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What it does

Real-Time Monitoring: Track progress of Work Orders for all CGIC product lines
  • Operation-Level Updates: Record completion at each production step (e.g., dough mixing → baking → packaging for Valdana Bread)
  • Performance Analytics: Compare planned vs. actual times and quantities
  • Automated Alerts: Notify supervisors about delays or quality failures
  • Shop Floor Integration: Update statuses via mobile devices or shop floor terminals

Why it matters

  • Prevents missed deadlines for high-demand products (e.g., summer surge for Ovita Waters)
  • Reduces waste by catching errors early (e.g., incorrect viscosity in Luca Engine Oil blending)
  • Provides data to optimize workstation utilization (e.g., oven scheduling for Valdana Bread)
  • Ensures consistent quality across batches
Prerequisites
  • **Active Work Orders **Created from Production Plans (Manufacturing > Work Order)
  • BOMs with operations defined (e.g., “Bottle Filling” for Ovita Waters)

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1.0 Access Active Work Orders

  1. Go to: Manufacturing > Work Order > List
  2. Apply filters:
    • Status: “In Process”
    • Item: “Valdana Bread”
    • Workstation: “Baking Line 3”
  3. Key columns:
    • WO No. (e.g., WO-033)
    • Planned Qty vs. Produced Qty
    • Delay % (red highlight if >10%)

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1.1 Update Progress via Job Cards (Shop Floor)

For per-operation tracking (e.g., Ovita Waters filling):
  1. Open Job Card:
    • Scan Work Order QR code at workstation
    • Or go to Manufacturing > Job Card > List
  2. Record Progress:
    • Select operation (e.g., “Bottle Filling”)
    • Enter Completed Qty (e.g., 4,500/10,000)
    • Log downtime/issues in Remarks
  3. Quality Check:
    • Record defects (e.g., “2% underfilled bottles”)
    • Attach photos if enabled
  4. Submit:
    • Status auto-updates to “Completed” when qty reached

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1.2 Monitor Real-Time Dashboards

  1. Production Dashboard (Manufacturing > Dashboard):
    • Work Order Status Tiles:
      • Not Started (Blue) · In Process (Yellow) · Completed (Green) · Stopped (Red)
    • Bottleneck Analysis:
      • Longest-running operations (e.g., “Valdana Bread Baking: Avg. 45 mins vs. Planned 40 mins”)
    • Quality Heatmap:
      • Defect rates by workstation (e.g., “Packaging Line 1: 3% damaged tissue packs”)
  2. Gantt View:
    • Drag/drop Work Orders to reschedule
    • Visualize overlaps (e.g., Luca Oil blending vs. Ovita filling)

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1.3 Handle Exceptions

  1. Pause Production:
    • In Job Card → Click Hold → Select reason (e.g., “Machine Breakdown”)
  2. Reroute Work:
    • Reassign Work Order to alternate workstation (e.g., move Valdana Bread to Oven 2)
  3. Short-Closing:
    • Mark Work Order as “Completed” early if partially finished (e.g., 8,000/10,000 Ovita Waters)

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2.0 CGIC Product Tracking Examples

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2.1 Onina Tissue Production

OperationsWorkstationStatusCompleted
Pulp MixingMixer 5✅ Completed10,000 kg
EmbossingLine 2🟡 In Process5,000 rolls
PackagingPack Station 1⚪ Not Started0
Delay: Embossing running 20% slow → Alert sent to maintenance

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3.0 Troubleshooting

IssueSolution
Job Card not openingCheck Work Order status = “In Process”
Completed Qty not updatingVerify “Allow Partial Completion” enabled in Work Order
Delay alerts not triggeringConfigure thresholds in Manufacturing Settings > Alerts