Mattress Manufacturing – End‑to‑End Process

Odoo MO / WO 10-Step Routing Traceability WIP Moves QC Gates

A. Triggers & Planning (Where work begins)

Manual MO per Section (Planner‑driven, MTS):
  • Who: Production Planner.
  • Why: Build stock (foam blocks, pocket springs, standard mattresses).
  • Action: Create MOs by department/section, set quantities, select routing (10 ops), assign work centers & planned dates.
Sales Order → MO (MTO / MTS‑replenish):
  • Who: Sales confirms SO; Odoo creates MO(s) for finished mattress (and any variant).
  • Variants: Size/material via BoM line “Apply on Variant.”
  • Planner review: Merge/split, sequence vs. capacity.
Low Stock / MPS / Reorder Rule (Auto):
  • Who: System proposes MOs to meet safety stock & forecast.
  • Planner review: Adjust quantities/dates, approve to launch.

B. Pre‑Production Staging (Materials, lots, readiness)

BoM explosion & reservations:
  • Who: System + Stores.
  • What: Reserve chemicals, wire, fabric, tape edge, wood parts. Pull subassemblies (Foam Blocks, Springs) from stock if available; else launch their MOs.
  • Traceability: Foam batch per pour; Springs batch per day/shift; Finished mattress lot per day/shift.
Internal pick to first WIP:
  • Who: Warehouse → WC WIP (Foam/ Cutting / …) via barcode transfer; labels printed for lots & bins.
Work center readiness & calendars:
  • Who: Production Supervisor verifies Shift A/B calendars, machine status green, operators assigned, QC tools available.

C. Production Flow (10 departments, sequential routing)

Routing: Linear with WIP location at each handoff. Each operation creates a Work Order (WO) on Shop Floor tablets.

WC‑Foam Foam Pouring — Input: Chemicals & recipe (density)
  • Action: Pour, cure.
  • QC (QCP‑Foam): Density (±2%), hardness recorded against MO/lot.
  • By‑products: Offcuts/waste logged.
  • Output: Foam Block lots → Foam WIP.
WC‑Cutting Cutting — Input: Foam Block lots
  • Action: Block slicing to size per variant matrix.
  • Scrap capture: Offcuts → Rebond input lot; % recorded. Move to Cutting WIP.
WC‑Wire/Springs Wire & Springs — Input: Wire, fabric strip
  • Action: Form coils; assemble pocket units (subassembly MO).
  • QC: Sample height / coil count / firmness.
  • Output: Pocket Spring lots → Springs WIP (storable subassembly).
WC‑Quilting Quilting — Input: Top fabric, foam layers, fiber
  • Action: Quilt panels per design.
  • QC: Visual defects, pattern alignment.
  • Output: Quilted panels → Quilting WIP.
WC‑Sewing Sewing — Input: Panels, borders, handles, labels
  • Action: Stitch panels; attach borders/handles; label prep.
  • Output: Sewn sets → Sewing WIP.
WC‑Upholstery Upholstery — Input: Foam layers, pads, latex/memory (variant)
  • Action: Layer build‑up per BoM.
  • Output: Upholstery packs → Upholstery WIP.
WC‑Assembly Assembly — Input: Upholstery + Pocket Springs + Wood (if any)
  • Action: Stack & align; adhere/laminate.
  • Check: Dimensions & corner alignment.
  • Output: Assembled cores → Assembly WIP.
WC‑Wood* Wood (if model includes base/frame/slats)
  • Action: Cut/sand/assemble frames.
  • Output: Wood components → Wood WIP → Assembly or semi‑finished.
WC‑Rebond* Rebond — Input: Foam offcuts
  • Action: Chip & rebond into sheets/blocks (by‑product tracked FIFO).
  • Output: Rebond sheets → Rebond WIP for future use / sale.
WC‑Packaging Packaging
  • Action: Final trim; tape edge; vacuum roll/box (if applicable); label with finished lot & attributes.
  • QC: Final Inspection (visual, dimensions, labeling, cleanliness).
  • Move: Transfer to Finished Goods location.

D. Quality, Non‑Conformance, and Rework

  • At any QCP failure: Operator raises Quality Alert (Shop Floor shortcut).
  • QC logs NC, assigns disposition: Rework, Use‑as‑is, or Scrap.
  • If design/BoM issue: open ECO (PLM) → revision control.
  • Rework loops back to last capable WC (e.g., Sewing/Quilting). Scrap & reason codes posted to MO (cost impact).

