Tolerance Management

The Tolerance Management module allows quality engineers and administrators to define acceptable scrap thresholds. When limits are exceeded, visual alerts appear on the dashboard to trigger corrective actions.

Overview

Tolerances define the maximum acceptable quantity and cost of scrap for a specific target (global, area, chain, line, or category) over a time period (daily, weekly, or monthly).

Multi-Level Targets

Set limits globally or for specific areas, chains, lines, or categories

Flexible Periods

Configure daily, weekly, or monthly monitoring windows

Dual Thresholds

Track both quantity (pieces) and cost (USD) limits

Progressive Alerts

Green → Yellow → Red status based on percentage consumed

Tolerance Structure

Each tolerance is defined by:

// From types.ts:119-129
export interface Tolerancia {
  id: number;
  nombre: string;                    // Descriptive name
  tipo_objetivo: 'global' | 'cadena' | 'linea' | 'area' | 'categoria';
  objetivo_id: string;               // Target identifier (e.g., "Assembly" for area)
  tipo_periodo: 'diario' | 'semanal' | 'mensual';
  cantidad_max: number;              // Maximum quantity (pieces)
  costo_max: number;                 // Maximum cost (USD)
  porcentaje_alerta: number;         // Alert threshold percentage (e.g., 80)
  activo: number;                    // Active flag (0/1)
}

Example Tolerance:

{
  "nombre": "Assembly Area Daily Limit",
  "tipo_objetivo": "area",
  "objetivo_id": "Assembly",
  "tipo_periodo": "diario",
  "cantidad_max": 500,
  "costo_max": 1500,
  "porcentaje_alerta": 80,
  "activo": 1
}

This tolerance alerts when Assembly area exceeds 400 pieces (80% of 500) or

1200 (80% of

1500) in a single day.

Tolerance Types

Global
Area
Chain
Line
Category

Target: Entire operationUse Case: Company-wide scrap reduction goalsExample: “Total scrap must not exceed 5000 pieces/month”

// From TolerancesPage.tsx:108
if (t.tipo_objetivo === 'area') rr = rr.filter(p => p.AREA === t.objetivo_id);

No filtering applied — all records counted.

Target: Specific production areaUse Case: Department-level accountabilityExample: “Paint area: max 300 pieces/day”

// From TolerancesPage.tsx:30
if (t.tipo_objetivo === 'area') recs = recs.filter(p => p.AREA === t.objetivo_id);

Only scrap from the specified area is counted.

Target: Production chain/lineUse Case: Track assembly line performanceExample: “Chain A: max $500/week”

// From TolerancesPage.tsx:31
else if (t.tipo_objetivo === 'cadena') recs = recs.filter(p => p.CADENA === t.objetivo_id);

Filters by CADENA field.

Target: Individual production lineUse Case: Granular line-level trackingExample: “Line 3: max 100 pieces/shift”

// From TolerancesPage.tsx:33
else if (t.tipo_objetivo === 'linea') recs = recs.filter(p => p.LINEA === t.objetivo_id);

Filters by LINEA field.

Target: Scrap categoryUse Case: Focus on specific defect typesExample: “Material defects: max $2000/month”

// From TolerancesPage.tsx:32
else if (t.tipo_objetivo === 'categoria') recs = recs.filter(p => p.CATEGORIA === t.objetivo_id);

Filters by CATEGORIA field.

Time Periods

Tolerances can monitor daily, weekly, or monthly windows:

Daily Tolerance

// From TolerancesPage.tsx:35
if (t.tipo_periodo === 'diario') 
  recs = recs.filter(p => isWithinInterval(new Date(p.FECHA_REGISTRO), { 
    start: startOfDay(now), 
    end: endOfDay(now) 
  }));

Window: Midnight to midnight
Reset: Automatically at 00:00
Use: Short-cycle production

Weekly Tolerance

// From TolerancesPage.tsx:36
else if (t.tipo_periodo === 'semanal') 
  recs = recs.filter(p => isWithinInterval(new Date(p.FECHA_REGISTRO), { 
    start: startOfWeek(now, { weekStartsOn: 1 }), 
    end: endOfDay(now) 
  }));

Window: Monday 00:00 to current time
Reset: Every Monday
Use: Weekly production planning

Monthly Tolerance

// From TolerancesPage.tsx:37
else { 
  const ms = new Date(now.getFullYear(), now.getMonth(), 1); 
  recs = recs.filter(p => new Date(p.FECHA_REGISTRO) >= ms && new Date(p.FECHA_REGISTRO) <= now);
}

