Food Manufacturing Control System
Inventory Upload
Upload one Excel workbook, or sync the same files from QuickBooks while it is open on this PC. The app reads QBDATA for Item Information, Lot and Expirations for Lot and Expiration File, and Purchase by item detail for Receiving File and for Purchase Orders (these replace the current files). If OpenPOs is included, only those open PO numbers stay open. Sales by Item Detail is accumulated from Excel only: Sync from QuickBooks leaves the saved sales in place.
Capture Data
Choose capture mode
Select how you want to capture the input items used for this production.
Select employee, then type an Item ID. Production Line fills from previous captures and can still be changed.
Output
Input
Capture items used. Type the Item ID used, then select the available lot and expiration.
Production Schedule
Requisition by Date
Lists ingredients and packaging needed for the Production Schedule. The requisition date is always one day before the production date. If you plan tomorrow, this requisition is today. If you plan the day after tomorrow, this requisition is tomorrow. Use Edit or Delete on a production item to change qty, date, or line, or to remove it from the schedule. Use Edit or Delete on Products to pull to change the requested qty or remove an ingredient from this requisition.
Requisition by Demand
Last-minute pull. Type the FG or WIP Item ID to load its BOM. Enter Qty to Produce, then check only the items that need to be pulled now. Print has blank Pulled qty, Lot, and Expiration.
Pending Exports to QBs
Closed production sheets and partial productions wait here until they are posted to QuickBooks. Close Production Sheet moves the item out of Production Schedule, even if you produced less than scheduled — leftover qty is cancelled. Post Partial to QBs keeps the remaining qty on Production Schedule. If this list is empty after a partial, the remaining qty is in Production History — use QB there.
Production History
Saved captures appear here. Choose whether the date range filters by Captured Day or Production Date.
Metal Detector Test Log
After Close Production Sheet, tests from that item join this combined record of all closed items. The individual item log prints with the Production Sheet.
Dry Roaster Temperature Monitoring
After Close Production Sheet, Dry Roasting temperature readings from that item join this combined roasting log.
Oil Roaster Temperature Monitoring
After Close Production Sheet, Oil Roasting temperature readings from that item join this combined roasting log.
Scale Verification
After Close Production Sheet, scale verifications from that item join this combined log. Any production line can be recorded.
Employee List
Social Security is stored for payroll matching; only the last 4 digits are shown. Click a row to edit, or Add Employee to create a new one.
CCP
Critical Control Points. Metal detector tests follow SOP 11.2.3 and replace the paper FO 2.5.2 log. More CCPs will be added here.
Metal Detector Test Log
Select the phase and the Production Schedule item. The test form opens after both are chosen. After Save, it hides again for the next test.
Record for this item
Dry Roaster Temperature Monitoring
PCP 2.5.2 Process Control Points - Dry Roasting. CCP for Salmonella. Peanut temperature must be 310 F to 315 F, instantaneous, before transfer to cooling bins. Monitor at start-up, every hour (+/- 1 hour), and end of shift. Sr Line Leader records time and temperature with a traceable thermometer. Out of range: hold product, re-establish CCP control, repair heating unit, and complete a Deviation Report (rework, discard, or release).
Out of range. Place product on hold. Re-establish CCP control. Repair heating unit if needed.
Roasting log for this item
Oil Roaster Temperature Monitoring
PCP 2.6.2 Process Control Points - Oil Roasting. CCP for Salmonella. Peanut temperature must be 355 F to 365 F, instantaneous, before transfer to cooling bins. Monitor at start-up, every hour (+/- 1 hour), and end of shift. Sr Line Leader records time and temperature with a traceable thermometer. Out of range: hold product, re-establish CCP control, repair heating unit, and complete a Deviation Report (rework, discard, or release).
Out of range. Place product on hold. Re-establish CCP control. Repair heating unit if needed.
Roasting log for this item
Scale Verification
Verify the scale for any Production Schedule product on any line, when needed. Record Scale ID, check weight / reading, and Pass or Fail. If the scale is off: recalibrate, then recheck before weighing product. PCQI or designated trained personnel.
Scale failed. Recalibrate the scale. Do not weigh product until a passing check is recorded.
