Number NO ALPHANUMERIC Enter in an Engineering Change Order to retrieve the single requested record. PAR Number NO ALPHANUMERIC Enter in a Preventative Action Request number to retrieve the single requested record. Risk N/A RADIOBUTTON Used to retrieve all records tagged with the selected Risk. Source N/A RADIOBUTTON Used to retrieve all records tagged with the selected Source. 9-55

56 Task Manager Field Req. Field Type Description Assigned To NO DROPDOWN Used to retrieve all records that are assigned to the selected user. Responsible Party NO DROPDOWN Used to retrieve all records whose identified Responsible Party is selected. Defined By NO DROPDOWN Used to retrieve all records that were defined by the selected user. Status NO DROPDOWN Used to retrieve all records containing the selected status. Disposition NO RADIOBUTTON Used to retrieve all records tagged with the selected Disposition. Department NO DROPDOWN Used to retrieve all quality records identified with the selected Department. Workcenter NO DROPDOWN Used to retrieve all quality records identified with the selected Workcenter. Type NO DROPDOWN Select the type of Task to retrieve from the dropdown menu. Standard Number NO DROPDOWN Used to retrieve all records identified with the selected quality standard number. Result Box Type N/A DISPLAY Displays the type of Task retrieved Number N/A DISPLAY Displays the corresponding number of the items retrieved (ex. Serial No., RMA No., CAR No., etc.) Inventory Number N/A DISPLAY Displays the inventory number identified in the retrieved quality record. Status N/A DISPLAY Displays the status of the retrieved quality record. Date N/A DISPLAY Displays the defined date of the retrieved record. Description N/A DISPLAY Displays the description defined in the corresponding quality task. 9-56

57 Task Manager Field Req. Field Type Description End Result Box Order Search Results by NO DROPDOWN Order the retrieved records by the selected criteria from the dropdown menu. The retrieved results maybe ordered by the following criteria - Serial Number - Inventory Number - Status - Part Number - Date Search N/A PUSHBUTTON Activate the pushbutton to generate a Task List using the selected search criteria. Update N/A PUSHBUTTON Activate pushbutton to retrieve the highlighted Task for update. Clear N/A PUSHBUTTON Activate pushbutton to clear the search criteria form for new entry. Cancel N/A PUSHBUTTON Activate pushbutton to cancel the search and return to the main Visual EstiTrack TM menu. Exit N/A PUSHBUTTON Activate pushbutton to exit the Task Manager to the main Visual EstiTrack TM menu Action Request Status Lob N/A PUSHBUTTON Activate pushbutton to print the Task Log using the generated search results. 9-57

58 PREVENTATIVE MAINTENANCE Visual EstiTrack TM provides the user the option to schedule routine preventative maintenance. Any type of routine tasks that need to be assigned to an employee can be captured within this form. The Preventative Maintenance form can be used to define these tasks, assign any associated workcenter to the task, and identify the frequency and estimated hours needed to complete the task. These defined tasks can further be assigned to an individual user, captured into a Preventative Maintenance Shop Order, and maintained using the Preventative Maintenance subsystem displayed in section 2 of figure Sect. 1 Sect. 2 Figure 9.20 Preventative Maintenance 9-58

59 Menu Selection Left click on the menu heading labeled Select Task Manager from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-59

60 Preventative Maintenance Field Req. Field Type Description PM ID (Preventative Maintenance ID) YES NUMERIC The Preventative Maintenance ID is a unique automatically generated number assigned to new opened preventative maintenance tasks. Date Created YES DATE Enter in the date the Preventative Maintenance task is captured. The Visual EstiTrack interactive date calendar can be used for date selection. Created By NO DROPDOWN Select the employee name of the user who defined the Preventative Maintenance Task from the dropdown menu. Task Description NO TEXT Enter in a short description of the Preventative Maintenance Task. Workcenter NO DROPDOWN Select the Workcenter affected by the Preventative Maintenance from the dropdown menu. Frequency Days NO NUMERIC Enter in the frequency in days that the Preventative Maintenance Task must be performed. Estimated Hours NO NUMERIC Enter in the estimated hours needed to complete the Preventative Maintenance Task. Next Due NO DATE Enter in the date the next Preventative Maintenance must be completed. This date is automatically updated according the frequency defined and the date of the last completion. Days Remaining NO NUMERIC This figure is automatically calculated using the frequency defined and the date of the last completion. PM Group Task Description Extended Task Description NO TEXT A free form text box used to describe the Preventative Maintenance Group Task description. The scroll bars attached to the field can be used to scroll up or down when necessary. NO TEXT A free form text box provided for any extended task description. PM Group NO DROPDOWN Select the associated Preventative Maintenance Group from the dropdown menu. 9-60

61 Preventative Maintenance Field Req. Field Type Description Edit PM Group NO PUSHBUTTON Activate pushbutton to edit or add any new Preventative Maintenance groups. The Preventative Maintenance Group subsystem is retrieved for maintenance. PM Assignments History Assigned Employee N/A DISPLAY Displays the employee assigned the actual Preventative Maintenance Task. Shop Order Number N/A DISPLAY Displays the Preventative Maintenance Shop Order Number used to complete the task. Status N/A DISPLAY Displays the status of the highlighted Preventative Maintenance Task. Date Completed N/A DISPLAY Displays the completion date of the highlighted Preventative Maintenance Task. Add N/A PUSHBUTTON Activate pushbutton to add a new occurrence of the Preventative Maintenance Task. The Assign Preventative Maintenance Task subsystem is retrieved allowing the user to capture and maintain any additional Preventative Maintenance Tasks. Update N/A PUSHBUTTON Activate pushbutton to retrieve the Assign Preventative Maintenance Task subsystem for update on the highlighted Preventative Task. Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted Preventative Task entry from the system. End PM Assignments History After a delete validation is performed, the record is permanently removed from the system. 9-61

62 Preventative Maintenance Field Req. Field Type Description Search Key N/A PUSHBUTTON Activate the search key to retrieve previously captured Preventative Maintenance entries. The Preventative Maintenance search criteria form is retrieved and can be used to filter the Preventative Maintenance entries by the following criteria: - PM ID (Preventative Maintenance ID) - Workcenter - Inventory Number - Next Due Date Range Add N/A PUSHBUTTON Activate pushbutton to retrieve a blank Preventative Maintenance form for entry. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Deletes the current Preventative Maintenance from the system. Once the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Preventative Maintenance subsystem back to the main Visual EstiTrack menu PM Listing Report N/A PUSHBUTTON Activate pushbutton to print a listing of all defined Preventative Maintenance Tasks assigned for a given Preventative Maintenance ID. A report criteria form is retrieved that provides the user several options for print for a given PM ID. Details of the actual Preventative Maintenance tasks can also be included in the report if the Include Maintenance Task Assignments checkbox is activated. 9-62

63 Editing Preventative Maintenance Groups Maintenance groups are used to simplify the entry of maintenance activities. If you have 100 machines that all have the same type of maintenance activities you can create these maintenance activities under the maintenance groups so they can be defined only once but then referenced (i.e., copied) into each workcenter as their maintenance requirements are being defined. The subsystem is divided into three tabulations: Data Tab is used to actually capture and define a Preventative Maintenance Group; The List by Group Code Tab is used to list all of the defined Preventative Maintenance Groups according to their group code; and the third tab, List by Description, is used to list all of the defined Preventative Maintenance Groups according to their description. The figure below shows an example of a defined Preventative Maintenance Group. Figure 9.21 Preventative Maintenance Group 9-63

64 Assigning a Preventative Maintenance Task To assign the defined Preventative Maintenance to an actual task for completion, the PM Assignments/History section is used to maintain the added entries. When a new task is entered, the Assign Preventative Maintenance form is retrieved for further entry. An example of the form is displayed in the figure below and further outlined in the corresponding table. Figure 9.22 Assign Preventative Maintenance Task 9-64

65 Preventative Maintenance Assign Preventative Maintenance Task Field Req. Field Type Description Assign To NO DROPDOWN Select the name of the user who is responsible for completing the Preventative Maintenance Task from the dropdown menu. Due Date NO DATE Enter in the date the Preventative Maintenance Task is due for completion. PM Shop Order Number NO ALPHANUMERIC Enter the Preventative Maintenance Shop Order number used to complete the task if previously defined. If left blank, the PM Shop Order number will be automatically populated if it is created via the associated PM Shop Order pushbutton. Create Shop Order for PM Task N/A PUSHBUTTON Activate the pushbutton to create a Preventative Maintenance Shop Order for the given task. The Shop Order Maintenance form is automatically retrieved for the given PM. The Preventative Maintenance defaults are automatically assigned to the shop order. This shop order can further be scheduled into the system. Update/Review Shop Order Assignment Task Description N/A PUSHBUTTON Activate the pushbutton to retrieve the Shop Order Maintenance form for the given PM Shop Order number. NO TEXT A free form text box is provided. Any additional comments, descriptions, instructions can be maintained within the text box. The attached scroll can be used to review the entire entered text. Task Status NO RADIOBUTTON Identify the status of the PM task. Date Completed NO DATE Enter in the completion date the PM task. The Visual EstiTrack interactive calendar can be used for date selection. Preventative Maintenance Recap NO TEXT A free form text box is provided to capture a recap of the preventative maintenance task. Edit Failure Codes N/A PUSHBUTTON Activate pushbutton to retrieve the Failure Code Maintenance subsystem. If multiple reasons for failure exist, each specific reason can be identified with its own corresponding failure code. 9-65

