Phase 4: Operations – Universal Mattress Manufacturing

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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 (Foam Blocks, Springs, Mattresses)
Planner review: Adjust quantities/dates, approve to launch

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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

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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 foam blocks using polyurethane chemical mix
QC (QCP‑Foam): Density (±2%, target 25 kg/m³), hardness recorded against MO/lot
By‑products: Offcuts/waste logged for valuation (~10% scrap rate)
Output: Foam Block lots → Foam WIP

Duration 120 min

Cost Rate $15/hr

Efficiency 95%

OEE Target >85%

Capacity 1 unit/batch

WC‑CUTTING Cutting — Input: Foam Block lots

Action: Block slicing to size per variant matrix (King 200×200, Queen 180×200, Twin 90×200)
Scrap capture: Offcuts → Rebond input lot; scrap % recorded (~15% offcuts)
Move: To Cutting WIP

Duration 60 min

Cost Rate $18/hr

Efficiency 92%

OEE Target >88%

Capacity 2 units/shift

WC‑WIRE/SPRINGS Wire & Springs — Input: Wire, fabric strip

Action: Form coils (2.0mm wire); assemble pocket units (subassembly MO)
QC: Sample height / coil count / firmness per batch
Output: Pocket Spring lots → Springs WIP (storable subassembly)
BoM Structure: Multi-level BoM (Wire + Fabric → Springs → Mattress)

Duration 90 min

Cost Rate $20/hr

Efficiency 90%

OEE Target >85%

Capacity 1 unit/shift

WC‑QUILTING Quilting — Input: Top fabric, foam layers, fiber

Action: Quilt panels per design (diamond, square patterns)
QC: QCP-Quilting visual defects, pattern alignment (±2mm tolerance)
Output: Quilted panels → Quilting WIP
Frequency: Each MO inspected

Duration 50 min

Cost Rate $22/hr

Efficiency 93%

OEE Target >90%

Capacity 3 units/shift

WC‑SEWING Sewing — Input: Panels, borders, handles, labels

Action: Stitch panels; attach borders/handles; label prep (brand tags, care labels)
Output: Sewn sets → Sewing WIP
Specifications: Border width 5cm, handle strength >50kg pull test

Duration 45 min

Cost Rate $18/hr

Efficiency 94%

OEE Target >92%

Capacity 4 units/shift

WC‑UPHOLSTERY Upholstery — Input: Foam layers, pads, latex/memory (variant)

Action: Layer build‑up per BoM (comfort layer sequence: foam → latex → memory foam for premium variants)
Output: Upholstery packs → Upholstery WIP
Variant Options: Memory foam layer (+$50), Latex layer (+$30), Standard foam only

Duration 40 min

Cost Rate $20/hr

Efficiency 91%

OEE Target >87%

Capacity 3 units/shift

WC‑ASSEMBLY Assembly — Input: Upholstery + Pocket Springs + Wood (if any)

Action: Stack & align; adhere/laminate layers; adhesive spray application
Check: Dimensions (±5mm tolerance) & corner alignment (±3mm)
Output: Assembled cores → Assembly WIP
Process: Pressure bonding 30 seconds; cure time 15 minutes

Duration 55 min

Cost Rate $25/hr

Efficiency 95%

OEE Target >90%

Capacity 2 units/shift

WC‑WOOD* Wood (if model includes base/frame/slats)

Action: Cut/sand/assemble frames (pine wood slats, 15 slats per King base)
Output: Wood components → Wood WIP → Assembly or semi‑finished
Conditional: Feeds Assembly for models with integrated base; stored separately for à la carte sales

Duration 65 min

Cost Rate $19/hr

Efficiency 88%

OEE Target >82%

Capacity 1 unit/shift

WC‑REBOND* Rebond — Input: Foam offcuts

Action: Chip & rebond into sheets/blocks (by‑product tracked FIFO)
Valuation: By-product cost share 15% of original foam value
Output: Rebond sheets → Rebond WIP for future use / sale (carpet underlay, packaging cushion)