Scale verification log for this item
Sanitation Control
GMP 11.2.5 Cleaning and Sanitation. Pre-Operational Check List is completed before production starts. Post-Operational Cleaning Checklist is completed after production, cleanup, and lockout. Report problems to a supervisor and record any corrective action.
FO 11.2.5 PRE-OPERATIONAL CHECK LIST
This form must be completed before each start-up or after a cleanup/setup. All equipment must be inspected before production begins. Report any problem to a supervisor using the work order for maintenance and/or hold for repair. Document and conduct a corrective action if necessary.
Inspection equipment for foreign material, clean and acceptable for food safety
| Equipment Description | Clean and Ready Y/N | If not, state corrective action taken |
|---|
Revision: 0.0
Document Status: Original
Page 1 of 1
Effective Date: 02/20/2025
Issued by: Jose Garcia, Controller
Revised by: Rosalia Haddock, Production Manager
Approved by: Aaron Ordaz, President
Saved pre-operational checks
Forms
Blank copies of the forms printed from Production Sheets. Item, description, quantity, lot, and line stay empty.
PC
Preventive Controls will be added here.
Production Catalog
Notes
Notes added from Production Catalog. Hover PP, then click an item in the BOM to add a note.
Units Produced - FG
Production report in FG / cases. Dates start on this week, Sunday through Saturday; change them if you need another range. With a date range, only items produced in those days are listed. Open Records to see Pallet Tally, Qty requested, and Yield loss. Edit opens that tally so qty, lot, and expiration can be changed. One production sheet can have more than one lot or expiration.
Units Produced - Units
Same production report as Units Produced - FG, shown in individual units. FG qty × packages per case × units per pack. Dates start on this week, Sunday through Saturday. Open Records to see Pallet Tally, Qty requested, and Yield loss in units.
Sales by Item
Finished goods (FG) sold from the accumulated QuickBooks Sales by Item Detail uploads. New uploads add rows and skip duplicates. Pick a date range to see how many of each FG you sold.
Item Purchase Price History
Items with Type of Item = RM, Film, Pouched Bags, or MEX. Click an item to open its purchase history here.
Bill Of Materials
Saved BOMs appear below. Choose FG or WIP to list them. For WIP, pick the production line. Click Search, or New to create one.
Item List
Inventory on containers
Film, Pouch/Bag, and Box items on containers, separate from the inventory upload and from Lots & Expirations. Packaging Type comes from Type of Item: Film, 3SSB as Pouch/Bag, and Boxes as Box. Container Type defaults to Roll, Case, or Pallet. Open a row to change Container Type and Units per Container, or to receive IN and issue OUT by lot. Qty of Containers is the sum of those lots. Total Units = Qty of Containers × Units per Container. Qty on Hand comes from the inventory upload. Difference = Qty on Hand − Total Units. Rack Qty = Difference ÷ Units per Container. Film units show as prints. Box units show as boxes.
Items from QBDATA with TYPE OF ITEM = MEX. Fill MXN Description, U/M, and price for Mexican POs sent to the vendor. Type MXN $ or Current Cost — the other converts automatically. Previous Cost comes from the inventory upload. Current Cost is the USD value used in QuickBooks.
| Item ID | Description | U/M | MXN Description | MXN U/M | MXN $ | Previous Cost | Current Cost |
|---|
Lots & Expiration (FG / RM)
View lot numbers and expiration dates from the uploaded Lot and Expiration File. Finished goods (FG) and raw materials (RM) only. Expired lots are not listed.
Production by Line
Production totals grouped by production line.
Production Value
Dashboard uses the selected dates. Dates start on this week, Sunday through Saturday; change them if you need another range. Total Production is Qty Produced × Current Item List price.
Production and Payroll Report
One row per two-week pay period, continuing the same sequence. Total Production is all captured FG in that period. Enter Labor Cost and the employee count. Payroll Cost % is Labor Cost ÷ Total Production. Click a pay period for the production source.
Downtime
Downtime captured on Production Sheets. Filter by line and date, then print the report.
Yield Loss
Qty requested stays on the Production Sheet. Pallet Tally is what actually came out. Yield loss % = (Qty requested − Qty produced) ÷ Qty requested. Partials of the same schedule are combined.
