This document defines the complete, end-to-end Osool Manufacturing Process. It is intended for:

• Operational alignment across all branches
• System implementation (Odoo Manufacturing & Inventory)
• Staff training and onboarding
• Audit and workflow control
• Management performance monitoring

The manufacturing lifecycle covers 12 major stages, from order registration to installation (التركيب). Each stage includes:

• Inputs & outputs
• Responsible roles
• Required data fields
• Status flow
• Validation rules
• Time tracking
• Exceptions and conditional logic

1. Order Registration (تسجيل الطلب)
2. Design (التصميم)
3. Warehouse & Materials (المستودعات)
4. Aluminum — if applicable (الألمنيوم)
5. Cutting — Panel Saw (منشار لوح)
6. Cutting — Nesting (تقطيع نَستينج)
7. Bending / Edge Banding (التغليف والتحريف)
8. CNC Drilling (التثقيب)
9. Assembly (التجميع)
10. Quality Control (الجودة)
11. Packaging (التغليف)
12. Delivery & Installation (التوريد والتركيب)

Every Manufacturing Order (MO) at Osool must have a unique, system-generated serial number. The format ensures traceability, branch separation, and annual reset.

Format: YY[Branch]-XXXX

• YY → Last two digits of year (e.g., 25 = 2025)
• [Branch] → Branch code
• XXXX → Sequential number from 0001–9999

Branch Codes:

• KH — Khalda (خلدا)
• MK — Mecca (مكة)
• PT — Petra (البتراء)
• FK — Fakhama (الفخامة)

Rules:

• Automatically generated upon order registration
• Cannot be edited under any circumstances
• Counter resets annually per branch
• Missing Items orders get their own new serial number

2.2.1 Customer & Project Information

• Project Name (اسم المشروع) — must be unique
• Customer Name (اسم الزبون)
• Customer Location (موقع العميل)
• Phone Numbers (أرقام الاتصال)
• Project Type (نوع المشروع)
• Delivery Type (نوع التوريد):
  • Factory Pickup (استلام من المصنع)
  • Delivery to Site (توصيل وتركيب)

2.2.2 Internal Planning Fields

These fields are used by Registration and Design departments:

• Branch (الفرع)
• Expected Installation Date (تاريخ التركيب المتوقع)
• Board Count (عدد الألواح)
• Contains Aluminum? (هل يحتوي ألمنيوم)
• Bending Quantity (كمية التحريف)
• Cutting Mode (وضع القص): Panel Saw / Nesting

Statuses vary by department. Below are the standard approved statuses across Osool.

Design Stage Status Flow (التصميم)

Production Stages (مراحل الإنتاج)

(warehouse, aluminum, cutting, bending, CNC, assembly)

Quality Control (الجودة)

Installation (التركيب)

Every stage records:

• Received At (وقت الاستلام)
• Started At (وقت البدء)
• Status Change Log (سجل التغييرات)
• Completed At (وقت الانتهاء)
• Duration (المدة)

Used for:

• Performance KPIs
• Bottleneck analysis
• SLA monitoring
• Staff productivity evaluation

Text-Based Workflow Logic

Text Logic

Text Logic

Text Logic

Text Logic

Text Logic

1. Single Source of Truth

   The Manufacturing Order (MO) is the master record for all production activities. All departments update only their own stage fields; no parallel Excel tracking is allowed.

2. Sequential Staging

   Stages must follow the approved order (Registration → Design → Warehouse → … → Delivery & Installation). Skipping stages is prohibited; rollback is allowed only where explicitly defined.

3. Stage Ownership

   Each stage has a clearly defined owner (department + role). Only the owner may change stage status or edit fields within that stage.

4. Auditability

   Every status change, field edit, and file upload must be timestamped and linked to a user. Deleted records are not permitted; only archiving is allowed.

5. Bilingual Labels

   All key fields and stage names must appear in English with Arabic labels in parentheses in the user interface.

5.2.1 Core Fields

Project Name (اسم المشروع)

Rule: Must be unique across all active and archived orders.
Error: "اسم المشروع مكرر - الرجاء اختيار اسم آخر"

Serial Number (الرقم التسلسلي)

Rule: Auto-generated, non-editable, format YY[Branch]-XXXX.
Error: "لا يمكن التعديل على الرقم التسلسلي"

Installation Date (تاريخ التركيب المتوقع)

Rule: Must be today or future date; cannot be in the past.
Visual rule:

• < 7 days from today → Red indicator
• ≥ 7 days from today → Green indicator

Error: "لا يمكن اختيار تاريخ في الماضي"

5.2.2 Quantity Limits

Board Count (عدد الألواح)

Normal range: 1–50
> 50 requires supervisor password/authorization.
Error: "العدد يتجاوز الحد المسموح"

Bending Quantity (كمية التحريف)

Normal range: 1–1000
> 1000 requires supervisor password/authorization.
Error: "الكمية تتجاوز الحد المسموح"

5.2.3 Mandatory Selection Fields

• Branch (الفرع) — required at Registration.
• Delivery Type (نوع التوريد) — required at Registration.
• Cutting Mode (وضع القص) — required at Design.
• Contains Aluminum (هل يحتوي ألمنيوم) — required at Design.

