Manufacturing Execution

Overview

The Manufacturing Execution module (MFG Mode) gives production teams a single pane of glass across the entire shop floor. Work orders move through a strict lifecycle — Pending → Released → In Progress → Completed — while production lines, bill-of-materials, and OEE metrics update in real time. Every screen supports both the dark Workstation style and the light Enterprise style, switchable from Settings → Appearance → Screen Style.

Quick Start

1. Switch to Manufacturing Mode via the mode badge in the header.
2. Open Bill of Materials and verify at least one active BOM exists for your product.
3. Go to Work Orders and click Create Work Order. Fill in product name, quantity, priority, scheduled dates, and production line.
4. The new work order lands in Pending status. Click the unlock icon to release it — this reserves raw materials.
5. When production begins, click the play icon to move the order to In Progress.
6. Monitor live output on the Shop Floor screen. Any machine alerts appear here automatically.
7. Once finished, click the checkmark icon to complete the order and log the finished-good quantity.
8. Review plant-wide efficiency on the OEE Dashboard.

Screen 1 — Work Orders

The Work Orders screen is the primary control surface for production operations. Every manufacturing job starts and ends here.

Work Order Lifecycle

Work orders follow a one-way state machine. Actions that are not valid for the current status are automatically hidden.

Any order in Pending, Released, or In Progress can be moved to Cancelled — completed orders cannot.

Creating a Work Order

1. Click Create Work Order in the top-right action bar.
2. Enter the Product Name (required — the Save button stays disabled until this is filled).
3. Set Quantity, Priority (High / Medium / Low), Scheduled Start, and Scheduled End.
4. Select the target Production Line.
5. Add optional Notes (customer references, special instructions).
6. Click Create WO. The order appears at the top of the table in Pending status.

Work Order Detail View

Click the eye icon on any row to open the detail modal. It has three tabs:

• Materials / BOM — lists every component with Required, Reserved, and Issued quantities and a status badge (Complete / Partial / Pending).
• Operations — the routing sequence with workstation assignments, planned durations, and current step status.
• Labor & Notes — assigned operators, sales order link, and free-text notes.

Filtering and Search

Use the status pill bar to narrow by lifecycle state. The priority dropdown filters by High, Medium, or Low. The search box matches against both the work order number (e.g. WO-2025-0001) and the product name.

Screen 2 — Production Scheduling

Production Scheduling gives planners a bird's-eye view across all production lines, with three tabs covering lines, Gantt, and the WO queue.

Production Lines Tab

Each line is shown as a card with:

• A live status badge — Running (green pulse), Idle (grey), Maintenance (amber), Stopped (red).
• The currently active work order number and product name.
• A capacity vs. output bar (e.g. 98 of 120 units/hr).
• Efficiency % as a progress bar — green ≥ 85%, amber ≥ 70%, red below 70%.
• The next scheduled maintenance date.

Gantt Schedule Tab

A 7-day week grid maps each production line to a row. Active work orders are rendered as coloured blocks labelled with the WO number. Completed orders appear at reduced opacity. Use the left/right chevrons to navigate weeks.

WO Queue Tab

A ranked table of all Pending and Released work orders sorted by priority (High first, then Medium, then Low). Within the same priority, earlier scheduled starts rank higher. This is the recommended view for a daily planning stand-up.

Screen 3 — Shop Floor Monitor

The Shop Floor Monitor is the real-time operations view. It is designed to run on a large display visible from the production floor and auto-updates every 2 seconds for running lines.

Line Overview Tab

One card per production line. Each card shows the current status, the active work order with a completion progress bar, and a three-column grid for capacity, current output, and efficiency. Maintenance lines display an amber badge and the next scheduled service date.

Alerts Tab

Active alerts are listed in chronological order with a coloured left border:

Click the ✕ button on any alert to mark it resolved. Resolved alerts move to a greyed-out section below. The header badge shows the count of critical active alerts at all times.

Live Output Tab

Running lines appear with an animated output ticker. The displayed unit/hr value updates every 2 seconds with a subtle sine-wave jitter to simulate real sensor data. A horizontal efficiency bar turns green, amber, or red based on the same threshold logic as the other screens. Idle and maintenance lines appear in a separate "Inactive Lines" panel below.

Screen 4 — Bill of Materials

The BOM screen is the engineering master for what each product is made of. Every work order references a BOM to calculate material requirements.

BOM Status Lifecycle

• Draft — BOM is under review; cannot be used to create work orders until activated.
• Active — The canonical BOM for this product. Work orders reference this version by default.
• Obsolete — Retained for historical reference only; not selectable for new work orders.

Creating a BOM

1. Click Create BOM. The form opens as a modal (or right panel if Add Record Mode is set to Panel).
2. Enter the Product Name and Version (e.g. v1.0, v2.3).
3. Set the initial Status — start with Draft until engineering review is complete.
4. Click Add Component for each raw material. For each component fill in:
   • Material Name — human-readable name (e.g. "Friction Material Block")
   • Code — internal part number (e.g. FMB-001)
   • Qty — quantity per finished unit
   • Unit — pcs, kg, L, m, set, kit, etc.
   • Scrap % — expected waste; the system inflates the total material requirement accordingly
5. Add optional Notes for the BOM as a whole.
6. Click Create BOM to save.

Inline Component Viewer

Click the chevron at the left of any BOM row to expand it in place without opening a modal. The expanded section shows the full component table — sequence, material name, part code, quantity, unit, scrap rate, and notes — and the total cost per finished unit. Click the chevron again to collapse.

Editing a BOM

Click the pencil icon to open the same form pre-populated with existing data. You can add, reorder, or remove components and change the status. All changes take effect immediately on save; the updatedAt timestamp is refreshed automatically.

