Upload OPSI T-1 June
Your planning workbook, read from the OPSI T-1 June sheet and shown back in the same rows and columns as your file. Switch the time grain — Month is the default and fits the screen; drill to Week or roll up to Quarter / Year. Load or replace it in the Files tab.
Auto-calculate Prod. OPSI
Production plan extracted from the Production TTL rows of your OPSI T-1 June upload — one figure per SKU per month. The default window shows this year month-by-month plus the last four months of last year, based on today’s date.
Build SFG plan (SFG OPSI)
Explodes each SKU’s monthly production from Step 2 · Production TTL into its semi-finished components. The routing is built in, so this runs automatically from Step 2 — every component line is filled with its parent FG’s monthly plan, linked by FG code, and totalled by year.
Section capacity plan
Aggregates the Step 3 SFG demand by SFG code for the chosen line and month, converts it to hours (demand ÷ UPH), then loads each machine with a waterfall: fill the standard shift first, bridge a small gap with daily overtime, open Shift B when the gap is larger (standard hours, no OT), add overtime on both shifts only when both are full, and flag anything over capacity.
Day-wise machine schedule
Schedules each line's monthly SFG plan day-by-day using standard UPH and machine capacity. Parts fill each machine's daily capacity in priority order (editable 1–5, 1 = first) on the earliest days first, then working-day overtime, then Sundays/holidays, and anything that still won't fit is flagged over capacity. Opening stock is netted; day cells stay editable for manual date shifts.
Actual vs plan tracking
Enter actual daily production against the plan you saved from Step 5, and see the gap at Day, week-to-date and month-to-date levels. Weeks start Tuesday; the as-of day drives WTD/MTD. Actuals are entered manually in units; the plan is the frozen Step 5 plan.
Production Report
A visual readout of the saved Step 5 daily plan snapshots and Step 6 actual production. Compare lines and periods without changing the schedule or actual-entry screens.
CKD order demand
Gross material-side demand driver: the CKD Order to HQ quantity per model per month, read from the shared Step 1 OPSI file. Switch the Rows control to see CKD Arrival, CKD Stock (Complete Set) and DIO CKD from the same file, or the Pipeline view comparing all three with implied in-transit. Step 3 always explodes the order row through the materials BOM.
SFG plan (CKD-based)
Explodes each model's CKD Order to HQ into its SFG lines using the same shared routing (FG → SFG, UOM 1) as the production pipeline. The materials BOM (Step 4) then links onto these SFG codes.
BOM explosion
Explodes each CKD kit's order (CKD Order to HQ) through the uploaded materials BOM into gross component/raw-material requirements per month. Purchased (procurement F) parts only, using each part's per-unit Required Qty from the BOM (already exploded through the levels); in-house/phantom assemblies aren't ordered. Summed by material in each material's own UOM.
Local order requirements & vendor monitoring
Shows monthly requirement per component × vendor with its Source. Local parts use the SFG OPSI plan (Production TTL × BOM) split by vendor quota; 3rd-source parts use the CKD-order explosion — plus a vendor rollup to monitor each vendor's total load. Links to Step 4 via the same CKD driver.
Purchase demand — BOM & vendor
Monthly demand by vendor for Local and 3rd Source materials (CKD excluded). Local parts use the locked total from Pipeline 1 (Production TTL × BOM), split across vendors by the monthly quota set in Step 5. 3rd-Source parts follow the CKD-order explosion. Parts with no vendor-file entry show unassigned.
Purchase demand — tracking baseline
The frozen starting point for order tracking, seeded from Loop 2. Records route to two tracks: Local parts follow a domestic delivery track (PO → weekly delivery → gap & reason); CKD and 3rd-source parts follow the import shipment track (PO → ETD/BL → in-transit → ETA Karachi → customs → ETA Factory). CKD demand comes from “CKD Order to HQ”; Local & 3rd-source from the Purchase demand grid.
Actual purchase order
Executed PO against the baseline. Actuals (qty, PO #, date, vendor) are read from the SAP PO export per part & month; the planned qty stays from the plan. Load or replace the PO file in the Files tab to refresh actuals.
Shipment & delivery
Import parts only — CKD and 3rd-source. Weekly shipment plan (from the ordered qty) vs actual shipped qty, each with its BL number and planned transit days. One PO may ship across several weeks / BLs (container split). Local parts are not tracked at this stage.
In-transit monitoring
One row per BL, carried forward from Step 3 with its PO, parts and quantity. Plan dates roll forward from the PO date using your transit standards; enter each actual and the status updates itself. Ocean transit counts calendar days; CRD, customs and inland use working days from the calendar.
ETA destination port
Ocean leg — vessel departure to arrival at Karachi, Port Qasim or Gwadar. Planned ETA comes from the lane's standard transit; enter the actual arrival to move the shipment into clearance.
Customs clearance
Arrival to GD filing and release. Port dwell is tracked against your free days so demurrage exposure is visible before it bites.
ETA factory & roll-up
Final inland leg to the assembly floor, with on-time delivery performance and total PO-to-factory lead time across all shipments.
Stock
Perpetual in-hand stock. Load the opening balance once at year start; the system then runs it forward with receipts and actual consumption, less your offline issues (MRU, CSD, R&D, transfers, rejection, misplaced). A fresh system stock is reconciled against the running number, never silently overwritten.
Files
Every source file in one place. Drop them together — each one is recognised by its contents and sent to the right place. The panel shows what’s loaded and when.
Vendor 360
Every order for a supplier in one place — what’s delivered, what’s open, their on-time record and the stage where they consistently lose time. Compare up to four vendors (parts are often split across suppliers by quota).
Order 360
One card for any purchase order — vendor, payment, every shipment on it and the full journey to the factory, with planned days against actual so you can see exactly which stage is costing you time.
Part 360
One card for any part, kit or material — demand, purchase orders, shipments in transit, stock on hand and open exceptions, gathered from every pipeline as at today.
Forecast calculation
Rolling material gap over the next three months for imported material — CKD and 3rd-source parts. The production plan drives the requirement; confirmed receipts, in-transit shipments and open purchase orders are the supply. Each month’s closing balance carries into the next, so you see the month a part actually runs out and how much is missing by the end of the window.