With version 11.2, Critical Manufacturing MES brings a more intelligent and flexible approach to Setup and Line Clearance, helping teams ensure that every material starts its journey on a clean, verified line.

This feature supports both always-on setup and changeover-triggered setup, giving manufacturers the tools to model real-world production logic with precision.

What Is Setup and Line Clearance?

Setup and Line Clearance is a feature which ensures that resources — equipment, workspaces, and tools — are properly prepared before processing begins. It helps prevent contamination, mix-ups, and leftover documentation from previous jobs.

Setup can be triggered:

• Always: Every time a material is tracked in.
• On Changeover: Only when a key characteristic (for example, Product, Product Group, Service) changes.

Configuration Highlights

There are several parts that play a role in the configuration of this feature, let’s break down how this works in practice.

🔧 Resource Configuration

Each resource can be configured with:

• Setup Mode: Choose between Always or On Changeover.
• Use Different Setup Operations: Enable if different checklists (and/or Documents and/or Data Collections) are needed for changeover vs. regular setup.

Example:

• Resource 1: Setup only when the service changes.
• Resource 2: Setup always required, with different checklists depending on product group.

⚙️ Step Configuration

Steps define which characteristic should be evaluated for changeover:

• Step 1: Setup triggered by Service change.
• Step 2: Setup triggered by Product Group change.

This allows fine-grained control over when and why setup is required, and ensures that the correct checklist is used.

📝 Checklist, Data Collection and Documents

Setup operations are supported by:

• Checklists: Executed during setup, tailored to the context.
• Data Collections: Capture key parameters during setup.
• Documents: Displaying relevant information to the user.

And these configurations address scenarios where a step may require one checklist for same product group, and a different one for changeover.

Pre-Setup Option

There is also a new option to prepare a resource before the material arrives, by using the Perform Pre-Setup operation to get ahead of the curve. This operation allows setup to be completed in advance, improving readiness and reducing delays.

Benefits

Features like Setup and Line Clearance in version 11.2 bring meaningful benefits across all levels of users in Critical Manufacturing MES, supporting operators, supervisors, and engineers alike with smarter, more structured transitions:

• Improved Quality: Prevents cross-contamination and misprocessing.
• Operational Efficiency: Setup logic is automated and context-aware.
• Traceability: Setup actions are recorded and auditable.
• Flexibility: Supports both reactive and proactive setup strategies.

Final Thoughts

Setup and Line Clearance in 11.2 reflects our ongoing commitment to modeling real-world manufacturing complexity. It’s not about fixing what was broken — it’s about evolving toward smarter, cleaner, and more reliable production.

For configuration steps and examples, check out the Setup and Line Clearance Tutorial.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

With version 11.2, Critical Manufacturing MES introduces a new way to ensure that materials in production are verified at the right moments, especially during sensitive transitions like shift changes or mid-shift breaks. This feature brings in-process control into sharper focus, helping teams maintain consistency, traceability, and compliance—without disrupting the flow.

What Is Line Verification?

Line Verification is an event-driven feature that enables in-process checks while a material is being processed. It’s particularly useful in high-sensitivity environments where conditions like temperature, humidity, or operator handovers can impact product quality.

Once a material is tracked in, MES dynamically assigns a Maintenance Plan Instance that stays active until the material is tracked out. During this window, verification activities can be triggered based on time or shift events.

Configuration Highlights

Let’s walk through the key elements that bring this feature to life.

🏭 Calendar and Shift Definition

To support time-based triggers, a calendar must be configured with a Shift Definition that reflects your operational schedule. For example, a 24-hour operation might use six 4-hour shifts.

This setup allows MES to calculate when shift breaks or changes occur, which is critical for triggering verifications at the right time.

⚙️ Step Configuration

To enable Line Verification at a specific step, set the Enable In-Process Verification property to True. This tells MES to monitor materials at that step and apply the appropriate verification logic.

📝 Checklist and Data Collection

Verification activities are defined using, for example checklists or data collection, and can be assigned for different events.

📋 Maintenance Plan

The core of Line Verification is a Maintenance Plan of scope In-Process Verification. It defines:

• Trigger: When the activity should occur (e.g., on shift change).
• Duration: How long the activity takes.
• Due Window: How soon it must be completed.
• Tolerance: Flexibility around the due time.

These plans are linked to steps using the Material In Process Verification Context Smart Table, which resolves the correct plan based on context.

