Production Lines & Chains - APTIV Scrap Control

Production lines and chains define the organizational structure of manufacturing operations in APTIV Scrap Control. This hierarchy enables granular scrap tracking and reporting.

Production Hierarchy

The system uses a two-level production hierarchy:

Cadenas (Production Chains)

Top-level grouping representing major production areas or product families

Líneas (Production Lines)

Individual production lines within each chain, can be fixed or flexible

Production Chains (Cadenas)

Chains group multiple production lines by product type or manufacturing process.

TypeScript Interface

types.ts

export interface Cadena {
  id: number;
  nombre: string;            // Chain name
  descripcion: string;       // Description
  activo: number;            // 1=active, 0=inactive
}

Database Schema

schema.sql

CREATE TABLE IF NOT EXISTS cadenas (
  id int AUTO_INCREMENT PRIMARY KEY,
  nombre varchar(50) NOT NULL,
  descripcion varchar(200) DEFAULT '',
  activo TINYINT DEFAULT 1
);

Sample Chains

Cadena 1

Producción arneses motorManufactures wire harnesses for automotive engines

3 fixed lines (A1, A2)
1 flexible line (A3)

Cadena 2

Conectores y terminalesProduces electrical connectors and terminals

2 fixed lines (B1, B2)

Cadena 3

Ensambles especialesSpecialized assemblies and custom components

1 flexible line (C1)
1 fixed line (C2)

Cadena 4

Soldadura y acabadoWelding and finishing operations

1 fixed line (D1)

Example Data

seed.ts

export const seedCadenas: Cadena[] = [
  { id: 1, nombre: 'Cadena 1', descripcion: 'Producción arneses motor', activo: 1 },
  { id: 2, nombre: 'Cadena 2', descripcion: 'Conectores y terminales', activo: 1 },
  { id: 3, nombre: 'Cadena 3', descripcion: 'Ensambles especiales', activo: 1 },
  { id: 4, nombre: 'Cadena 4', descripcion: 'Soldadura y acabado', activo: 1 },
];

Production Lines (Líneas)

Lines are the actual manufacturing workstations within each chain.

TypeScript Interface

types.ts

export interface Linea {
  id: number;
  cadena_id: number;         // Foreign key to cadenas table
  nombre: string;            // Line name (Línea A1, Línea B2)
  tipo: string;              // Type: 'Fija' or 'Flexible'
  supervisor_id?: number;    // Optional: assigned supervisor
  activo: number;            // 1=active, 0=inactive
}

Database Schema

schema.sql

CREATE TABLE IF NOT EXISTS lineas (
  id int AUTO_INCREMENT PRIMARY KEY,
  cadena_id int NOT NULL,
  nombre varchar(50) NOT NULL,
  tipo varchar(50) DEFAULT 'Fija',
  supervisor_id int DEFAULT NULL,
  activo TINYINT DEFAULT 1,
  FOREIGN KEY (cadena_id) REFERENCES cadenas(id) ON DELETE CASCADE
);

The cadena_id foreign key ensures referential integrity. Deleting a chain will cascade delete all its associated lines.

Line Types

Fija (Fixed Line)

Fixed production lines manufacture a specific product or product family:

Dedicated equipment and tooling
Consistent process flow
Standard staffing requirements
Most common in high-volume production

Example: Línea A1 - Always produces motor wire harnesses

Flexible (Flexible Line)

Flexible production lines can manufacture multiple products:

Modular equipment configuration
Quick changeover capability
Variable staffing based on product
Used for mixed-model production

Example: Línea A3 - Switches between different harness models

Sample Lines by Chain

seed.ts

export const seedLineas: Linea[] = [
  // Cadena 1 - Arneses motor
  { id: 1, cadena_id: 1, nombre: 'Línea A1', tipo: 'Fija', activo: 1 },
  { id: 2, cadena_id: 1, nombre: 'Línea A2', tipo: 'Fija', activo: 1 },
  { id: 3, cadena_id: 1, nombre: 'Línea A3', tipo: 'Flexible', activo: 1 },
  
  // Cadena 2 - Conectores
  { id: 4, cadena_id: 2, nombre: 'Línea B1', tipo: 'Fija', activo: 1 },
  { id: 5, cadena_id: 2, nombre: 'Línea B2', tipo: 'Fija', activo: 1 },
  
  // Cadena 3 - Ensambles especiales
  { id: 6, cadena_id: 3, nombre: 'Línea C1', tipo: 'Flexible', activo: 1 },
  { id: 7, cadena_id: 3, nombre: 'Línea C2', tipo: 'Fija', activo: 1 },
  
