GFS Design System — Production & Work Orders Portal

P1 Production Dashboard KPIs, Pipeline, Shift Summary

Active Work Orders

12

+3 vs. yesterday

Units Completed Today

4,820

+12.4% vs. target

Yield %

96.4%

+0.8% vs. standard

Downtime Hours

2.3

+0.8 hrs vs. yesterday

Production Pipeline

WO #	Assembly	Qty	Line	Status	% Complete	Scheduled
WO-2026-0419	Bongards Barrel Cheddar 40 lb	2,400 units	Line 1 — Hermitage	In Progress	72%	2026-05-19
WO-2026-0420	Brown Box Pancakes 144 ct	1,800 units	Line 3 — Hermitage	In Progress	45%	2026-05-19
WO-2026-0421	Unsalted Butter 36/1 lb	960 units	Line 2 — Hermitage	Complete	100%	2026-05-18
WO-2026-0422	Pepper Jack Sliced 5 lb	3,200 units	Line 4 — Hermitage	Scheduled	0%	2026-05-20
WO-2026-0423	Cream Cheese Spread 3 lb Tub	1,440 units	Line 5 — Hermitage	Scheduled	0%	2026-05-20

Shift Summary — Today

Day Shift (06:00 – 14:00)

2,180 units

Active Crew: 14 | Yield: 97.1% | Downtime: 0.4 hrs

Swing Shift (14:00 – 22:00)

2,640 units

Upcoming Crew: 12 | Target: 2,800 | Scheduled: 3 WOs

Night Shift (22:00 – 06:00)

—

Off Maintenance window | Line 2 PM scheduled

■ KPIs refresh every 5 minutes from NetSuite WO module. Pipeline sorted by scheduled date.

P2 Work Order Entry New WO Form — Assembly, BOM, Schedule, Priority

New Work Order

WO-2026-0424 (auto-generated)

Assembly Item

BOM auto-populates on selection

Quantity to Build

Standard batch: 2,400 units

Scheduled Date

Facility

Production Line

Priority

Linked Sales Order

Notes

BOM Preview — Bongards Barrel Cheddar 40 lb

Component

Qty / Unit

Total Qty

On Hand

Status

Scrap %

Raw Milk (gal)

10.2

24,480

68,200

Available

2.0%

Rennet Culture (oz)

0.8

1,920

5,400

Available

0.5%

Salt (lb)

0.6

1,440

12,800

Available

1.0%

Annatto Color (ml)

2.4

5,760

18,000

Available

0.2%

40 lb Barrel Liner (ea)

1.0

2,400

8,600

Available

1.5%

■ Assembly item selection triggers BOM auto-populate from NetSuite. Component availability checked in real time.

P3 Work Order Detail Full WO View — BOM, Availability, Completion, Quality

WO-2026-0419 In Progress Standard Priority

Bongards Barrel Cheddar 40 lb | ASM-CHD-4010 | Line 1 — Hermitage PA

Created: 2026-05-17 09:14 by M. Levine | SO: SO-2026-1842 | Customer: Good Eats Distribution

Completion

72%

1,728 / 2,400 units

BOM Components — Availability Status

Component

Required

Consumed

Remaining

Availability

Status

Raw Milk (gal)

24,480

17,626

6,854

68,200 on hand

OK

Rennet Culture (oz)

1,920

1,382

538

5,400 on hand

OK

Salt (lb)

1,440

1,037

403

620 on hand

Low

Annatto Color (ml)

5,760

4,147

1,613

18,000 on hand

OK

40 lb Barrel Liner (ea)

2,400

1,728

672

210 on hand

Short

Quality Checkpoints

#

Checkpoint

Specification

Actual

Result

Time

1

Milk Receiving Temp

≤ 45 F

38.2 F

PASS

06:22

2

Pasteurization Temp

161 F / 15 sec

162.4 F

PASS

07:45

3

pH at Cutting

6.35 – 6.45

6.40

PASS

09:18

4

Moisture Content

≤ 39%

35.2%

PASS

11:04

5

Final Weight Check

40.0 ± 0.5 lb

—

PENDING

—

■ Red availability triggers automatic purchase requisition. Quality holds freeze WO completion until resolved.

