Product Traceability

Traceability in PROD-SYS provides complete visibility into product genealogy - from raw materials through finished goods. This ensures quality accountability, enables rapid recall response, and supports regulatory compliance.

Understanding Traceability

Traceability answers three critical questions:

What went into this? (Inputs / Genealogy)
- Which raw material batches were consumed
- Which upstream production batches were used
- Material suppliers and batch numbers
How was it made? (Process)
- Production orders executed
- Machines and operators involved
- Process parameters and quality results
- Shifts and dates of production
Where did it go? (Outputs / Usage)
- Which downstream products consumed this batch
- Customer shipments and invoice numbers
- Current location and status

Traceability Architecture

PROD-SYS implements bidirectional traceability:

Raw Materials → Extrusor PP → Telares → Laminado → Imprenta → Conversión → Customer
       ↓             ↓           ↓          ↓           ↓           ↓
    Supplier     Lote 1     Lote 2     Lote 3      Lote 4      Lote 5
     Batch      (pellets)   (fabric)   (laminate)  (printed)   (bags)

Key Traceability Tables

Table	Purpose
`lotes`	Production batch master records
`consumo_lote_telar`	Fabric weaving consumption (Telares using Extrusor output)
`registros_trabajo`	Production records linking orders, machines, shifts
`lineas_ejecucion`	Execution context (order + process + machine)
`bitacoras`	Shift logs capturing time and operator context
`muestras`	Quality test results by batch
`historial_estado_lote`	Batch status changes and approvals

Tracing a Batch

Navigate to Control → Trazabilidad.

Enter Batch Code

Input the código_lote you want to trace:

Standard format: {codigo_orden}-{correlativo} (e.g., “2000145-001”)
Laminado format: {codigo_rollo}-L{correlativo} (e.g., “2000145-001-L1”)
Product serial numbers (future enhancement)

Execute Query

Click Consultar Historia. The system queries:

GET /api/lotes/:id/trazabilidad

View Complete Chain

The traceability view displays:Batch Details

Código_lote and internal ID
Production order (codigo_orden)
Source process
Production date and shift
Current status (activo, pausado, cerrado)

Upstream Genealogy (Inputs)

Raw material batches consumed
Supplier information
Material specifications
Receiving dates and quantities

Production Context

Machine used (from linea_ejecucion)
Operator and inspector (from bitacora)
Process parameters recorded
Quality test results (from muestras)

Downstream Usage (Outputs)

Which batches consumed this material
Destination orders and processes
Quantities used by shift
Customer shipments (future)

Status History

All status transitions
Approval timestamps
Comments and justifications
User attribution

Process-Specific Traceability

Extrusor PP (Process 1)

Inputs tracked:

Raw polymer batches (supplier + batch number)
Additives and colorants (from mezcla data)
Recycled material (regrind %)

Production data:

Extruder machine ID
Barrel temperature zones (T1-T6)
Screw RPM and pressure
Output rate (kg/hr)
Melt flow index (MFI) from quality samples

Outputs:

Pellet batches (lote codes)
Weight per batch
Packaging (bulk bags, gaylords)

Telares (Process 2)

Inputs tracked:

Extrusor PP batches consumed (via consumo_lote_telar)
Yarn specifications
Loom setup parameters

Production data:

Weaving machine (T-01, T-02, etc.)
Fabric width (ancho cm)
Linear meters produced
Operator per shift
Resistance and weight tests

Outputs:

Fabric roll batches (lote codes)
Roll length and weight
Quality grade

Laminado (Process 3)

Inputs tracked:

Telares fabric rolls (input lote codes)
Lamination film supplier and batch
Adhesive batch number

Production data:

Lamination machine
Temperature and speed settings
Bond strength (from quality samples)
Linear meters laminated

Outputs:

Laminated roll batches (format: -L)
Roll dimensions
Peel strength test results

Imprenta (Process 4)

Inputs tracked:

Laminado rolls consumed
Ink batch numbers by color
Print plate identification

Production data:

Printing press ID
Print registration (mm)
Color density readings
Print count (thousands)

Outputs:

Printed material batches
Customer artwork version
Color proofing results

Conversión (Processes 5, 7, 9)

Inputs tracked:

Printed material batches (from Imprenta)
Accessory components (handles, valves, zippers)
Thread/stitching material batches

Production data:

Converting/sewing machines
Cutting die identification
Stitch density and strength
Unit count produced

Outputs:

Finished goods batches
Packaging configuration (units per box/pallet)
Customer order linkage

Traceability Queries

Forward Trace (Where Did It Go?)