66 Preventative Maintenance Assign Preventative Maintenance Task Field Req. Field Type Description Failure Codes NO DISPLAY If the PM Task status is identified as Failed, the user can identify the reason for failure using Failure Codes. Any identified Failure Codes and their corresponding part numbers are displayed for the given failed PM task. -- Add N/A PUSHBUTTON Activate pushbutton to retrieve the Failure Definition form. Form can be used to capture specific details regarding the failure. -- Update N/A PUSHBUTTON Activate pushbutton to edit the highlighted Failure Definition. The Failure Definition form for the given entry is retrieved for further update. -- Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted failure code. The record is permanently removed from the system after the delete is validated. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. 9-66

67 Failure Definition The Failure Definition form can be used to capture the reasons for a failed PM task. Each reason can be separately classified using the established Failure Codes. The figure below displays an example of a Failure Definition. Figure 9.23 Failure Definition 9-67

68 GAGE MAINTENANCE Visual EstiTrack provides the user the option to schedule routine calibrations and maintenance of gages. The Gage Maintenance Form can be used to define the scheduled gage maintenance by identifying the associated inventory numbers using the gage, assign any associated workcenter, as well as identify the frequency and estimated time needed to complete the maintenance. These defined tasks can further be assigned to an individual user, captured into a Gage Maintenance Shop Order, and maintained using the Gage Calibration Task subsystem displayed in section 2 of figure Sect. 1 Sect. 2 Figure 9.24 Gage Maintenance 9-68

69 Menu Selection Left click on the menu heading labeled Select Gage Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-69

70 Gage Maintenance Field Req. Field Type Description Gage ID YES NUMERIC Enter in the ID of the gage to be checked for calibration. Date Created YES DATE Enter in the date the Gage Maintenance is captured. The Visual EstiTrack interactive date calendar can be used for date selection. Created By NO DROPDOWN Select the employee name of the user who defined the Gage Maintenance task from the dropdown menu. Gage Description NO TEXT Enter in a short Gage description. Gage Type NO DROPDOWN Select the type of gage to be calibrated from the dropdown menu. The entries included in the dropdown menu are maintained Gage Type Maintenance subsystem accessed via the attached Edit Gage Type pushbutton. Used for F/G No. NO ALPHANUMERIC Enter in the Inventory Number the gage is used to monitor. Cal Outside By NO ALPHANUMERIC Enter in the Supplier used to calibrate the gage when calibration is done on the outside. The search button can be used to select the supplier. Workcenter NO DROPDOWN Select the Workcenter that uses the gage. Frequency Days NO NUMERIC Enter the frequency in days the Gage Maintenance Task must be performed. Estimated Hours NO NUMERIC Enter in the estimated hours needed to complete the Gage Maintenance Task. Next Due NO DATE Enter in the date the next Gage Maintenance must be completed. This date is automatically updated according the frequency defined and the date of the last completion. 9-70

71 Gage Maintenance Field Req. Field Type Description Days Remaining NO NUMERIC This figure is automatically calculated using the frequency defined and the date of the last completion. Calibration Method NO TEXT Enter in a description of the Calibration Method used to calibrate the gage. PM Assignments History Assigned Employee N/A DISPLAY Displays the employee assigned the actual Gage Maintenance Task. Shop Order Number N/A DISPLAY Displays the Gage Maintenance Shop Order Number used to complete the task. Status N/A DISPLAY Displays the status of the Gage Calibration Task. Date Completed N/A DISPLAY Displays the completion date of the Gage Calibration Task. Add N/A PUSHBUTTON Activate pushbutton to add a new occurrence of the Gage Maintenance Task. The Assign Gage Calibration Task subsystem is retrieved allowing the user to capture and maintain any additional Gage Calibration Tasks. Update N/A PUSHBUTTON Activate pushbutton to retrieve the Assign Gage Calibration Task subsystem for update for the current highlighted Gage Calibration Task. Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted Gage Calibration Task entry from the system. End Calibration Assignments/History After a delete validation is performed, the record is permanently removed from the system. 9-71

72 Gage Maintenance Field Req. Field Type Description Search Key N/A PUSHBUTTON Activate the search key to retrieve previously captured Gage Maintenance entries. The Gage search criteria form is retrieved and is available for filtering the Gage Maintenance entries by the following criteria: - Gage ID - Gage Type - Gage Location - Next Calibration Date Range Add N/A PUSHBUTTON Activate pushbutton to retrieve a new Gage Maintenance form for entry. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Deletes the current Gage Maintenance from the system. Once the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Gage Maintenance subsystem back to the main Visual EstiTrack menu Gage Listing Report N/A PUSHBUTTON Activate the pushbutton to print a listing of the Gage Maintenance records. If the Gage ID field is left blank, all captured records are included in the report. A report criteria form is first retrieved that provides the user several options to print the listing report. Records can be filtered by the gage type and gage location. All calibration entries for a given Gage ID can also be included by activating the Include Calibration checkbox. 9-72

73 Assign Gage Calibration Task To assign the defined Gage Maintenance to an actual calibration task, the Calibration Assignments/History section is used to maintain the added calibration entries. When a new task is added, the Assign Gage Calibration Task form is retrieved for further entry. An example of the form is displayed in the figure below and further outlined in the corresponding table. Figure 9.25 Assign Preventative Maintenance Task 9-73

74 Gage Maintenance Assign Gage Calibration Task Field Req. Field Type Description Assign To NO DROPDOWN Select the name of the user who is responsible for completing the Gage Calibration from the dropdown menu. Due Date NO DATE Enter in the date the Gage is due to be calibrated. Calibration Shop Order Number NO ALPHANUMERIC Enter the Calibration Shop Order number used to complete the task if previously defined. If left blank, the Calibration Shop Order number will be automatically populated if it is created via the associated Create Calibration Shop Order pushbutton. Create a Calibration Shop Order N/A PUSHBUTTON Activate the pushbutton to create a Calibration Shop Order for the given task. The Shop Order Maintenance form is automatically retrieved for the given Gage Calibration. The Gage Calibration defaults are automatically assigned to the shop order. This shop order can further be scheduled into the system. Update/Review Shop Order Assignment Task Description N/A PUSHBUTTON Activate the pushbutton to retrieve the Shop Order Maintenance form for the given Calibration Shop Order number. NO TEXT A free form text box is provided for any additional comments, descriptions and instructions. The attached scroll can be used to review the entire entered text. Task Status NO RADIOBUTTON Identify the status of the PM task. The following statuses are available: - Task Incomplete - Passed - Failed - Complete Date Completed NO DATE Enter in the date the gage was calibrated. The Visual EstiTrack interactive calendar can be used for date selection. Calibration Readings/Results NO TEXT A free form text box is provided to capture the calibration readings and results. 9-74

75 Gage Maintenance Assign Gage Calibration Task Field Req. Field Type Description Edit Failure Codes N/A PUSHBUTTON Activate pushbutton to retrieve the Failure Code Maintenance subsystem. If multiple reasons for failure exist, each specific reason can be identified with its own corresponding failure code. Failure Codes NO DISPLAY If the PM Task status is identified as Failed, the user can identify the reason for failure using Failure Codes. Any identified Failure Codes and their corresponding part numbers are displayed for the failed Calibration task. -- Add N/A PUSHBUTTON Activate pushbutton to retrieve the Failure Definition form. Form can be used to capture specific details regarding the failure. -- Update N/A PUSHBUTTON Activate pushbutton to edit the highlighted Failure Definition. The Failure Definition form for the given entry is retrieved for further update. -- Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted failure code. The record is permanently removed from the system after the delete is validated. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. 9-75

76 INTERNAL AUDIT MAINTENANCE Visual EstiTrack s Internal Audit Maintenance subsystem provides the opportunity to define and manage all internal company audits from one central location. The Internal Audit Maintenance Subsystem is broken down into three tabulations: Audit Definition, Audit Questionnaire, and Audit Results. The Audit Definition Tab is used to capture the focus of the audit along with the key contacts involved in the Audit. The Audit Questionnaire provides the user an open text box used to capture audit questions. The third tabulation, Audit Results, manages the exact audit outcome. Ratings, Audit results and any nonconformance found during the audit are all maintained within this form. Figure 9.26 Internal Audit Maintenance 9-76

77 Menu Selection Left click on the menu heading labeled Select Internal Audit from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-77