Window: 1st of month 00:00 to current time
Reset: 1st of each month
Use: Monthly KPI tracking

Status Calculation

Tolerances have three status levels based on percentage consumed:

// From TolerancesPage.tsx:38-44
const qty = recs.reduce((s, r) => s + Number(r.TOTAL_PZAS || 0), 0);
const cost = recs.reduce((s, r) => s + (r.COSTO || 0), 0);
const qPct = t.cantidad_max > 0 ? (qty / t.cantidad_max) * 100 : 0;
const cPct = t.costo_max > 0 ? (cost / t.costo_max) * 100 : 0;
const maxPct = Math.max(qPct, cPct);
const status = maxPct >= 100 ? 'red' : maxPct >= t.porcentaje_alerta ? 'yellow' : 'green';
return { qty, cost, qPct, cPct, maxPct, status };

Status Levels

🟢 Green (Within Meta)

Condition: maxPct < porcentaje_alertaMeaning: Scrap is below alert thresholdExample: 65% of limit consumedAction: Normal operation, no concern

🟡 Yellow (Warning)

Condition: porcentaje_alerta <= maxPct < 100Meaning: Approaching limitExample: 85% of limit consumed (alert set at 80%)Action: Review processes, prepare corrective action

🔴 Red (Exceeded)

Condition: maxPct >= 100Meaning: Limit has been exceededExample: 110% of limit consumedAction: Immediate investigation, 8D report, CAPA

Red status triggers animated pulse effect to grab attention.

Dual-Threshold Logic

The status uses the higher of quantity or cost percentage:

const maxPct = Math.max(qPct, cPct);

Example Scenario:

Quantity: 400 / 500 = 80% ✅
Cost: $1400 /$ 1500 = 93% ⚠️
Overall Status: 🟡 Yellow (93% is higher)

This ensures alerts trigger if either quantity or cost exceeds the threshold, providing comprehensive monitoring.

Tolerance Configuration

Navigate to Tolerances

Click Pérdida Tolerable in the admin menu (requires manage_tolerances permission).

Click 'Nueva Tolerancia'

The configuration modal appears with the following fields:

// From TolerancesPage.tsx:157-226
<form>
  <input name="nombre" placeholder="Tolerance name" />
  <select name="tipo_objetivo">
    <option value="global">Global</option>
    <option value="cadena">Por Cadena</option>
    <option value="linea">Por Línea</option>
    <option value="area">Por Área</option>
    <option value="categoria">Por Categoría</option>
  </select>
  <select name="tipo_periodo">
    <option value="diario">Diario</option>
    <option value="semanal">Semanal</option>
    <option value="mensual">Mensual</option>
  </select>
  <select name="objetivo_id">{/* Dynamic options */}</select>
  <input name="cantidad_max" type="number" placeholder="Max quantity" />
  <input name="costo_max" type="number" placeholder="Max cost $" />
  <input name="porcentaje_alerta" type="number" placeholder="Alert %" />
</form>

Fill Configuration

Example Configuration:

Name: “Assembly Area Weekly Limit”
Target Type: Por Área
Target: Assembly (dropdown auto-populates with active areas)
Period: Semanal
Max Quantity: 2000 pieces
Max Cost: $5000 USD
Alert %: 80

Save

Click Guardar. The tolerance immediately becomes active and starts monitoring.

// From TolerancesPage.tsx:56-60
const handleSave = (t: Tolerancia) => {
  if (editItem) store.updateItem('tolerancias', t.id, t as unknown as Record<string, unknown>);
  else store.addItem('tolerancias', { ...t, id: 0 } as unknown as Record<string, unknown>);
  setShowModal(false); setEditItem(null);
};

Tolerance Display

Tolerances appear in two places:

1. Tolerances Page

// From TolerancesPage.tsx:104-150
{filtered.map(t => {
  const s = getStatus(t);
  return (
    <div key={t.id} style={cardStyle}>
      <div style={{ display: 'flex', justifyContent: 'space-between' }}>
        <div>
          <h3>{t.nombre}</h3>
          <p>{t.tipo_periodo} | {t.objetivo_id || 'Global'} | Alerta al {t.porcentaje_alerta}%</p>
        </div>
        <span style={{ color: statusColor(s.status) }}>
          {s.status === 'green' ? '🟢 Dentro de meta' : s.status === 'yellow' ? '🟡 Advertencia' : '🔴 Excedido'}
        </span>
      </div>
      <div style={{ display: 'grid', gridTemplateColumns: '1fr 1fr', gap: '12px' }}>
        {/* Quantity bar */}
        <div>
          <span>Cantidad: {s.qty} / {t.cantidad_max} pzas</span>
          <div style={{ width: '100%', height: '12px', background: 'var(--border-color)' }}>
            <div style={{ width: `${Math.min(s.qPct, 100)}%`, background: statusColor(s.status) }} />
          </div>
        </div>
        {/* Cost bar */}
        <div>
          <span>Costo: ${s.cost.toFixed(0)} / ${t.costo_max} USD</span>
          <div style={{ width: '100%', height: '12px', background: 'var(--border-color)' }}>
            <div style={{ width: `${Math.min(s.cPct, 100)}%`, background: statusColor(s.status) }} />
          </div>
        </div>
      </div>
    </div>
  );
})}

