1. Receiving Module #
Reference: Receiving Module Overview #
Overview #
The Receiving Module efficiently manages raw materials through three stages: Check-In, Status, and Check-Out to ensure traceability and inventory management.
Workflow #
1.1 Check-In #
- Raw materials are registered upon arrival.
- Key details recorded:
- Check-In Ref No.
- Date & Time
- Process Type (Pallets/iTubes)
- Status
- Materials are physically scanned into the system using the Scanner App.
1.2 Status #
- Materials are managed for further processing.
- Options include:
- To Production: For processing (Frozen materials go to Defrosting Area).
- To Store: Inventory storage (creates a Store Check-In order).
1.3 Check-Out #
- Outgoing materials are processed.
- Frozen Materials: Sent to Defrosting Area.
- Fresh Materials: Sent to Collecting Pool Area.
2. Defrosting Workflow #
Reference: Defrosting Workflow and Process Documentation #
Overview #
The Defrosting Module handles frozen materials by checking in pallets, allocating them to containers, and tracking the entire process.
Workflow #
2.1 Check-In #
- Materials enter the defrosting area.
- Key details:
- Order Reference Number
- Pallet Barcode
- Product Details
- Scanner Status
2.2 Processing Pallets #
- Pallets are allocated to blue containers.
- Key steps:
- Select pallet and container capacity.
- Allocate blocks to containers.
- System updates remaining pallet quantities.
2.3 Monitoring Process #
- Real-time updates in the Process Table.
- Status indicators for Processing, Completed, Pending.
2.4 Check-Out #
- Materials are scanned and checked out for further processing.
- Materials become available in the Collecting Pool Area.
3. Collecting Pool Workflow #
Reference: Collecting Pool Workflow #
Overview #
The Collecting Pool Module manages materials for production, tracking, and reserving pallets.
Workflow #
3.1 Check-In #
- Raw materials are checked in.
- Users can view details, reserve materials, or send them to production.
3.2 Reserving Materials #
- Materials can be reserved for next-day production.
- Reserved pallets won’t be available in current-day production.
3.3 Production Process #
- Materials enter Live Production.
- Depending on material type:
- Foam Box / Blue Containers: Enter quantity.
- iTube Material: Sent directly to production.
3.4 History Tracking #
- Log of all completed operations, including:
- Material Check-In
- Production Start & Completion
- Reservation & Processed Records
4. Block Entries & Freezer Workflow #
Reference: Block Entries Workflow – Block 1 Section #
Overview #
Blocks are recorded and frozen using Plate Freezers or Blast Freezers.
Workflow #
4.1 Block Entries #
- Blocks are assigned to production batches.
- Key details recorded:
- Product Selection
- Block Quantity
- Packaging Batch No.
- Raw Material Batch No.
- System automatically adjusts batch quantities.
4.2 Plate Freezer Process #
Reference: Plate Freezer Workflow
- Blocks are checked into plate freezers.
- Each freezer has 16 rows with 12 blocks per row.
- Freezing time: 150 minutes (extendable).
- Status Indicators:
- Red: Not frozen
- Green: Ready for checkout
- Orange: Multiple entries in a row
4.3 Checkout from Plate Freezer #
- Blocks are sent to Live Production > Plate Freezer > Check Out Material.
4.4 Blast Freezer (Special Case) #
- Used when Plate Freezers are full.
- Pallets are directly stored in the Blast Freezer.
5. Blast Freezer Workflow #
Reference: Blast Freezer Workflow #
Overview #
The Blast Freezer is used for rapidly freezing vacuum-packed products.
Workflow #
5.1 Adding a Pallet #
- Navigate to Production And Processing > Blast Freezer > Record.
- Enter required details:
- Basket Size (Small or Large)
- Processing Line
- Product Selection
- Physical Pallet Inclusion
- Click Add Pallet.
5.2 Pallet Actions #
Once the pallet is added, the following actions are available:
- Print Pallet Label: Print a label for pallet identification and tracking.
- Update Quantity: Modify the basket quantity assigned to the pallet.
- Check-In to Freezer: Move the pallet into the blast freezer for freezing.
5.3 Freezer Management #
- Navigate to Production And Processing > Blast Freezer > Record.
- Enter required details:
- Basket Size (Small or Large)
- Processing Line
- Product Selection
- Physical Pallet Inclusion
- Click Add Pallet.
5.2 Freezer Management #
- Pallets appear in the Freezer Section.
- Default freezing time is 720 minutes (extendable).
- Status Indicators:
- Red: Freezing in progress.
- Green: Freezing complete, ready for checkout.
5.4 Freezer Actions #
- Move to Freezer 4 (IQF Freezer for additional processing)
- Move to Other Freezers (For alternate storage needs)
- Checkout Process:
- Select location and weight.
- Confirm checkout.
- After checkout, material becomes available in Live Production > Blast Freezer > Check Out Material.
6. IQF Freezer Workflow #
Overview #
The IQF (Individually Quick Frozen) Freezer is used for freezing materials that require a rapid freezing process while maintaining individual product separation.
Important Note #
🚨 There is no record for IQF Freezer in the Production & Processing module.
- IQF materials do not go through a structured check-in process like Plate Freezer or Blast Freezer.
- Instead, after freezing, the materials become directly available in Live Production > Packing Area.
Workflow #
- Products requiring IQF Freezing are sent directly for processing.
- Freezing is performed within the IQF Freezer with automated time management.
- Once frozen, materials are directly available in Live Production > Packing Area.
- No manual check-in or processing is required in Production & Processing.
7. Fresh Record Workflow #
Reference: Fresh Record Workflow #
Overview #
Handles freshly vacuum-packed materials, preparing them for packing.
Workflow #
5.1 Adding a Pallet #
- Navigate to Fresh Record.
- Enter:
- Basket Size
- Processing Line
- Product Details
- System assigns pallets based on batch production.
5.2 Updating Pallet Status #
- Open Status: Pallets remain editable.
- Close Pallet: No further modifications allowed.
5.3 Sending to Packing Area (Checkout from Production Area) #
- Pallets are moved from Production to Packing Area.
- Becomes available in Live Production > Fresh > Check Out Material.
8. Scanner Integration in Production #
Reference: Scanner App Functionality Overview #
- The Scanner App facilitates Check-In and Check-Out by scanning pallet barcodes.
- Devices registered in Store will display relevant sections.
- Devices registered in Production will display:
- Receiving
- Defrosting
- Collecting
- Packing Block
- Packing Vacuum
- Blast Freezer
- Scanner is used for real-time inventory tracking and movement processing.
Summary #
This structured Production System Flow ensures efficiency, accuracy, and seamless integration between production, storage, and packing processes. The Scanner App plays a crucial role in ensuring real-time material tracking, reducing manual errors, and automating key check-in/check-out processes.
