Phase 1: Discovery & Requirements – Universal Mattress Manufacturing

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Discovery Questionnaire

Targeted business requirements across 10 key categories

Production Strategy & Planning

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Do you want weekly production plans generated automatically from Sales Orders + Forecasts via the Master Production Schedule (MPS), or manually by planners?

BOTH – Hybrid approach with MPS automation and planner review/override capability.

Should Odoo trigger Manufacturing Orders (MOs) automatically based on reorder rules + safety stock, or remain planner-driven?

YES – Auto MO generation from reorder rules with planner approval workflow.

For Make-to-Order (custom) items — will you use Product Variants (size/type) or create a new product per order?

Product Variants – Size and material attributes drive variant BoMs.

Work Centers & Routing

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Will each of the 10 departments (Foam, Cutting, Wire, Quilting, etc.) be a separate Work Center with defined capacity, OEE target, and cost rate?

YES – 10 work centers: Foam Pouring, Cutting, Wire/Springs, Quilting, Sewing, Upholstery, Assembly, Wood, Rebond, Packaging. Each with capacity, cost rate ($15-25/hr), efficiency (90-95%), and OEE targets.

Do you operate two or three shifts per day? If yes, should we create separate calendars per shift for scheduling and cost accuracy?

2 shifts – Shift A and Shift B calendars required for accurate capacity planning and costing.

Should internal moves between departments (e.g., Foam → Cutting) be automatically triggered internal transfers upon MO completion?

No, manually done – Warehouse operators perform manual internal transfers with barcode scanning.

Materials & BoMs

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For foam and spring lines, are BoMs multi-level (e.g., Pocket Spring = Wire + Pocket + Adhesive → Mattress Assembly)?

Yes for springs, No for foam:
• Foam: Manufactured and stored as blocks → sent to Cutting (flat BoM)
• Springs: Manufactured as subassembly (Wire + Fabric → Pocket Springs) → stored → used as raw material in Mattress Assembly (multi-level BoM)

Do you need by-product tracking (offcuts, rebond foam) with valuation in FIFO costing?

YES – By-products tracked and valued: offcuts from Cutting → Rebond WIP, valued using FIFO method with cost share percentage.

Are rework or scrap ratios available for each operation, or should Odoo calculate them from historical data?

Odoo calculate them from historical data – System will track scrap/rework percentages per operation over time.

Quality & Traceability

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Which stages require quality checks? Should we create Quality Control Points (QCPs) automatically for each?

YES – Auto QCPs at 3 stages:
• Foam Pouring: Density ±2%, hardness
• Quilting: Visual defects, pattern alignment
• Final Inspection: Checklist (visual, dimensions, labeling, cleanliness)

Do you require lot tracking only for intermediate materials (foam blocks, springs), or also for finished mattresses (batch traceability)?

Require lot tracking for finished mattresses – Full batch traceability: Foam batch per pour, Spring batch per day/shift, Finished mattress lot per production day/shift.

Should non-conformances (defects, rework) trigger Quality Alerts → Corrective Actions → PLM ECO workflow?

YES – NC workflow: Quality Alert → QC logs disposition (Rework/Use-as-is/Scrap) → If design issue, open ECO (PLM) → BoM revision control.

Costing & Accounting

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Confirm: costing = FIFO, valuation = Periodic (monthly).

YES – FIFO costing method with monthly periodic valuation.

Would you like operation costs (labor + machine) rolled up automatically into MO Cost reports?

YES – Automatic cost roll-up including work center rates (labor + machine hours) per operation.

Do you want standard costing for planning (budget) and actual costing for variance analysis per Work Center?

YES – Standard vs. Actual variance analysis by work center using analytic accounts.

Maintenance & Downtime

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Will preventive maintenance be scheduled by MTBF/MTTR automatically from machine data?

NO, manually – Manual preventive maintenance scheduling based on equipment logs and 30-day frequencies.

Should operators on the Shop Floor interface be able to create maintenance requests during production?

YES – Operators can raise maintenance requests (Preventive/Corrective) via Shop Floor interface shortcut.

Warehouse & Logistics

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How many warehouses will Odoo manage? (Raw Materials, WIP, Finished Goods — or more per site?)

All – more per site:
• Raw Material Warehouse
• 10 WIP locations (one per work center: Foam WIP, Cutting WIP, etc.)
• Finished Goods Warehouse
• Distribution Warehouse (central dispatch hub)

Should WIP be visible as intermediate stock locations between stages (e.g., Foam WIP → Cutting WIP)?

YES – WIP locations visible with stock tracking; manual barcode transfers between stages.

Will finished goods move directly to customers, or through a central Distribution Warehouse?

Through a central Distribution Warehouse – FG → Distribution WH → Customer delivery.

Data & Integration

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You mentioned BOMs/routings exist in Excel. Are these complete with UoM, yield, and work time?

We need import templates – Excel data requires standardization; import templates needed for Products, BoMs, Routings, Work Centers, QCPs, and Equipment.

Will you integrate Barcode, Shop Floor IoT, or PLM modules in Phase 1, or defer to later?

YES in stage 1 – Barcode scanning, Shop Floor tablets, PLM for ECO control, and IoT gateway (optional) all in Phase 1.

Any requirement for API integration (e.g., sales portal, web shop sync with Odoo)?

Not now – in 2nd stage – API integrations (web shop sync, sales portal) deferred to Phase 2.

Organization & Change Management

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How many users will operate Odoo MRP daily (production, store, quality, maintenance)?

About 40 – Breakdown: Planners (3), Warehouse/Stores (8), Operators across 10 work centers (20), Quality (4), Maintenance (3), Management (2).

Should we design role-based menus and dashboards (Planner, Operator, Manager)?