Duration 80 min

Cost Rate $16/hr

Efficiency 85%

OEE Target >80%

Capacity 1 unit/shift

WC‑PACKAGING Packaging

Action: Final trim; tape edge binding (8m for King); vacuum roll/box (compression packaging for export models); label with finished lot & attributes (size, model, firmness, date)
QC: Final Inspection QCP checklist (visual, dimensions, labeling, cleanliness) — mandatory for all finished lots
Move: Transfer to Finished Goods location (barcode scan)
Lot Label Format: MMYY-DDSHIFT-MODELCODE (e.g., 1125-15A-ROYAL-K)

Duration 30 min

Cost Rate $15/hr

Efficiency 96%

OEE Target >93%

Capacity 4 units/shift

Work Center Specifications Summary

Code	Work Center	Duration	Cost/hr	Efficiency	OEE Target	Capacity
WC-FOAM	Foam Pouring	120 min	$15	95%	>85%	1/batch
WC-CUTTING	Cutting	60 min	$18	92%	>88%	2/shift
WC-WIRE	Wire & Springs	90 min	$20	90%	>85%	1/shift
WC-QUILTING	Quilting	50 min	$22	93%	>90%	3/shift
WC-SEWING	Sewing	45 min	$18	94%	>92%	4/shift
WC-UPHOLSTERY	Upholstery	40 min	$20	91%	>87%	3/shift
WC-ASSEMBLY	Assembly	55 min	$25	95%	>90%	2/shift
WC-WOOD	Wood	65 min	$19	88%	>82%	1/shift
WC-REBOND	Rebond	80 min	$16	85%	>80%	1/shift
WC-PACKAGING	Packaging	30 min	$15	96%	>93%	4/shift

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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 with effectivity date/lot
Rework loops back to last capable WC (e.g., Sewing/Quilting). Scrap & reason codes posted to MO (cost impact tracked)
NC Workflow: Quality Alert → QC Review → Disposition → Corrective Action → (if systemic) ECO → BoM revision N+1

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E. Traceability & Barcoding

Lots: Foam batch (per pour), Spring batch (per day/shift), Finished mattress lot (per production day/shift) — labels printed at Packaging with barcode + QR code
Scans: Start/stop WO, component consumption, internal moves (WIP transfers), pack/label — all via barcode (Zebra scanners)
Audit: MO keeps full genealogy (which foam/spring lots went into which finished lot) for ISO traceability and recall capability
Lot Naming: MMYY-DDSHIFT-MODELCODE format ensures unique identification and chronological sorting

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F. Maintenance & Downtime (while running)

Operator request: Create Maintenance Request (Preventive/Corrective) from Shop Floor interface
Effect: Downtime coded (electrical/mechanical/changeover), feeds OEE calculation (Availability component)
Planner: Resequence WOs if a center is down; trigger cross‑line moves as needed (e.g., use backup Quilting machine)
Preventive Schedule: 30-day cycles for all 10+ machines (tracked in Maintenance module)
MTBF/MTTR: Tracked manually; target MTBF >500 hours, MTTR <4 hours

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

Capture: Labor & machine hours (per WO from time logs), materials (FIFO consumption), by‑product credit (15% foam value)
Roll‑up: MO cost includes WC rates (labor $15-25/hr + machine overhead)
Variance: Standard vs Actual by WC (analytic accounts linked to each WC)

Core KPIs & Formulas

OEE = Availability × Performance × Quality (target >85%)
Cycle Time = Σ(Operation Durations) + Queue Time
Scrap % = (Scrap Qty / Total Input) × 100 (target <2%)
Cost Variance = ((Actual - Standard) / Standard) × 100
On‑time = (Completed on Time / Total MOs) × 100 (target >95%)

KPI Dashboard Access by Role

Planner Dashboard

MPS overview (12-week horizon)
Capacity heatmap by WC
MO approval queue
On-time completion rate