If a material is still in-process when a verification is due, MES will block track-out until the activity is completed—ensuring nothing slips through the cracks.

Benefits

Line Verification in 11.2 brings meaningful improvements to how in-process quality is managed:

• Proactive Control: Verifications are triggered by real-world events, not just process steps.
• Improved Traceability: All actions are logged and linked to the material.
• Operational Clarity: Operators know exactly what to do and when.
• Compliance Support: Helps meet regulatory and quality standards.

Final Thoughts

Line Verification reflects our ongoing effort to bring MES logic closer to the realities of the shop floor. It’s not just about tracking what happens — it’s about ensuring the right things happen, at the right time, with the right accountability.

For configuration steps and examples, check out the Line Verification Tutorial.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

With version 11.2, Critical Manufacturing MES brings powerful support for negative BOM item quantities, enabling real tracking of by-products generated alongside main products.

This innovation answers real user requests and opens the door to smarter, ecologically aware production management. Let’s explore what this feature means, the problems it solves, and how it helps turn production “waste” into value.

The Challenge: Tracking By-Products in Manufacturing

In many manufacturing processes, producing a final product also creates by-products or leftovers that must be accounted for. Simple examples include:

• Juice production generating fruit peels usable for essential oils or bio-fuels.
• Metalworking creating scrap material that can be recycled.
• Food processing yielding waste products possible as feed or compost.

It is common for systems to be focused only on components consumed during assembly, making it difficult to record by-products as part of the production flow.

This gap caused:

• Lack of traceability for valuable leftovers or secondary materials.
• Difficulty integrating by-products in inventory and reporting.
• Missed opportunities to repurpose or recycle materials efficiently.

What’s New in 11.2: Negative BOM Item Quantities

Critical Manufacturing 11.2 introduces native support for negative quantity BOM items, allowing by-products to be defined and tracked directly within the BOM. Here’s what that entails:

• By-products are BOM items with negative quantities, configurable only under Materials scope.

  

• Consumption happens in reverse: Instead of reducing inventory, assembly increases the quantity of by-products.

• Substitutes are not allowed for negative items, ensuring clear material tracking.

Practical Benefits

• Integrates by-product tracking seamlessly into BOM-driven assembly/disassembly.
• Provides full visibility and traceability of all materials flowing through production.
• Simplifies setup by avoiding the need for separate “waste” processes or manual inventory adjustments.
• Enhances data quality for cost control, reporting, and sustainability initiatives.

Final Thoughts

Handling by-products efficiently is vital for modern manufacturing - both for operational accuracy and environmental stewardship. Critical Manufacturing MES 11.2’s negative quantity BOM items empower companies to track, manage, and repurpose leftovers.

By embracing this feature, manufacturers align with sustainability goals while gaining operational clarity. It’s another step toward smarter, greener production that benefits the business and the planet. 🌱

For more details and configuration tips, explore our full BOM Tutorial series and User Guide.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

How do you achieve that without compromising traceability, efficiency, or shop floor clarity?

Critical Manufacturing MES 11.2 introduces this capability with Mixed Assembly. This feature allows multiple BOM assembly types to coexist seamlessly within the same production step.

Let’s dive into what Mixed Assembly means, the challenges it solves, and how it unlocks new operational flexibility.

The Challenge: Diverse Assembly Needs in One Step

Typical BOM consumption behavior in MES systems has historically been fixed at a contextual level, all items in a BOM consumed the same way per step. But manufacturing reality is - if you allow me - messier:

• Some components need manual tracking and explicit assembly to ensure quality or customization.
• Others suit an automated assembly triggered at material track-in or track-out events for speed and reliability.
• Attempts to blend these had complex workarounds: splitting steps, reconfiguring BOM contexts, customizations, or compromising traceability.

Introducing Mixed Assembly: The Best of Both Worlds

In version 11.2, the Mixed Assembly feature shifts control from BOM context to the BOM Item level, enabling different assembly type side-by-side within the same production step.

How it Works

• At the BOM level, enable the “Assembled Mix Mode” and define a base explicit assembly type: Explicit, Explicit Add, or Explicit Long Running, and this behavior is fixed per BOM and cannot vary per context.

  

• At the BOM item level, override the manual behavior for selected components by specifying automatic consumption behaviors: Automatic at Track-In or Automatic at Track-Out.

  

• In the BOMContext Smart Table, set the Assembly Type to Mixed.

  

• Available only for BOM Scope is set to Material.

