Manufacturing

Manufacturing turns recipes into batches. You define a recipe with its costed bill of materials, release work orders to a production line, record what was produced and wasted, check each lot against quality specs, and ship finished goods with the right export documents. The module is generic recipe-based batch production; the demo dataset is a food manufacturer making fried onions, dehydrated onions, pickles and sauces.

Navigating the module

Every manufacturing screen carries the MfgNav chip row: Dashboard, Work Orders, Recipes & BOMs, Raw Materials, Finished Goods, Costing, Quality and Exports. Production lines in the demo are Fry Line 1, Fry Line 2, Dryer Line A, Dryer Line B, Pickle Bay 1, Pickle Bay 2 and Sauce Line 1.

Dashboard

/manufacturing is titled Manufacturing with a New work order button. Two rows of KPIs summarise the month:

Below the KPIs: Work orders / production runs (Work order, Product, Batch / Lot, Planned, Produced, Wastage, Status), Recipes (bills of materials) (Recipe, Category, Output, Yield, Ingredients, Batch cost, Cost / unit), a Raw material stock card with a "4 to reorder" badge (Material, On hand, Reorder, Status Reorder or OK) and a Finished goods card with a "2 below par" badge (Product, Category, In stock, Status Low or In stock).

Work orders

/manufacturing/work-orders lists every production run across the fry, dryer, pickle and sauce lines. KPIs: In process, Completed, Planned and Total output in units produced. The Production runs table has the same columns as the dashboard plus a Line column. Click a work order to open its detail.

Lifecycle and statuses

A run moves Planned to In Process to Completed. The demo work order WO-001 (Fried Onions 1kg, lot LOT-FO-2609, Fry Line 1, operator Imran Qadri) is Completed with 213 of 220 produced and 3.2% wastage.

How to create a work order

Click New work order on the dashboard or the list, or open /manufacturing/work-orders/new. A notice at the top reminds you the record is saved to this workspace.

1. Pick the recipe

   Choose the product in Product / recipe. The planned quantity fills from the recipe output; adjust it for the batch size you are running.

2. Assign the run

   Set the Production line, type the Operator and confirm the start and target dates.

3. Set the status

   Leave it Planned to schedule the run, or choose In Process or Completed and fill in Produced qty and Wastage %.

4. Save

   Click Save work order. Validation stops you with "Select a product / recipe." or "Planned quantity must be greater than zero." New orders are numbered from WO-101 and show the New badge in every list.

Work order detail

/manufacturing/[wo] opens with a banner showing the category and line, the product, and chips for the work order id, lot and operator. Header buttons: View recipe, Exports and Inventory. Four stats sit beneath: Planned, Produced, Wastage and Cost / unit. A Back to Manufacturing link returns to the dashboard.

Recipes and bills of materials

/manufacturing/recipes lists standard recipes, their input-to-output yields and costed bills of materials. KPIs: Recipes / BOMs, Avg yield, Ingredients and Categories. The Recipes table matches the dashboard card. The demo has four recipes: Fried Onions 1kg, dehydrated flakes, mango pickle and garlic chilli sauce.

Recipe fields

A recipe holds the product, its category (Fried Onions, Dehydrated, Pickles, Sauces), the output quantity and UOM per batch, the target yield percentage, the raw input in kg, labour and overhead per batch, a sell price and unit, a list of ingredients (item, quantity, UOM, unit cost) and the process steps (step, detail, time).

Costing formulas

Recipe detail

/manufacturing/recipe/[id] is titled with the product name and an id badge; the subtitle gives the category, output per batch and yield. All recipes returns to the list. KPIs: Batch output (from the kg of input), Yield (with the ingredient count), Cost / unit (with the batch cost) and Gross margin. Two cards follow: Ingredients (per batch) with Item, Qty, Unit cost, Total and % cost plus a Total raw material line, and the Cost per unit build-up. The Process steps table lists #, Step, Detail and Time.

How to create a recipe

Click New recipe or open /manufacturing/recipes/new. Costing is computed live in the right-hand panel as you type.

1. Name the recipe and set the batch

   Enter the name, product and category, then the output quantity, UOM and target yield.

2. Build the bill of materials

   Add one row per ingredient with its quantity and unit cost. The line totals and the raw material subtotal update as you go.

3. Add labour and overhead

   Type the per-batch labour and overhead in the Live costing panel. It shows Raw material, Direct labour, Factory overhead, Total batch cost, the division by output quantity and the Cost per unit, with a margin bar against the sell price.

