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┌─────────────────────────────────────────────────────────────────────┐
│ CUSTOMER INQUIRY │
│ (A2: Follow-Up Record) │
└─────────────────────────────────────────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ QUOTATION (B1) │
│ Enquiry Review Checklist → Quote │
│ ├─ Item description │
│ ├─ Technical requirements │
│ ├─ Feasibility check │
│ └─ Review completion date │
└─────────────────────────────────────────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ SALES ORDER (B2) │
│ Order Acceptance #001 → Sales Order Created │
│ ├─ Order Acceptance Number (Auto-Generated) │
│ ├─ Design Manager Link │
│ ├─ Design Input Reference │
│ └─ Auto-generate Transmittal to Design │
└─────────────────────────────────────────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ DESIGN INPUT (C1) │
│ Auto-linked to Sales Order upon Order Acceptance │
│ ├─ Sales Order Reference │
│ ├─ Design Parameters (Table) │
│ ├─ Design Engineer Assignment │
│ ├─ Design Drawings (Attachment) │
│ └─ Revision Tracking (Rev.00 → Rev.01) │
└─────────────────────────────────────────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ BOM CREATION (C2-C3) │
│ Drawing & BOM Rev.00 → Item + BOM Creation │
│ ├─ Design Input Reference (Auto-linked) │
│ ├─ Approved Drawing Attachment │
│ ├─ Design Approval Status (Workflow) │
│ ├─ POS Generation (Parts/Specifications) │
│ └─ Auto-generate Transmittal (Design → PUR, PRD, QC) │
└─────────────────────────────────────────────────────────────────────┘
│
┌───────────────┼───────────────┐
▼ ▼ ▼
┌──────────────┐ ┌──────────────┐ ┌──────────────┐
│ PURCHASE │ │ PRODUCTION │ │ QUALITY CTRL │
│ (D Module) │ │ (G Module) │ │ (H Module) │
└──────────────┘ └──────────────┘ └──────────────┘
│ │ │
└───────────────┼───────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ QUALITY CONTROL PLAN (H1) │
│ Auto-created based on Sales Order + Item ASME Info │
│ ├─ ASME Standard Reference (ASME Sec VIII Div 1) │
│ ├─ Inspection Activities (Linked to each stage) │
│ ├─ WPS/PQR/WPQ References │
│ ├─ NDE Procedures (LPT, RT, VT) │
│ └─ Acceptance Criteria per ASME │
└─────────────────────────────────────────────────────────────────────┘
│
┌───────────────┼───────────────┐
▼ ▼ ▼
┌──────────────────┐ ┌──────────────────┐ ┌───────────────────────────────┐
│ RAW MATERIAL │ │ IN-PROCESS │ │ FINAL TESTING │
│ INSPECTION (H4) │ │ INSPECTION (H5-6)│ │ (H6-7) │
│ │ │ │ │ │
│ ├─ Material ID │ │ ├─ Heat Treat │ │ ├─ Pressure Test │
│ │ │ │ │ │ │ ├─ Final Dimension Inspection │
│ ├─ MTC Attached │ │ ├─ Stage Insp │ │ ├─ Painting Insp │
│ ├─ Plate/Pipe │ │ ├─ LPT Report │ │ └─ Final Release │
│ │ Inspection │ │ ├─ Visual Insp │ │ │
│ └─ Discrepancies │ │ └─ RT Reports │ │ │
└──────────────────┘ └──────────────────┘ └───────────────────────────────┘
│ │ │
└───────────────┼─────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ WORK ORDER COMPLETION │
│ All Quality Checks PASSED → Ready for Dispatch │
│ ├─ Manufacturing Processes Completed │
│ ├─ Quality Status = ACCEPTED │
│ ├─ All Inspection Reports Linked │
│ └─ Final Inspection Released │
└─────────────────────────────────────────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ DELIVERY NOTE & DISPATCH │
│ Delivery Challan (E8) → Delivery Note Created │
│ ├─ Packing List │
│ ├─ All Quality Documents Attached │
│ ├─ Customer Reference │
│ └─ Shipping Details │
