Material Staging
Pull BOM-required materials from warehouse shelves and confirm them staged to the workstation rack before production begins.
Overview
Material Staging is the first step in the production material lifecycle. Before a work order can start on the shop floor, every BOM component must be physically moved from its warehouse location to the designated workstation staging rack. This screen tracks that movement — line by line — and confirms to the Manufacturing Execution module that materials are ready.
BOM-Driven Checklist
The table pre-populates from the selected work order's Bill of Materials. Required quantities come directly from the BOM — you never enter them manually.
Barcode / Manual Entry
The staging modal accepts a numeric quantity directly. A barcode scanner field is available for warehouse label scanning — scan to populate the quantity automatically.
Color-Coded Status
Each row shows Not Started (grey), Partial (amber), or Complete (green) based on how much of the required quantity has been staged.
Staging Confirmation
Once all items show Complete, the "Confirm Staging" button becomes active. Confirmation updates the work order's internal state to materials_ready.
Work Order Eligibility
Only work orders with status Released or In Progress appear in the work order dropdown. Draft and Pending orders are excluded — release the work order in Manufacturing Execution first.
Quick Start
- Switch to Inventory Ops Mode and open Material Staging in the sidebar.
- Use the work order dropdown at the top to select the released work order you want to stage for.
- The table loads automatically with all BOM components, their required quantities, and current staged quantities.
- For each row that is not yet complete, click the Stage button on the right.
- In the modal, enter the quantity being staged and the location (e.g. Workstation 3 Rack A). Click Stage.
- Repeat for all remaining items. Each row updates its staged quantity and status badge immediately.
- When all rows show Complete, click Confirm Staging in the top-right to lock the staging record.
Partial Staging
You can stage partial quantities — the row will show Partial status and the remaining quantity highlighted in amber. This is useful when warehouse stock is split across multiple picks. The Confirm button only activates once every item reaches Complete.
Table Columns
| Column | Description |
|---|---|
| Material | Product name and internal material ID from the BOM |
| Required | Quantity required per BOM for the work order's production quantity |
| Staged | Quantity confirmed staged to the workstation rack so far |
| Remaining | Required minus Staged; shown in amber when > 0, em-dash when fully staged |
| Location | The physical staging rack or bin where this material was placed |
| Status | Not Started / Partial / Complete |
| Action | Stage button — opens the staging modal. Hidden once the item is Complete or the staging record is confirmed. |
Staging Modal
Clicking Stage on any incomplete row opens a modal for that specific material. The modal shows the required quantity and remaining quantity at the top so you always know the maximum you can enter.
Fields
| Field | Description |
|---|---|
| Required / Remaining | Read-only summary. Remaining = Required − already staged. The quantity field is capped at this value. |
| Qty to Stage | Numeric input (or barcode scanner). Must be > 0 and ≤ remaining. The Save button is disabled until a valid number is entered. |
| Staging Location | Free-text description of where the material is being placed — e.g. Workstation 3 Rack A, Floor Pallet B12. Pre-filled with the previous location if the item was partially staged before. |
Over-Staging Prevention
The quantity field is bounded by the remaining amount. You cannot stage more than the BOM requires. If physical stock exceeds the BOM quantity, stage only the required amount and return excess to the warehouse.
Status Lifecycle
Individual item status follows the first three steps automatically as quantities are entered. The overall staging record moves from pending to complete only when you explicitly click Confirm Staging. This two-level design lets supervisors review the staging before it is locked.
After Confirmation
Once the staging record is confirmed, all Stage buttons are hidden and the screen shows a Staging Complete badge in the top right. The staging record cannot be un-confirmed from within Inventory Operations — to reopen it, contact a manufacturing supervisor who has access to the underlying data store.
Business Rules
| Rule | Detail |
|---|---|
| Eligible work orders | Only Released or In Progress work orders appear in the picker. Pending orders have not yet had their materials reserved. |
| Staging creates a reservation | Each staging action calls the warehouse service to create a soft reservation on the staged quantity so that it cannot be allocated to another order. |
| Cannot exceed required quantity | The max quantity per staging action is requiredQuantity − stagedQuantity. Entering a higher value disables the Save button. |
| Confirm requires all-complete | The Confirm Staging button is only enabled when every BOM item shows status = Complete. Partially staged records cannot be confirmed. |
| Confirmed staging enables Consumption | The Material Consumption screen checks staging status before allowing the "Consume Materials" action. Staging must be confirmed first. |
AI Assistant
Click the AI Assistant tab anchored to the right edge of the screen to open a chat panel with full context on the selected work order's staging list — required quantities, staged quantities, remaining shortages, staged locations, and per-item status. It can flag which materials are still short, suggest what to stage first, point out items missing a staged location, and assess whether the work order is ready to confirm.
Example Prompts
- "Which materials are still short?"
- "What should we stage first?"
- "Any items missing a staged location?"
- "Is this work order ready to confirm staging?"
Saving a Response as a Report
After the assistant replies, a Save as Report button appears at the bottom of the panel. Click it to save the response instantly to My Reports — no dialog or title entry required. The title is generated automatically from your prompt and the current month.
Select a Work Order First
The assistant needs an active staging record to answer questions. Pick a released or in-progress work order from the dropdown before opening the panel — the suggestion chips stay disabled until staging data is loaded.