Starting from a raw material or intermediate batch, find all downstream products:

Start with Source Batch

Enter the early-stage batch code (e.g., Extrusor PP batch “1000234-001”).

Query Consumption Records

The system searches consumo_lote tables:

SELECT * FROM consumo_lote_telar WHERE lote_id = ?

Follow to Next Process

For each consumption record:

Find the registro_trabajo_id
Get the linea_ejecucion (order + process + machine)
Identify output batches from that registro

Recurse Downstream

Repeat for each output batch until reaching finished goods or customer shipments.

Display Tree View

Show hierarchical tree:

1000234-001 (Extrusor PP, 5000 kg)
├─ 2000145-001 (Telares, 18000 m², T-03)
│  ├─ 3000567-001-L1 (Laminado, 8000 m², LAM-01)
│  │  └─ 4000789-001 (Imprenta, 400 MIL, IMP-02)
│  │     └─ 5001234-001 (Conversión, 20000 UND, CONV-03)
│  │        └─ Shipment SO-98765 (15000 units to Customer ABC)
│  └─ 3000567-001-L2 (Laminado, 9500 m², LAM-01)
└─ 2000145-002 (Telares, 17500 m², T-05)

Backward Trace (Where Did It Come From?)

Starting from a finished product, find all source materials:

Start with Finished Goods

Enter the final batch code (e.g., “5001234-001” - finished bags).

Find Source Order

Get orden_produccion_id and bitacora_id from lote.

Query Input Consumption

Find what this order consumed:

SELECT * FROM consumo_lote_telar 
WHERE registro_trabajo_id IN (
  SELECT id FROM registros_trabajo WHERE bitacora_id = ?
)

Recurse Upstream

For each input batch, repeat the query to find its sources.

Display Reverse Tree

Show inverted hierarchy:

5001234-001 (Conversión, Bags, 20000 UND)
└─ 4000789-001 (Imprenta, Printed, 400 MIL)
   └─ 3000567-001-L1 (Laminado, Laminate, 8000 m²)
      └─ 2000145-001 (Telares, Fabric, 18000 m²)
         └─ 1000234-001 (Extrusor PP, Pellets, 5000 kg)
            ├─ Supplier: Polymer Corp, Batch PC-45678
            ├─ Additive: UV Stabilizer, Batch UV-2345
            └─ Colorant: Blue Masterbatch, Batch MB-8901

Quality Integration

Traceability includes complete quality context:

Quality Samples

For each batch, view linked quality samples:

{
  lote: "2000145-001",
  muestras: [
    {
      parametro: "Ancho",
      valor: 105.2,
      unidad: "cm",
      resultado: "Cumple",
      especificacion_min: 100,
      especificacion_max: 110,
      fecha_analisis: "2024-01-25T10:30:00Z",
      analista: "qc_user1"
    },
    {
      parametro: "Resistencia",
      valor: 485,
      unidad: "N",
      resultado: "Cumple",
      especificacion_min: 450,
      fecha_analisis: "2024-01-25T10:35:00Z",
      analista: "qc_user1"
    }
  ]
}

Rejected Batches

If quality samples show rejections:

Batch status changes to “pausado”
Historial records rejection reason
Downstream usage is blocked
Traceability query highlights the rejection:
- Shows rejection timestamp
- Links to corrective action (if documented)
- Indicates disposition (rework, scrap, conditional release)

Recall Simulation

In a recall scenario:

Identify Problem Batch

Customer reports issue, provides batch code or shipment number.

Backward Trace to Root Cause

Query backward to identify all source materials and processes involved.

Identify Potentially Affected Batches

If root cause is a specific raw material batch:

Find all production runs using that material
Query forward from that batch to all finished goods

Generate Recall List

System produces:

All finished goods batches affected
Customer shipments containing those batches
Quantities by customer and shipment date
Current inventory locations

Update Status

Change affected batch status to “pausado” with recall comment:

RECALL ALERT: Lote asociado a material defectuoso.
Batch de polímero PC-45678 contaminado con humedad excesiva.
Todos los productos derivados deben ser retenidos e inspeccionados.
Contactar a Quality Manager antes de disposición.

