Production Management

PROD-SYS provides comprehensive production management capabilities to track work orders from SAP integration through shop floor execution, quality validation, and completion.

Key Capabilities

Production Orders

Import from SAP, track execution across multiple processes, and manage order lifecycle from creation to closure.

Shift Operations

Open daily shift logs (bitácoras), assign personnel, record production data, and close shifts with automatic validation.

Multi-Process Execution

Execute orders across 9 industrial processes including extrusion, weaving, lamination, printing, and conversion.

Real-Time Tracking

Monitor production progress, machine status, downtime events, and quality checkpoints in real-time.

Production Order Lifecycle

Creating Orders

Production orders are imported from SAP using the Import Orders workflow:

Upload Excel Export: Users upload the SAP production orders report (Series de documentos format)
Preview & Validation: System parses the file and validates:
- 7-digit document numbers
- SAP series mapped to internal process IDs (ExtruPP→1, Telar→2, etc.)
- Duplicate detection against existing PROD-SYS orders
Confirm Import: User reviews new orders, already-existing orders, and unrecognized series before confirming

Database Schema (orden_produccion table):

CREATE TABLE orden_produccion (
  id INTEGER PRIMARY KEY,
  codigo_orden TEXT UNIQUE NOT NULL,  -- 7-digit SAP document number
  producto TEXT NOT NULL,              -- Product description
  cantidad_objetivo REAL,              -- Target quantity
  unidad TEXT,                         -- Unit (KG, M2, MIL, UND)
  fecha_planificada TEXT,              -- Planned/due date
  prioridad TEXT,                      -- Alta/Media/Baja
  estado TEXT DEFAULT 'Creada',       -- Creada, Liberada, En producción, Pausada, Cerrada, Cancelada
  especificaciones TEXT,               -- JSON: SAP metadata, custom specs
  motivo_cierre TEXT,
  fecha_creacion TEXT DEFAULT CURRENT_TIMESTAMP
);

Source Reference:

Parser: backend/domains/production/ordenProduccion.parser.js
Service: backend/domains/production/ordenProduccion.service.js:106 (procesarImportacionExcel)
Repository: backend/domains/production/ordenProduccion.repository.js:45 (create)

Order States

Orders progress through these states:

State	Description	Allowed Actions
Creada	Imported from SAP, not yet released to production	Edit specifications, update quantity/dates, release
Liberada	Released to production, ready for execution	Start execution, pause, cancel
En producción	Active execution in at least one process	Record production, pause, close
Pausada	Temporarily halted	Resume, close, cancel
Cerrada	Completed (requires motivo_cierre)	View only
Cancelada	Cancelled (requires motivo_cierre)	View only

State Transition Rules:

Orders in Liberada, En producción, Pausada, Cerrada, or Cancelada only allow status changes (no technical modifications)
Closing or cancelling requires a motivo_cierre (closure reason)
Auditing: All state changes are logged via auditService.logStatusChange

Source Reference: backend/domains/production/ordenProduccion.service.js:69 (update method)

Shift Operations (Bitácoras)

Opening a Shift

Production supervisors open a bitácora de turno at the start of each shift: UI Flow:

Navigate to Operations → Open Shift
Select shift (Día/Noche), operational date, and inspector name
System validates: only one active bitácora allowed at a time
System creates bitácora record with state ABIERTA

Database Schema (bitacora_turno table):

CRETE TABLE bitacora_turno (
  id INTEGER PRIMARY KEY,
  turno TEXT NOT NULL,                 -- 'Día' or 'Noche'
  fecha_operativa TEXT NOT NULL,       -- Production date (YYYY-MM-DD)
  inspector TEXT NOT NULL,             -- Shift supervisor name
  fuera_de_horario INTEGER DEFAULT 0,  -- Off-hours flag
  estado TEXT DEFAULT 'ABIERTA',      -- ABIERTA, REVISION, CERRADA
  fecha_apertura TEXT DEFAULT CURRENT_TIMESTAMP,
  fecha_cierre TEXT
);

Source Reference: backend/domains/production/bitacora.service.js:36 (openBitacora)

Recording Production Data

During the shift, operators record production for each process: UI Flow:

Navigate to active bitácora → Select process (e.g., “Extrusor PP”)
If process is non-operational: Mark as “No Operativo” with reason (e.g., “Mantenimiento preventivo”)
If operational:
- Quality First: Record quality samples (muestras) before production
- Production: Record output quantities per order and machine
- Downtime: Log any stoppages (paros) with motivo and duration

Execution Line Model (lineas_ejecucion):

CREATE TABLE lineas_ejecucion (
  id INTEGER PRIMARY KEY,
  orden_produccion_id INTEGER NOT NULL,
  proceso_id INTEGER NOT NULL,
  maquina_id INTEGER,
  estado TEXT DEFAULT 'ACTIVA',  -- ACTIVA, PAUSADA, COMPLETADA, CANCELADA
  fecha_inicio TEXT DEFAULT CURRENT_TIMESTAMP,
  fecha_fin TEXT,
  FOREIGN KEY (orden_produccion_id) REFERENCES orden_produccion(id)
);

Each order-process-machine combination creates a línea de ejecución (execution line). Work Record Model (registros_trabajo):

CREATE TABLE registros_trabajo (
  id INTEGER PRIMARY KEY,
  linea_ejecucion_id INTEGER,
  bitacora_id INTEGER NOT NULL,
  maquina_id INTEGER,
  cantidad_producida REAL DEFAULT 0,
  merma_kg REAL DEFAULT 0,              -- Waste/scrap in KG
  observaciones TEXT,
  parametros TEXT,                      -- JSON: machine params, batch composition, etc.
  usuario_modificacion TEXT,
  fecha_hora TEXT DEFAULT CURRENT_TIMESTAMP,
  FOREIGN KEY (linea_ejecucion_id) REFERENCES lineas_ejecucion(id),
  FOREIGN KEY (bitacora_id) REFERENCES bitacora_turno(id)
);

Source Reference: backend/domains/production/bitacora.service.js:350 (saveProcesoData)

Process State Dashboard

The bitácora summary shows real-time status for all 9 processes: Status Indicators:

⚪ Sin datos: No activity recorded
🟡 Esperando Calidad: Production blocked until minimum quality samples recorded
🟡 Esperando Producción: Quality validated, awaiting production records
🟡 Parcial: Some data recorded, not yet complete
🔴 Revisión: Rejected quality samples or incidents detected
🟢 Completo: All required data recorded, quality validated

Validation Rules:

Quality samples must meet minimum count per process (defined in process contracts)
Production cannot be recorded until quality is validated
Rejected samples trigger REVISION state and require observaciones

Source Reference: backend/domains/production/bitacora.service.js:167 (getResumenProcesos)

Closing a Shift

When the shift ends, the supervisor closes the bitácora: Closure Validation:

Personnel Check: All processes with recorded activity must have assigned personnel for the shift
Downtime Validation: Total paro time cannot exceed programmed time (default 480 minutes)
Quality Validation: Check for rejected samples or incidents
Observations Required: If deviations detected, detailed observations are mandatory

Closure States:

CERRADA: Normal closure (all validations passed, no quality issues)
REVISION: Requires supervisor review (quality rejections or incidents detected)

Authorization:

Shift owner (inspector who opened the bitácora) can close
Administrators and Supervisors can close any bitácora

Source Reference: backend/domains/production/bitacora.service.js:58 (closeBitacora)

Multi-Process Execution

Process Registry

PROD-SYS supports 9 industrial processes, each with a dedicated Process Contract defining:

processId: Numeric identifier (1-9)
nombre: Display name
unidadProduccion: Production unit (KG, M2, MIL, UND)
parametrosRequeridos: Required operational parameters
frecuenciaMuestreo: Quality sampling requirements (e.g., muestrasMinTurno: 2)
validaUnidad(): Unit validation method
validarParametro(): Parameter validation method

Registered Processes:

ID	Process	Unit	Description
1	Extrusor PP	KG	Polypropylene extrusion
2	Telar	M2	Weaving
3	Laminado	M2	Lamination
4	Imprenta	MIL	Printing (thousands)
5	ConverSA	UND	Bag conversion
6	ExtruPE	KG	Polyethylene extrusion
7	ConverLI	UND	Liner conversion
8	Peletiza	KG	Pelletizing
9	VestidoM	UND	Bag dressing