• Components flagged for automatic assembly consume themselves during standard material events, while others require manual operator assembly.

Real-World Benefits

⚡ Enhanced Flexibility

Manufacturers can now:

• Mix delicate, manually assembled parts with automated consumables on a single line.
• Avoid splitting production steps unnecessarily, simplifying flow and operator training.

🚀 Optimized Efficiency

• Automated consumables (like adhesives or fasteners) reduce manual errors and speed up throughput.
• Manual assembly items maintain the needed control for quality and customization.

🔖 Improved Traceability

• All assembly actions remain fully recorded and traceable, regardless of consumption mode.
• BOM item-level assembly types offer granular insights into exactly how components were consumed.

Example Use Case

Imagine a production step where:

• Product A requires manual assembly of a customer-specific BOM Item Module, to be assembled with Explicit assembly type.
• Meanwhile, BOM Items like screws and labels are automatically assembled at Track-Out.

The BOM would have to be configured to have the Assembled Mix Mode set to Explicit, and the BOM Item Module would inherit this assembly type. When configuring the BOM Items screws and labels, the Assembly Type needs to be Automatic at Track-out.

When configuring the BOM Context Smart Table, the system will automatically assume the Assembly Type as Mixed. The BOM should be configured with the Assembled Mix Mode set to Explicit, so that the BOM Item Module inherits this assembly type. For BOM items such as screws and labels, set their Assembly Type to Automatic at Track-out. When configuring the BOM Context Smart Table, the system will automatically recognize the Assembly Type as Mixed.

This way, Mixed Assembly enables this blend effortlessly, matching shop floor needs without complicated workarounds.

Final Thoughts

Mixed Assembly feature in Critical Manufacturing MES 11.2 is a game changer — joining flexibility, efficiency, and traceability on the factory floor. It addresses the diverse assembly needs within unified production steps, reflecting the true complexity of modern manufacturing.

Consult our detailed BOM Tutorial and User Guide to configure and roll out Mixed Assembly smoothly.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

In version 11.2, Critical Manufacturing MES raises the bar for BOM flexibility. Fixed consumption, tolerance ranges, information capture and assembly ad-hoc operations - these features solve longstanding challenges for every manufacturing engineer who has faced a process that refuses to fit a strict mold.

This post explores new capabilities, why it matters, and how it solves everyday problems on the shop floor.

Fixed Quantity BOM Items

What is the real challenge?

Most BOMs scale linearly: 10 products require 10 times the parts. But some processes break this rule. Think of disinfectants for sanitizing a line - whether you are assembling 1 or 1,000 units, only one bottle is used for the whole batch. The same is true for quality test kits or glue packs included per order, not per unit.

With 11.2, fixed quantity BOM Items enhancement, we enable direct configuration of BOM Items with a fixed quantity, regardless of batch size. Set it, and production reporting reflects reality.

This feature addresses concerns such as:

• Inaccurate material planning for fixed-use items
• Over-consumption and waste when “per unit” logic is reused by force
• Workflow rigidity for items needed just once per order

Setting up Fixed Quantity BOM Items

To use this feature, choose the option Fixed Quantity in the BOM Item.

Note: This is only applicable for BOMs of Scope Materials and when the Assembly Type is Automatic At TrackIn, Automatic At TrackOut or Explicit Long Running.

BOM Consumption Tolerances

Why does this come up?

Real life rarely matches CAD. For example, a BOM might call for 1.2m² of insulation foam, but the operator uses 1.5m² to ensure coverage, and cutting isn’t always perfect. There are numerous cases where the theoretical quantity and the actual consumed quantity are not the same.

New in 11.2 is the option to configure upper and lower tolerance limits for BOM Items. If operators use a little, it’s OK - the system registers the actual quantity, as long as it falls within the allowed range. Processes become smoother, and data reflects what really happened.

This feature ensures that the following needs are met:

• Frustrating failures or extra transactions when the consumed quantity doesn’t exactly match the theoretical value
• Operators forced to “cheat” the system or run extra steps to reconcile usage

Setting up BOM Consumption Tolerances

To use this feature, choose the option Use Tolerance at the BOM Level. Also, for each BOM Item, define the percentage values for Lower and Upper Tolerance (0% if no tolerances are applied).

Note: This is only applicable for BOMs of Scope Materials and when the Assembly Type is Manual.

Capture Information for BOM Items

Where is the pain point?