└─────────────────────────────────────────────────────────────────────┘
│
▼
┌─────────────────────────────────────────────────────────────────────┐
│ CUSTOMER SATISFACTION │
│ (B5-B8) Post-Delivery Follow-up │
│ ├─ Satisfaction Survey (B6) │
│ ├─ Complaint Register (B8) │
│ └─ Analysis Report (B7) │
└─────────────────────────────────────────────────────────────────────┘
┌──────────────┐
│ MARKETING │
│ Lead, Opp │
└──────────────┘
│ (A2, A3, A4)
│ Tender Submission
│
▼
┌──────────────┐
│ SALES │
│ Quotation, │
│ Sales Order │
└──────────────┘
│ (B1, B2)
│ Order Acceptance
│
▼
┌──────────────┐
│ DESIGN │
│ Design Input,│
│ Drawing, BOM │
└──────────────┘
│ (C1, C2, C3)
│ Auto-transmit to PUR, PRD, QC
│
├─────────────────┬──────────────────┐
▼ ▼ ▼
┌──────────┐ ┌──────────┐ ┌──────────┐
│ PURCHASE │ │ PRODUCTION│ │ QUALITY │
│ │ │ │ │ CONTROL │
└──────────┘ └──────────┘ └──────────┘
Data Flow:
- Lead → Opportunity (when tender identified)
- Opportunity → Quotation (when interested)
- Quotation → Sales Order (when accepted)
- Sales Order → Design Input (automatic creation)
- Design Input → Item + BOM (when design finalized)
- BOM → Work Order (triggers to PUR, PRD)
- Work Order → Quality Plan (automatic creation)
┌──────────────────────────────────────┐
│ PURCHASE ORDER (D2) │
│ Material Stock Verified Check │
│ Quality Inspection Flag │
│ Supplier Performance Score Auto- │
│ fetched from Supplier Master │
└──────────────────────────────────────┘
│
▼
┌──────────────────────────────────────┐
│ PURCHASE RECEIPT (E1: GRIR) │
│ ├─ Material Inspection Status │
│ ├─ Quality Inspector Assignment │
│ ├─ MTC (Material Test Cert) Link │
│ ├─ Visual Inspection Details │
│ └─ Auto-flag if ASME required │
└──────────────────────────────────────┘
│
▼
┌──────────────────────────────────────┐
│ STOCK ENTRY (E3, E4, E5) │
│ ├─ Shelf-Life Tracking (E7) │
│ ├─ Oven Storage Req. (E9 Register) │
│ ├─ Material Requisition (E4) │
│ ├─ Issue Slip (E5) │
│ └─ Stock Summary (E2) │
└──────────────────────────────────────┘
│
▼
┌──────────────────────────────────────┐
│ PRODUCTION PLANNING (G1) │
│ ├─ Work Order Creation │
│ ├─ Manufacturing Processes │
│ ├─ Gantt Chart Display │
│ └─ Equipment Assignment │
└──────────────────────────────────────┘
│
▼
┌──────────────────────────────────────┐
│ DAILY PRODUCTION REPORT (G2) │
│ ├─ Date-wise Operations │
│ ├─ Employee & Equipment Tracking │
│ ├─ Production Qty & Quality Status │
│ └─ Supervisor Approval │
└──────────────────────────────────────┘
QC FLOW - 8 SECTIONS:
━━━━━━━━━━━━━━━━━━━━━━
SECTION 1: PLANNING
┌─────────────────────────────┐
│ Quality Control Plan (H1) │ ← Based on: Item + Design Input
├─────────────────────────────┤
│ • ASME Standard Reference │
│ • Inspection Activities │
│ • Acceptance Criteria │
│ • WPS/PQR/WPQ Links │
└─────────────────────────────┘
│
├─→ MDR (H2) - Master Data Reference
└─→ Inspection Checklist (H3)
SECTION 2: RAW MATERIAL
┌─────────────────────────────┐
│ Material Identification (H4)│ ← From: Purchase Receipt
├─────────────────────────────┤
│ ├─ Plate Inspection (H4a) │
│ ├─ Pipe Inspection (H4b) │
│ ├─ Flanges Inspection (H4c) │
│ └─ Fitting Inspection (H4d) │
├─────────────────────────────┤
│ • Attaches MTC Document │
│ • Verifies Chemistry │
│ • Verifies Mechanical Props │
│ • Links to Material Spec │
└─────────────────────────────┘
SECTION 3: IN-PROCESS INSPECTION
┌─────────────────────────────┐
│ Dish End Forming (H5) │
│ Heat Treatment (H6-H7) │ ← From: Production WO
