Easy Production and Quality Management
Run plans, recipes and batches on every piece of equipment, QC at every stage, mass balance from silo to dispatch, and pouch packing with yield and loss, all traceable for FSSAI.
Easy Production and Quality Management follows the milk from the moment it arrives at the plant to the moment it is dispatched. Procured milk flows into production with its QC information; every batch is planned, run on named equipment, tested at each stage and traced; and the solids, stock and pouches are balanced every day. Each function is explained below.
On this page
Overview
From silo to dispatch, step by stepReceive
Bulk arrivals, QC test and production acceptancePlan and run
Run plans, job cards, recipes and BOMQuality
Real-time QC, batch results, logs and the Certificate of AnalysisBatch traceability for FSSAIStock
Silo to FG to dispatch: stock, mass balance and correctionsPacking
Pouch packing, yield, leakage and weightSolids and costs
TS matching, CIP, utilities and utilisationMore
At a glanceFrequently asked questionsOverviewFrom silo to dispatch, step by step
Receive, plan, run, test, pack, trace and balance: the diagram shows the order in which a plant uses the module. Production is linked to procurement, so the milk accepted at the dock arrives in production with its quantity and quality already recorded.
The module supports all equipment, silos, PHE, separators, tankers and the rest, so each step is recorded against the machine it happened on.
- Supports all equipment: Silo, PHE, separators, tankers etc.
ReceiveBulk arrivals, QC test and production acceptance
Bulk milk arriving at the plant is tested by QC and accepted for production. The quality of all incoming and outgoing milk and products is recorded with its parameters, including inter-company and intra-company transfers.
Milk moves on only after QC approves it, and QC approval is recorded at each level. The weighbridge records the plant in and out movement, so the quantity accepted is cross-checked with the weight.
- The tanker arrives and is weighed in.
- QC tests the milk and records the parameters.
- QC approves; the milk is accepted for production.
Nothing enters production without a recorded test and approval.
- Bulk arrivals; QC test and production acceptance
- Quality of incoming / outgoing milk and products: Records all material quality with parameters, incl. inter- and intra-company transfers
- QC approval at each level
Plan and runRun plans, job cards, recipes and BOM
Production is planned with the run plan: Run Plan, Run Plan In, Run Plan Out (with machine details) and the multiple run plan job card. Recipe management defines each product’s ingredients, and the recipe master carries the BOM cost of the recipe, so recipe costing and ingredient utilisation reports come from the same data.
The batch master holds the batch configuration; batch tracking records who did what, on which equipment and at what time, and batch-wise equipment usage feeds maintenance monitoring. With IoT from the machines, advanced batch tracking logs all the parameters.
- Create the run plan and job card.
- Pick the recipe; the BOM and cost follow.
- Record run plan in and out on each machine.
- The batch record shows who, what, which equipment and when.
Every batch has a plan, a recipe cost and a complete history.
- Recipe management and ingredient utilisation reports
- Recipe master; BOM cost of the recipe; recipe costing & BOM
- Run Plan; Run Plan In; Run Plan Out 1 and 2; Multiple Run Plan Job Card
- Batch master
- Batch tracking: Who did what, on which equipment, at what time
- Batch tracking advanced (IoT from machines): All parameter logging
- Batch-wise equipment usage recording: For maintenance monitoring
- Stage-wise monitoring
QualityReal-time QC, batch results, logs and the Certificate of Analysis
QC entries are made in real time for batch clearance, and the QC team activity sheet and quality acknowledgements record who tested what. Live batch results are published on the web, and customers can take the Certificate of Analysis from the web.
All quality logs are recorded in the system, including the chemical analysis log and the microbiology analysis log, and batch-wise quality records make traceability quick. Food Safety Management (FSMS) integration covers complete quality management.
Quality evidence is captured as the work is done and is ready for customers and auditors.
