¶ Purpose
The Alloy Master is used to define and maintain different alloy compositions or metal grades used in manufacturing. It helps the ERP system to standardize alloy/metal grade definitions, maintain chemical composition details, ensure correct material usage in production, support quality control and traceability, link alloys to items, BOMs, and processes, enable compliance with industry standards. The Alloy Master ensures accurate material specification, traceability, and production consistency.
¶ Prerequisites
- Access rights must be assigned to the user responsible for adding, editing or deleting alloy details.
- The Element master must be defined.
- The Alloy Type master must be defined.
¶ Add Alloy Details
The Alloy Master- Mode: New screen allows the user to add the alloy details.
Navigation: Main – Menu → Masters → Master -Items → Alloys → Add
- The user can search for a particular alloy based on the Code, Name/ Description, Long Description, Alloy Type and Attachment.
- Click Add to add the new alloy details, and the screen will appear as shown below.
- The Alloy Master- Mode: New screen allows the user to add details such as the Code, Name/ Desc, Long Description, Alloy Type and Attachment.
- The user must enter the Code and Name or Description of the alloy.
- The user must select the Alloy Type from the dropdown list.
- The user can enter the Long Description.
- The user can upload an attachment if required.
- Click the Attachment icon, to select the file from the specific location.
- Click the Delete icon, to delete the added file.
- Click Save, the following message will appear.
- Click Yes, to add Alloy Composition, Alloy -Mechanical Properties and Alloy Microstructure details.
¶ Add Alloy Composition Details
The Alloy - Composition Master - Mode: New screen allows the user to define and maintain the chemical composition of each alloy grade. It ensures that the percentage of elements (such as Carbon, Chromium, Nickel, Manganese, etc.) is accurately recorded and linked to the corresponding alloy.
Navigation: Main – Menu → Masters → Master -Item → Select Alloy Name → Edit →Alloy Composition → Add
- The user must select the appropriate Name/Desc from the left panel of the screen.
- Once the user selects the name/desc, the corresponding details will appear automatically.
- Click Edit, the following screen will appear.
- Click Add, and the following screen will appear.
- The Alloy - Composition Master - Mode: New screen displays the Alloy.
- The user must enter details such as the Element.
- The user can enter details such as the Sl No., LCL, UCL, Unit, Min, AIM and Max.
- Click Save.
- Click Close, the added details will appear as shown below.
- Click Save.
- The user can view or edit, or delete the added details.
- The user must select the appropriate element to view or edit, or delete details.
Example: The table below describes the Alloy Composition Values for Carbon (C).
| Sl. No. | Field | Meaning | Purpose | Sample Value |
|---|---|---|---|---|
| 1 | Unit | Measurement type | Defines how composition is measured | % |
| 2 | Min | Minimum acceptable value | Material must not go below this | 0.18 |
| 3 | Max | Maximum acceptable value | Material must not exceed this | 0.22 |
| 4 | AIM | Ideal or target value | Used as a reference during melting, production, or purchase | 0.20 |
| 5 | LCL | Lower Control Limit | Internal process control lower limit | 0.19 |
| 6 | UCL | Upper Control Limit | Internal process control upper limit | 0.21 |
¶ Add Mechanical Properties
The Alloy - Mechanical Properties Master - Mode: New screen in ERP is used to record and maintain key physical and performance characteristics of each alloy grade—such as tensile strength, yield strength, hardness, and elongation. This ensures that materials meet required engineering standards, quality specifications, and customer requirements during production and inspection.
Navigation: Main – Menu → Masters → Master -Item → Select Alloy Name → Edit →Alloy Mechanical Properties → Add
- The user must select the appropriate Name/Desc from the left panel of the screen.
- Once the user selects the name/desc, the corresponding details will appear automatically.
- Click Edit, the following screen will appear.
- Click Add, and the following screen will appear.
- The Alloy - Mechanical Properties Master - Mode: New screen displays Alloy.
- The user must enter details such as the Col Name.
- The user can enter details such as the Sl No., LCL, UCL, Unit, Min, AIM and Max.
- Click Save.
- Click Close, the added details will appear as shown below.
- Click Save.
- The user can view or edit or delete the added details.
- The user must select the appropriate grid to view or edit or delete details.
Example: The table below describes the Alloy Mechanical Properties (Hardness).
| Sl. No. | Field | Purpose | Example Value |
|---|---|---|---|
| 1 | Unit | Defines the measurement unit used for hardness. | BHN (Brinell Hardness Number) |
| 2 | Min | Minimum acceptable hardness value. Material must not be softer than this. | 180 BHN |
| 3 | Max | Maximum acceptable hardness value. Material must not be harder than this. | 220 BHN |
| 4 | AIM | Target or ideal hardness value used as a reference for heat treatment/production. | 200 BHN |
| 5 | LCL | Lower Control Limit. If the hardness drops below this level, the process may become unstable. | 185 BHN |
| 6 | UCL | Upper Control Limit. If hardness exceeds this, it may indicate overheating or over-hardening. | 215 BHN |
¶ Add Alloy Microstructure Details
The Alloy Microstructure Master - Mode: New screen in ERP is used to record and maintain the metallurgical structure of each alloy grade—such as grain size, phases, inclusions, carbide distribution, and other microscopic characteristics. This information ensures that materials meet the required metallurgical standards before being used in production.