├─────────────────────────────┤
│ • Heat Cycle & Sketch │
│ • Heat Treatment Report │
│ • Temperature Monitoring │
│ • Soaking Time Verification │
├─────────────────────────────┤
│ Stage Inspections (H9-H12) │ ← During: Manufacturing
├─────────────────────────────┤
│ • Long Seam Setup │
│ • Dish End Inspection │
│ • Back Chip & PT │
│ • Circular Seam Fit-up │
│ • Nozzle Inspections │
│ • Internal Weld Visual │
│ • Measuring Instruments │
└─────────────────────────────┘
│
├─→ Liquid Penetrant Test (H10) [LPT]
├─→ Radiography Report (H13-H15) [RT]
└─→ Visual Inspection Report (H17)
SECTION 6: TESTING & CODE STAMPING
┌─────────────────────────────┐
│ Pressure/Hydro Test (H16) │ ← After: All fabrication
├─────────────────────────────┤
│ • Test Medium (Water/Air) │
│ • Design Pressure Calc │
│ • Gauge Calibration Links │
│ • Holding Time │
│ • Result: Pass/Fail │
├─────────────────────────────┤
│ Painting Inspection (H18) │ ← Surface Prep & Paint
├─────────────────────────────┤
│ • Surface Preparation Grade │
│ • DFT (Dry Film Thickness) │
│ • Paint Batch Details │
│ • Humidity/Temp Recording │
└─────────────────────────────┘
SECTION 7-8: DOCUMENTATION & FINAL RELEASE
┌─────────────────────────────┐
│ Weld Summary (H11-H12) │
│ • Weld Details by Joint │
│ • All NDE Reports Linked │
│ • Final Acceptance Status │
├─────────────────────────────┤
│ Name-plate Details (H19-H20)│
├─────────────────────────────┤
│ Welder Qualification │
│ • Continuity Record (H21) │
│ • Qualified Welder List (H22)
│ • WPS/PQR/WPQ Links │
├─────────────────────────────┤
│ Instrument Calibration │
│ • Calibration List (H23) │
│ • Out of Cal Form (H24) │
├─────────────────────────────┤
│ Deviation/Non-Conformity │
│ • Deviation Change Note (H25)
│ • NCR Record (if any) │
├─────────────────────────────┤
│ FINAL INSPECTION RELEASE │
│ ✓ All documents linked │
│ ✓ All tests passed │
│ ✓ Ready for delivery │
└─────────────────────────────┘
│
▼
DISPATCH
Sales Order (SO)
├─ Links to: Quotation
├─ Links to: Customer/Opportunity
├─ Creates: Design Input (auto)
├─ Creates: Item (via Design)
├─ Creates: BOM (via Design)
├─ Creates: Work Order
├─ Creates: Quality Control Plan (auto)
├─ Creates: Material Requisitions (via BOM)
├─ Generates: Document Transmittals (auto)
└─ References in: Purchase Orders
Item (Product)
├─ ASME Compliance flag
├─ Material Specification
├─ Pressure/Temperature Ratings
├─ Links to: Multiple Sales Orders
├─ Links to: BOMs
├─ Links to: Quality Control Plans
└─ References in: Purchase Orders
BOM
├─ Links to: Sales Order
├─ Links to: Design Input
├─ Links to: Item(s)
├─ Design Approval Workflow
├─ Revision Tracking (Rev.00 → Rev.01)
└─ Generates: Work Orders
Work Order
├─ Links to: Sales Order
├─ Links to: BOM
├─ Links to: Quality Control Plan
├─ Manufacturing Processes (Table)
│ └─ Equipment, Timeline, Employee
├─ Generates: Production Reports
├─ Triggers: Inspection Checkpoints
└─ References: All Quality Documents
Quality Control Plan
├─ Links to: Sales Order
├─ Links to: Item (ASME reference)
├─ ASME Standard + Edition
├─ Inspection Activities (Table)
├─ WPS/PQR/WPQ Links
├─ NDE Procedure Links
└─ Acceptance Criteria
Material Identification Report
├─ Links to: Work Order
├─ Links to: Item
├─ Links to: Purchase Receipt (GRIR)
├─ Attaches: Material Test Certificates (MTC)
└─ Quality Inspector Assignment
Liquid Penetrant Test Report
├─ Links to: Work Order
├─ Links to: Weld Specification (WPS)
├─ References: ASME Procedure
