Orders & shippingHard gate
Ship only from checked pallets
ProblemThe same stock was counted for two orders, and unchecked cartons could end up on the truck.
SolutionWhen the warehouse puts goods on a pallet, those lots are locked to the order and leave free stock. A shipment can only be created from a checked pallet. Stock is allocated to open orders in sequence, so the coverage view shows the real picture.
Orders & shippingHard gate
Missing line: produce it or ship without it
ProblemOne line is short. Does the whole order wait, or does it leave incomplete? Without a decision, the truck waits at the gate.
SolutionA short line requires a decision: send it to production (the chemist gets an urgent production alert) or ship without it. Shipment approval stays closed while any line is undecided. Once decided, the other options lock; changing course means undoing first.
Confidential formulas
ProblemThe formula is the factory’s most valuable knowledge. It should not sit in front of everyone on the production floor.
SolutionA formula opens only for the operator assigned to the job, scaled to that job’s quantity. Ingredients marked confidential are not named to people without permission. No work order can be opened with a formula the chemist has not approved.
What can we produce?
ProblemWith the materials on hand, how many units of which product can we make today?
SolutionThe board shows, for each product, how many materials are short at the target quantity and the maximum units possible with stock on hand, taking free stock, quantities reserved for other jobs, approved alternatives and expiry into account. Products added to a basket share materials in order, and work orders are opened from there.
Quarantine gate
ProblemNobody could tell what was in quarantine; the screen only offered a “release” button.
SolutionThe quarantine queue shows product, shade, lot, quantity, the work order it came from, how many days it has waited and the issue. Goods that have not been released never enter saleable stock.
General ledger: entries post themselves
ProblemSales, purchases, collections and payments were entered once in the ERP and again in the accounting software.
SolutionInvoices, collections, payments and cash records create their own journal entries. Sub-ledgers, trial balance, customer and supplier balances with ageing, the VAT return summary with its offset entry, and month-end exchange-difference entries are calculated from the ledger.