P4 Production Schedule Calendar View, Gantt Timeline, Capacity

Week View

Month View

Gantt Timeline

Week of May 19 – May 25, 2026

Mon 19

Tue 20

Wed 21

Thu 22

Fri 23

Sat 24

Sun 25

19

WO-0419 Cheddar

WO-0422 PepJack

20

WO-0422 PepJack

WO-0425 Mozz

21

WO-0425 Mozz

22

WO-0426 Pancakes

WO-0427 Butter

23

WO-0426 Pancakes

WO-0428 CrmCheese

24

PM - Line 4

25

Gantt Timeline — Lines 1–6

Line

Mon

Tue

Wed

Thu

Fri

Sat

Sun

Line 1 Cheese

WO-0419

WO-0422

WO-0425

Line 2 Butter

WO-0427

Line 3 Pancake

WO-0420

WO-0426

Line 4 Slice

WO-0422 Slice

PM

Line 5 Specialty

WO-0423

WO-0428

Line 6 Packaging

Packaging all WOs (continuous)

Capacity Utilization — This Week

Line 1 — Cheese

88% utilized | 4.2 hrs available

Line 3 — Pancake

65% utilized | 12.6 hrs available

Line 5 — Specialty

52% utilized | 17.3 hrs available

■ Drag WOs on Gantt to reschedule. Red bars indicate maintenance windows. Conflict detection alerts when lines are overbooked.

P5 Assembly Build Tracker Real-Time Progress, Consumption, Yield Variance, Waste

Active Builds

WO-2026-0419

Bongards Barrel Cheddar 40 lb

Completed

1,728

Remaining

672

Yield Variance

+0.8%

ETA: 14:30 today | Rate: 320 units/hr

WO-2026-0420

Brown Box Pancakes 144 ct

Completed

810

Remaining

990

Yield Variance

-1.2%

ETA: 18:15 today | Rate: 180 units/hr

Component Consumption Log — WO-2026-0419

Time	Component	Qty Used	Batch Lot	Operator	Variance
06:30	Raw Milk	8,160 gal	ML-2026-0518-A	J. Martinez	-0.3%
06:32	Rennet Culture	640 oz	RC-2026-0510-B	J. Martinez	0.0%
07:15	Salt	480 lb	SL-2026-0501-C	A. Rodriguez	+1.1%
07:18	Annatto Color	1,920 ml	AN-2026-0415-A	A. Rodriguez	0.0%

Waste Tracking — Today

Trim/Cut Loss

1.8%

Below 2.0% target

Moisture Loss

0.6%

Below 1.0% target

QC Rejects

0.4%

Below 0.5% target

Total Waste

2.8%

Below 3.5% target

■ Build progress updates in real time from production line sensors. Yield variance = (actual output / standard output) - 1.

P6 BOM Management Bill of Materials Editor, Cost Rollup, Substitutes, Versioning

Brown Box Pancakes 144 ct

ASM-PAN-1440 | Rev 3.2 | Effective: 2026-03-01 | Last Modified: 2026-04-18

Component

Qty / Unit

UOM

Scrap %

Unit Cost

Actions

Pancake Batter Premix RM-BAT-0100

12.5

lb

3.0%

$0.82/lb

Sub: All Purpose Flour 50 lb SUBSTITUTE

12.5

lb

3.0%

$0.68/lb

Large Grade A Eggs RM-EGG-2001

8.0

dz

1.5%

$2.14/dz

Whole Milk RM-MLK-1010

4.2

gal

0.5%

$3.85/gal

Soybean Oil RM-OIL-5510

1.8

gal

0.2%

$4.20/gal

Sugar RM-SUG-3300

2.0

lb

0.5%

$0.52/lb

Brown Box Packaging PK-BBX-1440

1.0

ea

2.0%

$1.45/ea

Cost Rollup Summary

Material Cost / Unit

$38.42

Labor Cost / Unit

$4.80

Overhead / Unit

$2.15

Total Cost / Unit

$45.37

Version History

Rev	Date	Changed By	Change Summary	Status
3.2	2026-04-18	M. Levine	Updated egg qty from 7.5 to 8.0 dz per USDA spec	Active
3.1	2026-03-01	M. Levine	Added substitute: AP Flour for Premix	Archived
3.0	2026-01-15	M. Levine	New packaging spec for Brown Box rebrand	Archived

■ BOM revisions tracked in NetSuite. Substitute items flagged in orange during WO creation if primary component is short.