System must prevent stage completion if any mandatory field is empty.

The following table summarizes allowed transitions between stages.

System must block any unlisted transition.

1. Aluminum Stage Visibility
   • Visible only when Contains Aluminum = Yes.
   • Hidden when Contains Aluminum = No.
2. Cutting Mode Sub-Stages
   • Panel Saw stage visible only when Cutting Mode = Panel Saw.
   • Nesting stage visible only when Cutting Mode = Nesting.
3. Delivery & Installation Stages
   • Installation fields visible only when Delivery Type = Delivery to Site.
   • For Factory Pickup, installation-related fields are hidden and order can close after Packaging/Delivery.
4. Missing Items Sections
   • Missing Items fields appear only when status = Missing Items (in Assembly / QC / Installation).

1. Automatic Archiving

   Orders with final status Completed or Received for more than 24 hours move automatically to an Archive area.

2. Archive Access
   • Archive is read-only.
   • Access protected by a shared password defined by management.
   • Only Factory Manager and authorized users can open archived orders.
3. Data Retention
   • All history (status changes, timestamps, comments) must be preserved.
   • No physical deletion; only logical archive.
4. Audit Trail

   Every record must store: user, date/time, previous value, new value for key fields.

The system must generate alerts when certain conditions are met:

1. Overdue Orders
   • Trigger: Installation date is within 7 days and order is not yet at Installation stage.
   • Action: Highlight order in red + email to Factory Manager.
2. Blocked Stages
   • Trigger: Any stage remains in Blocked status for more than 4 hours.
   • Action: Email to Factory Manager + Stage Supervisor.
3. Material Delays
   • Trigger: Warehouse internal/external/glass material status = In Request for more than 2 days.
   • Action: Email to Factory Manager + Warehouse Manager.
4. Quality Rejections
   • Trigger: QC status = Rejected.
   • Action: Immediate email to Factory Manager + Assembly Team Lead.
5. Installation Delays
   • Trigger: Actual installation date is later than expected installation date.
   • Action: Email + optional SMS to Factory Manager + Installation Team.

1. Order Cancellation
   • Only Factory Manager can cancel an MO.
   • Cancellation reason is mandatory.
   • Cancelled orders move to Archive with status = Cancelled.
2. Design Change After Production Starts

   Any design change after Warehouse stage requires:

   • New design version upload.
   • Impact assessment on BOM and stages.
   • Formal approval by Factory Manager.

   System must log design version used at each stage.

3. Partial Delivery
   • Allowed only when explicitly requested by customer or required by schedule.
   • Remaining items must be tracked as open in the same MO or via Missing Items MO.
4. Manual Data Corrections
   • Critical fields (dates, quantities, customer details) can only be corrected by authorized roles.
   • System must log who changed what and when.
5. System Downtime Procedure
   • If system is unavailable, departments may temporarily record work manually on paper or Excel.
   • Once system is restored, all data must be entered retroactively the same day, preserving true timestamps where possible.

The Bill of Materials (BOM) is the technical backbone of the manufacturing process. It defines every component—panel, hardware, glass, aluminum, and accessories—required to produce a project. This section documents the structure, required fields, parsing rules, costing logic, and validation requirements.

The system must support the following BOM categories:

1. Panels (الألواح)
2. Hardware (الإكسسوارات / الحدادة)
3. Glass Panels (الزجاج)
4. Aluminum Profiles (الألمنيوم)
5. Special Items (قطع خاصة)
6. Custom Notes (ملاحظات خاصة)

Each category has its own required fields, validations, and workflow interactions.

Each panel line must include:

• Panel Code (رمز اللوح)
• Material Type (نوع المادة)
• Thickness (السماكة)
• Length (الطول)
• Width (العرض)
• Quantity (الكمية)
• Edge Banding Requirements (متطلبات التغليف)
• CNC Requirements (متطلبات التثقيب)

Rules:

• Dimensions must match values in PolyBoard/CutRite files.
• Quantity must be ≥ 1.
• Edge banding fields must be populated for all sides requiring PVC.

