Overview:

Blending process involves the following three broad stages:

  1. Blend Planning and release of blend sheets for production
  2. Master Blend Sheet generation, Pick list generation, Kitting and Kit Transfer for production
  3. Blend Production

Blending Process steps:

Following steps describe the individual operations involved in this process:

  1. Create Blend Requirement: Tea department creates the blend requirement based on the FG work orders

  2. Create Blend Sheet Template: Tea department creates a template for the blend sheet

  3. Create Sample Blend and approval from the customer: Tea department creates sample blend using the template blend sheet. The sample blend is sent to the customer for approval, If the customer approves, the sample blend sheet template will be used to produce the whole blend qty, If the customer does not approve, the tea department re-creates the template with different combination of input material as per customer requirement and repeats the process

  4. Create and Release the required number of blend sheets for production using the approved template : As the customer has approved the sample, the tea department creates required number of  blend sheets based on blender capacity Blend sheets will be released for production with specific due date and execution order as priority

  5. Generate Master Blend Sheet: Warehouse team will select a non-kitted blend sheet to generate master blend sheet for the demand to which the selected blend sheet belongs to Master blend sheet will be generated accumulating the quantity of raw materials of the non-kitted blend sheets for the selected blend demand

  6. Generate pick list for the Blend Sheet: The pick list will list the input materials for the blend with all the available locations and the quantity Warehouse team will generate this pick list to pick the raw for staging before kitting

  7. Stage raw tea from warehouse bin to the kitting area: The master blend sheet and the pick list will be used to bring the raw material from the warehouse bin to the staging area The staging area is the place where kitting will takes place

  8. Blend Kits creation: Using master blend sheets, the individual blend kits will be created for each blend sheet One kit will have required raw material quantity for a blend sheet

  9. Transfer kits to factory: The blend kits can be transferred from one warehouse to another warehouse or to the factory

  10. Blend production: At factory, the blend kits are consumed in blend production

 

Blending Flow

 

 

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