- Real-time QC entry for batch clearance
- Live batch result; live batch results on web (dynamic publishing)
- QC team activity sheet and quality acknowledgements
- Batch-wise quality records: For quick traceability
- Certificate of Analysis on web: Customer can take it
- Chemical Analysis Log
- Microbiology Analysis Log
- Quality: record all logs in the system
- Food Safety Management System (FSMS): complete quality management with FSMS integration
QualityBatch traceability for FSSAI
Batch traceability is instant: by batch number, from the finished product back through the stages and the milk that went into it. Traceability reports 01 to 03 present the trail for FSSAI.
Because batch, equipment and QC data are recorded at each step, the trail is assembled from records, not reconstructed from registers.
A query from a customer or an auditor is answered from the batch number: the trail shows the input milk, the stages, the equipment and the QC results.
- Batch traceability: Instant batch traceability for FSSAI; batch number-wise traceability; Traceability Reports 01-03
StockSilo to FG to dispatch: stock, mass balance and corrections
Stock is visible from the silo to finished goods, to the MCR and to dispatch, with store stock and production-area stock managed separately. Material balances and batch configurations produce the Mass Balance Report, and variety-wise production details show what was made.
FG stock corrections and internal (SFG) stock corrections are reported, and stock transfer updation has been improved.
- Material balances and batch configurations; Mass Balance Report
- Variety-wise Production Details
- Silo to FG to MCR to dispatch stock visibility
- Store stock and production area stock management
- FG stock correction; internal (SFG) stock correction reports
- Stock transfer updation improvements
PackingPouch packing, yield, leakage and weight
Packing is tracked to the single pouch, including leakages and flush milk. The pouch packing machine input entry needs additional hardware; the milk packing log details record each run, and handling loss is logged with the log details report.
Packing pouch yield shows the yield of each run, pouch-wise production is matched to sale, and weight-scale sampling controls pouch excess and accuracy.
Pouch losses are counted, not estimated.
- Single pouch tracking incl. leakages and flush milk
- Pouch packing machine pouch input entry: Needs additional hardware
- Milk Packing Log Details
- Packing pouch yield / milk pouch yield
- Pouch-wise production-to-sale matching; sales pouch to production stock
- Log the handling loss
- Log Details Report
- Weight scale weight sampling: Pouch excess control and accuracy
Solids and costsTS matching, CIP, utilities and utilisation
Milk total solids are managed with configurable TS calculations. TS matching compares purchase, despatch and acknowledgement to identify TS loss, and the production day-close TS report is emailed automatically to management and production.
Transport CIP is recorded, utility consumption such as firewood for the boiler is controlled, and the utilisation report shows how resources were used.
Utility and CIP records sit with production so that the cost of a run includes the resources it used, not only the milk and ingredients.
- TS matching: purchase vs despatch vs acknowledgement: Identifies TS loss
- Production day-close TS report by email; TS mail automation
- Milk total solids management; configurable TS calculations
- Transport CIP
- Cost control: utility consumption: e.g. firewood for the boiler
- Utilization report
SpecificationsAt a glance
| Equipment | Silos, PHE, separators, tankers and others |
|---|---|
| Planning | Run plan, run plan in/out, job cards, recipes and BOM cost |
| Batches | Batch master, batch tracking, IoT parameter logging, equipment usage |
| Quality | Real-time QC, approvals, live results, CoA on web, chemical and microbiology logs, FSMS |
| Traceability | Batch number traceability, reports 01-03 |
| Stock | Silo, FG, MCR, dispatch; corrections; mass balance |
| Packing | Single pouch, leakage, flush milk, yield, handling loss, weight sampling |
| Solids | Configurable TS, day-close TS mail |
FAQFrequently asked questions
Can a batch be traced for FSSAI?
Yes, instantly by batch number, with traceability reports 01 to 03.
Can customers get the CoA?
Yes, the Certificate of Analysis is available on the web.
Does it need machine integration?
No for the core module; advanced batch tracking (IoT) and pouch packing machine input need additional hardware.
Is the TS report automatic?
Yes, emailed at every production day close.
Keep exploring at your own pace
Every module page walks through the screens, reports and mobile apps in the same way, so you can see exactly how EasyDairyERP fits your dairy.
When you have seen enough, we are happy to show it to you live on our sample data: book a demo or call +91 94880 59495.