CHEMFAB ALKALIS LIMITED (CAL)

(TO- BE Process Document)

PROCESS QUALITY

Author

Saravanakumar M.R

Creation Date

02-Dec-2014

Last Updated

06-Dec-2014

Control Number

Prod/Process/01

Version

Approvals:

Chemfab Alkalis Ltd

Chain-Sys

1.0

Document Control
Record of Changes
Date

02-Dec2013

Author

Version

Changes

Laura

Saravanakumar M R

Reviewers
Name

Position

Distribution
Copy
No.

Name

Location

File

Craftsman

Note To Holders:
If you receive an electronic copy of this document and print it out,
please write your name on the equivalent of the cover page, for
document control purposes.
If you receive a hard copy of this document, please write your name on
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To Be Process V1.0
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Contents
Document Control

A. Introduction

B.Manufacturing - (To Be Process)

Oracle Process Manufacturing Quality:

Business Process Identification

To Be Process V1.0
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A. Introduction

Objective
The objective of the document is to provide an overview of solution design for Oracle Quality,
which will be implement in Chem Fab Alkalies with respect to Oracle EBS 12.1.3.
Scope
The scope of the document is to provide To Be process based on the understanding from the
reference manuals and interaction with the process owners. The existing process has been
identified based on the study conducted at Chem Fab Alkalies.
This document will help the process owners in understanding the existing quality process
followed in Chem Fab Alkalies and the To Be process which will be implemented that best suits
the business requirements.
The To Be process has been designed considering the functionalities available in Oracle EBS
12.1.3, limitations of the application and the common process followed in Chem Fab Alkalies.
The process has been considered common for all the divisions.
The document will help in understanding the high level and detail To Be process. The activities
under each process are explained in detail where ever applicable.
The document will be considered for update if any process needs to be amended in line with
Oracle EBS 12.1.3 and the changes will be accommodated and recorded based on the approval
from core process owners.

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B.Manufacturing - (To Be Process)

Oracle Process Manufacturing Quality:
Oracle Process manufacturing Quality Module is part of the Oracle E-Business Suite
and Consistent testing of products and materials reduces waste by detecting potential
problems before they become major issues. A total quality approach designs the manufacturing
process in parallel with the quality testing process. Oracle Process Manufacturing (OPM) Quality
Management interfaces quality testing into all aspects of research, development,
commercialization, production, purchasing, and shipping operations. This seamless interfacing
across the supply chain assists in the consistent development and application of quality
standards.
Process Quality is one of the modules in Oracle Process Manufacturing. This module is
intended to handle and recording of all testing data and controlling of quality approvals for
input and final products which are using in production process.
This module is closely integrated with Oracle Process Manufacturing, Oracle Inventory,
Oracle Purchasing and Oracle Order Management. Process Quality includes test methods and
tests. This includes entering test methods, understanding tests, and entering test data. This
includes item specifications, monitoring specifications, and their validity rules, procedures for
entry of base and overlay item specifications and monitoring specifications, the status approval
process, editing and adding status codes, optional tests, creating samples automatically, and
entry of item specification validity rules and monitoring specification validity rules.
This includes information on the sampling process, entering item samples and
monitoring samples, entering results, editing results, completing receiving inspection based on
sample results, and how to prevent the completion of a batch step until acceptable results are
recorded and approved. The process for selecting samples and tests for mass results entry is
described.
Quality Tests
A test helps determine a quality characteristic or attribute of an item or lot. A test
method describes how a test is performed. A test method can refer to a test protocol or
standard operating procedure.
Sampling Plans
The Sampling Plan is a plan which helps in deriving how much and how often to
sample. By entering the number, size, and frequency of samples to take, the sampling plan lets
you prescribe sample groups. They are associated to a specification validity rule on the Validity
Rules.
A sampling plan becomes effective for a process quality-enabled item and optionally,
for a grade when it is associated with a specification validity rule.
Specifications
Specifications state the quality conformance requirements for materials, such as an
item or a lot, or for environmental conditions, such as a resource or a sub-inventory.
Item specifications identify a target or ideal result for each quality test performed by
listing test requirements that specify these characteristics or attributes. The specifications
entered are used to compare against actual test results from samples taken. For range-

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validated tests, define the minimum and maximum acceptable range values for the test as well
as the out-of-specification action to perform when a test fails.
Samples
Samples are a part of or a population of the whole product which intended to show the
whole product. Sampling supports quality inspection of materials during various points in the
supply chain. This includes sample collection at events such as receiving, batch reaction, batch
step release, production yield, and lot expiration. Sampling inspection also occurs for material
received from suppliers, for work in process material, for inventory, for specific customers, and
for shipments.
Results
Results are the output of a test performed based on a predetermined test method and
sampling rules and procedures. Quality results serve as the basis for measuring actual material
characteristics against expected quality records, and for assigning follow-up actions to be
taken. Results are logged against an individual sample, where scheduled tests are driven by
the specification and additional impromptu tests can be added to the sample analysis. After a
technician enters results, a Quality Manager has the option to evaluate the results set against
targets and limits to determine the sample disposition based on whether the results are
acceptable.