└─ Result: Accepted/Rejected
Radiography Report
├─ Links to: Work Order
├─ Covers: Multiple Joints
├─ Film Numbers
└─ Defects Documentation
Pressure Test Report
├─ Links to: Work Order (final gate)
├─ Links to: Item (pressure rating)
├─ Gauge Calibration Records
└─ Test Duration & Results
Weld Summary
├─ Links to: Work Order
├─ References: All Weld Joints
├─ Links to: Visual Inspection Reports
├─ Links to: LPT Reports
├─ Links to: RT Reports
└─ Final Acceptance Status
Delivery Note
├─ Links to: Sales Order
├─ References: Work Order
├─ Attaches: All QC Documents
├─ Attaches: Test Reports
├─ Attaches: Certificates
└─ Includes: Packing List
Sales Order Created
│
▼
Design Input Created (auto)
│
▼
BOM Approved (Design Approval)
│
├─→ Material Requisition Created
│
▼
Work Order Created (auto)
│
├─→ Purchase Orders Created
├─→ Quality Control Plan Created (auto)
│
▼
Raw Materials Received & Inspected
│
├─→ If PASS: Proceed
└─→ If FAIL: Deviation/NCR → Supplier Action
│
▼
Production Started
│
├─→ Daily Production Reports
├─→ Stage Inspections (multiple gates)
│
├─→ Gate 1: Material ID Report ✓
├─→ Gate 2: Heat Treatment Report ✓
├─→ Gate 3: Stage Inspection ✓
├─→ Gate 4: Weld Visual ✓
├─→ Gate 5: LPT Report ✓
├─→ Gate 6: RT Report ✓
│
├─→ If ANY GATE FAILS: Rejection → Rework or Deviation
│
▼
Pre-Pressure Test Internal Inspection
│
▼
Pressure Test (Hydrostatic/Pneumatic)
│
├─→ If PASS: Proceed
└─→ If FAIL: Rejection
│
▼
Surface Preparation & Painting
│
├─→ Painting Inspection ✓
│
▼
Final Inspection Release
│
├─ Verify all documents linked
├─ Verify all tests passed
├─ Verify welder qualifications
├─ Verify instrument calibration
└─ Verify name-plate details
│
▼
Delivery Note Created
│
├─→ Attach all QC documents
├─→ Attach test certificates
├─→ Attach AS-BUILT drawings
│
▼
Goods Dispatched
│
▼
Customer Satisfaction Survey (post-delivery)
MASTER DATA
├── Supplier
│ ├─ Category (Mfg/Trader/Service)
│ ├─ Quality Rating (1-5)
│ ├─ Performance Score (calculated)
│ ├─ Approvals & Certifications
│ ├─ Audit History
│ └─ Corrective Actions
│
├── Employee
│ ├─ Skill Matrix
│ ├─ Training Records
│ ├─ Welder Qualifications
│ ├─ Quality Inspector Status
│ ├─ Incident History
│ └─ Certifications
│
├── Item
│ ├─ ASME Compliance Flag
│ ├─ Material Specification
│ ├─ Pressure/Temperature Ratings
│ ├─ Revision History
│ └─ Standard Inspection Plan
│
├── Asset
│ ├─ Machine Identification
│ ├─ Capacity/Specifications
│ ├─ Maintenance Schedule
│ ├─ Calibration History
│ └─ Last Service Date
│
└── Document Template
├─ Quality Control Plan
├─ Inspection Checklist
├─ Acceptance Criteria
└─ Standard Procedures
OPERATIONAL DATA (per Sales Order)
├── Sales Order
│ ├─ Order Acceptance # (unique)
│ ├─ Design Input (1:1)
│ ├─ Work Order (1:1)
│ └─ Quality Control Plan (1:1)
│
├── Design Input
│ ├─ Sales Order Link (1:1)
│ ├─ Items Created (1:M)
│ ├─ BOM Created (1:M)
│ └─ Revisions Tracked
│
├── Work Order
│ ├─ BOM Link (1:1)
│ ├─ Manufacturing Processes (1:M)
│ ├─ Quality Inspections (1:M)
│ ├─ Purchase Requisitions (1:M)
│ └─ Production Reports (1:M)
│
├── Quality Control Plan
│ ├─ Inspection Activities (1:M)
│ ├─ Material ID Report (1:1)
│ ├─ Heat Treatment Report (1:1)
│ ├─ Stage Inspections (1:M)
│ ├─ LPT Reports (1:M)
│ ├─ RT Reports (1:M)
│ ├─ Pressure Test Report (1:1)
│ ├─ Weld Summary (1:1)
│ └─ Final Inspection Report (1:1)
│
└── Delivery Note
├─ Sales Order Link (1:1)
├─ Work Order Reference