78 Audit Definition Internal Audit Maintenance Audit Definition Field Req. Field Type Description IA Number YES ALPHANUMERIC A unique automatically generated number used to identify the defined internal audit. Date Defined YES DATE The current date is auto-populated into the field. The date maybe overridden if necessary. Status YES OPEN Identify the status of the Internal Audit. The field is defaulted with an Open status. Defined by NO DROPDOWN Select the employee name of the user who defined the Internal Audit from the dropdown menu. Lead Auditor NO DROPDOWN Select the name of the Lead Auditor from the employee dropdown menu. Dept. Audited NO DROPDOWN Select the audited department from the dropdown menu. Dept. Contact NO DROPDOWN Select the contact of the audited department from the dropdown menu. Meeting Date NO DATE Enter in the date of the audit. The Visual EstiTrack interactive calendar is available for date selection. Meeting Time NO ALPHANUMERIC Enter in the time of audit. Audit Focus NO TEXT A free form text box used to highlight the general focus of the audit. The attached scroll bars can be used to review the entire contents of the text box. Areas to be Covered NO TEXT A free form text box used to identify the areas to be covered by the audit. The attached scroll bars can be used to review the entire contents of the text box. Search Key N/A PUSHBUTTON Activate the search key to retrieve previously captured Internal Audit records. Add N/A PUSHBUTTON Activate pushbutton to retrieve a new Internal Audit Maintenance form for entry. Save N/A PUSHBUTTON Saves any changes made to the form. 9-78

79 Internal Audit Maintenance Audit Definition Field Req. Field Type Description Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Deletes the current Internal Audit record from the system. Once the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the Internal Audit Maintenance subsystem to the main Visual EstiTrack menu. Scrolls to First N/A PUSHBUTTON Scrolls back to first record. Scrolls Back N/A PUSHBUTTON Scrolls back one record. Scrolls Forward N/A PUSHBUTTON Scrolls forward one record. Scrolls to Last N/A PUSHBUTTON Scrolls to last record. Internal Audit Questionnaire N/A PUSHBUTTON Activate pushbutton to print an Internal Audit Questionnaire. The information included in the report is as follows: -- Key Audit information (auditors, contacts, department, status, rating, etc.) -- Audit Focus -- Audit Scope -- Audit Questions defined in the Audit Questionnaire tab. The information can be viewed, printed, and ed via PDF via the Internal Audit Report Criteria form retrieved. Notification of Internal Audit N/A PUSHBUTTON Activate pushbutton to print a Notification of Internal Audit. This report displays the key information captured in the Audit Definition form. Information included is as follows: -- Auditors, Contacts, Department, Status, Meeting Date and Time -- Audit Focus -- Audit Scope The information can be viewed, printed, and ed via PDF via the Notification of Internal Audit Report Criteria form retrieved. Internal Audit Schedule N/A PUSHBUTTON When activated, an Internal Audit Schedule report criteria form is retrieved. The user is provided the ability to create 9-79

80 Internal Audit Maintenance Audit Definition Field Req. Field Type Description a list of scheduled internal audits using a number of report criteria. Some of the included criteria are as follows: -- Defined by -- Focus Description -- Date range -- Status -- Current Rating A list scheduled audits is generated according the criteria entered above. The list includes key information such as: -- Audit Number -- Status -- Date -- Contacts (Auditors) -- Department -- Rating -- Date/Time -- Re-audit required. Internal Audit Recap N/A PUSHBUTTON The Internal Audit Recap report is a complete fully detailed overview of the selected audit number. The items included in the report are as follows: -- Key Audit information (auditors, contacts, department, status, rating, etc.) -- Audit Focus -- Audit Scope -- Audit Questions (defined in the Audit Questionnaire tab.) -- Audit Results and Comments -- Non-conformances identified during the audit. The information can be viewed, printed, and ed via PDF via the Internal Audit Recap Report Criteria form retrieved. 9-80

81 Audit Questionnaire The Audit Questionnaire provides the user an open text box used to capture the audit questions and protocol for the particular Internal Audit ID. An example of the Audit Questionnaire form is displayed in the figure below. Figure 9.27 Internal Audit: Audit Questionnaire 9-81

82 Audit Results The Audit Results tab is used to maintain the outcome of the Audit. The user may capture the ratings of the audit, if the audit requires a re-audit along, and is also provided a text field for maintaining any observations and comments regarding the audit. All revealed non-conformances are also captured directly within the Audit Results tabulation. The Action Request Maintenance form is automatically retrieved with the associated internal Audit defaults in place. The user may then complete the Action Request form with any additional required input. After the entry is SAVED, an EXIT from the Action Request form returns the user to the Internal Audit Maintenance subsystem. Figure 9.28 Internal Audit: Audit Results 9-82

83 Internal Audit Maintenance Audit Results Field Req. Field Type Description Date Completed NO DATE Enter in the date the Audit is completed. The Visual EstiTrack interactive date calendar is available for date selection. Re-audit Required NO CHECKBOX Activate checkbox if a Re-audit is required. If it is activated, it will be included in all of the available Internal Audit reports. Current Rating NO RADIOBUTTONS Select the current rating of the audit. The following options are available for selection: - Excellent - Satisfactory - Conditional - Unacceptable - Not Rated Previous Rating NO RADIOBUTTONS Select the previous rating of the audit. The following options are available for selection: - Excellent - Satisfactory - Conditional - Unacceptable - Not Rated Audit Observations/ Comments/Recap NO TEXT The text box is made available to capture all of the observations, comments and recaps compiled during the audit meeting. The attached scroll bars can be used to review the entire contents included. Audit Revealed Non-Conformances All revealed non-conformances can be captured directly within the Audit Results tabulation. The Action Request Maintenance form is automatically retrieved with the associated internal Audit defaults in place. The user may then complete the Action Request form with any additional required input. After the entry is SAVED, an EXIT from the Action Request form returns the user to the Internal Audit Maintenance subsystem. Serial Number N/A DISPLAY Displays the non-conformance serial number of the added non-conformance. Status N/A DISPLAY Displays the Status of each added non-conformance. 9-83

84 Internal Audit Maintenance Audit Results Field Req. Field Type Description Risk N/A DISPLAY Displays the Risk of each added non-conformance. Non-Conformance Problem Description N/A DISPLAY Displays the description of the problem defined in the Action Request form for the given non-conformance. Add N/A PUSHBUTTON Activate the pushbutton to add and associate a new nonconformance for the internal audit defined. Update N/A PUSHBUTTON Activate the pushbutton to edit the highlighted nonconformance. A double click on the highlighted entry will also retrieve the Action Request Maintenance form for the given Non-Conformance End Audit Revealed Non-Conformances

85 DOCUMENT CONTROL MANAGER The Document Control Manager is available to group and track all external documents from a central, controlled location. Any external files kept outside of Visual EstiTrack, (ex. Word documents, Pictures, Certifications, etc.) can be tracked and associated to a defined attribute. The Document Control Manager is a means to organize all external files and classify them according to a particular attribute (quality standard, part number, shop order number, etc.). These attributes are later recognized along with the correct document manager configuration as a means to trigger a printout of the external file. The figure below displays the main Document Control Manager screen. It is divided into two main sections. Section 1 provides a filtering means used to retrieve previously defined documents. The system generates a more refined search list if more criteria defined within this section. The primary function of section 2 is to display the results of the document search defined in section 1 and is further divided into two tabulations: Controlled Documents tab and ISO/TS/QMS Standards Tab. The Controlled Documents tab is used to display the results of the document search defined in Section 1. The ISO/TS/QMS Standards tab is used to filter all previously defined controlled documents by their associated Standard Number. Sect. 1 Sect. 2 Figure 9.29 Document Control Manager 9-85

86 Menu Selection Left click on the menu heading labeled Select Document Control from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-86

87 Document Control Manager Field Req. Field Type Description Section 1 Figure 9.29 A filtering means used to retrieve previously defined document types. Document Type NO DROPDOWN Select the type of document to be retrieved. Update N/A PUSHBUTTON The pushbutton is used to retrieve the Document Type table. The Document Type Manager retrieved is used to maintain or add Document Types. Document Number NO ALPHANUMERIC Enter in the Document Number to retrieve a specific document from the system. Document Revision NO ALPHANUMERIC Enter in the revision of the documents to be retrieved. Department NO DROPDOWN Select the Department of the documents to be retrieved from the dropdown menu. Standard Number NO DROPDOWN Select the Standard Number of the documents to be retrieved from the dropdown menu. Shop Order Number NO ALPHANUMERIC Enter in the Shop Order Number of the documents to be retrieved. Quote Number NO ALPHANUMERIC Enter in the Quote Number of the documents to be retrieved. Customer NO DISPLAY SEARCH KEY Using the search key, select the customer from the Customer Search form. Part Number NO ALPHANUMERIC Enter in the part number of the documents to be retrieved. Rev (Part Revision) NO ALPHANUMERIC Enter in the Revision of the Part number to retrieve all documents identified with the part number revision from the system. Standard Type NO DROPDOWN Select the Standard Type from the dropdown menu. The following options are available for selection: -- ISO -- ISO/TS -- QMS -- OTHER Inventory Number NO ALPHANUMERIC Enter in the Inventory Number of the documents to be 9-87