Features:

Grouped by tabs (Global, Cadena, Línea, Área, Categoría)
Progress bars for quantity and cost
Status badge with color coding
Edit/Delete buttons

// From Dashboard.tsx:154-190
{toleranceStatus.length > 0 && (
  <div style={cardStyle}>
    <h3>Estado de Tolerancias</h3>
    <div style={{ display: 'grid', gridTemplateColumns: 'repeat(auto-fit, minmax(260px, 1fr))', gap: '12px' }}>
      {toleranceStatus.map(t => (
        <div key={t.id}>
          <div style={{ display: 'flex', justifyContent: 'space-between' }}>
            <span>{t.nombre}</span>
            <span style={{ color: statusColor(t.status) }}>
              {t.status === 'green' ? '🟢 OK' : t.status === 'yellow' ? '🟡 Alerta' : '🔴 Excedido'}
            </span>
          </div>
          <div style={{ width: '100%', height: '8px', background: 'var(--border-color)' }}>
            <div className={t.status === 'red' ? 'animate-pulse-red' : ''} style={{ width: `${Math.min(t.maxPct, 100)}%`, background: statusColor(t.status) }} />
          </div>
          <div style={{ display: 'flex', justifyContent: 'space-between' }}>
            <span>{t.totalQty}/{t.cantidad_max} pzas</span>
            <span>${t.totalCost.toFixed(0)}/${t.costo_max} USD</span>
          </div>
        </div>
      ))}
    </div>
  </div>
)}

Features:

Compact card layout
Responsive grid (auto-fit)
Animated pulse on exceeded status
Quick at-a-glance monitoring

Summary Statistics

The Tolerances page displays an overview:

// From TolerancesPage.tsx:48-53
const summary = useMemo(() => {
  const all = state.tolerancias.filter(t => t.activo);
  let inMeta = 0, inWarn = 0, exceeded = 0;
  all.forEach(t => { 
    const s = getStatus(t); 
    if (s.status === 'green') inMeta++; 
    else if (s.status === 'yellow') inWarn++; 
    else exceeded++;
  });
  return { total: all.length, inMeta, inWarn, exceeded };
}, [state.tolerancias, pesajes]);

Total Configured

Number of active tolerances

Within Meta

Count of green tolerances

In Warning

Count of yellow tolerances

Exceeded

Count of red tolerances — requires immediate action

Edit & Delete

Edit Tolerance
Delete Tolerance

Click the Edit (pencil) icon on a tolerance card
Modal opens with pre-filled values
Modify any field
Click Guardar

// From TolerancesPage.tsx:124
<button onClick={() => { setEditItem(t); setShowModal(true); }}>
  <Edit3 size={16} />
</button>

Changes take effect immediately. The status recalculates with current data.

Click the Delete (trash) icon
Confirm deletion prompt
Tolerance is removed from configuration

// From TolerancesPage.tsx:55
const handleDelete = (id: number) => { 
  if (confirm('¿Eliminar?')) 
    store.setCollection('tolerancias', state.tolerancias.filter(t => t.id !== id));
};

Deletion is permanent. The tolerance will no longer appear on the dashboard or in reports.

Dynamic Target Selection

The “Objetivo” dropdown dynamically populates based on target type:

// From TolerancesPage.tsx:161-169
const objetivoOptions = () => {
  switch (form.tipo_objetivo) {
    case 'cadena': return state.cadenas.filter(c => c.activo).map(c => c.nombre);
    case 'linea': return state.lineas.filter(l => l.activo).map(l => l.nombre);
    case 'area': return state.areas.filter(a => a.activo).map(a => a.AREA);
    case 'categoria': return state.categorias.filter(c => c.activo).map(c => c.nombre);
    default: return [];
  }
};

Example Flow:

Select “Por Área” → Dropdown shows: Assembly, Paint, Welding, etc.
Select “Por Categoría” → Dropdown shows: Material, Process, Quality, etc.
Select “Global” → No dropdown (applies to all)

Permissions

Only users with manage_tolerances permission can access:

// From TolerancesPage.tsx:23
if (!can('manage_tolerances')) 
  return <div>Sin permisos.</div>;

Default Roles:

❌ Operator — No access
❌ Supervisor — No access
✅ Quality — Can configure tolerances
✅ Admin — Full access

All users can view tolerance status on the dashboard, but only Quality/Admin can configure them.