├─ QC Documents (1:M attachments)
├─ Test Certificates (1:M attachments)
└─ Packing List Items (1:M)
Sales Order Submitted
│
▼
Design Input Created & Assigned to Design Engineer
│
▼
Design Engineer Completes Design
├─→ Uploads Drawing (Attachment)
├─→ Sets Design Parameters
└─→ Marks "Ready for Approval"
│
▼
Design Manager Review
├─→ Reviews Drawings
├─→ Verifies ASME Compliance
├─→ Checks WPS/PQR/WPQ References
└─→ Approval/Rejection with Comments
│
├─→ If APPROVED (Design Manager):
│ └─→ Proceed to BOM
│
└─→ If REJECTED:
└─→ Send back to Design Engineer
(revision cycle)
BOM Approval Workflow:
BOM Created from Design Input
│
▼
Design Manager Approval
└─→ Verify Component Selection
└─→ Verify Against Drawing
└─→ Approve or Reject
│
├─→ If APPROVED:
│ ▼
│ Work Order Creation (auto)
│ ▼
│ Transmittal Generated to:
│ ├─ Purchase Department
│ ├─ Production Department
│ └─ Quality Control Department
│
└─→ If REJECTED:
└─→ Return to Design Input
Inspection Report Submitted (LPT/RT/Pressure Test)
│
▼
Quality Inspector Review
├─→ Verify Test Parameters
├─→ Compare to Acceptance Criteria
├─→ Check Attachments/Photos
└─→ Inspection Complete
│
├─→ If PASS:
│ ▼
│ Mark as "Accepted"
│ └─→ Update Quality Status
│
└─→ If FAIL:
├─→ Create NCR/Deviation
├─→ Assign Rework/Repair
└─→ Update Quality Status
Final Inspection Release:
All QC Gates Passed
│
├─ Material ID Report ✓
├─ Heat Treatment ✓
├─ All Stage Inspections ✓
├─ LPT/RT/Pressure Tests ✓
├─ Painting Inspection ✓
└─ Welder Qualifications Verified ✓
│
▼
Quality Manager Final Review
│
├─→ Verify All Documents Linked
├─→ Check for Any Outstanding NCRs
├─→ Review Welder Continuity
├─→ Verify Instrument Calibration
└─→ Approve Final Release
│
├─→ If APPROVED:
│ ▼
│ Release for Delivery (auto)
│ └─→ Update Work Order Status
│
└─→ If REJECTED:
└─→ Identify Issues
└─→ Corrective Action Required
| Trigger | Auto-Generated Document | Condition |
|---|---|---|
| Sales Order Submitted | Design Input | Always |
| Design Input Approved | Item + BOM | When design finalized |
| BOM Approved | Work Order | When design approved |
| BOM Approved | Document Transmittal (to PUR, PRD, QC) | Always |
| Work Order Created | Quality Control Plan | When Item has ASME flag |
| Work Order Created | Material Requisition (from BOM) | Always |
| Purchase Receipt Submitted | Material ID Report (pending) | When QC flag set |
| Work Order Started | Daily Production Report (template) | On demand |
| Daily Production Report Submitted | Stage Inspection Report (pending) | When inspection needed |
| Stage Inspection Complete | Transmittal (to QC) | If issues found |
| Pressure Test Passed | Final Inspection Report (template) | Automatically created |
| Final Inspection Approved | Delivery Note (draft) | When all gates passed |
- Setup Custom Doctypes: Create the 24+ custom doctypes first
- Add Custom Fields: Use the provided JSON specifications
- Configure Workflows: Set up approval state machines
- Build Automations: Create server-side events for auto-generation
- Setup Notifications: Email alerts for approvals, failures, due dates
- Create Reports: Dashboard for quality metrics, production status
- Integrate Documents: Setup file attachments and links
- Test Data Flow: End-to-end testing with sample SO
- Train Users: Department-wise training sessions
- Go-Live: Phased rollout starting with most critical departments
Document Version: 1.0
Last Updated: December 12, 2025
Status: Ready for Development Phase