88 Document Control Manager Field Req. Field Type Description retrieved. PO Number NO ALPHANUMERIC Enter in the PO Number of the documents to be retrieved. Lot Number NO ALPHANUMERIC Enter in the Lot Number of the documents to be retrieved. Receipt Number NO NUMBER Enter in the Receipt Number of the documents to be retrieved. Show Approved Only NO CHECKBOX Activate checkbox to retrieve approved documents only. Show Current Revision Only NO CHECKBOX Activate checkbox to retrieve the most current version of the maintained documents. This is very convenient when multiple versions of documents exist (ex. If multiple drawings exist for a part, the activated checkbox will retrieve the latest revision of the document only.) Search N/A PUSHBUTTON Activate pushbutton to create a document list using to the search criteria entered. A list of documents meeting all of the defined criteria is retrieved and listed section 2. Sort By NO DROPDOWN Select the Sort by Criteria from the dropdown menu. The documents retrieved are automatically sorted according the selected criteria. Add N/A PUSHBUTTON Activate the pushbutton to add a new Document to the Document Control Manager. The Document Control Details form is retrieved for further entry. Update N/A PUSHBUTTON Activate pushbutton to retrieve the highlighted entry for update. The Document Control Details form is retrieved for the highlighted record. Delete N/A PUSHBUTTON Removes the highlighted entry from the system. Once a delete validation is confirmed, the record is permanently removed from the system. View Document N/A PUSHBUTTON Used to view highlighted entry s attached document. Exit N/A PUSHBUTTON Exits the Document Control Manager to the main Visual EstiTrack menu system. 9-88

89 Assigning an External Document to a Document Number The ADD pushbutton located on the bottom of the figure 9.29 is used to assign an external document to a new document number. The Document Control Details is retrieved for entry. Document Control Details The Document Control Details form is used to create and maintain each individual controlled document number for every external maintained file. It is divided into three main sections displayed in figure The General Document Specifications box is used to capture the Document Number, Description, and any associated Standard Numbers. The Other Document Attributes box is used to tie key attributes to the document number. In the example below, the new document number 3.00TUBE_D represents a drawing for the part number 3.00TUBESS rev. 1. Since the Print with Router checkbox is activated, the file is automatically sent to the printer every time a router is printed for the part number and revision. In this example, the attributes Part Number and Revision are used to trigger a printout of the external file. The list of available attributes is further described in the corresponding Document Control table. The Filename of Document box is used to point the document number to the actual file located on the hard drive. Note: It is very important to carefully select the attributes tied to the external document. Only an exact match of all defined attributes will trigger the printout of the external file. Therefore only key unique attributes that can be associated with either the packing slip or router should be selected. 9-89

90 Sect. 1 Sect. 2 Sect. 3 Figure 9.30 Document Control Details Document Control Manager Document Controlled Details Field Req. Field Type Description General Document Specifications Section 1 of Figure 9.30 Document Number NO ALPHANUMERIC Enter in the document number that will be used as a pointer to the external file. It is helpful to apply a naming convention that provides meaning to the external document. Description NO TEXT Enter in the description of the external document. Extended Description N/A PUSHBUTTON An extended description maybe captured within the attached text box. Standard Number NO DROPDOWN The external document maybe associated to a specific quality standard by selecting the specific standard from the available dropdown list. Type YES DROPDOWN Select the document type from the dropdown list. Document Types are maintained in the table: TABLES OTHER TABLES DOCUMENT TYPES 9-90

91 Document Control Manager Document Controlled Details Field Req. Field Type Description Date Approved NO DATE Enter in the approval date. The Visual EstiTrack interactive calendar is available for selection. Revision NO ALPHANUMERIC Enter in the revision of the document number. Status NO DROPDOWN Select the status of the document. The following selection is offered: -- Open -- Approved -- Pending Approval -- Obsolete Department NO DROPDOWN Select the department responsible for the external document from the dropdown list of entries. Defined By NO DROPDOWN Select the user creating the link between the document number and the external document. --- End General Document Specifications Box Other Document Attributes Section 2 of Figure 9.30 Part Number NO ALPHANUMERIC If applicable, enter in the part number associated with the external document. Revision NO ALPHANUMERIC If applicable, enter in the part revision associated with the external document. Customer Code NO ALPHANUMERIC If applicable, enter in the customer code associated with the external document. Quote Number NO ALPHANUMERIC If applicable, enter in the quote number associated with the external document. Shop Order Number NO ALPHANUMERIC If applicable, enter in the shop order number associated with the external document. Inventory Number NO ALPHANUMERIC If applicable, enter in the inventory number associated with the external document. Operation Number NO ALPHANUMERIC If applicable, enter in the operation number associated with the external document. 9-91

92 Document Control Manager Document Controlled Details Field Req. Field Type Description Workcenter NO DROPDOWN If applicable, enter in the workcenter associated with the external document. Receipt Number NO ALPHANUMERIC If applicable, enter in the receipt number associated with the external document. Lot Number NO ALPHANUMERIC If applicable, enter in the lot number associated with the external document. PO Number NO ALPHANUMERIC If applicable, enter in the PO Number associated with the external document. Vendor NO ALPHANUMERIC If applicable, enter in the vendor associated with the external document. Print with Router NO CHECKBOX Activate the checkbox to automatically trigger a printout of the external document when a router is printed for a given part. Print with Packing Slip NO CHECKBOX Activate the checkbox to automatically trigger a printout of the external document when a packing slip is printed for a defined attributes (ex. part number, revision and shop order number.) Prompt for Number of Copies NO CHECKBOX Activate the checkbox to prompt the user to enter the number of copies to print when a printout is triggered. --- End Other Document Attributes Filename of Document Section 3 of Figure 9.30 Filename field NO ALPHANUMERIC Enter the filename and path of the external document. This step creates the actual link between the document number and the external document. Open File N/A PUSHBUTTON Activate the pushbutton to locate an external graphic file in the hard drive. Any Files N/A PUSHBUTTON Activate the pushbutton to locate the external file from within the hard drive. All files are accessible via this pushbutton. 9-92

93 Document Control Manager Document Controlled Details Field Req. Field Type Description View Using YES DROPDOWN Select the tool used to view the external document from the dropdown list. Store Document in Database as a Controlled Document NO CHECKBOX In Progress --- End Filename of Document Box Add N/A PUSHBUTTON Activate pushbutton to add a new document. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Deletes the open record from the system. The record is permanently removed after the delete validation is confirmed. Create New Revision N/A PUSHBUTTON Activate pushbutton to create a new revision to an existing document number. Exit N/A PUSHBUTTON Exits form to the Document Control Manager. E-Advisor Task Maintenance N/A PUSHBUTTON Activates the E-Advisor task manager. Print N/A PUSHBUTTON In Progress Last Updated YES DATE Displays the last update date of the document. View Document N/A PUSHBUTTON Activate the pushbutton to view the attached external document. 9-93

94 CUSTOMER EFFICIENCY REPORTS The Customer Efficiency Reports are tools that measure the delivery performance of a customer. The delivery performance is calculated by comparing the actual quantity of outgoing product to the initially promised quantity for each customer. Data from the General tab of the Customer Maintenance screen, the Delivery Schedule tab of the Sales Order Detail Update Mode as well as the General tab of the Shipping Maintenance screen is also used in the provided reports. A total of six Customer Efficiency reports are offered. They are as follows: Report Description Customer Summary Summarizes per customer both the late and on time quantities including the value of the late products as well as the percent efficiency. SO (Sales Order) Detail with Shipments Displays an efficiency report per customer including actual sales order line item along with shipment date and details. Various quantities (ordered, on-time, late), are included in the report along with the actual value of the late orders. The percent efficiency and actual number of days late are also calculated and displayed. SO Detail The Sales Order Detail Report is an efficiency report per customer that includes the actual sales order line item alone. Various quantities (ordered, on-time, late), are included in the report along with the actual value of the late orders. The percent efficiency and actual number of days late are also calculated and displayed. Efficiency Graph Displays a 12 month graphic representation of the information on the Sales Order Detail Report per month for a customer. By Division Presents the information present in a standard Sales Order Efficiency report grouped by product codes. Customer Sum by Line A report calculating the total number on-time items, late items, total value and total late days for each customer. 9-94

95 Menu Selection Left click on the in the menu heading Select Customer Efficiency Reports from the drop down list Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option. 9-95

96 Report Criteria The Customer Efficiency reports can be selected from the retrieved Report Criteria form displayed below. Enter in as much or as little detail in the following fields to generate the Customer Efficiency Reports. The more search criteria entered in the fields, the more isolated the report will be. A description of the form below is given in the proceeding table: Customer Efficiency Report Criteria. Figure 9.31 Customer Efficiency Report Criteria 9-96

97 Customer Efficiency Reports Search Criteria Field Required Field Type Description Report Type YES RADIO BUTTON User can select the type of report to view. The reports included are: - Customer Summary - SO Detail with Shipment - SO Detail - Efficiency Graph - By Division - Customer Sum by Line Sales Order Due Shipped/ Shipped Only YES RADIO BUTTON Determines the type of records pulled within the date range. User can select to pull records with both items due and shipped or shipped only. Date Range Start NO DATE Enter in the start date range. A double-click on the date field will activate the pop-up interactive calendar. If a date field is left blank, its value will default to All Dates. The report will pull in all data where the Sales Orders fall between the two defined dates. Date Range End NO DATE Enter in the end date range. A double-click on the date field will activate the pop-up interactive calendar. If the field is left blank, its value will default to the current date. The report will pull in all data where the Sales Orders fall between the two defined dates. Based On: Due /Promised Date YES RADIO BUTTON View report based on either the customer s due date or the date promised to the customer. Customer NO TEXT The customer code can be entered for a specific customer. The search key is available for selection. Late Only NO CHECKBOX Activate checkbox to view late orders only. Exclude Closed Orders NO CHECKBOX Activate checkbox to exclude all closed orders. To Printer N/A PUSHBUTTON Generates the selected report to the printer. View N/A PUSHBUTTON Generates the selected report to the monitor. Clear N/A PUSHBUTTON Clears the selected criteria from the form. 9-97

