Quality Batch Management

Quality batches (lotes) are the traceability units in PROD-SYS. They represent discrete production outputs that can be tracked, tested, and traced through the manufacturing process.

Understanding Batches

A batch is created when production is recorded against an order:

Batch Code: {codigo_orden}-{correlativo}
Example: Order 2000145 → Batches 2000145-001, 2000145-002, 2000145-003
Scope: One batch per order + shift combination
Lifecycle: activo → pausado → cerrado

Why Batches Matter

Quality Control: Batches are the unit of quality testing and hold/release decisions
Traceability: Track materials from raw input to finished goods
Recall Management: Identify and isolate specific production runs
Inventory Control: Manage stock by discrete, testable units
Customer Shipments: Ship and invoice by batch

Automatic Batch Generation

Batches are created automatically during shift log recording.

Record Production

During shift log (Bitácora de Turno), log production against an order:

Select production order
Enter quantity produced
Save process data

System Generates Batch

The generarOObtenerLote() service method:

Checks if a batch already exists for this bitácora + orden
If yes: Returns existing batch
If no: Creates new batch:
- Calculates next correlativo (max + 1)
- Generates código_lote: {codigo_orden}-{correlativo}
- Sets estado: “activo”
- Links to bitácora_id and orden_produccion_id
- Records creation user and timestamp

Batch Becomes Active

The batch is now available for:

Quality testing
Consumption by downstream processes
Inventory tracking
Customer shipment

Batches are created per order + bitácora (shift). If the same order runs across multiple shifts, each shift gets its own batch with incrementing correlativo.

Viewing Batches

Navigate to Control → Trazabilidad or access the internal lotes module.

Batch List

The batch table displays:

Column	Description
Código Lote	Format: -
Proceso	Source production process
Orden	Linked production order (codigo_orden)
Estado	activo, pausado, cerrado
Acciones	View details, change status, traceability

Filtering

Available batches only:

GET /api/lotes/disponibles

Returns batches with estado = “activo” or “pausado” (not “cerrado”). By order:

GET /api/lotes/orden/:ordenId

Returns all batches for a specific production order.

Batch Status Management

Batches move through a controlled lifecycle:

Active (activo)

Initial state after creation:

Available for consumption by downstream processes
Quality testing in progress or completed
Can be used in production

Paused (pausado)

Temporarily held:

Quality issue under investigation
Material verification pending
Customer specification review needed
Inventory hold for administrative reasons

Closed (cerrado)

Final state:

All material consumed or shipped
Quality approved and documented
No longer available for use
Irreversible status

Changing Status

Navigate to Batch

Find the batch in the lotes list and click “Acciones” → “Cambiar Estado”.

Select New Status

Choose the target status:

activo → pausado (hold batch)
activo → cerrado (finalize batch)
pausado → activo (release hold)
pausado → cerrado (finalize held batch)

Invalid transitions (e.g., cerrado → anything) are blocked.

Provide Comment

For pausado or cerrado status:

Comment is mandatory
Explain the reason for status change
Include any test results, approvals, or justifications

Example (pausado):

Lote en espera de resultados de laboratorio externo.
Resistencia a la tracción fuera de especificación en muestra inicial.
Esperando contramuestra antes de liberar.

Example (cerrado):

Lote completamente consumido en proceso de Laminado.
Total utilizado: 15,000 m² en turnos T1 y T2 del 25/01.
Calidad aprobada, sin rechazos.

Confirm Change

Click Confirmar. The system:

Validates the state transition
Updates estado in lotes table
Creates historial_estado_lote entry
Logs change in audit trail
Records changed_by username and timestamp

Batches in “cerrado” state cannot be reopened. Ensure all quality and inventory actions are complete before closing.

Batch Consumption (Process Inputs)

Downstream processes consume upstream batches:

Example: Telares Consuming Extrusor PP Output

Open Shift Log

In Bitácora de Turno, navigate to Proceso 2 (Telares).