Each hardware item must include:

• Hardware Code (رمز الإكسسوار)
• Description (الوصف)
• Quantity (الكمية)
• Mounting Location (مكان التركيب)

Rules:

• Must match design file specifications.
• Missing hardware lines must prevent Assembly from completing.

Each glass panel entry includes:

• Glass Type (نوع الزجاج)
• Thickness (السماكة)
• Dimensions (الأبعاد)
• Quantity
• Edge finishing notes

Rules:

• Warehouse must track glass separately due to external vendor dependencies.

Each aluminum line includes:

• Profile Code (رمز المقطع)
• Length (الطول)
• Quantity (الكمية)
• Cut Angle / Notes (زاوية القص)

Rules:

• All aluminum profiles must be processed in the Aluminum stage.
• If Aluminum BOM exists → Contains Aluminum must be YES.

Used for:

• Custom wooden shapes
• Decorative elements
• Non-standard components

Required fields:

• Item Name
• Description
• Dimensions / Specs
• Quantity

Designers upload:

• PolyBoard files
• CutRite files
• Nesting files

System automatically extracts:

• Panel list
• Hardware list
• Glass list
• Aluminum list
• Cutting plans
• Nesting plans

Validation Requirements:

• File must not be empty.
• File version must match the design version.
• System must flag mismatches (e.g., PolyBoard says 32 panels, sheet count says 28).

Each BOM line must include cost fields for future cost management:

• Unit Cost (تكلفة القطعة)
• Total Cost = Quantity × Unit Cost
• Cost Center Number (مركز الكلفة)

Cost Center Rules:

• Must be filled before Warehouse completes.
• Helps track material expenses per project.

• Only Designers may edit BOM (before Warehouse).
• After Warehouse stage begins → BOM becomes read-only.
• Any change requires Manager approval + new design version.

1. Panels must match Cutting mode output.
2. Hardware lists must match drilling CNC file.
3. Aluminum profiles must not be shorter than required cut lengths.
4. Total quantities must match assembly unit requirements.

If mismatches are found:

• System highlights BOM section in red.
• Stage cannot be completed until corrected.

For External Glass or External Hardware:

• Warehouse sets Material Status = "In Request".
• Expected Vendor Delivery Date required.
• If delayed > 2 days → automatic alert.

All design and BOM-related files must be stored permanently:

• PolyBoard
• CutRite
• Nesting files
• CNC files
• Any manual sketches or approvals

Naming Convention:

[Serial]_[Stage]_[Designer]_[Date]

Example: 25KH-0235_Design_Ahmed_2025-04-03

Approval Required From:

• Designer
• Design Supervisor

This section defines all roles involved in the Osool Manufacturing Process, their permissions, security controls, and restrictions. Access rights are structured to ensure:

• Full traceability
• Prevention of unauthorized edits
• Clear ownership per stage
• Audit compliance
• Controlled visibility based on duties

Below is the official list of system roles:

1. Factory Manager (مدير المصنع)
2. Design Supervisor (مشرف التصميم)
3. Designer (مصمم)
4. Warehouse Supervisor (مشرف المستودع)
5. Procurement Officer (قسم المشتريات)
6. Aluminum Technician (فني ألمنيوم)
7. Panel Saw Operator (مشغل منشار لوح)
8. Nesting CNC Operator (مشغل نَستينج)
9. Edge Banding Technician (فني التحريف والتغليف)
10. CNC Drilling Operator (مشغل CNC)
11. Assembly Team Lead (رئيس قسم التجميع)
12. Quality Control Inspector (مفتش الجودة)
13. Packaging Team (فريق التغليف)
14. Delivery Driver (سائق التوصيل)
15. Installation Team (فريق التركيب)
16. Admin / Sales Coordinator (المبيعات والإدارة)

7.3.1 Factory Manager

• Full access to all orders and stages
• Can override and correct data
• Approves cancellations
• Approves major design changes after Warehouse
• Access to all reporting dashboards
• Access to archived orders

7.3.2 Design Supervisor

• Approves BOM
• Reviews design files
• Can reopen Design stage
• Cannot change Registration fields
• Cannot modify Warehouse or Production fields

7.3.3 Designer

• Can edit only Design stage fields
• Can upload PolyBoard/CutRite files
• Cannot edit Registration fields
• Cannot change Warehouse or Production fields
• Cannot see cost fields unless allowed

7.3.4 Warehouse Supervisor

• Can update Warehouse material statuses
• Can confirm internal/external/glass receipt
• Cannot edit Design or Registration
• Cannot change Production fields
• Can request procurement

7.3.5 Procurement Officer

• Can view BOM
• Can change External Material Status
• Cannot edit any other stage
• Cannot complete Warehouse stage alone

Each stage is accessible only to its responsible department.