  // Cadena 4 - Soldadura
  { id: 8, cadena_id: 4, nombre: 'Línea D1', tipo: 'Fija', activo: 1 },
];

Scrap Record Integration

When operators register scrap, they select both chain and line:

Scrap Record Fields

types.ts

export interface Pesaje {
  // ... other fields
  CADENA: string;            // Chain name (legacy text field)
  CADENA_ID?: number;        // Chain ID (new FK)
  LINEA?: string;            // Line name (legacy text field)
  LINEA_ID?: number;         // Line ID (new FK)
  // ... other fields
}

The system maintains both text fields (CADENA, LINEA) and ID references (CADENA_ID, LINEA_ID) for backward compatibility with existing data.

Database Schema

schema.sql

CREATE TABLE IF NOT EXISTS pesaje (
  ID int NOT NULL AUTO_INCREMENT,
  AREA varchar(50) DEFAULT NULL,
  NP varchar(50) DEFAULT NULL,
  MATERIAL varchar(50) DEFAULT NULL,
  PESO double(6,4) DEFAULT NULL,
  COSTO double(10,3) DEFAULT NULL,
  CADENA varchar(20) DEFAULT NULL,
  TURNO varchar(20) DEFAULT NULL,
  TIPO varchar(50) DEFAULT NULL,
  SUPERVISOR varchar(50) DEFAULT NULL,
  FECHA_REGISTRO datetime DEFAULT NULL,
  TOTAL_PZAS varchar(50) DEFAULT NULL,
  MODO_FALLA varchar(100) DEFAULT '-',
  USUARIO_ID int DEFAULT NULL,
  COMENTARIOS text DEFAULT NULL,
  FOTO varchar(255) DEFAULT NULL,
  ELIMINADO TINYINT DEFAULT 0,
  CATEGORIA varchar(50) DEFAULT NULL,
  UNIDAD varchar(20) DEFAULT NULL,
  CADENA_ID int DEFAULT NULL,
  LINEA_ID int DEFAULT NULL,
  LINEA varchar(50) DEFAULT NULL,
  UPDATED_AT datetime DEFAULT NULL,
  PRIMARY KEY (ID)
);

Managing Production Lines

Adding a New Chain

Navigate to Catalogs

From the main menu, select Catálogos → Cadenas

Create Chain

Click + Agregar and enter:

Nombre: Chain name (e.g., “Cadena 5”)
Descripción: Purpose or product family

Save

Click Guardar to create the chain. It will be assigned an auto-incremented ID.

Adding a New Line

Note: The Lines catalog is currently hidden in the UI (Catalogs.tsx:104) but can be managed via API or database.

API Method (Recommended)

Use the /api/catalogs/lineas endpoint:

POST /api/catalogs/lineas
{
  "cadena_id": 1,
  "nombre": "Línea A4",
  "tipo": "Fija",
  "activo": 1
}

Database Method

Insert directly into the lineas table:

INSERT INTO lineas (cadena_id, nombre, tipo, activo) 
VALUES (1, 'Línea A4', 'Fija', 1);

Enable UI Management (Optional)

Remove line 104 filter in Catalogs.tsx:

// Remove this line:
.filter(t => t.id !== 'lineas')

Reporting by Chain and Line

The production hierarchy enables powerful reporting capabilities:

By Chain Report

GET /api/reports/by-cadena?start=2024-01-01&end=2024-01-31

Returns scrap totals aggregated by production chain:

[
  {
    "cadena": "Cadena 1",
    "total_pzas": 450,
    "total_peso": 56.25,
    "total_costo": 1125.00
  },
  {
    "cadena": "Cadena 2",
    "total_pzas": 320,
    "total_peso": 14.40,
    "total_costo": 576.00
  }
]

Drill-Down Capability

Reports allow drilling down from chain → line → area:

Chain Level

View total scrap for each production chain to identify problematic chains

Line Level

Filter by specific chain to see which lines within that chain generate the most scrap

Area Level

Further filter by line to identify which process areas need attention

Supervisor Assignment

Lines can be assigned to supervisors for accountability:

Linking Supervisor to Line

UPDATE lineas 
SET supervisor_id = 3 
WHERE id = 1;

Use Cases

Scrap Accountability

Track which supervisor is responsible for scrap generated on each line

Filtered Reports

Supervisors can view reports filtered to only their assigned lines

Performance Metrics

Calculate scrap rates per supervisor for performance reviews

Alert Routing

Send scrap alerts to the line supervisor when tolerances are exceeded

Best Practices

Naming Conventions

Chain Naming

Use descriptive names that reflect the product family:

✅ “Cadena 1 - Arneses Motor”
✅ “Cadena 2 - Conectores”
❌ “Línea Principal” (too generic)
❌ “Producción A” (unclear)

Line Naming

Use alphanumeric codes that reference the parent chain:

✅ “Línea A1” (A = Cadena 1, 1 = first line)
✅ “Línea B2” (B = Cadena 2, 2 = second line)
❌ “Línea 1” (doesn’t indicate chain)
❌ “Producción 001” (unclear hierarchy)

Hierarchy Design

Group by Product Family

Create chains based on similar products or processes, not physical location

Balance Line Count

Aim for 2-5 lines per chain. Too few suggests chains are too granular; too many suggests they’re too broad

Consider Flexibility

Designate lines as “Flexible” if they produce multiple products to ensure accurate scrap attribution

Plan for Growth

Leave numeric gaps in line numbering (A1, A3, A5) to allow for future line additions

Tolerance Configuration

Production chains and lines can have specific scrap tolerance limits:

Chain-Level Tolerances

types.ts

export interface Tolerancia {
  id: number;
  nombre: string;
  tipo_objetivo: 'global' | 'cadena' | 'linea' | 'area' | 'categoria';
  objetivo_id: string;       // Chain name or ID
  tipo_periodo: 'diario' | 'semanal' | 'mensual';
  cantidad_max: number;      // Max pieces
  costo_max: number;         // Max cost (USD)
  porcentaje_alerta: number; // Alert threshold (80 = 80%)
  activo: number;
}

Example Configuration

seed.ts

{
  id: 3,
  nombre: 'Límite semanal Cadena 1',
  tipo_objetivo: 'cadena',
  objetivo_id: 'Cadena 1',
  tipo_periodo: 'semanal',
  cantidad_max: 300,
  costo_max: 3000,
  porcentaje_alerta: 80,
  activo: 1
}

When Cadena 1 reaches 240 pieces (80% of 300) in a week, the system triggers an alert.

API Reference

Chains Endpoints

Method	Endpoint	Description
GET	`/api/catalogs/cadenas`	List all chains
POST	`/api/catalogs/cadenas`	Create new chain
PUT	`/api/catalogs/cadenas/:id`	Update chain
DELETE	`/api/catalogs/cadenas/:id`	Deactivate chain

Lines Endpoints

Method	Endpoint	Description
GET	`/api/catalogs/lineas`	List all lines
GET	`/api/catalogs/lineas?cadena_id=1`	List lines for specific chain
POST	`/api/catalogs/lineas`	Create new line
PUT	`/api/catalogs/lineas/:id`	Update line
DELETE	`/api/catalogs/lineas/:id`	Deactivate line

All endpoints require authentication and the manage_catalogs permission.

Get Started

Core Features

User Management

Configuration

Deployment

​Production Hierarchy

​Production Chains (Cadenas)

​TypeScript Interface

​Database Schema

​Sample Chains

Cadena 1

Cadena 2

Cadena 3

Cadena 4

​Example Data

​Production Lines (Líneas)

​TypeScript Interface

​Database Schema

​Line Types

​Sample Lines by Chain

​Scrap Record Integration

​Scrap Record Fields

​Database Schema

​Managing Production Lines

​Adding a New Chain

​Adding a New Line

​Reporting by Chain and Line

​By Chain Report

​Drill-Down Capability

​Supervisor Assignment

​Linking Supervisor to Line

​Use Cases

Scrap Accountability

Filtered Reports

Performance Metrics

Alert Routing

​Best Practices

​Naming Conventions

​Hierarchy Design

​Tolerance Configuration

​Chain-Level Tolerances

​Example Configuration

​API Reference

​Chains Endpoints

​Lines Endpoints

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Production Hierarchy

Production Chains (Cadenas)

TypeScript Interface

Database Schema

Sample Chains

Example Data

Production Lines (Líneas)

TypeScript Interface

Database Schema

Line Types

Sample Lines by Chain

Scrap Record Integration

Scrap Record Fields

Database Schema

Managing Production Lines

Adding a New Chain

Adding a New Line

Reporting by Chain and Line

By Chain Report

Drill-Down Capability

Supervisor Assignment

Linking Supervisor to Line

Use Cases

Best Practices

Naming Conventions

Hierarchy Design

Tolerance Configuration

Chain-Level Tolerances

Example Configuration

API Reference

Chains Endpoints

Lines Endpoints