P7 Quality Checkpoints Inspection Points, Pass/Fail, Temp Readings, Photo Upload, Hold Trigger

Inspections Today

47

All shifts combined

Pass Rate

97.9%

+0.4% vs. 30-day avg

Holds Active

1

WO-0420 moisture check

Failures (7d)

3

+1 vs. prior week

Quality Inspection Entry

Work Order

Checkpoint

Result

Actual Reading

Specification

Inspector

Visual Inspection Notes

Photo Upload

Click to upload or drag & drop

JPG, PNG up to 10 MB

Active Quality Holds

!

HOLD — WO-2026-0420 (Brown Box Pancakes)
Batter viscosity reading 18.4 cP exceeds upper spec of 16.0 cP. Checkpoint: Batter Consistency. Triggered by T. Chen at 10:42. Resolution pending QA manager review.

■ Failed checkpoints auto-trigger a quality hold on the work order. Holds prevent completion until resolved by QA manager.

P8 Batch & Lot Tracking Lot Assignment, Traceability Chain, Expiry, Recall Lookup

Active Lot Assignments

GFS Lot #	Work Order	Product	Qty	Mfg Date	Expiry	Status
GFS-L-20260519-001	WO-2026-0419	Bongards Barrel Cheddar 40 lb	800 units	2026-05-19	2027-05-19	In Production
GFS-L-20260519-002	WO-2026-0420	Brown Box Pancakes 144 ct	810 units	2026-05-19	2026-11-19	On Hold
GFS-L-20260518-003	WO-2026-0421	Unsalted Butter 36/1 lb	960 units	2026-05-18	2026-08-18	Released

Traceability Chain — GFS-L-20260519-001

Vendor Lot

BNG-ML-0518A

Bongards Creameries
Raw Milk Tanker

Receiving Lot

ML-2026-0518-A

Hermitage PA
Receiving Dock 2

GFS Production Lot

GFS-L-20260519-001

WO-2026-0419
Line 1 Cheese

Customer Lot

GE-INV-84721

Good Eats Distribution
SO-2026-1842

Expiry Management — Next 90 Days

Lot #	Product	Qty on Hand	Expiry Date	Days Remaining
GFS-L-20260218-008	Cream Cheese Spread 3 lb	48 units	2026-05-25	6 days
GFS-L-20260312-012	Unsalted Butter 36/1 lb	120 units	2026-06-12	24 days
GFS-L-20260401-005	Pepper Jack Sliced 5 lb	340 units	2026-07-31	73 days

Recall Lookup

Search Lot Number

Date Range

Traces full chain: vendor lot → GFS receiving → production lot → customer shipment. Returns all affected orders within 60 seconds.

■ Lot numbers auto-generated on WO start. Full traceability chain enables 4-hour recall response per FSMA requirements.

P9 Equipment & Line Management Line Status, Maintenance Schedule, Downtime Log

Production Line Status — Hermitage PA

Line 1 — Cheese Processing

Running

Current WO: WO-2026-0419
Speed: 320 units/hr (target: 300)
Uptime today: 5.6 hrs / 8.0 hrs
Next PM: 2026-05-24

Line 2 — Butter/Cream

Idle

Current WO: None
Last run: WO-2026-0421 (complete)
Uptime today: 4.2 hrs / 8.0 hrs
Next PM: 2026-05-22

Line 3 — Pancake Assembly

Running

Current WO: WO-2026-0420
Speed: 180 units/hr (target: 200)
Uptime today: 4.8 hrs / 8.0 hrs
Next PM: 2026-05-28

Line 4 — Slicing/Shredding

Maintenance

Current WO: None
Issue: Blade replacement + calibration
ETA back online: 14:00 today
Technician: R. Williams

Line 5 — Specialty

Idle

Current WO: None
Next scheduled: WO-2026-0423
Uptime today: 0.0 hrs / 8.0 hrs
Next PM: 2026-06-01

Line 6 — Packaging

Running

Current WO: WO-0419 + WO-0420
Speed: 480 units/hr (target: 500)
Uptime today: 5.2 hrs / 8.0 hrs
Next PM: 2026-05-26