98 Customer Efficiency Reports Search Criteria Field Required Field Type Description Exit N/A PUSHBUTTON Exits form. Formulas Two key formulas are used and displayed within the customer efficiency reports. They are as follows: Efficiency Value Calculation (Detailed Efficiency %) (100*(Number of Shipments) = Summary Efficiency % Efficiency Value Calculation (100)* (ShippedOntime) (TotalShipped) = Detailed Efficiency % 9-98

99 VENDOR EFFICIENCY REPORTS Vendor Efficiency Reports are tools to measure the performance of on time deliveries from the Vendor. The efficiency is calculated by measuring the Purchase Order date and quantities against the actual date and quantities received. A total of four Vendor Efficiency reports are offered. They are as follows: Report Description Vendor Summary Summarizes the total quantities ordered, late quantities and on time quantities for a vendor. The value of the late products, the percent efficiency and the actual number of days late are all calculated and displayed. PO Detail Displays an efficiency report per vendor detailing the actual Purchase Order line item. Various quantities (ordered, on-time, late), are included in the report along with the actual value of the late receipts. The percent efficiency and actual number of days late are also calculated and displayed. PO Detail with Receipts Displays an efficiency report per vendor detailing the actual Purchase Order line item including the date and quantities of receipt. Various quantities (ordered, on-time, late), are included in the report along with the actual value of the late receipts. The percent efficiency and actual number of days late are also calculated and displayed. Efficiency Graph Provides a 12 month running Vendor Efficiency Graph. A bar graph displays the percent efficiency per month for a given vendor. 9-99

100 Menu Selection Left click on the in the menu heading Position cursor over Vendor Efficiency Report from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

101 Report Criteria The Vendor Efficiency reports can be selected from the retrieved Report Criteria form displayed below. Enter in as much or as little detail in the following fields to generate the Vendor Efficiency Reports. The more search criteria entered in the fields, the more isolated the report will be. A description of the form below is given in the proceeding table: Vendor Efficiency Report Criteria. Figure 9.32 Vendor Efficiency Report Criteria 9-101

102 Vendor Efficiency Reports Search Criteria Field Required Field Type Description Report Type YES RADIOBUTTON User can select the type of report to view. The reports included are: - Vendor Summary - PO Detail - PO Detail with Receipts - Efficiency Graph Purchase Order Due Date NO DATE Enter in the start date range. A double-click on the date field will activate the pop-up interactive calendar. If a date field is left blank, its value will default to All Dates. Received Date NO DATE Enter in the end date range. A double-click on the date field will activate the pop-up interactive calendar. If the field is left blank, its value will default to the current date. Vendor NO ALPHANUMERIC The vendor code can be entered for a specific vendor. The search key is available for selection. Late Only NO CHECKBOX Activate checkbox to view late orders only. Approved Vendors Only NO CHECKBOX Activate checkbox to view approved vendors only. Exclude Closed POs NO CHECKBOX Activate checkbox to exclude all closed Purchase Orders. Sort by NO RADIO BUTTON Select the criteria for sort from the three available options: - Vendor Name - Ascending Efficiencies - Descending Efficiencies To Printer N/A PUSHBUTTON Generates the selected report to the printer. View N/A PUSHBUTTON Generates the selected report to the monitor. Clear N/A PUSHBUTTON Clears the selected criteria from the form. Exit N/A PUSHBUTTON Exits form

103 Formulas Two key formulas are used in the vendor efficiency reports. They are as follows: Efficiency Value Calculation (Detailed Efficiency %) (100*(Number of Receipts) = Summary Efficiency % Efficiency Value Calculation (100)* (OntimeReceipts) (TotalReceived) = Detailed Efficiency % 9-103

104 INSPECTION MAINTENANCE The Inspection Maintenance subsystem provides the user the ability to capture inspection results for a given item. The form is divided into three tabulations. The Search tab displays a list of all inspection records. The middle Details tab is used to capture an overview of the Inspection Part Number, description, inspection type, etc. The last tab is used to capture the actual inspection results for a defined dimension. Figure 9.33 Inspection Maintenance Search Tab Menu Selection Left click on the in the menu heading Position cursor over Inspection Maintenance from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

105 Inspection Maintenance Inspection Information Overview The 2 nd inspection Tab Details is used to record an overview of the inspection taking place. The form is used to capture information such as inspection type, inspection number, inventory number, part description, lot information and the AQL level. Further information defining all of the fields displayed in figure 9.34 are outlined in the corresponding table found below. Figure 9.34 Inspection Maintenance Inspection Information Overview 9-105

106 Inspection Maintenance First Details Tab (Inspection Information Overview) Field Required Field Type Description Date YES DATE Enter in the date of inspection. The current date is automatically updated when a new inspection is added. This date can be overridden if necessary. Inspection Type N/A DISPLAY The inspection type is automatically displayed. The inspection type is selected when a new inspection is added to the system. Two types of inspections are available: Final Inspection and First Article Inspection. Inspection Number YES ALPHANUMERIC The Inspection Number is automatically created incremental number defined by the parameters set in the table: QUALITY INSPECTION TABLES INSPECTION STEP UP NUMBERS. Inspector NO TEXT Enter in the name of the Inspector inspecting the sample. Shop Order Number NO ALPHANUMERIC Enter in the related shop order number or use the search button for selection. Inventory Number NO ALPHANUMERIC Enter in the inspected Inventory Number. The search button is available for item selection. Part Number YES ALPHANUMERIC Enter in the inspected Part Number. The Part Number field defined along with the Revision Number are both used to retrieve the previously entered inspection parameters defined in the Inspection Table: QUALITY INSPECTION TABLES INSPECTION INSTRUCTIONS Revision NO ALPHANUMERIC Enter in the Part Revision Number into the field. The entered Revision along with the Part Number are both used to retrieve the previously entered inspection parameters defined in the Inspection Table: QUALITY INSPECTION TABLES INSPECTION INSTRUCTIONS Part Description NO TEXT Enter in the part description. Customer Code NO ALPHANUMERIC Enter in the Customer Code if applicable. Customer Name NO TEXT Enter in the Customer Name if applicable

107 Inspection Maintenance First Details Tab (Inspection Information Overview) Field Required Field Type Description P.O. Number NO ALPHANUMERIC Enter in the related Purchase Order number if applicable. Lot Quantity YES NUMBER Enter in the Lot Quantity of the inspected item. Lot Number NO ALPHANUMERIC Enter in the Lot Number of the inspected item. AQL Level YES DROPDOWN Select the AQL level (Accepted Level) from the dropdown menu. The dropdown selections are maintained in the table: QUALITY INSPECTION TABLES AQL Levels / Tables Search NO PUSHBUTTON Activate pushbutton to return to the previous Search tab. Save NO PUSHBUTTON Activate pushbutton to save all changes made to the form. Cancel NO PUSHBUTTON Activate pushbutton to cancel all changes made to the form. Print NO PUSHBUTTON Activate pushbutton to print the inspection reports. The following reports are available for print: Inspection Worksheet First Article Final Inspection Provides an overall inspection for the selected part number. The dimension, method, accepted, rejected and actual quantities are also displayed. An Inspection Worksheet titled First Article is created. Most of the key details defined in the 1 st Details tab are displayed as a header. The actual results including the measured dimension, method and quantities (accepted, rejected, actual) are listed below. An Inspection Worksheet titled Final Inspection is created. Most of the key details defined in the 1 st Details tab are displayed as a header. Listed below are the measured dimension, AQL level, Sample size and Method of Inspection. Exit NO PUSHBUTTON Exits the form back into the Main Visual EstiTrack menu

108 Inspection Maintenance Inspection Information Details The 3 rd Inspection Maintenance tab is used to display and record the actual inspection outcome. The figure below (figure 9.35) displays the inspection parameters defined for the given part number. These parameters are defined in the following table: QUALITY -> INSPECTION TABLES -> INVENTORY INSPECTION MAINTENANCE. The user can drill down on each defined parameter to record the actual inspection results. The Information Worksheet Details form (figure 9.35) is used to record the inspection results for the selected parameter. It can be retrieved for a selected parameter by highlighting the entry and by either double clicking on the item or by activating the UPDATE pushbutton found on the bottom of the form. Further details regarding the final Details tab are provided in the corresponding table found below. Figure 9.35 Inspection Maintenance Inspection Information Details 9-108