Operator Dashboard

Active WOs (my work center)
Maintenance requests
Scrap logging interface
Quality alert shortcut

Manager Dashboard

Executive KPI summary
Cost variance by WC
OEE trends (weekly)
Output vs Plan

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H. Warehouse Moves & WIP Control

Rule: Each WC has a WIP location; every handoff = internal transfer (barcode scanned by warehouse operators)
Avoid ghosts: No invisible moves; physical and system locations must match to keep reservations & traceability clean
4-Layer Topology: Raw Material WH → 10 WIP locations → Finished Goods WH → Distribution WH
Transfer Documents: Manual creation per move with source/destination verification

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I. MO Closure & Finished Goods

WO completion: All 10 ops marked done; QC pass at Packaging (Final Inspection mandatory)
Backflush or manual: Components/time posted (configure per product: backflush for standard, manual for custom)
Produce lot: Finished qty entered; serial/lot labels printed (format: MMYY-DDSHIFT-MODELCODE)
Close MO: System posts cost (material FIFO + operation costs rolled up); FG moved to Finished Goods WH
Cost Report: Available immediately showing material cost, labor cost, overhead, by-product credit, total unit cost

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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 (size/material) ensuring FIFO rotation
Pack/Stage: Load plan → vehicle (route optimization for multiple deliveries)
Ship: Validate delivery; CMR/waybill printed as needed (international shipments)
Invoice: Per policy (on delivery); accounting posts COGS (periodic valuation monthly)
End Event: Mattress delivered & delivery validated (customer signature/photo proof)

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K. Exceptions & Special Cases

Material shortage at any WO

Planner substitutes allowed equivalents (BoM alt lines) or partial produce & backorder remainder
Auto RFQ triggered if below min stock (reorder rules)

Urgent SO preempts plan

Reprioritize MO; assign to earliest capacity slot; notify Sales with realistic promise date from capacity + WIP analysis

Machine breakdown

Maintenance request logged; reroute to parallel center (if exists) or reschedule; OEE loss tracked under Availability

Design change mid‑run

ECO with effectivity date/lot; WIP continues with old rev (BoM N); new lots start at rev N+1

Returns / rework after delivery

RMA created; if manufacturing defect → MO (rework) or replacement MO; NC logged and linked to ECO if systemic issue

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L. Roles & Ownership (who does what)

Planner (3 users)

Creates/approves MOs; sequences production; balances load across WCs; manages MPS/reorders; reviews capacity

Warehouse/Stores (8 users)

Picks materials; executes internal transfers; manages WIP moves; prints/scans barcode labels

Operators (20 users, 2 per WC)

Execute WOs on Shop Floor tablets; scan start/stop time; report scrap/by‑products; raise maintenance/quality alerts

QC (4 users)

Executes QCPs at 3 stages; handles NC/CAPA workflow; performs final release; maintains ISO records

Maintenance (3 users)

Executes preventive schedules (30-day cycles); responds to breakdown requests; tracks MTBF/MTTR

Accounting/Costing (2 users)

Reviews MO costs post-closure; analyzes variances; performs monthly valuation; reconciles to GL

Sales/Logistics (2 users)

SO confirmation; delivery planning; route optimization; invoicing & dispatch coordination

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M. End‑to‑End Flow Summary

Trigger (Manual MO / SO / MPS) → Materials reserved & staged → 10‑step routing (Foam Pouring 120min → Cutting 60min → Springs 90min → Quilting 50min → Sewing 45min → Upholstery 40min → Assembly 55min → Wood* 65min → Rebond* 80min → Packaging 30min) with QC gates (3 checkpoints) and WIP transfers (10 locations) → MO cost roll‑up & closure (FIFO + operation costs) → FG to stock (Finished Goods WH) → Delivery order (Distribution WH) → Shipment & invoice (COGS posted) → Delivered (customer confirmation).
*Wood/Rebond may run in parallel or as feeder lines depending on model (Wood conditional for base-inclusive models; Rebond processes offcuts from Cutting).