Source Reference: backend/domains/production/contracts/ProcessRegistry.js

Machine Management

Each process has multiple machines tracked in the system: Machine States:

Operativa: Active and available
Mantenimiento: Under maintenance
Parada: Stopped/inactive
Baja: Decommissioned

Machine Schema (MAQUINAS):

CREATE TABLE MAQUINAS (
  id INTEGER PRIMARY KEY,
  codigo TEXT UNIQUE NOT NULL,
  nombre_visible TEXT NOT NULL,
  proceso_id INTEGER NOT NULL,
  estado_actual TEXT DEFAULT 'Operativa',
  activo INTEGER DEFAULT 1,
  fecha_baja TEXT,
  motivo_baja TEXT,
  updated_at TEXT DEFAULT CURRENT_TIMESTAMP
);

State Change Audit (maquina_estados_historial):

CREATE TABLE maquina_estados_historial (
  id INTEGER PRIMARY KEY,
  maquina_id INTEGER NOT NULL,
  estado_anterior TEXT NOT NULL,
  estado_nuevo TEXT NOT NULL,
  motivo TEXT,
  categoria_motivo TEXT,           -- 'Preventivo', 'Correctivo', 'Operacional'
  usuario TEXT,
  fecha_hora TEXT DEFAULT CURRENT_TIMESTAMP,
  FOREIGN KEY (maquina_id) REFERENCES MAQUINAS(id)
);

Source Reference: backend/domains/production/maquina.repository.js

Downtime Tracking

Downtime events (paros) are recorded per process and shift: Downtime Schema (PARO_PROCESO):

CREATE TABLE PARO_PROCESO (
  id INTEGER PRIMARY KEY,
  bitacora_id INTEGER NOT NULL,
  proceso_id INTEGER NOT NULL,
  motivo_id INTEGER NOT NULL,          -- FK to CATALOGO_MOTIVO_PARO
  minutos_perdidos INTEGER NOT NULL,
  observacion TEXT,
  fecha_hora TEXT DEFAULT CURRENT_TIMESTAMP,
  FOREIGN KEY (bitacora_id) REFERENCES bitacora_turno(id)
);

Downtime Catalog (CATALOGO_MOTIVO_PARO):

CREATE TABLE CATALOGO_MOTIVO_PARO (
  id INTEGER PRIMARY KEY,
  nombre TEXT NOT NULL,                -- e.g., "Falla mecánica", "Falta de materia prima"
  categoria TEXT,                      -- 'Mecánico', 'Eléctrico', 'Logístico', 'Calidad'
  activo INTEGER DEFAULT 1
);

Time Calculation:

Programmed time: 480 minutes (8-hour shift) by default
Effective time = Programmed time - Total paro minutes
Validation: Total paros cannot exceed programmed time

Source Reference: backend/domains/production/paro.repository.js

Incident Management

Incidents are recorded for production issues requiring corrective action: Incident Schema (incidentes):

CREATE TABLE incidentes (
  id INTEGER PRIMARY KEY,
  titulo TEXT NOT NULL,
  descripcion TEXT NOT NULL,
  severidad TEXT NOT NULL,             -- 'Baja', 'Media', 'Alta', 'Crítica'
  linea_ejecucion_id INTEGER,          -- Link to specific order execution
  estado TEXT DEFAULT 'abierto',       -- 'abierto', 'en_proceso', 'cerrado'
  accion_correctiva TEXT,
  fecha_creacion TEXT DEFAULT CURRENT_TIMESTAMP,
  fecha_cierre TEXT,
  FOREIGN KEY (linea_ejecucion_id) REFERENCES lineas_ejecucion(id)
);

Workflow:

Operator creates incident with severity level
Supervisor assigns corrective action
Incident tracked until closure
Closed incidents with severity ≥ Media trigger bitácora REVISION state

Source Reference: backend/domains/production/incidente.repository.js

Weekly Planning

Supervisors create weekly production plans (plan_semanal): Planning Workflow:

Create Plan: Define ISO week (year + week number)
Assign Orders: Schedule orders to specific days, shifts, processes, and machines
Assign Personnel: Assign workers to processes and shifts
Activate Plan: Change state from BORRADOR to ACTIVO
Create Baseline Snapshot: Lock the current plan as a baseline for deviation tracking