Some assembled products include externally sourced or ad-hoc items (like a cable tie, customer-supplied component, or anything with a serial number). These parts aren’t always MES materials, and perhaps the operator just needs to capture their details for traceability or compliance.

In version 11.2, you can mark the BOM Item with “Capture Information”, and the user can now enter key data (serial, batch, notes, etc.) at assembly time, associating it directly with that product and process.

Barriers removed with this feature:

• No easy way to tie serials or batch numbers to the operation
• Missing traceability for critical, non-inventoried items

Setting up Capture Information for BOM Items

To use this feature, choose the option Information Capture Required in the BOM Item, then enter text freely for Information Capture Text.

Note: This is only applicable for BOMs of Scope Materials or Parts and when the Assembly Type is Manual.

Material Assembly History

What is the real-world challenge?

Repairs and rework are inevitable in manufacturing. Typically, processes require well-defined rework flows and steps, and MES systems are designed to handle these strict scenarios, such as replacing or removing faulty components. However, in some cases, removal or replacement must happen at any time and is not tied to a specific step in production. Addressing these situations often requires extra configuration, reduced flexibility, and sometimes even disorganization when reality didn’t align with the modeled process.

What is new on 11.2 is a new Assembly History Section for each material, where information is centralized and provides flexibility. Operators see the full record of what was assembled for Explicit Long Running assemblies, and can perform assembly related operations, independent of the step the material is at, namely:

• Add more of a component if needed
• Remove excess or faulty parts
• Replace specific pieces

This has the potential to decrease workflow bottlenecks. Corrections can be made when and where the issue is found, keeping production running and records accurate.

Roadblocks cleared with this feature:

• Painful setup - dedicated flows and BOMs just for repairs
• Delays if the “repair” step wasn’t planned where it’s needed

Setting up Material Assembly History

No initial setup is required to use this feature. However, it can only be used if the Assembly Type is long-running (manual) and only once the BOM instance is closed.

Final Thoughts

Manufacturing is rarely one-size-fits-all. These latest BOM enhancements put the power and nuance back in the hands of teams building real products, not just following idealized flows.

Want to learn more? Explore our BOM User Guide BOM User Guide and Tutorial.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

If your customer’s warehouse operator has ever found themselves manually entering material data while their coworker is already on their third break… this one’s for them.

What is Register Materials?

Picture this: raw materials arrive at the production site. Instead of keying in data field by field, possibly cloning materials, the user can just scan the relevant barcodes, and the material is created, filled in with the correct information, and ready to go.

No typos, no missing data or misinformation. No system integrations. This is what the Register Materials feature is all about.

Critical Manufacturing MES supports native barcode formats like GS1, ECIA, and MAT-Label, while also allowing full customization to support specific label formats.

Note: This feature requires the Material Logistics module license.

Key Configurations

If you want to configure the system to use this feature, here’s your checklist:

✅ 1. Create a Business Partner

This Business Partner will later on be used as a Product Manufacturer. To make this possible:

• Set it as a “Manufacturer”
• Assign a label specification

✅ 2. Validate the Label Specification

Make sure your label configuration matches the operational context. The following Generic Tables need to be reviewed and updated accordingly:

• Label Specification
• Label Symbology Identifier
• Label Material Property
• Label Specification Field

✅ 3. Configure a Product

Setup a Product considering the following details:

• Product Type Raw Material, Durables
• Default: Start Flow Path, Units, Material Type and Form
• Product Manufacturer: with a Business Partner and a distinct part number

✅ 4. Configure time-saving details

There are three elements that can enhance the experience of the user:

• The Facility field can have a predefined default value. To configure this, use the GUI Element Default Value Generic Table
• The configuration for the system automatically populate fields using data from the Product Manufacturer.
• The configuration for the system to infer the Manufacturer based on the provided Manufacturer Part Number.

This video walks you through the configuration process for the execution:

Feature in action

The star of the show. Test it with a barcode scanner, or hit the camera icon, point it at a barcode, and let the system take care of the rest. If you’ve got auto-populate configs enabled, it’ll even pull values from the Product Manufacturer setup.

Watch it in action in the next video:

Why this feature matters

• Efficiency: Register dozens of materials in seconds.
• Consistency: Fewer human errors.
• Flexibility: Supports standard and custom barcode label formats.
• Integration-ready: Capture additional fields like ERPCode to sync with external systems like ERP.