109 Inspection Maintenance 2 ND Details Tab (Inspection Detail Overview) Field Required Field Type Description Part Number N/A DISPLAY Displays the part number defined in the 2 nd details tabulation. Lot Qty N/A DISPLAY Displays the lot quantity defined in the 2 nd details tabulation. AQL Level N/A DISPLAY Displays the selected AQL level. Line Number N/A DISPLAY Displays the incremental inspection line number. Dimension N/A DISPLAY Displays the defined dimension on the drawing. Method N/A DISPLAY Displays the defined inspection method. AQL N/A DISPLAY Displays the defined AQL level. Sample N/A DISPLAY Displays the sample size of the inspected item. Accepted N/A DISPLAY Displays the amount of accepted items. Accepted items meet the dimension tolerance criteria. Rejected N/A DISPLAY Displays the amount of rejected items. Rejected items do not meet the dimension tolerance criteria. Actual N/A DISPLAY Displays the actual measured dimension for one inspected item. The additional inspected items can be kept maintained in the text field of the Inspection Worksheet Details form

110 Inspection Maintenance 2 ND Details Tab (Inspection Detail Overview) Field Required Field Type Description Update N/A PUSHBUTTON Activate the pushbutton to update the highlighted dimension. The Inspection Worksheet Details form. is retrieved for the selected dimension. Add N/A PUSHBUTTON Activate the pushbutton to add an inspection dimension for the part number. A new line item is added in the Inspection Worksheet Details form. The line item for the new dimension is automatically incremented to be placed at the end of the dimension list. Insert N/A PUSHBUTTON Activate the pushbutton to insert a new inspection dimension in between two previously defined dimensions. The system will automatically place the dimension above the highlighted entry. The remaining dimensions are renumbered to accommodate the insert.. Delete N/A PUSHBUTTON Activate pushbutton to delete the highlighted entry. After the delete validation is confirmed, the entry is permanently removed from the system

111 Inspection Worksheet Details The Information Worksheet Details form (figure 9.36) is used to record the inspection results for the selected inspection parameter displayed in the previous Inspection Maintenance Details tab. The Line Number, Dimension on Drawing, Method, and AQL are all pre-populated from the INVENTORY INSPECTION MAINTENANCE table defined for the part number. The remaining fields are available for entry and are further described in the corresponding table found below. Figure 9.36 Inspection Worksheet Details 9-111

112 Inspection Maintenance Inspection Worksheet Detail Field Required Field Type Description Line Number N/A DISPLAY The inspection line item is an incremental number automatically assigned to the defined dimension. Dimension on Drawing YES TEXT Enter in the inspected drawing dimension. The dimension is automatically displayed if the inspected part was previously defined in the table: QUALITY INSPECTION TABLES INSPECTION INSTRUCTIONS. Method YES DROPDOWN Select the method of inspection from the dropdown menu. The dropdown values are maintained in the table: QUALITY INSPECTION TABLES INSPECTION METHODS. The method is automatically displayed if the inspected part was previously defined in the table: QUALITY INSPECTION TABLES INSPECTION INSTRUCTIONS. Device Number YES ALPHANUMERIC Enter in the identification number of the actual device used to inspect the line item. AQL YES ALPHANUMERIC Enter in the AQL applied to the inspected line item. The AQL is automatically displayed if the inspected part was previously defined in the table: QUALITY INSPECTION TABLES INSPECTION INSTRUCTIONS. Sample NO NUMBER Enter in the sample size of the inspected item. Accepted NO NUMBER Enter in the number of Accepted parts that measured within the dimensional tolerance. Rejected NO NUMBER Enter in the number of Rejected parts that measured outside of the dimensional tolerance. Actual NO NUMBER Enter in the actual dimension measured of an inspected part. Text Box NO TEXT A free form text box used to capture the measurements of the remaining parts measured in the inspected lot. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form

113 INSPECTION TABLES The Inventory Inspection Maintenance tables are used to establish an inspection procedure for a defined part number and revision. Each dimension needing measurement is defined with three main characteristics: A description of the dimension on the drawing, the method used for part measurement, and the Accepted Level (AQL) established for the part dimension. One the inspected procedure is established, the user can collect the inspection results for the part number and revision using the Inspection Maintenance form via the menu scheme: QUALITY INSPECTION MAINTENANCE. Figure 9.37 Inventory Inspection Maintenance Menu Selection Left click on the menu heading labeled Highlight Inspection Tables from the drop down list. A list of all inspection tables is accessible by moving the cursor over the right arrow. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

114 Inventory Inspection Maintenance The Details tab of the Inventory Inspection Maintenance form (figure 9.37) is used to capture the inspected part and all corresponding dimensions. The following table provides a detail overview and description of the fields and attributes included in the Inventory Inspection Maintenance Details tab displayed in figure Inventory Inspection Maintenance Details Field Required Field Type Description Inventory Number NO ALPHANUMERIC Enter in the Inventory Number of the inspected part. Part Number YES ALPHANUMERIC Enter in the Part Number of the inspected part. Revision NO ALPHANUMERIC Enter in the Part Revision of the inspected part. Description YES ALPHANUMERIC Enter in the part description. The description is automatically populated if the Inventory Number is entered and recognized by the system. Line Item N/A DISPLAY Displays the inspection line item. When a new dimension is added for inspection, the system automatically generates a sequential line item assigned to the new dimension. Dimension on Drawing N/A DISPLAY Displays a list of captured dimensions to be inspected. Method N/A DISPLAY Displays a list of methods used to inspect the corresponding dimension. AQL N/A DISPLAY Displays the AQL level assigned to the corresponding dimension. Update N/A PUSHBUTTON Activate the pushbutton on the selected entry, to retrieve the Inspection Instruction Maintenance form for update. Add N/A PUSHBUTTON Activate the pushbutton to add a new inspection dimension. The Inspection Instruction Maintenance form is further retrieved for update. The entry is automatically placed at the end of the inspection list. Insert N/A PUSHBUTTON Activate the pushbutton to insert a new inspection dimension above the highlighted entry. The Inspection Instruction Maintenance form is further retrieved for update

115 Inventory Inspection Maintenance Details Field Required Field Type Description Delete N/A PUSHBUTTON Deletes the highlighted entry. The record is permanently removed from the system after the delete validation is confirmed. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Print N/A PUSHBUTTON Prints the Inspection Instruction Report. The report includes the information added in the Details tab (Part number, revision, description, and the defined inspection parameters.) 9-115

116 Adding an Inspection Dimension To add a new Inspection Dimension for a given Part Number and Revision, activate the ADD pushbutton located on the bottom of the screen. The Inspection Instruction Maintenance form is retrieved for the entry. Inspection Instruction Maintenance The Inspection Instruction Maintenance form is used to add an inspection line item for every measured dimension. Once the dimension on the drawing, the inspection method and the AQL level are established, the SAVE pushbutton permanently captures the procedure to the system. Figure 9.38 Inspection Instruction Maintenance 9-116

117 Inspection Method Maintenance This subsystem is used to establish all of the inspection methods used to measure parts. The form is broken down into two tabulations. The Search tab displays a list of defined inspection methods. The Details tab is used to actually enter in the name of the inspection method. It is also used when a new Inspection Method is added to the system using the ADD pushbutton located on the Search Tab. Additional information regarding the functions of the tabs and their corresponding fields and pushbuttons are provided in the proceeding table below. Figure 9.39 Inspection Method Maintenance: Search and Details tabulations 9-117

118 Inspection Tables Inventory Inspection Maintenance Field Required Field Type Description Search Tab Inspection Method Description N/A DISPLAY Displays the list of defined Inspection Methods Update N/A PUSHBUTTON Used to retrieve the Details tab for the selected highlighted entry. The user may then proceed to update the description of the Inspection Method and Save any changes to the system. Add N/A PUSHBUTTON Used to add an additional Inspection Method to the system. Once activated, the Details tab is retrieved for entry. Delete N/A PUSHBUTTON Used to remove the highlighted inspection method. After a delete validation is made, the record is permanently removed from the system. Print N/A PUSHBUTTON Used to print the list of all defined inspection methods. The user may view the list on the monitor or send it to the printer. Exit N/A PUSHBUTTON Exits the form back to the main Visual EstiTrack Menu. Details Tab Description YES TEXT Enter in the description of the defined inspection method. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form

119 AQL Level Maintenance Visual EstiTrack s inspection procedures are currently designed using the Accepted Level (AQL) for quality measurement. Current plans to expand the module to include PPM (parts per million) are expected for completion in The figure below displays an example of an AQL entry using the AQL Level Maintenance form displayed below. Further descriptions regarding each AQL tab and the included fields and attributes are further described in each proceeding corresponding table. Figure 9.40 AQL Level Maintenance: Search Tab 9-119

120 AQL Level Maintenance Search Tab Inspection Tables AQL Level Maintenance: Search Tab Field Required Field Type Description AQL Level / Customer Name N/A DISPLAY Displays a list of previously defined AQL levels for each corresponding customer name. Update N/A PUSHBUTTON Updates the existing highlighted entry. The details tab is returned for further update. Add N/A PUSHBUTTON Adds a new AQL level for a given Customer. The details tab is returned for entry. Delete N/A PUSHBUTTON Deletes the highlighted entry. After a delete validation is made, the entry is removed from the system. Print N/A PUSHBUTTON Prints a list defined AQL Levels and their corresponding customers. Exit N/A PUSHBUTTON Exits back into the main Visual EstiTrack menu system

