Print Dash — Production Module User Guide

Audience: Finalizers (Prep-Press), floor operators, production managers (manager panel)
Version: 1.0.0 · Date: 2026-04-23
Language: English — العربية

1. The Finalizer's Launchpad (Prep-Press)

💡 Role Tip: As a Finalizer, you are the bridge between design and production. Your job is to turn a sales order into a material-ready, machine-ready production order. You don't run machines — you prepare everything so operators can.

1.1 Requirement Calculation: Turning a Design into a Material List

When a production order is created, it starts with a Bill of Materials (BOM) — a recipe that says which materials are needed to make the product. The BOM does not tell you how much material you need for this specific order. That is what the Requirement Calculator does.

How It Works

The calculator uses three inputs:

1. The BOM — What materials are needed (for example vinyl, CMYK ink, laminate film)
2. The outputs — What you are producing (for example 100 copies of a 2 m × 1 m banner)
3. Nests (optional) — How the outputs are laid out on material sheets

It then works out, for each material in the BOM:

• Required quantity = physical area × BOM multiplier
• Physical area comes from either:
  • Nest layout area (when outputs are nested) — includes waste
  • Output area × copies (when outputs are not nested) — raw material only

Step-by-Step: Calculating Requirements

1. Open the Production Order you are preparing.
2. Scroll to the Requirements section on the order page.
3. Click Calculate material requirements in the header.
4. A window opens with Run nesting first:
   • ✅ Check this if you want the system to create nests before calculating (recommended for large-format jobs).
   • ❌ Leave unchecked if nests already exist or the job is simple.
5. Click Confirm.
6. The system will:
   • Process each output (or nest) and compute material needs
   • Create or update requirement lines
   • Check stock for each material
   • Set each line to ALLOCATED (enough stock) or PENDING (not enough stock)

⚠️ Warning: If any requirement is PENDING, the production order cannot be started. Every requirement must be ALLOCATED before operators can begin.

What If Stock Is Insufficient?

If stock is short:

1. The requirement is set to PENDING.
2. The production order moves to PAUSED.
3. Production managers receive a notification.
4. A warning explains which materials are short.

🛠️ Troubleshooting: "Why is my order paused after calculating requirements?" — One or more materials do not have enough stock. In the Requirements table, look for PENDING rows. Purchase more stock, or change the warehouse on the line to one that has enough.

Adjusting Requirements Manually

Sometimes the calculator’s estimate needs a tweak:

1. In Requirements, click Adjust on a line.
2. You can change:
   • Allocated item — which inventory item to use
   • Allocated warehouse — which warehouse to pull from
   • Required quantity — how much is needed
3. Click Save.

💡 Role Tip: The system checks your adjustment immediately. If you allocate more than is on hand, you get an error right away so you do not over-allocate across several lines.

🛠️ Troubleshooting: "Why can't I edit this requirement?" — If the line was user adjusted, the calculator skips it on the next run. Use Reset adjustments & recalculate in the header to start fresh.

1.2 Nesting & Tiling: Preparing Large-Format Jobs

What Is Nesting?

Nesting arranges several outputs (signs, panels, banners) on one material sheet to cut waste — like fitting shapes on a sheet of paper with as little leftover as possible.

When to Create a Nest

• ✅ Use nesting when: Several outputs fit on the same sheet (for example 20 small signs on one 3 m × 2 m sheet).
• ❌ Skip nesting when: Each output uses a full sheet by itself, or outputs have no dimensions set.

Step-by-Step: Creating a Nest

1. Open the Production Order.
2. Ensure every output has width and length filled in.
3. Click Calculate material requirements.
4. Check Run nesting first.
5. Click Confirm.

The system tries several layout strategies, picks the one with the least waste, creates nest groupings, and assigns each output to a nest.

💡 Role Tip: Multi is the default and recommended option. It runs all strategies and keeps the best layout automatically.

Understanding Nest Strategies

What Is Tiling?

Tiling is not the same as nesting. Nesting groups several outputs on one sheet. Tiling splits one large output into smaller pieces your machine can run in one pass.

Example: You need a 10 m × 3 m banner, but the printer handles 2 m × 3 m per run. Tiling creates five child pieces (each 2 m × 3 m).

How Tiling Works

1. A parent output (the full banner) is split into several child tiles.
2. Each child tile is one copy with its own area.
3. The parent still represents the full job; produced quantity on the parent rolls up from the children when tiles finish.
4. Progress is tracked on each child tile separately; the parent follows the tiles.