Upcoming Maintenance Schedule

Line	Type	Scheduled	Duration	Technician	Parts Needed	Status
Line 4 — Slicing	Corrective	2026-05-19 (NOW)	3.5 hrs	R. Williams	2x Blade Set #BL-440	In Progress
Line 2 — Butter	Preventive	2026-05-22	2.0 hrs	R. Williams	Churn bearings, seals	Scheduled
Line 1 — Cheese	Preventive	2026-05-24	4.0 hrs	J. Park	Vat seals, temp probes	Scheduled

Downtime Log Entry

Production Line

Downtime Category

Duration (hrs)

Root Cause Description

■ Equipment status feeds from PLC sensors. Green = running, yellow = idle/standby, red = maintenance/down. Maintenance windows blocked on production schedule automatically.

P10 Production KPIs Units/Hr, OEE, Waste Trend, Yield Comparison, Shift Performance

Units per Hour — Today by Line

L1

L2

L3

L4

L5

L6

L2/L4/L5 idle or in maintenance. Target line shown as dashed.

Overall Equipment Effectiveness (OEE)

78.6%

OEE Score

Availability

89.2%

Performance

91.4%

Quality

96.4%

Waste % Trend — Last 10 Days

3.5% target

May 10

11

12

13

14

15

16

17

18

19

Trending down 0.6% over 10 days. May 13 spike due to Line 4 blade issue.

Yield Comparison — Actual vs. Standard

Product	Standard Yield	Actual Yield	Variance
Barrel Cheddar 40 lb	95.6%	96.4%	+0.8%
Brown Box Pancakes 144 ct	97.0%	95.8%	-1.2%
Unsalted Butter 36/1 lb	98.2%	98.5%	+0.3%

Shift Performance Comparison — This Week

Day Shift (06:00 – 14:00)

Avg Units/Hr

312

Avg Yield

97.1%

Downtime

1.8 hrs

QC Pass Rate

98.4%

Swing Shift (14:00 – 22:00)

Avg Units/Hr

298

Avg Yield

96.2%

Downtime

3.1 hrs

QC Pass Rate

97.6%

Night Shift (22:00 – 06:00)

Avg Units/Hr

--

Avg Yield

--

Downtime

--

QC Pass Rate

--

Night shift currently offline — maintenance only

■ OEE = Availability x Performance x Quality. Target: 85%+. Current 78.6% driven by Line 4 downtime impacting availability.

P11 Ingredient / Component Inventory Raw Material Levels, WO Allocation, Shortages, Purchase Requisitions

Total Components

84

Active raw materials

Inventory Value

$1.8M

+4.2% vs. last month

Allocated to WOs

62%

of total on-hand

Shortage Alerts

3

PR auto-triggered

Raw Material Levels — Key Components

Component	SKU	On Hand	Allocated	Available	Status
Raw Milk	RM-MLK-0100	68,200 gal	42,640 gal	25,560 gal	OK
Pancake Batter Premix	RM-BAT-0100	4,200 lb	2,250 lb	1,950 lb	OK
Large Grade A Eggs	RM-EGG-2001	280 cs (30 dz)	210 cs	70 cs	Low
Salt	RM-SLT-3100	620 lb	580 lb	40 lb	Low
40 lb Barrel Liner	PK-BRL-4000	210 ea	672 ea	-462 short	Short
Brown Box Packaging	PK-BBX-1440	840 ea	990 ea	-150 short	Short

Shortage Alerts — Auto-Triggered Purchase Requisitions

Component	Shortage	PR #	Vendor	Qty Ordered	ETA	Status
40 lb Barrel Liner	-462 ea	PR-2026-0891	Sealed Air Corp	1,000 ea	2026-05-21	Pending Approval
Brown Box Packaging	-150 ea	PR-2026-0892	International Paper	500 ea	2026-05-22	Pending Approval
Salt (bulk)	40 lb avail	PR-2026-0893	Morton Salt	2,000 lb	2026-05-20	Approved

Manual Purchase Requisition

Create a PR for any component below reorder point or to replenish stock ahead of scheduled WOs.

■ Shortages auto-trigger purchase requisitions when allocated qty exceeds on-hand. PRs route to procurement for vendor PO creation in NetSuite.