Plan Schema (plan_semanal):

CREATE TABLE plan_semanal (
  id INTEGER PRIMARY KEY,
  anio INTEGER NOT NULL,
  semana_iso INTEGER NOT NULL,         -- ISO 8601 week number (1-53)
  fecha_inicio TEXT NOT NULL,
  fecha_fin TEXT NOT NULL,
  estado TEXT DEFAULT 'BORRADOR',      -- BORRADOR, ACTIVO, CERRADO
  updated_at TEXT DEFAULT CURRENT_TIMESTAMP,
  UNIQUE(anio, semana_iso)
);

Order Assignments (plan_detalle_ordenes):

CREATE TABLE plan_detalle_ordenes (
  id INTEGER PRIMARY KEY,
  plan_id INTEGER NOT NULL,
  orden_id INTEGER NOT NULL,
  proceso_id INTEGER NOT NULL,
  maquina_id INTEGER,
  turno TEXT NOT NULL,                 -- 'Día', 'Noche'
  dia_semana INTEGER NOT NULL,         -- 0=Sunday, 6=Saturday
  secuencia INTEGER,                   -- Execution order within shift
  FOREIGN KEY (plan_id) REFERENCES plan_semanal(id),
  FOREIGN KEY (orden_id) REFERENCES orden_produccion(id)
);

Deviation Tracking (desviaciones_plan):

CREATE TABLE desviaciones_plan (
  id INTEGER PRIMARY KEY,
  plan_id INTEGER NOT NULL,
  bitacora_id INTEGER NOT NULL,
  proceso_id INTEGER,
  maquina_id INTEGER,
  tipo_desviacion TEXT NOT NULL,       -- 'ORDEN', 'PERSONAL', 'CANTIDAD'
  valor_planificado TEXT,
  valor_ejecutado TEXT,
  motivo_id INTEGER,                   -- FK to catalogo_motivo_desviacion
  comentario TEXT,
  usuario TEXT,
  fecha_hora TEXT DEFAULT CURRENT_TIMESTAMP,
  FOREIGN KEY (plan_id) REFERENCES plan_semanal(id),
  FOREIGN KEY (bitacora_id) REFERENCES bitacora_turno(id)
);

When actual execution deviates from the plan, the system records:

Order deviations: Planned order not executed, or unplanned order executed
Personnel deviations: Different workers assigned than planned
Quantity deviations: Actual production differs from planned

Source Reference: backend/domains/production/planning.repository.js

Next Steps

Quality Control

Learn how quality samples, batch management, and traceability work

Resource Tracking

Track material consumption and inventory integration

Personnel Management

Manage workers, assignments, and shift groups

API Reference

Explore the REST API endpoints for production management

Get Started

Core Features

User Guides

Production Processes

Administration

Production Management

Key Capabilities

Production Orders

Shift Operations

Multi-Process Execution

Real-Time Tracking

Production Order Lifecycle

Creating Orders

Order States

Shift Operations (Bitácoras)

Opening a Shift

Recording Production Data

Process State Dashboard

Closing a Shift

Multi-Process Execution

Process Registry

Machine Management

Downtime Tracking

Incident Management

Weekly Planning

Next Steps

Quality Control

Resource Tracking

Personnel Management

API Reference

Build docs developers (and LLMs) love

Get Started

Core Features

User Guides

Production Processes

Administration

​Key Capabilities

Production Orders

Shift Operations

Multi-Process Execution

Real-Time Tracking

​Production Order Lifecycle

​Creating Orders

​Order States

​Shift Operations (Bitácoras)

​Opening a Shift

​Recording Production Data

​Process State Dashboard

​Closing a Shift

​Multi-Process Execution

​Process Registry

​Machine Management

​Downtime Tracking

​Incident Management

​Weekly Planning

​Next Steps

Quality Control

Resource Tracking

Personnel Management

API Reference

Build docs developers (and LLMs) love

Key Capabilities

Production Order Lifecycle

Creating Orders

Order States

Shift Operations (Bitácoras)

Opening a Shift

Recording Production Data

Process State Dashboard

Closing a Shift

Multi-Process Execution

Process Registry

Machine Management

Downtime Tracking

Incident Management

Weekly Planning

Next Steps