Some fields require elevated permissions:

• Critical Date Fields: Installation date, delivery date → Factory Manager
• Quantity Overrides: Board count > 50, bending > 1000 → Supervisor password
• Design Version Control: Only Design Supervisor can change versions
• Cost Fields: Visible only to Factory Manager + specific finance roles
• Cancel Order: Factory Manager only

1. Password-Protected Actions
   • Quantity overrides
   • Date corrections
   • Archive access
2. Multi-Step Approval Requirements
   • Major design change after Warehouse
   • BOM modification after Warehouse
3. Unauthorized Access Prevention
   • Users cannot modify stages not assigned to their role
   • System must log any unauthorized attempt
4. Device and Location Rules
   • Installation team must update status from job site (GPS optional)
   • Factory edits allowed only from internal network unless VPN authorized
5. File Integrity
   • Only PDFs, images, and supported design files allowed
   • Executable files (.exe, .bat, .sh) blocked

• Archived orders become read-only
• Only Factory Manager can unarchive
• Archived orders retain all historical data, comments, and attachments

Every user action must be logged:

• Username
• Timestamp
• Stage
• Old value → New value
• Attachments uploaded or removed

This ensures full traceability for audits and quality assurance.

Reporting and KPIs ensure visibility, accountability, and operational control across the manufacturing workflow. This section defines:

• Daily dashboards
• Department-specific reports
• KPIs for performance measurement
• Alerts for delays, bottlenecks, and exceptions

8.2.1 Daily Factory Dashboard

Used by Factory Manager and Production Supervisors

Includes:

• Total active Manufacturing Orders
• Orders per stage (Registration → Delivery)
• Orders delayed beyond expected installation date
• Missing Items orders
• Material request delays
• QC rejection counts

8.2.2 Stage Throughput Report

Shows:

• Number of orders completed per stage
• Average processing time per stage
• Bottleneck stages highlighted in red

Used for productivity analysis.

8.2.3 Material Availability Report (Warehouse)

Includes:

• Internal materials status
• External vendor items pending
• Glass orders pending
• Expected delivery dates
• Alerts for overdue vendor items

8.2.4 BOM Consistency Report

Flags mismatches:

• PolyBoard vs CutRite mismatches
• CNC vs BOM mismatches
• Aluminum length inconsistencies
• Missing hardware lines

8.2.5 Missing Items Report

Tracks:

• Number of missing items requests
• Average time to complete missing items
• Stage where most missing items occur (Assembly, QC, Installation)
• Recurring issues per Designer / Assembly team

8.2.6 Installation Performance Report

Shows:

• On-time installations
• Delayed installations
• Customer signature logs
• Site issues encountered

8.2.7 Designer Productivity Report

Includes:

• Number of designs completed
• Revisions required per design
• BOM accuracy score

8.3.1 Lead Time KPIs

• Total Order Lead Time: Registration → Delivery
• Stage Lead Time: Duration per stage
• Waiting Time: Time order sits idle before work begins

8.3.2 Quality KPIs

• QC Rejection Rate
• First-Time Pass Rate (FTPR)
• Missing Items Rate
• Assembly Accuracy Score (QC-reported)

8.3.3 Material KPIs

• Material Availability Time
• External Material Delay Rate
• Glass Vendor Compliance %

8.3.4 Efficiency KPIs

• Machine Utilization % (Panel Saw / Nesting / CNC)
• Assembly Team Efficiency (units/day)
• Designer Efficiency (designs/week)

8.3.5 Delivery & Installation KPIs

• On-Time Delivery Rate
• Installation Completion Time
• Customer Acceptance Rate

8.4.1 Stage Delay Alerts

• Trigger: Stage idle for more than defined SLA
• SLA Examples:
  • Design > 2 days
  • Warehouse > 3 days
  • Assembly > 1 day idle
• Action: Email + dashboard red flag

8.4.2 Material Delay Alerts

• Trigger: Internal/External/Glass material status = "In Request" > 48 hours
• Action: Email Warehouse Manager + Factory Manager

8.4.3 BOM Inconsistency Alerts

• Trigger: Any mismatch detected between BOM and production files
• Action: Prevent stage completion

8.4.4 QC Rejection Alerts

• Trigger: QC status = Rejected
• Action: Notify Assembly Lead + Factory Manager

8.4.5 Installation Delay Alerts

• Trigger: Expected installation date is today but installation not started
• Action: Email Installation Team Lead

8.4.6 Missing Items Alerts

• Trigger: Missing items created during Assembly/QC/Installation
• Action: Auto-create new MO + notify relevant teams

