Lot management and container management

Purpose of this feature

In manufacturing, it is crucial to be able to track "which raw material lot this finished product was made from" and "which product the defective raw material ended up in." Lot management and container management is a system that records the entire process from raw material receipt to finished product shipment as a single continuous line.

This article will provide a comprehensive explanation of the following four screens and functions.

What is a "container"? Here, "container" refers not only to physical tanks or boxes, but also to a unit for managing the status of work-in-progress in lot units. On the screen, the quantity and process progress are recorded for each container.

Lot Number Naming Convention

Lot numbers are assigned in three different formats depending on the manufacturing stage.

Process symbols and line symbols are registered in the equipment master as follows: "A = Immersion", "B = Steaming", "C = Inoculation", "D = Fermentation".

Container condition

A container (work-in-progress in lot units) goes through three states.

Image of state transitions

利用可能 → （処理中）→ 利用可能 → 消費済み

Discontinuous processes such as fermentation involve a step where the status changes to "processing" and then returns to "available" upon completion of the process.

Manufacturing Flow (Lot Tracking by Process)

Overall Flow

graph LR
  subgraph 原料受入
    A["R260302-01<br/>黒豆 3000g"]
  end
  subgraph 初工程_浸漬
    B["W260302-A1<br/>浸漬完了 60個"]
  end
  subgraph 中間工程_蒸煮
    C["W260302-B1<br/>蒸煮完了 60個"]
  end
  subgraph 中間工程_接種
    D["W260302-C1<br/>接種完了 60個"]
  end
  subgraph 最終工程_発酵
    E["260302-D-01<br/>発酵完了 60個"]
  end
  A -->|親| B
  B -->|親| C
  C -->|親| D
  D -->|親| E

Operation of each step

1. Receiving raw materials

2. Initial Process (First Processing Step)

3. Intermediate Processes (Second and subsequent processing steps)

4. Time-consuming processes (fermentation, etc.)

Processes that take time, such as fermentation, are handled in two stages: "addition" and "discharge".

When inserted:

At the time of payout (at the time of process completion):

5. Final stage (the stage in which the product is completed)

6. Shipping

Operation of the Lot Performance Input Screen

URL:/app/lot-work-entry

Screen Configuration

1. Select Manufacturing Order: Choose the appropriate order.
2. Process List: The processes registered in the Bill of Materials (BOM) are displayed in order.
3. Operations at each stage: Perform operations such as completion, loading, and unloading at each stage.

Completion of continuous processes (immersion, steaming, inoculation, etc.)

1. Select a process
2. Enter the completed quantity.
3. (First step only) Select the raw materials to be consumed (by scanning the barcode or selecting from the list).
4. Click the "Complete Process" button.
5. The lot number will be displayed on the screen, and the label printing button will also be displayed.

Time-consuming processes (such as fermentation)

Input:

1. Select the target process (the process that displays "Processing").
2. Enter the quantity and location of input.
3. Click the "Input" button.
4. A lot in the "Processing" state is created.

Disbursement (Process Complete):

1. Select the process currently being processed (displays "Processing")
2. Enter the quantity of good products.
3. Click the "Complete" button.
4. A new lot number is issued.

Completion of the final step

1. Confirm that all intermediate processes have been completed.
2. Select the final step
3. Enter the completed quantity.
4. Click the "Manufacturing Complete" button.
5. Manufacturing inventory entries are automatically created, and the finished product lot number and label printing URL are displayed.

Cancel operation

You can cancel the completion of the previous step.

1. Specify the equipment ID.
2. Click the "Cancel" button.
3. The record of completion of the final process is canceled.

Traceability

Parent-child relationships of lots

Each lot has a parent lot recorded, allowing you to trace back to the previous lot. This establishes complete traceability from raw materials to finished products.

R260302-01 （原料：黒豆）
  └─ W260302-A1 （浸漬）  ← 親: R260302-01
       └─ W260302-B1 （蒸煮）  ← 親: W260302-A1
            └─ W260302-C1 （接種）  ← 親: W260302-B1
                 └─ 260302-D-01 （発酵 = 完成品）  ← 親: W260302-C1

Record of changes in containers

All changes to the container's state are recorded in the history.

Graph Display

/app/commit-link-graphThen, you can visually trace the preceding and succeeding processes starting from the lot number. You can view information on raw material suppliers, quantity changes at each stage of the process, and even the final product's shipping destination, all in a single graph.

Relationship with cost accounting

Records of container creation and consumption are used in the following processes of monthly cost accounting:

Tips for Use

• Label Printing: You can print labels with barcodes (Code39 format) from the URL displayed upon completion of the process.
• Barcode Scanning: Scanning the barcode of the lot number will automatically take over the lot number from the previous process.
• Prevention of duplicate entries: The system automatically checks to prevent duplicate entries even if you attempt to complete the same process twice.
• Prevention of skipped steps: An error will occur if you attempt to complete the next step before the previous step is completed.
• Quality Notes: You can record quality notes and the amount of waste incurred at the completion of each process.