Scrap Rate Explained

The Scrap % field tells the system how much raw material is consumed beyond the nominal quantity due to process waste (off-cuts, rejected units, evaporation, etc.). A 5% scrap rate on a 1-unit component means 1.05 units of that material are reserved per finished product. This avoids stock shortages mid-run.

Screen 5 — OEE Dashboard

OEE (Overall Equipment Effectiveness) is the industry-standard metric for production efficiency. TotalApp calculates it as:

OEE Benchmarks

Reading a Line Card

Each production line has its own card showing:

• Circular gauge ring — the OEE% for the most recent day, colour-coded by the benchmark above.
• Three horizontal bars — Availability, Performance, and Quality broken out individually. The weakest bar is the first place to investigate.
• Stats row — Planned production, Actual production, and Defect count for the latest day.
• 7-day trend chart — an SVG line chart of daily OEE over the past week. Grid lines at 60%, 70%, 80%, and 85% mark the benchmark thresholds. Blue dots mark each data point.
• Trend indicator — an arrow icon and delta value (e.g. "+2.1pp vs yesterday") give an instant sense of direction.

Plant-Wide KPI Row

The four tiles at the top of the page show weighted averages across all active lines for OEE, Availability, Performance, and Quality. These update whenever you hit Refresh or select a different line filter. Each tile has its own colour-coded progress bar and benchmark label.

Filtering by Line

Use the line selector dropdown in the top-right toolbar to isolate a single production line. The plant-wide KPI tiles update to reflect only that line's data, and only that line's card is shown in the grid below. Select "All Lines" to return to the full view.

Screen 6 — Work Instructions

Work Instructions is the digital SOP (Standard Operating Procedure) library for the shop floor. Operators read step-by-step instructions and sign off on quality checkpoints without leaving TotalApp.

Instruction List

The main table lists all work instructions with their operation ID, version number, step count, and current status. Use the search box to filter by title or operation ID. The status pill bar narrows results by Draft, Active, or Archived.

Reading an Instruction (WI Reader Modal)

Click the book icon on any active row to open the full-screen reader. The reader displays:

• Safety Warnings panel — red bordered block listing every hazard. Scroll past this to reach the steps.
• Numbered steps — each step shows the instruction text and, optionally, a reference image or video URL for guided assembly.
• Quality Checkpoints — amber-highlighted steps with a numeric input field. Enter the measured value; TotalApp immediately shows a PASS or FAIL badge based on the configured min/max tolerance.
• Confirmation checkbox — the operator must tick "I have read and understood these instructions" before the Verify & Sign Off button becomes active.
• Language selector — switch between EN and TR at the top-right of the reader without closing the modal.

Creating a Work Instruction

1. Click Create Instruction in the top-right action bar.
2. Enter the Title (required — Save stays disabled until filled).
3. Set an Operation ID that links this instruction to the corresponding routing operation (e.g. op_001).
4. Enter the Version number (integer, default 1).
5. Add any Safety Warnings — one per line in the text area. These are displayed prominently in the red panel at the top of the reader.
6. Use Add Step to append steps in order. For each step:
   • Write the instruction text.
   • Optionally attach an image URL or video URL for visual guidance.
   • Enable Quality Checkpoint if this step requires a measured value. Set the measurement unit, and optionally a min/max tolerance range (e.g. 12.0–12.5 mm). Leave min/max blank for a zero-defect count checkpoint.
7. Click Save. The instruction is created in Draft status.
8. To release it to operators, click the verify checkmark icon on the row to set it to Active.

Inline Expand

Click the chevron at the left of any row to expand a compact step summary in-place — without opening the full reader. This lets a supervisor quickly verify step count and safety warning count at a glance.

Screen 7 — Production Counters

Production Counters is the real-time shift performance dashboard. It aggregates every active work order into a single view showing how the current shift is tracking against target, with OEE breakdown and an hourly bar chart. The screen auto-refreshes every 5 seconds.

KPI Tile Row

Four tiles summarise the selected shift's aggregate performance:

OEE Breakdown Panel

Below the KPI tiles, a dedicated panel shows individual Availability, Performance, and Quality bars for the shift aggregate. Each bar is colour-coded by the same green/amber/red threshold as the OEE tile. A brief description below each bar explains what that component measures.

Hourly Bar Chart

An SVG bar chart plots the last 8 hours of production. Each hour slot shows two bars:

• Dashed outline bar (indigo) — the hourly target quantity.
• Filled bar — actual produced quantity. Green if ≥ target, amber if ≥ 80% of target, red if below 80%.

This chart makes it immediately obvious which hours were productive and which had slowdowns, without needing to export data to a spreadsheet.

Active Work Orders Table

Below the chart, every work order currently active in the selected shift is listed with:

• WO number and product name
• Assigned production line
• Produced vs. target quantity with a compact progress bar
• Scrap count
• Operator name
• Shift name

Shift Filter & Date Picker

Use the date picker at the top of the filter row to look back at any previous shift's performance. The shift pill tabs (Day / Evening / Night) filter the KPI tiles and chart to the selected shift's time window. Only active shifts configured in Shift Settings are shown as tabs.

Auto-Refresh

The screen fetches fresh production summary data every 5 seconds automatically. A pulsing green dot next to the subtitle confirms the auto-refresh is active. You can also trigger an immediate refresh with the Refresh button in the toolbar. The auto-refresh interval pauses if you open the Shift Settings modal and resumes when it closes.

API Reference

All manufacturing data is stored server-side via the /api/data/manufacturing endpoint. The following REST-style operations are supported:

Settings & Customisation

Frequently Asked Questions