121 AQL Level Maintenance Details Tab The details tab displays the listings of an external AQL table that was entered into the system. Figure 9.41 AQL Level Maintenance: Details Tabs Inspection Tables AQL Level Maintenance: Details Tab Field Required Field Type Description Description YES TEXT The description of the AQL level defined. This description is available in the dropdown menu for AQL selection during Inspection Maintenance entry. Customer NO ALPHANUMERIC Enter in the Customer Code or use the search key for selection. AQL N/A DISPLAY Displays a list of previously defined AQL ratings for the customer. AQL Range N/A DISPLAY Displays the range of production lot sizes defined in the system. SAMP (Sample Size) ACC (Accepted) N/A DISPLAY Displays the defined sample inspection size for the given AQL range. N/A DISPLAY Displays the defined Accepted quantity for the given AQL range. REJ N/A DISPLAY Displays the defined Rejected quantity for the given AQL 9-121

122 Inspection Tables AQL Level Maintenance: Details Tab Field Required Field Type Description (Rejected) range. Update N/A PUSHBUTTON Activate the pushbutton to retrieve the highlighted AQL level for update. The AQL Table Maintenance pop-up displayed below is retrieved for entry. Add N/A PUSHBUTTON Activate the pushbutton to add a new AQL entry for the defined AQL level. The AQL Table Maintenance pop-up is retrieved for entry. Delete N/A PUSHBUTTON Activate the pushbutton to remove the highlighted entry. After the delete validation is made, the record is permanently removed from the system. Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Print N/A PUSHBUTTON Prints a list of defined AQL entries for a given AQL level

123 AQL Table Maintenance The form below is a provision provided that allows that user to capture an outside AQL table into the Visual EstiTrack system. It is retrieved when an ADD is activated from within the AQL Level Maintenance Details tab. Figure 9.42 AQL Table Maintenance Inspection Tables AQL Level Maintenance: Search Tab Field Required Field Type Description AQL YES TEXT Enter in the AQL entry found on an external AQL table. AQL Range (Upper and Lower) YES NUMBER The AQL Range (lower and upper) capture the lower and upper production runs for a given AQL entry. This range is found on an outside AQL Table. Sample Type YES DROPDOWN The Sample type allows the user to select the type of sample being taken. Both Quantities and Percentages are available for selection. SAMP (Sample Size) NO NUMBER Enter in the sample size that needs to be taken for the given AQL Range. This number is found on the AQL Table. ACC (Accepted Amount) REJ (Rejected Amount) NO NUMBER Enter in the accepted amount of good pieces (parts with measurements that fall within the defined dimension tolerance). This number is found on the AQL Table. NO NUMBER Enter in the amount of rejected parts allows. This number is found on the AQL Table

124 Certification of Compliance Note The Certification of Compliance note is used to record the Customer s Certification of Compliance that is later printed and sent to the customer along with any additional required certifications. The free form text box is available for entry. Figure 9.43 Certification of Compliance Note 9-124

125 Inspection Setup Numbers The Default Inspection Numbers form below is used to set the starting point of the incremental inspection numbers generated during Inspection Maintenance. Two types of inspections are available with their own corresponding inspection number range. The fields below allow the user to set the desired naming convention for both the First Article Inspection numbers as well as the Final Inspection Numbers. Figure 9.44 Default Inspection Numbers 9-125

126 CERTIFICATION OF COMPLIANCE The Certification of Compliance subsystem is used to capture all required material and process specifications provided by external vendors. It allows the user to record information such as material lot numbers, heat numbers, and material sources. The Certification of Compliance Search Tab displayed below displays a list of all certifications entered for each associated Shipper number. The remaining three tabulations are further described in the chapter below. Figure 9.45 Certification of Compliance: Search Tab Menu Selection Left click on the menu heading labeled Select Certification from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

127 Certification of Compliance Details Tab The Details tab shown below maintains general certification information. The corresponding table provides additional information regarding the fields and attributes included within the tab. Figure 9.46 Certification of Compliance Details Tab Certification of Compliance Details Tab Field Required Field Type Description Shipper Code NO ALPHANUMERIC Enter in the Ship Code of the item to be shipped or use the search key for selection. Once the information is entered, additional information regarding the customer, part number and shipped quantity are automatically retrieved and populated into the corresponding fields. Sales Order Number NO ALPHANUMERIC Enter in the Sales Order Number of the item to be shipped or use the search key for selection. Ship Date NO DATE Enter in the items ship date. Once the information is entered, additional information regarding the customer and part number are automatically retrieved and populated into the corresponding fields. Ship Quantity NO NUMBER Enter in the quantity to be shipped

128 Certification of Compliance Details Tab Field Required Field Type Description Inventory Number NO ALPHANUMERIC The inventory number is auto-populated if either the sales order or ship code entered is recognized by the system. Part Number NO ALPHANUMERIC The part number is auto-populated if either the sales order or ship code entered is recognized by the system. Part Number Revision NO ALPHANUMERIC The part number revision is auto-populated if either the sales order or ship code entered is recognized by the system. Description NO TEXT The description is auto-populated if either the sales order or ship code is entered. Material NO TEXT Enter in the material used to manufacture the part. Specification NO TEXT Enter in any related material specifications. Revision NO TEXT Enter in the revision of the material specification. Amendment NO TEXT In Progress Notice NO TEXT In Progress Customer Code NO ALPHANUMERIC The Customer Code is auto-populated if either the sales order or ship code entered is recognized by the system. Material Furnished by Customer NO CHECKBOX Activate pushbutton if the material was furnished by the customer. Customer Name NO TEXT The Customer Name is auto-populated if either the sales order or ship code entered is recognized by the system. Address Lines (1,2,3) NO TEXT The Customer s Address is auto-populated into the three available lines if either the entered ship code or sales order is recognized by the system. Material Customer Reference NO TEXT Enter in the cross reference to the customer material number. P.O. Number NO ALPHANUMERIC Enter in any corresponding Purchase Order Number. Notes NO TEXT A free form text box used to capture any additional notes. Signed By NO DROPDOWN Select the user name from the dropdown menu of the user 9-128

129 Certification of Compliance Details Tab Field Required Field Type Description designated to sign the Certification of Compliance. Title NO TEXT Enter in the Title of the user designated to sign the Certification of Compliance. Date NO DATE Enter in the date the Certification of Compliance is signed by the designated user. The current date is auto-populated into the field

130 Certification of Compliance Ship Details Tab The Ship Details tab below is used to capture the lot and material numbers of the shipped quantity. At times, multiple material lots are used to ship out the entire ship quantity. A Certification Shipped Details can be used for every lot/material number included in the shipment. The example below displays one lot/material number used for the entire shipment. The ADD pushbutton found on the main Ship Details tab can be used to add any lot/material numbers included. Additional details regarding the fields and attributes are provided in the corresponding table below. Figure 9.47 Certification of Compliance Ship Details 9-130

131 Certification of Compliance Ship Details Tab Field Required Field Type Description Ship Details Tab Ship Code N/A DISPLAY Displays the Ship Code selected. Ship Date N/A DISPLAY Displays the selection s Ship Date Ship Quantity N/A DISPLAY Displays the total quantity of parts shipped to the customer. Certification Shipped Details Pop-Up Quantity Shipped NO NUMBER Enter in the shipped quantity of parts manufactured with the given material lot and material heat number. Lot Number NO ALPHANUMERIC Enter in the Lot Number of the quantity of parts shipped. Material Heat Number NO ALPHANUMERIC Enter in the Material Heat number of the quantity shipped. Supplier Code NO ALPHANUMERIC Enter in the material supplier code or user the attached search key for selection. Material Source NO TEXT Enter the name of the material source. This field is automatically populated if the Supplier was previously defined in the system. Ship Details Tab Update N/A PUSHBUTTON Activate the pushbutton on a highlighted record to retrieve the Certification Shipped Details Pop-Up for entry. Add N/A PUSHBUTTON Activate the pushbutton to add a new quantity shipped and its corresponding lot and heat numbers. The Certification Shipped Details Pop-Up is retrieved for entry. Delete N/A PUSHBUTTON Activate the pushbutton on a highlighted record to remove the entry from the system. The record is permanently removed after the delete validation is made

132 Certification of Compliance Lot Details Tab The Lot Details tab displayed below is used to capture additional information regarding the lot certification. Details regarding the fields and attributes are provided in the corresponding table below. Figure 9.48 Certification of Compliance Lot Details: Certification Lot Details 9-132

133 Certification of Compliance Lot Details Tab Field Required Field Type Description Lot Details Tab Ship Code N/A DISPLAY Displays the Ship Code selected. Ship Date N/A DISPLAY Displays the selection s Ship Date Ship Quantity N/A DISPLAY Displays the total quantity of parts shipped to the customer. Certification Lot Details Pop-Up Quantity NO NUMBER Enter in the shipped quantity of parts manufactured with the given material lot and material heat number. Process NO TEXT In Progress SPEC NO TEXT In Progress REV NO TEXT In Progress AMD NO ALPHANUMERIC In Progress NOT NO ALPHANUMERIC In Progress Cert./Heat Number NO ALPHANUMERIC Enter in the Material Heat number of the quantity shipped. Supplier Code NO ALPHANUMERIC Enter in the material supplier code or user the attached search key for selection. Material Source NO TEXT Enter the name of the material source. This field is automatically populated if the Supplier was previously defined in the system. Date NO DATE In Progress Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form