Final thoughts

Register Materials is one of those features where upfront configuration pays off big time. Once it’s set, the shop floor runs smoother.

If you’re ready to learn more, check out the Tutorial and the User Guide.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

So the question is: how easy is it, really? Let’s take a look.

Introduction to Business Workflows

Before this feature existed, implementing straightforward automatic actions required scripting or configurations that could be out of reach for non-technical users.

Business Workflows changed that. It allows you to model and automate logic using a drag-and-drop visual interface, as it creates a DEE action to be triggered by business events such as Material Dispatch, Release, Abort, Step Change, just to name a few, or even Resource State changes.

From there, it’s possible to perform a variety of operations represented by tasks, for example: Send Material to Rework, Terminate Material, Ship Material and Resource State Change.

These tasks can be combined and sequenced visually, enabling quick implementation of logic that would otherwise require code.

The result? Less dependency on developers which all parties are thankful for. 😊

Things to look out for

Before putting this feature to use, here are a few key things to look out for:

1. Available triggers

   Business Workflows can be triggered by business events such as:

   • Material.Dispatch.Post or Material.Dispatch.Pre
   • Material.ChangeStep.Post or Material.ChangeStep.Pre
   • Material.Abort.Post or Material.Abort.Pre
   • Resource.ChangeState.Post or Resource.ChangeState.Pre

   Each event corresponds to a specific action happening in the system, so choosing the right trigger is essential to ensure your workflow behaves as expected.

2. Available tasks

   Once the trigger is defined, you can build logic using predefined tasks, including:

   • Logic Tasks: If
   • MES Material Tasks: Change Flow and Step, Dispatch, Hold, Move Next, Retrieve, Rework, Ship, Store, Terminate, Track In, Track Out.
   • Notification Tasks: Create Notification
   • Resource Tasks: Change State

   These tasks are designed to handle common MES actions and can be combined to create powerful workflows without code.

   If you’d like to explore more examples and see a scenario for each task, check out the Product Documentation.

3. Understand the syntax

   Referencing data within workflows follows a specific structure based on C#. To reference an input or output this is the syntax: {{$task_name.input_or_output_name}}

   Example: To reference the input “Material” of a task with the name “MaterialTrackOutPost_1”, the syntax would be: {{$MaterialTrackOutPost_1.Material}}

   This syntax ensures that the correct data flows through your workflow logic.

   Check out the Product Documentation for more details on the syntax Product Documentation.

4. Which information is available

   Data used in tasks can either be hardcoded or accessed through direct properties of the entities passed to them. This means:

   • Information available: Properties like Material.Name, Resource.State, Material.Type.Name etc.
   • Information not available: Inherited Product Characteristics and attributes.

Let’s see it

In the following videos we will walk through a use case. First we will see the modeling phase, and then we will see it working.

Consider the scenario with the following requirement: if a Material of type Production is dispatched and the primary quantity of that Material is below 10 units, the production of the Material should be prevented and two actions should take place:

• The Material should be put on hold with the reason “Quantity Below Minimum”
• A notification should be sent indicating that the Material has been prevented from starting production. This notification must have the information about the Product, Step, and Facility associated with the Material.

Let’s build the Business Workflow together: Business Workflow Model

Let’s see the magic happening:

Business Workflow Execution

What makes this feature so helpful

Here are a few things that stand out:

• It’s low-code. Drag tasks, set conditions, map inputs. That’s it.
• It’s clean. Visual logic is easier to understand and maintain.
• It’s functional analyst friendly. You don’t need to write scripts or debug code.
• Bonus: you can even override task settings using dynamic inputs, giving you flexibility to personalize content like notification messages without editing core logic.

Final thoughts

This post is a short intro into a feature that packs a lot of potential. Whether you’re automating production flows, improving exception handling, or simply reducing manual steps, Business Workflows gives you the tools to do it with ease.

It’s not just about building logic visually - it’s about putting that power in the hands of more people.

If you’d like to go deeper, check out the product documentation or explore the Business Workflow tutorial.

Here’s a Tutorial and the User Guide on Business Workflows.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me on LinkedIn

Skills: Functional Analysis | System Testing | User Training | Technical Writer

Does it answer to all the requirements? Does it hit the nail on the head? We’ll see.

Intro

Before version 11.1, addressing batch management scenarios required project teams to create a custom solution.

While they ensured traceability and met functional requirements, they were time and effort consuming.

Introducing Batch Management

First things first. What is batch management?