Isolate and Disposition

Hold all affected inventory
Inspect finished goods
Determine rework feasibility
Scrap if necessary
Document all actions in audit trail

Audit Trail Integration

Every traceability record has audit context:

Who, What, When

Production: Username from bitacora.inspector or registro_trabajo.usuario_modificacion
Quality: Username from muestras.usuario_modificacion
Status changes: Username from historial_estado_lote.changed_by
Timestamps: All operations recorded in UTC

Viewing Audit Details

In traceability view:

Click on any batch or production record
View “Audit Trail” tab
See all CRUD operations:
- CREATE: Initial batch generation
- UPDATE: Data corrections or additions
- STATUS_CHANGE: Quality approvals or holds
- DELETE: (Not allowed - soft deletes only)

Material Balance Verification

Use traceability to validate material usage:

Select Time Period

Choose date range (e.g., weekly, monthly).

Query Production by Process

For each process:

Sum all output quantities (from registros_trabajo.cantidad_producida)
Sum all input consumption (from consumo_lote tables)

Calculate Material Efficiency

Efficiency % = (Output Quantity / Input Quantity) × 100
Waste % = 100 - Efficiency %

Compare to:

Expected yield (from process specifications)
Reported waste (from registros_trabajo.merma_kg)

Investigate Variances

If efficiency is below target:

Drill into specific batches
Review quality rejections
Check for unreported waste
Identify process improvement opportunities

Traceability Reports

Batch Genealogy Report

For regulatory compliance, generate PDF report:

BATCH GENEALOGY REPORT

Finished Product: Batch 5001234-001
Customer: ABC Corporation
Shipment: SO-98765, Shipped 2024-01-28
Quantity: 15,000 units (Bags, 50kg capacity)

--- PRODUCTION HISTORY ---

1. Conversión (Process 5)
   Machine: CONV-03
   Shift: T1, 2024-01-27
   Operator: operator5
   Quantity: 20,000 UND
   Quality: All samples pass
   
   Inputs:
   - Batch 4000789-001 (Printed Material, 400 MIL)
   - Thread: Supplier ThreadCo, Batch THR-5678
   - Handles: Supplier HandleInc, Batch HDL-3456

2. Imprenta (Process 4)
   Machine: IMP-02
   Shift: T2, 2024-01-26
   Operator: operator7
   Quantity: 400 MIL (thousand impressions)
   Quality: Color density OK, Registration ±0.5mm
   
   Inputs:
   - Batch 3000567-001-L1 (Laminated Roll, 8000 m²)
   - Inks: Cyan INK-C-1234, Magenta INK-M-2345, Yellow INK-Y-3456, Black INK-K-4567

[... continued for each upstream process ...]

--- RAW MATERIALS ---

Polymer: Supplier Polymer Corp, Batch PC-45678
  Received: 2024-01-10
  COA: Certificate PC-45678-COA
  Specs: MFI 12±2, Density 0.905 g/cm³

UV Stabilizer: Supplier Additives Inc, Batch UV-2345
  Received: 2024-01-08
  COA: UV-2345-COA

Colorant: Supplier MasterBatch Ltd, Batch MB-8901
  Received: 2024-01-05
  COA: MB-8901-COA

--- QUALITY SUMMARY ---

All processes: Quality samples within specification
No rejections or holds
No deviations or incidents

--- CERTIFICATION ---

This report certifies complete traceability from raw materials
to finished goods for the above batch.

Generated: 2024-01-30 10:45:00 UTC
Generated by: quality_manager1

Best Practices

Record batch consumption immediately during production, not retrospectively

Validate traceability chains before customer shipments

Maintain consistent batch numbering across all processes

Link quality samples to batches, not just orders

Document all batch status changes with detailed comments

Perform periodic material balance audits to validate traceability

Test recall procedures quarterly with simulated scenarios

Gaps in traceability (missing consumption records) break the chain and prevent effective recall.