Record Production

Enter production data:

Select weaving order
Choose machine (T-01, T-02, etc.)
Enter quantity produced

Declare Input Batches

Select which extruder batches were consumed:

System queries available batches (estado = activo or pausado)
Operator selects batches used on this machine
Multiple batches can be selected

Save Consumption

The system:

Creates consumo_lote_telar records linking:
- registro_trabajo_id (the production record)
- maquina_id (the weaving machine)
- bitacora_id (the shift)
- lote_id (each consumed batch)
Records created_by user
Builds traceability chain

Consumption Validation

// From lote.service.js:74-84
const lote = await this.loteRepository.findById(loteId);
if (!lote) {
  throw new ValidationError(`El lote con ID ${loteId} no existe.`);
}
if (lote.estado === 'cerrado') {
  throw new ValidationError(
    `El lote ${lote.codigo_lote} está cerrado y no puede ser declarado como consumido.`
  );
}

Only batches with estado “activo” or “pausado” can be consumed. Closed batches are blocked.

Special Batch Formats

Standard Format (Most Processes)

Format: {codigo_orden}-{correlativo} Example:

Order: 1000234 (Extrusor PP)
Batches: 1000234-001, 1000234-002, 1000234-003

Generated by: generarOObtenerLote()

Laminado Format (Custom)

Format: {codigo_rollo_entrada}-L{correlativo} Example:

Input batch: 2000145-001 (fabric roll from Telares)
Laminated batches: 2000145-001-L1, 2000145-001-L2

Generated by: crearLoteDirecto() with custom código_lote This preserves the input-output relationship in the batch code itself.

Batch History

Every status change is recorded in historial_estado_lote:

{
  id: 1,
  lote_id: 123,
  estado_anterior: "activo",
  estado_nuevo: "pausado",
  comentario: "Esperando resultados de laboratorio",
  changed_by: "supervisor1",
  changed_at: "2024-01-25T15:30:00Z"
}

Viewing History

Access Batch Details

Click on a batch in the lotes list.

View History Tab

Navigate to the “Historial” section.

Review Changes

See all status transitions:

Timestamp of change
User who made the change
Previous and new status
Comment explaining the change

This provides complete audit trail for regulatory compliance and quality investigations.

Batch Traceability

The traceability query links all related data:

GET /api/lotes/:id/trazabilidad

Returns:

{
  lote: {  // Batch details
    id: 123,
    codigo_lote: "2000145-001",
    orden_produccion_id: 456,
    codigo_orden: "2000145",
    bitacora_id: 789,
    turno: "T1",
    fecha_operativa: "2024-01-25",
    estado: "activo"
  },
  consumos: [  // Where this batch was used
    {
      proceso_nombre: "Laminado",
      maquina_nombre: "LAM-01",
      turno: "T2",
      fecha_operativa: "2024-01-25",
      cantidad_producida: 8000,
      orden_destino: "3000567"
    }
  ],
  historial: [  // Status changes
    {
      estado_anterior: "activo",
      estado_nuevo: "cerrado",
      comentario: "Lote completamente consumido",
      changed_by: "operator2",
      changed_at: "2024-01-25T22:15:00Z"
    }
  ]
}

Navigate to Trazabilidad

Go to Control → Trazabilidad.

Enter Batch Code

Input the código_lote (e.g., “2000145-001”).

View Complete Chain

The system displays:

Upstream: Raw materials or input batches consumed to make this batch
This Batch: Production details (order, shift, date, quantity, quality results)
Downstream: Where this batch was consumed and what output batches it produced
Status History: All state transitions with timestamps and users

Integration with Quality Control

Batches are the unit of quality sampling:

Quality Sample Linkage

Production creates batch (lote)
Quality team takes samples from batch
Samples are tested and recorded in muestras table
Samples linked to batch via bitacora_id + orden_produccion_id
Quality results determine batch disposition:
- Cumple: Batch approved, remains activo
- Rechazo: Batch held, status → pausado
- En espera: Batch held pending retest

Quality Hold Workflow

Quality Rejection Detected

During shift log recording, a quality sample returns “Rechazo”.

Shift Status Updates

Process status becomes ”🔴 Revisión”, requiring justification.

Supervisor Reviews

Supervisor evaluates:

Sample results
Batch disposition (rework, scrap, conditional release)
Corrective actions

Update Batch Status

Based on decision:

Rework possible: Keep activo, add observations
Investigation needed: Change to pausado with comment
Scrapped: Change to cerrado with comment

Document in System

All decisions recorded in:

Batch status and comment
Historial_estado_lote
Bitácora observations
Audit trail

Best Practices

Let the system generate batch codes automatically - don’t override correlativo

Update batch status immediately when quality decisions are made

Provide detailed comments for all status changes (especially pausado and cerrado)

Close batches promptly when fully consumed or shipped

Use batch consumption tracking to validate material usage against production

Review batch traceability before shipment to ensure quality compliance

Never close a batch that may still be needed for production or has open quality issues.