Yes – Role-based dashboards: Planner (MPS, capacity), Operator (active WOs, maintenance requests), Manager (KPIs, variance).

What's your desired go-live timeframe (3 / 6 / 12 months) and pilot plant (if multi-site)?

6 months – Single-site pilot with full scope, then scale to other sites.

KPI Expectations

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Please confirm which indicators are mandatory for dashboards:

CONFIRMED – Mandatory KPIs:
• OEE per Work Center (target >85%)
• MO Cycle Time / Lead Time
• Scrap % / Defect Rate (target <2%)
• Operation-Level Cost Variance
• On-Time Completion Rate (target >95%)
• Maintenance Uptime %
• Optional: Energy Usage per shift (if IoT integrated)

✓

Validated Assumptions Summary ✓ Confirmed

Business policies and operational parameters validated by Universal Mattress Management

1. Company & Production Model

Industry

Mattress & Bedding Manufacturing

Production Mode

Mixed MTS + MTO (standard + custom orders)

Production Volume

~500 mattresses per week

Planning Approach

Hybrid: Master Production Schedule (MPS) for foam/springs + manual planner control

MO Triggering

Auto MOs from Reorder Rules + Safety Stock

Customization Handling

Product Variants for size/material differences

Work Shifts

2 shifts/day — separate calendars for capacity & costing accuracy

Inter-department Transfers

Manual internal moves (not system-triggered)

2. Manufacturing Structure

Work Centers

10 main departments: Foam Pouring, Cutting, Wire/Springs, Quilting, Sewing, Upholstery, Assembly, Wood, Rebond, Packaging (each with defined capacity, OEE target, and cost rate)

Routing

Sequential, single-line flow across 10 main operations

WIP Control

Intermediate WIP locations between stages

Shifts & Calendars

Two distinct calendars for shift capacity planning

MPS Products

Foam Blocks, Pocket Springs, Finished Mattresses

Demand Source

Sales Orders + Forecast (via MPS dashboard)

3. Materials & BoM Logic

Foam Production

Stand-alone manufacturing → stored as stock → used in Cutting

Spring Line

Manufactured as sub-assembly → stored → used as raw material in Assembly

BoM Structure

Multi-level for spring/mattress assembly; flat for foam process

By-products

Tracked & valued (FIFO) → offcuts, rebond foam, waste

Scrap Ratios

System-calculated from historical data

UoM & Yield Setup

Import templates required for all BoMs + routings

4. Quality & Traceability

QCP Stages

Foam Pouring (density ±2%), Quilting (visual), Final Inspection (checklist)

Traceability

Lot tracking for finished mattresses + key intermediates (foam blocks, springs)

Non-Conformance Workflow

Quality Alert → Corrective/Preventive Action → PLM ECO

Quality Logs

ISO-compliant digital records linked to MOs

5. Costing & Accounting

Costing Method

FIFO

Valuation Method

Periodic (Monthly)

Operation Cost Rollup

Enabled (labor + machine)

Cost Variance Analysis

Standard vs Actual by Work Center

Cost Drivers

Work Center rate ($15-25/hr) + Labor hour + Machine hour

6. Maintenance & Downtime

Preventive Maintenance

Manual scheduling based on equipment logs (30-day cycles)

MTBF/MTTR Tracking

Tracked manually within Maintenance Module

Operator Access

Operators can raise maintenance requests via Shop Floor interface

7. Warehouse & Logistics

Raw Material Warehouse

Chemicals, wire, fabric, tape edge, wood parts, etc.

WIP Locations

One per Work Center (Foam WIP, Cutting WIP, Springs WIP, Quilting WIP, Sewing WIP, Upholstery WIP, Assembly WIP, Wood WIP, Rebond WIP, Packaging WIP)

Finished Goods

Ready mattresses and accessories

Distribution Warehouse

Central dispatch hub for all deliveries

Internal Transfers

Manual using Odoo Inventory Transfer documents with barcode scanning

8. Data & Integrations

BoM/Routing Data

Excel source → import via Odoo templates (6 templates required)

Barcoding & Shop Floor IoT

Included in Phase 1 (scanners, tablets, IoT gateway)

PLM Module

Active in Phase 1 for ECO control + BoM versioning

API Integrations

Deferred to Phase 2 (web shop sync, sales portal)

9. Organization & Change Management

Active Users (MRP Suite)

~40 users: Planners (3), Warehouse/Stores (8), Operators (20), Quality (4), Maintenance (3), Management (2)

Roles & Dashboards

Planner, Operator, Manager views with role-based menus

Timeline

6-month implementation (Nov 2025 - May 2026)

Pilot Scope

Single site full scope pilot, then scale to others

Training

Digital literacy good; structured training plan to be developed

10. KPI Framework for Dashboards

Production Performance

MO Cycle Time, Lead Time, Output vs Plan

Efficiency

OEE per Work Center (target >85%)

Quality

Scrap %, Defect Rate (target <2%), Rework Cost

Cost Control

Operation-Level Cost Variance (Standard vs Actual)

Planning Accuracy

On-Time Completion Rate (target >95%)

Maintenance

Uptime %, Request Closure Time, MTBF/MTTR

Optional Expansion

Energy usage / shift efficiency (if IoT integrated)

Implementation Timeline (6 Months)

Month 1: Discovery & Design

Requirement validation, Odoo module mapping, KPI framework definition

Month 2: Configuration & Data Prep

Import template creation, product/BoM/routing setup, work center configuration

Month 3: System Build

Quality/Maintenance setup, Shop Floor/Barcode integration, role-based dashboards

Month 4: Testing & Validation

Pilot testing, 5-stage validation plan, operator training

Month 5: UAT & Refinement

User acceptance testing, process refinement, data migration

Month 6: Go-Live & Support

Production cutover, hypercare support, post-live optimization