134 Certification of Compliance Lot Details Tab Field Required Field Type Description Ship Details Tab Update N/A PUSHBUTTON Activate the pushbutton on a highlighted record to retrieve the Certification Lot Details Pop-Up for entry. Add N/A PUSHBUTTON Activate the pushbutton to add a new quantity shipped and its corresponding lot details. The Certification Lot Details Pop-Up is retrieved for entry. Delete N/A PUSHBUTTON Activate the pushbutton on a highlighted record to remove the entry from the system. The record is permanently removed after the delete validation is made

135 GENERAL EMPLOYEE TRAINING The General Employee Training form shown below captures all training events performed. Each recorded event is assigned a unique training ID and can be assigned to an ISO standard number. Additional information regarding fields and attributes included in the form are provided in the corresponding General Employee Training table. Figure 9.49 General Employee Training Menu Selection Left click on the menu heading labeled Select General Employee Training from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

136 General Employee Training Field Required Field Type Description Training Task Definition Training ID YES ALPHANUMERIC The Training ID is a unique automatically generated number that is assigned when a new General Employee Training document is opened. Date Trained NO DATE Enter in the training date. Description NO TEXT Enter in the subject of the training. Workcenter NO DROPDOWN If the training procedure is using a particular workcenter, select the workcenter used from the dropdown menu. Trained By NO DROPDOWN Select the employee instructing the training. Employee Trained NO DROPDOWN Select the employee completing the training. Hours Trained NO NUMBER Enter in the number of hours taken to complete the training. Expiration Date NO DATE Enter in the expiration date for the training. The user will need to be retrained after the training is expired. Trained on F/G No. NO ALPHANUMERIC If the training is focused on a particular finished goods inventory number, enter in the number or select the entry using the attached search key. Standard Number NO DROPDOWN Select the Standard number best relating to the subject of the training. A list of predefined standards is offered in the dropdown menu. Training Description NO TEXT A free form text box is available for a detailed description of the exact training procedure. The attached scroll bar allows the user to scroll up and down if the description exceeds the visible number of lines. --- Search Key N/A PUSHBUTTON The search key retrieves a search criteria form for used to retrieve previously captured Employee Trainings event. Add N/A PUSHBUTTON Activate pushbutton to capture a new General Employee Training event

137 General Employee Training Field Required Field Type Description Save N/A PUSHBUTTON Saves any changes made to the form. Cancel N/A PUSHBUTTON Cancels any changes made to the form. Delete N/A PUSHBUTTON Deletes the open training entered into the form. After the delete validation is confirmed, the record is permanently removed from the system. Exit N/A PUSHBUTTON Exits the form to the main Visual EstiTrack menu. Scroll to First N/A PUSHBUTTON Scrolls to the first General Employee Training record. Scroll Back N/A PUSHBUTTON Scrolls back one General Employee Training record. Scroll Forward N/A PUSHBUTTON Scrolls forward one General Employee Training record. Scroll to Last N/A PUSHBUTTON Scrolls to the last General Employee Training record. Training Report N/A PUSHBUTTON Activate pushbutton to print a training summary. The report can be printed for a specific training ID, or can list numerous Training IDs that meet the specified Report Criteria

138 EMPLOYEE OPERATIONAL TRAINING The Employee Operational Training log is used to record part and operation specific training procedures that are performed on specific operation workcenters. The verifications are captured for a specific operator and are approved by an authorized employee. Training expiration dates are also monitored within the form. The form is divided into two main sections. Section 1 of figure 9.50 offers search criterion to retrieve a list of previously defined inspection procedures. Section 2 of figure 9.50 lists the retrieved entries and provides the user a means to add new entries to the system. Information regarding additional functionality and attributes are provided on the corresponding tables. Sect. 1 Sect. 2 Figure 9.50 Employee Training Inspection and Procedure Verification Menu Selection Left click on the menu heading labeled Select General Employee Training from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

139 Employee Operational Training Field Required Field Type Description Criteria Section 1 of Figure 9.50 The search criterions entered in the fields below are used as a filtering means for the compiled results list. Inventory Number NO ALPHANUMERIC Enter in the inventory number to be retrieved. The search key is available for selection. Operator NO DROPDOWN Select the operator to be retrieved from the dropdown menu. Starting Date NO DATE Enter in the starting date for retrieval. The interactive calendar is available for date selection. Operation Number NO DROPDOWN Select the operation number to be retrieved from the dropdown menu. Workcenter NO DROPDOWN Select the workcenter to be retrieved from the dropdown menu. Approved By NO DROPDOWN Select the employee from the dropdown list to retrieve a list of inspection and procedure verifications approved by the selected employee. Search N/A PUSHBUTTON Activate the search button to create a list using the criterion entered above. The generated list is displayed in section 2 described below. Results List Section 2 of Figure 9.50 Inventory Number N/A DISPLAY Displays the inventor number captured in the verification. Approved Operator N/A DISPLAY Displays the operator approved the specific inventory number, workcenter and operation training procedure. Approved By N/A DISPLAY Displays the employee who approved the training. Date Approved N/A DISPLAY Displays the approved training date captured in the verification. Expiration Date N/A DISPLAY Displays the training s expiration date. Workcenter N/A DISPLAY Displays the workcenter the operator was trained upon

140 Employee Operational Training Field Required Field Type Description Operation N/A DISPLAY Displays the operation the operator was trained upon. Current/History YES RADIOBUTTON Both current verifications and expired verifications can be individually viewed by the selecting the corresponding radio button. Add N/A PUSHBUTTON Activate pushbutton to add a new verification of a completed training procedure. The Inspection Procedure Verification form is retrieved in Add mode. Archive N/A PUSHBUTTON The records maintained in the Employee Training can be archived by highlighting the selected record and activating the Archive pushbutton. Print N/A PUSHBUTTON Activate pushbutton to print an An Inspection and Procedure, Verification System Employee Approval Report. Reports for both current and expired verification can be individually printed. Exit N/A PUSHBUTTON Exits form into the main Visual EstiTrack menu system

141 Adding a New Inspection and Procedure Verification To add a new verification for a completed employee training on a specific part number, operation and workcenter, activate the ADD pushbutton located on the bottom of the screen. The Inspection Procedure Verification Add form is retrieved for the entry. Figure 9.51 Inspection Procedure Verification Add Employee Operational Training Inspection Procedure Verification Field Required Field Type Description Inventory Number YES ALPHANUMERIC Enter in the Inventory number used during the training or use the attached search key for selection. Operation Number YES DROPDOWN Select the operation number of the trained procedure. The operation dropdown menu is automatically populated according the operations defined for the selected inventory number. Employee YES DROPDOWN Select the name of the employee who received the training for the selected inventory number and operation. Starting Date YES DATE Enter in the starting date of the approved training. The training procedure is valid only through the duration period defined

142 Employee Operational Training Inspection Procedure Verification Field Required Field Type Description Expiration Date N/A DISPLAY The expiration date is automatically calculated using the starting date defined above and the number of days defined in the Employee Training Expiration Days field of the Company Maintenance Table. The field is maintained in the Miscellaneous tab of the table: TABLE COMPANY. Workcenter YES DROPDOWN Select the workcenter used during the training procedure from the dropdown menu. Save and Add N/A PUSHBUTTON Activate pushbutton to save the current entry and add a new verification to the system. Save and Exit N/A PUSHBUTTON Activate the pushbutton to save the current entry and to return back to the main Employee Training form. Cancel and Exit N/A PUSHBUTTON Activate the pushbutton to cancel any changes made to the form and to return back to the main Employee Training form 9-142

143 DOCK AUDIT Periodic auditing of the shipping process can be enforced by activating the Dock Audit interval within the Company tables. The Dock Audit form displayed below in figure 9.52 is automatically initiated prior to allowing the shipping procedure to be completed. Routine checks on the packing system found within the form, forces the employee to review the open shipment for correct labeling, packaging and weight. Once all of the check procedures are completed, the Audit can be saved and the shipment may be completed Figure 9.52 Dock Audit Menu Selection Left click on the menu heading labeled Select Dock Audit from the drop down list. Security The system administrator controls access to this menu item via User Access Rights (see User Table). Careful consideration should be given regarding who is authorized to manage this menu option

144 Defining an Audit Interval The Dock Audit interval is maintained in the Shipping Receiving tab of the Company Tables: TABLES COMPANY Shipping/Rec. Tab. The Dock Audit Interval field found within the tab is circled in red in the figure below. The Dock Audit will initiate for every defined number of completed shipments. In the example below, the dock audit will initiate after the shipper completes 100 shipments. Figure 9.53 Dock Audit Interval Definition 9-144

145 Monitoring the Dock Audit History All completed audits are logged into the Dock Audit History table displayed in the figure below. The details regarding the shipment auditing are all included along with the actual audit results. The user may also print a Dock Audit History report by using the Print Audit Report pushbutton located on the bottom of the form. Figure 9.54 Dock Audit History 9-145