4. Describe the process and save

   Add the process steps in order, then click Save recipe.

Raw materials

/manufacturing/materials tracks raw material and packaging inventory. KPIs: Material SKUs (with the category count), Below reorder ("replenish soon" or "all stocked"), Stock value (on-hand at cost) and In stock (at or above par). The Raw-material stock table has Material, Category (Onions, Oil, Salt, Vinegar, Produce, Spices, Packaging), On hand, Reorder level, Unit cost, Stock value and Status (Low or OK). In the demo, Mustard oil, Pickle spice mix, Garlic paste and Glass jars 500g are below reorder.

Raising a purchase order

Purchase order opens the Raise purchase order modal: Material (low items are tagged "(low)" and the first low item is preselected), Quantity in the material's unit (suggested so stock reaches twice the reorder level), Expected delivery and Supplier (Al Ain Farms Co-op, Emirates Refined Oils, Gulf Salt Works, Jebel Ali Packaging or Spice Route Trading). A footer shows on hand, reorder level and the estimated cost. Raise PO needs a material and a quantity above zero.

Orders appear in the Purchase orders list below the table with their id (PO-), quantity, supplier, order and expected dates and an Ordered badge. Receive books the quantity into stock (the material row gains an Updated badge and its status recalculates) and turns the order Received; Archive then removes it from the list. Like the rest of the module, purchase orders are saved in this workspace.

Finished goods

/manufacturing/finished-goods is the finished-goods warehouse: on-hand stock, batch traceability and value by SKU. KPIs: Finished SKUs (with categories), Units in stock, Stock value and Below par. Columns: Product, SKU (for example FO-011, SC-08500), Category, Batch / Lot, On hand, Value and Status.

Posting a stock adjustment

Stock adjustment opens a modal with Product, Direction (Write off / reduce, or Add to stock), Quantity in the product's unit and Reason (Stock count correction, Damaged / expired, Samples issued, Returned from customer, Production overrun). The footer previews on hand before and after posting. Post adjustment needs a quantity above zero and refuses to take stock below zero ("Only {n} on hand."). Adjusted rows gain an Adjusted badge and every posting is listed in the Adjustment log beneath the table with its ADJ- id, date and reason; Reverse undoes it. Adjustments are saved in this workspace. General stock outside manufacturing lives in Inventory.

Product costing

/manufacturing/costing shows the standard cost build-up per unit for every recipe against its sell price. KPIs: Products costed, Avg margin, Highest margin and Lowest margin, each naming the product. The Cost build-up per unit table has Product (linked to the recipe), Raw cost, Labour, Overhead, Total cost / unit, Sell price and Margin. Margin is green at 40% or more, amber at 20% or more and red below that.

Quality assurance

/manufacturing/quality checks each batch against its category spec. KPIs: Batches tested, Passed (with the pass rate), Failed (needs rework) and Avg moisture. The Recent batch checks table has Batch / Lot, Product, Category, Checks (chips such as "Moisture 2.8% (≤3.0)") and Result (Pass or Fail).

Specs by category

Exports and shipments

/manufacturing/exports covers local and international shipments: countries, incoterms, documentation and delivery status. KPIs: Export orders (with destination markets), In transit (with how many are booked), Export value and Top destination with its value.

The Shipments table has Shipment, Buyer, Destination (flag and country), Product, Qty, Incoterm, Value, Documents (ticks for INV, PL, COO and PHYTO) and Status. Two cards follow: Export value by destination as bars and a Documentation checklist with Shipment, Destination, Docs ready (n / 4) and a Complete or Pending status.

How to book a shipment

Click New shipment or open /manufacturing/exports/new.

1. Enter the buyer and destination

   Buyer is required ("Enter a buyer."). Destination country defaults to Saudi Arabia; the list also offers United Kingdom, United States, Germany, India, Canada and UAE.

2. Describe the consignment

   Set Product, Qty (greater than zero, or "Quantity must be greater than zero."), Unit (pcs or sacks), Incoterm (FOB by default) and Value (AED). The Shipment value figure updates live.

3. Tick the documents

   Invoice is ticked by default; add Packing List, COO and Phyto as they are ready. The checklist card shows how many of the four are done.

4. Set the status and save

   Leave Status as Booked and click Save shipment. New shipments are numbered from EXP-2049.