OPM Quality Process

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Standard QC Inspection Process

TO-BE Process
Description/Modification
Process Execution Reason:
Items procured from supplier
are to be Inspected to check
whether they confirm to the

Oracle Standard Business process

Material

sent

by

the

supplier

are

received, Inspected and delivered into

the sub-inventory.
Receiving Process :

specification agreed.
Nav:
Return the goods to the vendor
if the quality of the product
does

not

Oracle

PurchasingReceivingReceipts.

match

the Enter the quantity of item received.

specification defined or if the Save the record.
deviation is within acceptable
limits then payment may be QC Inspection:
corrected to the extent of the
deviation.
Items

1. Item, Supplier, Supplier Site, PO and

Receipt will default against the sample

covered

are

Raw

Materials (Chemicals, Furnace

generation.
2. Select a Laboratory to do the Sample
testing and Save the record which will

Oil, etc)

create a Sample number.

Process Description:

3. Enter [Results] for this Sample

After doing a receipt process for

Purchased

Item,

Sample

(document) can be created for

4. The sample result will be defined as

per the Inspection results captured
after testing. Save the record.
5. If the sample test value falls within
To Be Process V1.0
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Gaps /
Workaroun
ds /
Customizat
ion

AS-IS
Doc
Ref

TO-BE Process
Description/Modification

Oracle Standard Business process

spec

then

the

disposition

status

the Item & will be inspected

automatically changes from Pending to

and

Complete.

Delivered

to

the

Sub-

inventory.

Rejected

6. If the sample test value falls out of

item

will

be

returned to supplier.

spec

then

the

disposition

status

automatically changes from Pending to

In-Progress.

minimal 7. Approver will Change the Disposition

as per the result to Reject/Accept
deviation or any urgent
Under Deviation
material requirement due to
If

there

is

any

shortage or any other reason

then the rejected material
may be used by changing

To Change Disposition Status:

ActionsChange Disposition

AUD Disposition status will be changed to

( accepted Under Deviation) Accept from Complete status and to
with due approval from the Reject/AUD from In-Progress status.
the

disposition

quality

head

to

and

authorities (unit Head).

other
Receiving Transaction:
Nav:

Oracle

Transactions

Inventory

Receiving

Receiving Transactions.
The Receiving User verifies the result of
Inspection in Collection plan.
Deliver to Sub-Inventory:
Nav:

Oracle

Transactions

Inventory

Receiving

Receiving Transactions.
1. The

Receiving

accepted
8

User

quantity

delivers
to

the

the
Sub-

To Be Process V1.0
Company Confidential - For Internal Use Only

Gaps /
Workaroun
ds /
Customizat
ion

AS-IS
Doc
Ref

TO-BE Process
Description/Modification

Oracle Standard Business process

inventory.
2. Rejected items would be considered
with approval from the Quality Head;
the status will be changed to AUD and
delivered to the sub inventory.
3. If not the material will be returned to
the supplier as per the Standard return
process.

To Be Process V1.0
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Gaps /
Workaroun
ds /
Customizat
ion

AS-IS
Doc
Ref

Business Process Identification

1. Quality Inspection at Purchase Receipt
a.
b.
c.
d.
e.
f.

Receipt the Raw-materials Against the Purchased order for the Production
Collecting Samples from the received Raw materials
Creating Samples in the system for the Received Raw Materials
Testing Samples in the Quality Lab
Entering Quality Results against the Created samples, separate Result entered for each
Test.
Based on the Results the raw material can be delivered or rejected or accepted with
deviation based on results and subsequent deduction in supplier invoice.

10

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2. Quality Inspection at Work-In-Process

a.
b.
c.
d.

Collecting Samples of Intermediate material in the production process

Creating Samples in the system for the Received WIP Materials
Testing Samples in the Quality Lab
Entering Quality Results against the Created samples, separate Result entered for each
Test with respect to the test parameters pre-specified.
e. Based on the Results the In process material can be accepted , corrective actions taken
if there is less deviation from the test parameters or alarming the production supervisor
for immediate action

11

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3. Quality Inspection FG Items

a. Collecting Samples of Finished goods from the batch completion or storage (eg,. For
CSL33%, CSL48%, Sodium Hypo Chlorite, etc)
b. Creating Samples in the system for the Received Raw Materials
c. Testing Samples in the Quality Lab
d. Entering Quality Results against the Created samples, separate Result entered for each
Test with respect to the test parameters pre-specified.
e. Based on the Results the Finished goods can be accepted, rejected or accepted with
deviation based on the approval from process head.

12

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4. Quality Inspection Dispatches/Trucks

a.
b.
c.
d.

Collecting Samples of Finished goods from the Dispatch truck

Creating Samples in the system for the Received item from dispatch truck
Testing Samples in the Quality Lab
Entering Quality Results against the Created samples, separate Result entered for each
Test with respect to the test parameters pre-specified.
e. Caustic soda sample collected and put it Concentration meter. Based on the
concentration and weighbridge weight shipping quantity will be calculated.
f. Based on the Results the Dispatch material can be accepted, rejected or accepted with
deviation based on the approval from process head / Sales department.

13

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5. Quality Inspection Return Material from customers

g.
h.
i.
j.

Collecting Samples of Return material in the truck from the customers

Creating Samples in the system for the Received item from return materials
Testing Samples in the Quality Lab
Entering Quality Results against the Created samples, separate Result entered for each
Test with respect to the test parameters pre-specified.
k. Based on the Results the return material can be accepted and sent with filling the FG or
can be sent to other customers based on the approval from process head / Sales

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To Be Process V1.0
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department.

15

To Be Process V1.0
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