E. Traceability & Barcoding

  • Lots: Foam batch; Spring batch; Finished mattress lot per production day/shift — labels printed at Packaging.
  • Scans: Start/stop WO, component consumption, internal moves, pack/label — all via barcode.
  • Audit: MO keeps full genealogy (which foam/spring lots went into which finished lot).

F. Maintenance & Downtime (while running)

  • Operator request: Create Maintenance Request (Preventive/Corrective) from Shop Floor.
  • Effect: Downtime coded (electrical/mechanical/changeover), feeds OEE.
  • Planner: Resequence WOs if a center is down; trigger cross‑line moves as needed.

G. Costing & Analytics (real‑time and post‑MO)

  • Capture: Labor & machine hours (per WO), materials (FIFO), by‑product credit.
  • Roll‑up: MO cost includes WC rates (labor + machine).
  • Variance: Standard vs Actual by WC (analytic accounts).
Core KPIs
  • OEE
  • MO cycle / lead time
  • Scrap %
  • Cost variance
  • On‑time performance

H. Warehouse Moves & WIP Control

  • Rule: Each WC has a WIP location; every handoff = internal transfer (scanned).
  • Avoid ghosts: No invisible moves; physical and system locations must match to keep reservations & traceability clean.

I. MO Closure & Finished Goods

  • WO completion: All 10 ops done; QC pass at Packaging.
  • Backflush or manual: Components/time posted.
  • Produce lot: Finished qty entered; serial/lot labels printed.
  • Close MO: System posts cost; FG moved to Finished Goods WH.

J. Order Fulfillment & Delivery (End of the line)

  • For SO‑linked MOs (MTO) or from stock (MTS):
  • Pick: Warehouse creates delivery order; pick by lot & variant.
  • Pack/Stage: Load plan → vehicle.
  • Ship: Validate delivery; CMR/waybill as needed.
  • Invoice: Per policy (on delivery); accounting posts COGS.
  • End Event: Mattress delivered & delivery validated.

K. Exceptions & Special Cases

Material shortage at any WO
  • Planner substitutes allowed equivalents (BoM alt lines) or partial produce & backorder remainder.
  • Auto RFQ if below min.
Urgent SO preempts plan
  • Reprioritize MO; assign to earliest capacity; notify Sales with realistic promise date from capacity + WIP.
Machine breakdown
  • Maintenance request; reroute to parallel center (if exists) or reschedule; OEE loss tracked.
Design change mid‑run
  • ECO with effectivity date/lot; WIP continues with old rev; new lots start at rev N+1.
Returns / rework after delivery
  • RMA; if manufacturing defect → MO (rework) or replacement MO; NC logged and linked to ECO if systemic.

L. Roles & Ownership (who does what)

Planner
  • Creates/approves MOs; sequences; balances load; manages MPS/reorders.
Warehouse/Stores
  • Picks; internal transfers; WIP moves; labeling.
Operators (each WC)
  • Execute WOs; scan time; report scrap/by‑products; raise maintenance/quality alerts.
QC
  • Executes QCPs; handles NC/CAPA; final release.
Maintenance
  • Preventive schedules; breakdown response; MTBF/MTTR.
Accounting/Costing
  • Reviews MO costs, variances, monthly valuation.
Sales/Logistics
  • SO confirmation; delivery planning; invoicing & dispatch.

M. End‑to‑End Flow Summary (thin version)

Trigger (Manual MO / SO / MPS) → Materials reserved & staged → 10‑step routing (Foam → Cutting → Springs → Quilting → Sewing → Upholstery → Assembly → Wood* → Rebond* → Packaging) with QC gates and WIP transfers → MO cost roll‑up & closure → FG to stock → Delivery order → Shipment & invoice → Delivered.
*Wood/Rebond may run in parallel or as feeder lines depending on model.

Manufacturing Process Flow Start – MO Triggered Manual / Sales Order / MPS Planner Reviews MOs Merge/Split · Sequence vs Capacity Reserve & Stage Materials Warehouse / Stores Foam Pouring Foam Dept / Operator QC – Foam Density Quality Team Cutting Cutting Dept Wire & Springs Wire Dept QC – Springs Height · Count · Firmness Quilting Panels Quilting Dept QC – Quilting Defects Quality Team Sewing Borders & Labels Upholstery Layering Assembly Stack & Align Wood (if req.) Frames/Slats Rebond By‑product Final Packaging Label & Attributes Final QC & Lot Labeling Quality Team MO Closure & Cost Roll‑up Planner / Accounting End