Navigation: Main – Menu → Masters → Master -Item → Select Alloy Name → Edit →Alloy Microstructure → Add
- The user must select the appropriate Name/Desc from the left panel of the screen.
- Once the user selects the name/desc, the corresponding details will appear automatically.
- Click Edit, the following screen will appear.
- Click Add, and the following screen will appear.
- The Alloy Microstructure Master - Mode: New screen displays Alloy.
- The user must enter details such as the Description.
- The user can enter details such as the Min, Max and Unit.
- Click Save.
- Click Close, the added details will appear as shown below.
- Click Save.
- The user can view or edit or delete the added details.
- The user must select the appropriate grid to view or edit or delete details.
Example: The table below describes the Alloy Microstructure.
| Sl. No. | Field | Example Value |
|---|---|---|
| 1 | Description | Grain Size (ASTM) |
| 2 | Min | 5 |
| 3 | Max | 8 |
| 4 | Unit | ASTM No. |
¶ Edit or Delete Alloy Details
The Alloys Master - Mode: Edit screen allows the user to edit or delete added or existing alloy details if required.
Navigation: Main – Menu → Masters → Master -Item → Select Alloy Name → Edit
- The user must select the appropriate Name/Desc from the left panel of the screen.
- Once the user selects the name/desc, the alloy details will appear automatically.
- Click Edit, the following screen will appear.
- The user can edit alloy details such as the Code, Name/ Desc, Long Description, Alloy Type and Attachment.
- Click Save, to save the edited details.
- Click Delete, to delete and the alloy details will disappear from the left panel of the screen.
Note: The user can delete the alloy details only if they are not used in any transactions or masters.
¶ View Details in Tree or Grid
The Grid View and Tree View options allow the user to view alloy details either in a tabular format or in a hierarchical structure for easier navigation and understanding.
- Click Grid View to view details in tabular format (rows and columns), as shown below.
- Click Tree View to display data hierarchically (parent-child structure), as shown below.
- The user can expand or collapse nested items to view relationships or categories.
¶ Search Alloy Details
The Search option allows the user to search for a alloy based on the alloy type.
- Click Search, and the screen will appear as shown below.
- The user must select the appropriate Alloy Type from the dropdown list.
- The user must select the appropriate Filter On and Filter Text from the dropdown list.
- The user must enter the corresponding filter value and press Enter key.
- Once the user presses Enter key, the corresponding list will appear on the left panel of the screen.
¶ Print Alloy Details
The Print option allows the user to print the added or existing alloy details.
- Click Print, the following screen will appear.
- Click Filter, to search for details.
- Click Sort, to arrange details in either ascending or descending order.
- Click Settings, to adjust Columns, Fonts, Row Height, Fit To Page, Page Setup and Printer Setup.
- The Set Col Details option allows the user to adjust column width as required.
- The Font option allows the user to edit Font Family, Font Style, Size, Effects and Scripts as required.
- The Auto Row Height option allows the user to adjust row height if required.
- The Fit to Page option allows the user to scale the content to fit the page if required.
- The Printer Setup option allows the user to configure the Printer, Print Range and Copies details if required.
- The Page Setup option allows the user to set the Paper Size, Orientation (Portrait or Landscape) and Margins in Inches (Left, Right, Top and Bottom) details as required.
- Click Export to Excel, to view details in Excel.
- Click Print, to print details.
- Click Print Preview, to view details before printing.
- Click Close, to navigate to the Alloys screen.
¶ Bulk Update - Update Alloy Details
The Bulk Update option allows the user to edit existing alloy details at once.
- Click Bulk Update, and the following screen will appear.
- The user can edit Code, Name/Desc, Long Description, Alloy Type and Attachment if required.
- Click Save.
¶ Functional Use Case
| Sl. No. | Use Case | Business Scenario | Functional Outcome in ERP |
|---|---|---|---|
| 1 | Create New Alloy | New metal grade introduced. | Alloy available for item mapping. |
| 2 | Maintain Chemical Composition | Quality requires defined composition. | Accurate material specification stored. |
| 3 | Link Alloy to Item | Product must use specific grade. | Controlled production material usage. |
| 4 | Production Planning | Specific alloy required in BOM. | Correct raw material planning. |
| 5 | Compliance Management | Industry standard compliance required. | Standard reference stored. |
¶ Use Case Scenario
- Click here for a detailed use case scenario.
¶ Transaction Checklist
| Sl. No. | Checklist Item | Description |
|---|---|---|
| 1 | Alloy Code | Define unique alloy identification code. |
| 2 | Alloy Name | Enter alloy/grade name (e.g., SS304, Al6061, etc.). |
| 3 | Metal Category | Define base metal type (Steel, Aluminum, Copper, etc.). |
| 4 | Chemical Composition | Define percentage composition (C, Cr, Ni, etc.). |
| 5 | Standard Reference | Enter applicable industry standard (ISO, ASTM, etc.). |
| 6 | Density | Define material density (if required for calculation). |
| 7 | Hardness / Strength | Enter mechanical properties (optional). |
| 8 | Application Type | Define usage (Casting, Forging, Rolling, etc.). |
| 9 | Quality Parameters | Define inspection criteria if applicable. |
| 10 | Linked Item Mapping | Map to relevant items in Item Master. |
| 11 | Authorization Check | Confirm user rights. |
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