Best Practices

Setting Realistic Limits

Analyze historical data (3-6 months)
Set quantity max at 80th percentile of historical highs
Set cost max based on budget allocation
Start with 80% alert threshold, adjust based on team response

Choosing Time Periods

Daily: Fast-paced production, high-volume lines
Weekly: Standard manufacturing cycles
Monthly: Strategic planning, budgeting

Avoid overly short periods (causes alert fatigue) or too long (delays corrective action).

Granularity Strategy

Start broad, then narrow:

Set global monthly tolerance
Add area-level weekly tolerances
Add problematic line daily tolerances
Add category-specific limits for high-cost defects

Too many tolerances = alert fatigue.

Alert Threshold Tuning

Common values:

70% — Very aggressive, early warning
80% — Standard, balanced approach
90% — Conservative, late warning

Adjust based on:

Team response time
Corrective action effectiveness
Historical alert accuracy

Troubleshooting

Tolerance always shows red

Causes:

Max limits set too low (unrealistic targets)
Historical data skews calculation
Wrong target selected (e.g., filtering by wrong area)

Solution:

Review last period’s actual scrap
Increase max quantity/cost
Verify target ID matches intended area/chain

Tolerance not appearing on dashboard

Causes:

activo flag is 0 (inactive)
Target type mismatch (e.g., selected area that doesn’t exist)
No scrap data matches the filter

Solution:

Check tolerance is marked active
Verify target ID exists in catalog
Register some scrap to test

Percentage seems incorrect

Check:

Both quantity AND cost are tracked — status uses the higher percentage
Time period window (daily resets at midnight, weekly on Monday)
Soft-deleted records are excluded (ELIMINADO = 1)

Debug:

console.log('Quantity:', s.qty, '/', t.cantidad_max, '=', s.qPct + '%');
console.log('Cost:', s.cost, '/', t.costo_max, '=', s.cPct + '%');
console.log('Max:', s.maxPct, '→', s.status);

Dashboard

View live tolerance status with visual alerts

Reports

Analyze scrap trends to inform tolerance limits

Catalog Management

Manage areas, chains, and categories used in tolerances

Get Started

Core Features

User Management

Configuration

Deployment

Overview

Multi-Level Targets

Flexible Periods

Dual Thresholds

Progressive Alerts

Tolerance Structure

Tolerance Types

Time Periods

Daily Tolerance

Weekly Tolerance

Monthly Tolerance

Status Calculation

Status Levels

Dual-Threshold Logic

Tolerance Configuration

Tolerance Display

1. Tolerances Page

2. Dashboard Widget

Summary Statistics

Total Configured

Within Meta

In Warning

Exceeded

Edit & Delete

Dynamic Target Selection

Permissions

Best Practices

Troubleshooting

Dashboard

Reports

Catalog Management

Build docs developers (and LLMs) love

Get Started

Core Features

User Management

Configuration

Deployment

​Overview

Multi-Level Targets

Flexible Periods

Dual Thresholds

Progressive Alerts

​Tolerance Structure

​Tolerance Types

​Time Periods

​Daily Tolerance

​Weekly Tolerance

​Monthly Tolerance

​Status Calculation

​Status Levels

​Dual-Threshold Logic

​Tolerance Configuration

​Tolerance Display

​1. Tolerances Page

​2. Dashboard Widget

​Summary Statistics

Total Configured

Within Meta

In Warning

Exceeded

​Edit & Delete

​Dynamic Target Selection

​Permissions

​Best Practices

​Troubleshooting

​Related Pages

Dashboard

Reports

Catalog Management

Build docs developers (and LLMs) love

Overview

Tolerance Structure

Tolerance Types

Time Periods

Daily Tolerance

Weekly Tolerance

Monthly Tolerance

Status Calculation

Status Levels

Dual-Threshold Logic

Tolerance Configuration

Tolerance Display

1. Tolerances Page

2. Dashboard Widget

Summary Statistics

Edit & Delete

Dynamic Target Selection

Permissions

Best Practices

Troubleshooting

Related Pages