Operations · Module
Manufacturing & Quality
BOMs, MRP-lite, job work and quality checks with full batch traceability
Manufacturing & Quality plans production from bills of materials and routings, including job work at subcontractors. Quality checks run from receipt to dispatch with NCR, CAPA and batch genealogy.
What it does
Manufacturing & Quality is designed to plan and execute production from bills of materials and routings, including job work at subcontractors, with quality checks from receipt to dispatch and full batch traceability and cost.
Multi-level BOMs carry quantities, units, scrap percentages, alternates, by-products and co-products with effective dates and approved revisions; open MOs keep their revision. Work centres are linked to Assets with capacity per shift, efficiency and machine, labour and overhead rates. Routings sequence operations with setup and run times and inspection points.
Planning and execution
MRP-lite computes net requirements from demand, stock, open POs and MOs, and proposes planned MOs and purchase requisitions with lead times. MOs are released after a material availability check. Materials are issued from stores or WIP or backflushed. Shop-floor reporting on a tablet or phone records start and stop, good and scrap quantity, operator and downtime reason. Finished goods are received with batch or serial generation and labels, and actual material, labour and overhead cost per MO posts variances to Accounts.
Job work
Materials go to job workers under a job-work challan, stock at the job worker is tracked with an ageing watch against the permitted period, and processed goods, returned material and process losses are received and matched to the job-work bill. Rules are to be verified.
Quality
Inspection plans per item and stage define characteristics, specifications and methods. Results lead to dispositions: accept, rework, reject or use-as-is with concession approval. NCRs record containment, affected batches and root cause; CAPA tracks owners, due dates and effectiveness. Batch genealogy traces forward and backward from raw material to customers. Dispositions, concessions, NCR closure and engineering changes are always human decisions.
A receipt QC-lite is part of Inventory and Procurement in W4; this full module is planned for W5.
Features
What Manufacturing & Quality includes
Bills of materials and revisions
Multi-level BOMs with scrap, alternates, by-products and co-products; approved revisions that open MOs keep.
Work centres and routings
Work centres linked to Assets with capacity, efficiency and cost rates; operations with setup and run times and inspection points.
Manufacturing orders
From sales orders, stock targets, MRP or manual entry, released after a material availability check.
MRP-lite
Net requirements from demand, stock, open POs and MOs, producing planned MOs and purchase requisitions.
Material issue and backflush
Issue from stores or WIP, backflush at operation or completion, with batch selection.
Shop-floor reporting
Start/stop, good and scrap quantity, operator and downtime reason on tablet or phone.
Production receipt and MO costing
Finished goods receipt with batch/serial and labels; actual vs planned cost posted to Accounts; standard costing.
Job work
Job-work challans, stock at job worker, processed goods receipt, process losses and job-work bills (rules to verify).
Inspection plans and sampling
Plans per item and stage with characteristics and methods; acceptance sampling using tenant-licensed reference tables.
Quality checks and dispositions
Attribute and measured results with accept, rework, reject or use-as-is under concession approval.
NCR and CAPA
Non-conformance with containment, affected batches and root cause; corrective and preventive actions with effectiveness checks.
Batch genealogy
Forward and backward traceability from raw material batches to finished batches and customers.
Certificates and supplier quality
Certificates of analysis per batch, supplier certificates with expiry, SCARs feeding the vendor scorecard.
Engineering changes, rework and OEE-lite
Change orders with impact on open MOs and stock; rework orders; availability, performance and quality from shop-floor reports.
Workflow
Manufacturing order lifecycle
- 1
An MO is planned by MRP or manually
- 2
It is released after the availability check passes
- 3
The first operation starts; quality holds or shortages put it on hold
- 4
Final receipt completes the MO
- 5
Final QC releases it or sends it to rework
- 6
The MO closes once costs are settled
Workflow
Quality non-conformance
- 1
A failed check at receipt, in-process, final or from a customer complaint holds the lot
- 2
An NCR is created and affected batches are traced backward and forward
- 3
Containment is proposed: block batches, notify, stop a supplier
- 4
A person decides the disposition
- 5
Root cause is analysed and CAPA is raised where severity requires
- 6
Supplier SCAR and vendor score are updated and the NCR closes after an effectiveness check
Workflow
Job work cycle
- 1
A job-work PO is raised and materials go out under a job-work challan
- 2
Stock is tracked at the job-worker location with an ageing watch
- 3
Processed goods, returned material and losses are received
- 4
Inspection applies where required and stock moves to WIP or finished goods
- 5
The job-work bill is matched to the PO and receipt
AI
AI skills and Digital Employees
Finite capacity schedule proposals
Schedules by work-centre capacity and material availability for planner approval.
Shortage explanation
Explains blocked MOs and proposes POs to expedite, alternates or transfers.
Inspection checklist drafts
Drafts checklists from specifications and past defects for quality approval.
Defect trends and NCR drafts
Analyses defect trends and drafts NCRs with a genealogy summary.
Certificate extraction
Extracts certificates of analysis and supplier certificates with expiry dates.
Digital Employees that use this module
They act through the same governed Actions as people; risky steps wait for approval.
Frequently asked questions
When is Manufacturing & Quality planned?
W5 (Years 4–5). Receipt QC-lite with pass/fail and hold is part of Inventory and Procurement from W4.
Can AI release a batch or close an NCR?
No. Dispositions, concessions, NCR closure and engineering changes are always taken by people. Agents draft and analyse.
Does it support job work?
Yes. Job-work challans, stock at job workers, process losses and job-work bills are planned. The statutory rules must be verified.
Is this a full advanced planning system?
No. It plans MRP-lite and schedule proposals. A commercial planning solver, PLM/CAD vault and LIMS are not covered; specialist systems connect through Integration Hub.
See Manufacturing & Quality in your workflow
Tell us about your team and the outcomes you want. We will walk you through the apps, the Digital Employees and the plan for your industry.