Lots & Expirations
Finished goods (FG), raw materials (RM), Film, and Pouched Bags with quantity on hand. All hides expired lots. Choose Expired to see them.
Cycle Count Today: — | Julian: —
Count RM, PK, WIP, and FG from the uploaded Lot and Expiration file. Ghost lots (Item ID no longer in inventory) are removed automatically. Select items and print a count sheet. Type a number or an operation (for example 55-3) in Count and press Enter.
Lot Summary
| Vendor Name | Contact | Phone | Warehouse Address | Lead Time (days) | Delivery Method | Carrier | Notes |
|---|
| PO | Date | Vendor | Weight | Delivery method | Ready | Scheduled | Carrier | Pickup date | Confirmation number | Status | Actions |
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Suggested Purchasing
RM / packaging needed when an FG is below Max. Film is listed when on-hand film cannot make FG max × 4. Item Type filters Pouched Bags, Film, Boxes, or Raw Material. Where Used shows the BOMs that use the item you type. Choose a vendor, then Create PO. Select the suggested items and enter the quantity for each one.
| Item ID | Description | U/M | Qty OH | Qty OP | QTY PO | ORDER | PP | FG OH | FG max | FCST PROD | Last vendor |
|---|
Items by Vendor
Choose a vendor. This lists every item purchased from that vendor, plus any item you add with Add item to vendor. Click an item, or Remove, to take it off this vendor. Added and removed items stay that way. Then Create PO.
| Item ID | Description on QBs | U/M | Last price | Vendor description | Agreed price | Qty OH | Qty OP | QTY PO | ORDER | PP | FG OH | FG max | FCST PROD | Last vendor | OTHER VENDORS |
|---|
Expected receipts
Click Receive to take the PO out of Open Purchase Orders. Then print the receiving log, log the trailer inspection, and log the receiving report.
| PO | Vendor | Carrier | Pickup date | Status | Receive |
|---|
Received
Received items post to QuickBooks with lot, expiration, and site Tolteca. Check Close PO on QBs if qty received is not the qty ordered.
| PO | Vendor | Received | Close PO on QBs |
|---|
Product placed on hold cannot be used or shipped until QA releases it. This list is the live Product on Hold report.
| Hold date | Item | Description | Lot | Qty | Hold type | Location | PO | Vendor | Status |
|---|
WinCo
Enter the number of pallets. Each pallet asks for Customer, PO No, and Qty of Item 676552. Pallet Tags print like the WinCo pallet tag file.
Saved WinCo shipments
Open a row to print tags or copy the email again. Delete removes it.
| Pick up date | Pallets | Customers | PO No |
|---|
DD'S Discounts
Enter number of pallets, customer, and PO number once. All tags use that same information and print Pallet x of Y.
Saved DD'S Discounts shipments
Open a row to print tags again. Delete removes it.
| Pallets | Customer | PO No |
|---|
| Carrier Name | Contact Name | Phone | Notes |
|---|
| Delivery method |
|---|
Print Purchase Order
Choose a template
Traceability
FDA-style lot traceability. Search by Item ID + Lot Number. Finished lots come from Pallet Tally. Search 26257 to find 26257-A and 26257-B. Search 26257-A to see only that split.
Lab Results / COA
Capture laboratory results / Certificates of Analysis tied to Item ID + Lot Number. Supports multiple tests per lot, original PDF attachment, automatic Lot Hold/Release, and auto-CAPA on failing results.
1. Sample & Product
2. Lab Dates
3. Laboratory & Test
4. Status & PDF
Lab Results Log
FORMATO CAPA (Corrective and Preventive Action)
Sistema HACCP / Inocuidad Alimentaria. Se guarda en el registro central de CAPA (sharedCapaDeviationData / capa_records) y aparece en la app CAPA + Deviation.
1. Información General
2. Descripción de la No Conformidad
3. Evaluación de Riesgo
4. Acción de Contención Inmediata
5. Investigación de Causa Raíz (5 Why's)
6. Acción Correctiva
7. Acción Preventiva
8. Verificación de Efectividad
9. Seguimiento
10. Cierre y Aprobación
CAPA creados (Food Manufacturing Control System)
| Customer Name | Print As | Contact | Phone | Warehouse Address | Notes |
|---|