Troubleshooting

Batch Shows No Inputs

Issue: Forward trace finds batch but no source materials

Consumption may not have been recorded during production
Check if process contract supports consumption tracking
Review shift log to verify production was recorded correctly
Add missing consumo_lote records if data is available

Batch Shows No Outputs

Issue: Backward trace shows batch created but never consumed

Batch may still be in inventory (not yet used)
Could indicate production planning issue (excess inventory)
Verify batch estado (may be pausado or cerrado)
Check if downstream process is active

Material Balance Doesn’t Match

Issue: Input quantities don’t align with output quantities

Check for unreported waste (merma_kg in registros_trabajo)
Verify unit conversions (kg vs. m² vs. MIL vs. UND)
Look for quality rejections that removed material from production
Investigate data entry errors in cantidad_producida

Traceability Query Times Out

Issue: Large traceability chains cause slow queries

Optimize database indexes on lote_id, registro_trabajo_id
Limit tree depth (e.g., 5 levels max)
Cache frequently accessed genealogies
Use asynchronous query with progress indicator

Future Enhancements

Planned traceability improvements:

Graphical Genealogy View: Interactive tree/graph visualization
Customer Shipment Integration: Link batches to invoices and shipping docs
Material Certificates: Attach supplier COAs and test reports to batches
Barcode/QR Integration: Scan batch labels to query traceability
Real-Time Alerts: Notify when related batches are held or recalled
Blockchain Pilot: Immutable traceability records for export customers

Quality Batches - Managing batch lifecycle and status
Shift Logs - Recording production that generates traceability
Production Orders - Orders that batches fulfill
Incidents - Tracking quality issues by batch

Get Started

Core Features

User Guides

Production Processes

Administration

Product Traceability

Understanding Traceability

Traceability Architecture

Key Traceability Tables

Tracing a Batch

Process-Specific Traceability

Extrusor PP (Process 1)

Telares (Process 2)

Laminado (Process 3)

Imprenta (Process 4)

Conversión (Processes 5, 7, 9)

Traceability Queries

Forward Trace (Where Did It Go?)

Backward Trace (Where Did It Come From?)

Quality Integration

Quality Samples

Rejected Batches

Recall Simulation

Audit Trail Integration

Who, What, When

Viewing Audit Details

Material Balance Verification

Traceability Reports

Batch Genealogy Report

Best Practices

Troubleshooting

Batch Shows No Inputs

Batch Shows No Outputs

Material Balance Doesn’t Match

Traceability Query Times Out

Future Enhancements

Build docs developers (and LLMs) love

Get Started

Core Features

User Guides

Production Processes

Administration

​Understanding Traceability

​Traceability Architecture

​Key Traceability Tables

​Tracing a Batch

​Process-Specific Traceability

​Extrusor PP (Process 1)

​Telares (Process 2)

​Laminado (Process 3)

​Imprenta (Process 4)

​Conversión (Processes 5, 7, 9)

​Traceability Queries

​Forward Trace (Where Did It Go?)

​Backward Trace (Where Did It Come From?)

​Quality Integration

​Quality Samples

​Rejected Batches

​Recall Simulation

​Audit Trail Integration

​Who, What, When

​Viewing Audit Details

​Material Balance Verification

​Traceability Reports

​Batch Genealogy Report

​Best Practices

​Troubleshooting

​Batch Shows No Inputs

​Batch Shows No Outputs

​Material Balance Doesn’t Match

​Traceability Query Times Out

​Future Enhancements

​Related Topics

Build docs developers (and LLMs) love

Understanding Traceability

Traceability Architecture

Key Traceability Tables

Tracing a Batch

Process-Specific Traceability

Extrusor PP (Process 1)

Telares (Process 2)

Laminado (Process 3)

Imprenta (Process 4)

Conversión (Processes 5, 7, 9)

Traceability Queries

Forward Trace (Where Did It Go?)

Backward Trace (Where Did It Come From?)

Quality Integration

Quality Samples

Rejected Batches

Recall Simulation

Audit Trail Integration

Who, What, When

Viewing Audit Details

Material Balance Verification

Traceability Reports

Batch Genealogy Report

Best Practices

Troubleshooting

Batch Shows No Inputs

Batch Shows No Outputs

Material Balance Doesn’t Match

Traceability Query Times Out

Future Enhancements

Related Topics