Reporting and KPIs

Batch Yield Analysis

Compare:

Input batch quantities (from upstream process)
Output quantities (from downstream process)
Calculate material utilization %

Quality Performance

Track:

% batches with zero quality rejections
Average time from production to quality approval
% batches requiring hold or rework

Inventory Accuracy

Reconcile:

Batches created (from registros_trabajo)
Batches consumed (from consumo_lote tables)
Batches in activo state (current inventory)

Troubleshooting

Batch Not Generated

Issue: Production recorded but no batch created

Check if production was saved successfully
Verify orden_produccion_id is valid
Ensure bitacora_id is present
Review application logs for errors

Cannot Consume Batch

Error: “El lote está cerrado y no puede ser declarado como consumido”

The batch status is “cerrado”
Cannot reopen closed batches
Use a different batch or contact supervisor

Duplicate Batch Codes

Issue: Two batches with same código_lote

Should never happen - indicates data integrity issue
Check correlativo calculation logic
Review database constraints
Contact system administrator

Missing Traceability Data

Issue: Batch shows no consumption records

Batch may not have been used yet
Downstream process may not have declared consumption
Check if consumo_lote records were created
Verify process contract supports consumption tracking

Shift Logs - Recording production that generates batches
Traceability - Following batches through production chain
Production Orders - Orders that batches fulfill

Get Started

Core Features

User Guides

Production Processes

Administration

Quality Batch Management

Understanding Batches

Why Batches Matter

Automatic Batch Generation

Viewing Batches

Batch List

Filtering

Batch Status Management

Active (activo)

Paused (pausado)

Closed (cerrado)

Changing Status

Batch Consumption (Process Inputs)

Example: Telares Consuming Extrusor PP Output

Consumption Validation

Special Batch Formats

Standard Format (Most Processes)

Laminado Format (Custom)

Batch History

Viewing History

Batch Traceability

Integration with Quality Control

Quality Sample Linkage

Quality Hold Workflow

Best Practices

Reporting and KPIs

Batch Yield Analysis

Quality Performance

Inventory Accuracy

Troubleshooting

Batch Not Generated

Cannot Consume Batch

Duplicate Batch Codes

Missing Traceability Data

Build docs developers (and LLMs) love

Get Started

Core Features

User Guides

Production Processes

Administration

​Understanding Batches

​Why Batches Matter

​Automatic Batch Generation

​Viewing Batches

​Batch List

​Filtering

​Batch Status Management

​Active (activo)

​Paused (pausado)

​Closed (cerrado)

​Changing Status

​Batch Consumption (Process Inputs)

​Example: Telares Consuming Extrusor PP Output

​Consumption Validation

​Special Batch Formats

​Standard Format (Most Processes)

​Laminado Format (Custom)

​Batch History

​Viewing History

​Batch Traceability

​Integration with Quality Control

​Quality Sample Linkage

​Quality Hold Workflow

​Best Practices

​Reporting and KPIs

​Batch Yield Analysis

​Quality Performance

​Inventory Accuracy

​Troubleshooting

​Batch Not Generated

​Cannot Consume Batch

​Duplicate Batch Codes

​Missing Traceability Data

​Related Topics

Build docs developers (and LLMs) love

Understanding Batches

Why Batches Matter

Automatic Batch Generation

Viewing Batches

Batch List

Filtering

Batch Status Management

Active (activo)

Paused (pausado)

Closed (cerrado)

Changing Status

Batch Consumption (Process Inputs)

Example: Telares Consuming Extrusor PP Output

Consumption Validation

Special Batch Formats

Standard Format (Most Processes)

Laminado Format (Custom)

Batch History

Viewing History

Batch Traceability

Integration with Quality Control

Quality Sample Linkage

Quality Hold Workflow

Best Practices

Reporting and KPIs

Batch Yield Analysis

Quality Performance

Inventory Accuracy

Troubleshooting

Batch Not Generated

Cannot Consume Batch

Duplicate Batch Codes

Missing Traceability Data

Related Topics