Simply put, batch management groups and processes multiple materials simultaneously. It incorporates material-like operations such as track-in and track-out, while also covering batch creation, loading, and unloading processes.

Why Batch Management Became a Need

Let’s consider some of the general demands of a real project as an example, without diving too deep into context-specific requirements:

• Ability to group materials to be processed together and ensure that the track-in is performed for the entire group simultaneously, optimizing resource utilization.
• Materials in a batch might be in different steps or flow paths but share the same resource and recipe.
• Resources must be able to process multiple materials simultaneously.
• Loading and unloading materials from resources may occur in phases.
• The system must display the current batch state and the status of each top-most material within the batch.
• The system must assist users in creating batches manually, considering capacity and compatibility between materials.

A side note, for these requirements, the project leveraged significant factory automation with minimal manual and operator-oriented processes, so most shopfloor batches would be pre-formed to optimize equipment utilization.

There wasn’t a seamless out-of-the-box approach to address these concerns, and although we are just considering one project, it is not the only one. Batch management has become a common demand in SMT-related projects, but not only.

Batch Management Customization Before v11.1

Wait. Pause. Hold On. Why Customization? Wouldn’t Containers do the job?

Containers, frequently used in SMT and semiconductor industries for grouping materials, seemed like a natural solution. However, they fell short for batch management due to several limitations:

• Parent-Child Complexity: Containers may require aggregation into a parent container, complicating operations like docking without altering default behaviors.
• Limited Functionality: Material-like operations (e.g., track-in and track-out) were not applicable to containers.
• Lack of Transparency: Containers lacked information and process visibility crucial for batch management (consider the Resource View, for example).

So, to meet batch management needs before version 11.1, the solution often involved creating customized entities and logic, such as:

• Custom Entity Batch: represents groups of materials processed together and includes batch states.
• Custom Batch State Model: manages batch states regarding loading and processing
• Custom Relations: tracks the association and state of materials in the batch (e.g., not loaded, loaded, in process, processed, unloaded).
• Custom Logic: controls batch states and material-batch relations; considers restrictions on other entities, for example, resources to only deal with batch instead of materials.

While these customizations delivered results, they required significant time and effort and lacked standardization across projects.

Next, we’ll see the main functionalities of the out-of-the-box feature.

Batch Management Functionality

What value does version 11.1 add to the batch management requirements? Well, I’m glad you asked.

Version 11.1 introduces an out-of-the-box solution for batch management with features that eliminate the need for most customizations.

Batch Entity:

• Groups materials and containers to create a batch.
• Supports users in identifying compatible materials for a batch, based on step, product, or service restrictions.
• Incorporates a loading state model to reflect the batch loading process.
• Includes a system state to mimic the processing stage of a batch.
• Establishes clear relationships between materials and batches.

Impact on the Resource Entity:

• The possibility to configure resources to process batches, with resource views tailored to enhance the user experience.
• Facilitates batch creation, management, and tracking.

Customization vs Feature: The nitty-gritty

Now, let’s walk through the step-by-step operations, comparing how the project handled the customization versus how the 11.1 feature might simplify things.

It’s worth noting that the project’s customization was designed with heavy factory automation in mind. For this post, we’ll focus only on the manual workflow. Also, there are plenty of context-specific details that we’re leaving out to keep things concise and on point.

Here are a few limitations I’ve noticed in how the v11.1 system handles certain requirements so far:

• The load and unload process for materials can’t currently be manually replicated in the system.
• A more advanced container-related behavior is needed.
• It is not possible to perform a phased track-in and track-out of materials within a batch.
• The Resource View displays information for a single batch at the resource.
• Batch information isn’t reflected in the material report or traceability view.

Check out the video below where we walk through the process of batch creation all the way to dissolving it using the Batch Management 11.1 feature.

Batch Management Video

Final Thoughts

This new feature brings numerous advantages, as it responds to the batch process generic requirements, leading to faster implementation times and minimizing the volume of customizations.

This was a brief introduction to Batch Management — taking us from outside the box to out-of-the-box.

If you’d like to learn more, check out the product documentation on the Batch Entity.

Author

Hi! My name is Sofia Rodrigues. ☺️

I joined the Critical Manufacturing family back in the striking year of 2020 as an MES Consultant/Functional Analyst. In 2023, I transitioned to the Product Documentation team, where I now focus on designing and creating content.

You can check me at LinkedIn

Skills: Functional Analysis | System Testing | User Training