System will include the following dashboards:

1. Factory Manager Dashboard
   • End-to-end pipeline
   • Delays & bottlenecks
   • KPIs & trends
2. Designer Dashboard
   • Active designs
   • Pending approvals
   • BOM consistency results
3. Warehouse Dashboard
   • Material availability
   • Pending vendor items
4. Production Dashboard
   • Stage workloads
   • Machine utilization charts
5. QC Dashboard
   • Rejected items
   • Most common QC failures
6. Installation Dashboard
   • Daily installation schedule
   • On-site status updates

This section provides supplemental reference materials that support the full understanding, training, and implementation of the Osool Manufacturing Process. It includes:

• Glossary of English/Arabic terms
• Status definitions per stage
• Full field dictionary
• Templates and checklists
• Example manufacturing order lifecycle
• Technical conventions for Odoo implementation

Process & Operations Terms

Production Stages Terms

Warehouse & Materials Terms

Below is a consolidated list of all statuses across all stages.

Registration

Design

Warehouse

Aluminum / Cutting / Bending / CNC / Assembly

Quality Control

Packaging

Delivery & Installation

A complete dictionary of all fields used across the MO.

Registration Fields

• Project Name (اسم المشروع)
• Customer Name (اسم الزبون)
• Customer Location (موقع العميل)
• Delivery Type (نوع التوريد)
• Branch (الفرع)
• Expected Installation Date (تاريخ التركيب المتوقع)
• Sales Order Reference

Design Fields

• Board Count (عدد الألواح)
• Bending Quantity (كمية التحريف)
• Contains Aluminum? (هل يحتوي ألمنيوم)
• Cutting Mode (وضع القص)
• Design Version (نسخة التصميم)

Warehouse Fields

• Internal Material Status
• External Material Status
• Glass Material Status
• Cost Center Number

Production Fields (Aluminum, Cutting, Edge Banding, CNC, Assembly)

Each production stage has specific fields for tracking quantities, statuses, and quality metrics.

Delivery & Installation Fields

• Delivery Status (حالة التوريد)
• Installation Status (حالة التركيب)
• Customer Signature (توقيع العميل)
• Missing Items List (قائمة النواقص)

9.5.1 QC Checklist Template

• All units match design specs
• No missing hardware
• Finishing quality verified
• Dimensions match tolerances
• Doors & drawers operate smoothly
• Aluminum pieces aligned and fixed
• Defects logged in system
• QC inspector signature

9.5.2 Packaging Checklist Template

• All units wrapped properly
• Room labels attached
• Fragile items labeled
• Hardware bag included
• Accessories included
• Quantity of packages confirmed
• Ready for transport

9.5.3 Installation Checklist Template

• Site readiness verified
• Power & space available
• Correct items delivered
• Installation completed per plan
• Customer signature required
• Missing items logged

9.5.4 Missing Items Request Form Template

• Original MO Number
• Item Description
• Quantity Needed
• Reason for Missing Item
• Stage where issue was found
• Technician/Inspector name

A sample lifecycle showing how an MO flows from start to finish:

1. Registration: Project created → Serial generated
2. Design: Files uploaded → BOM extracted → Supervisor approval
3. Warehouse: Materials confirmed → External items requested
4. Aluminum: Profiles cut and prepared (if applicable)
5. Cutting: Panel Saw / Nesting operations completed
6. Edge Banding: PVC applied
7. CNC Drilling: All drilling completed
8. Assembly: Units assembled → Missing items flagged
9. QC: Items inspected → Rejected items returned
10. Packaging: Items wrapped and labeled
11. Delivery: Transported to customer site
12. Installation: Completed → Customer signature
13. Archive: Order closed and archived

This section provides guidelines for implementing the above workflow inside Odoo.

Model Structure

• mrp.production → Extended to support multi-stage workflow
• stock.move → Used for material tracking
• mrp.bom → Synchronized with PolyBoard/CutRite
• Custom model osool.missing.items for Missing Items Orders

Automation Rules

• Automatic stage transitions based on validations
• Auto-create Missing Items MO
• Auto-archive upon completion
• Alerts triggered by scheduled actions

User Interface Design

• Tabbed layout per stage
• Status bar showing all 12 stages
• Color-coded warnings for delays
• Embedded PDF viewer for design files

Security Implementation

• Record rules per department
• Field-level access control via ir.model.access
• Password-protected fields via custom wizard

End of Document

This comprehensive documentation covers all aspects of the Osool Manufacturing Process from order registration through installation. The workflow ensures quality, traceability, and operational excellence across all 12 manufacturing stages.