💡 Role Tip: Rejecting one tile affects only that tile. Siblings and the parent keep going. The system can create a remake tile to replace a bad one.

🛠️ Troubleshooting: "Why can't I log production on the parent after a tile rejection?" — After a tile rejection with remake, work may be tied to the remake child, not the parent. Use Log Production on the remake tile row instead.

1.3 Order Activation: Assigning a Routing and Moving to Queued

What Is a Routing?

A routing is the fixed sequence of steps a product goes through, for example:

• Print → Laminate → Cut (three steps)
• Print → UV coat → Package (three steps)

Each step is tied to a work center (Printing, Lamination, Cutting, and so on).

Step-by-Step: Activating an Order

1. Open the Production Order.
2. Select a routing (operation steps).
3. Select a BOM (material requirements).
4. Click Calculate material requirements (see §1.1).
5. Confirm every requirement is ALLOCATED.
6. Click Send to Production (or set status to QUEUED).

⚠️ Warning: You cannot send an order to production if:

• No routing is selected
• No BOM is selected
• Any requirement is still PENDING

The system creates one operation row per routing step, in order (step 1, 2, 3, and so on).

💡 Role Tip: Once the order is QUEUED, it appears on the Kanban board at the first work center. Operators can pick it up from there.

2. The Floor Operator's Workflow

💡 Role Tip: As a floor operator, you run production. You do not create orders or change requirements — you pick up jobs, run machines, record progress, and hand batches to the next step.

2.1 Starting a Session: Picking Up a Job at a Work Center

The Kanban Board

The Work Center Kanban is your main screen. Cards sit in columns by status:

Card Types

• Operation card: Shown when the step has no incoming transfer batch yet — the whole operation is one card.
• Batch card: Shown when work arrived from the previous step as a transfer lot. Each physical batch gets its own card.

💡 Role Tip: A batch card means work was physically handed to you from the prior step. The card shows only what was transferred — not necessarily the full order quantity.

Step-by-Step: Starting a Job

1. Find the card in Queued.
2. Drag the card to In Progress.
3. Choose the machine you will use.
4. Click Confirm.

The system starts a session, marks the operation IN_PROGRESS, and records machine, start time, and operator.

⚠️ Warning: You cannot start if:

• The card shows a yellow warning (materials not fully allocated)
• The card shows a gray clock (previous step not finished — operation not released yet)
• The operation is not QUEUED or PAUSED

🛠️ Troubleshooting: "Why can't I drag this card to In Progress?" — Check the badges. Yellow = materials not ready. Gray clock = previous step not done. Ask your production manager if needed.

Resuming a Paused Job

1. Find the card in Paused.
2. Drag it to In Progress.
3. Pick a machine:
   • Same machine as before: Your previous session continues.
   • Different machine: The old session is closed as completed and a new session starts on the new machine.

💡 Role Tip: Switching machines mid-job splits time per machine so utilization reports stay accurate.

2.2 Recording Progress: Updating Processed Quantities

Planned vs Processed

Each operation tracks, per output:

• Planned copies / planned quantity — how much this step should handle
• Processed copies / processed quantity — how much you have actually done

Log Production adds to the processed amounts.

Step-by-Step: Logging Production

1. Open the Production Order (or open the card from the Kanban).
2. Go to the Outputs section on the order page.
3. Find the output you are working on.
4. Click Log Production.
5. Enter:
   • Copies — how many copies you finished
   • Quantity — area or measure completed (for example m²)
   • Machine — which machine was used
   • Notes — anything worth recording
6. Click Confirm.

The system updates processed totals, and on the last operation also updates produced quantity on the output. The Kanban progress bar moves forward.

⚠️ Warning: You cannot log more than the maximum allowed for this step. That limit is based on what is still unprocessed on this operation — or, in batch mode, what remains on the incoming transfer lines.

🛠️ Troubleshooting: "Why is Log Production disabled?" — The operation may not be IN_PROGRESS, everything may already be logged, or in batch mode the lot may be voided or complete.

Logging for Nested Outputs

When outputs belong to nests:

1. Log Production groups lines by nest.
2. You can log several outputs in one submission.

💡 Role Tip: For tiled jobs, log each child tile separately. The parent’s produced quantity updates when the tiles are done.

2.3 The Handoff: Moving Transfer Lots to the Next Step

What Is a Transfer Lot?

A transfer lot is a physical batch moved from one operation to the next — like a delivery note:

• From — the step you finished (for example Printing)
• To — the next step (for example Lamination)
• Lines — which outputs are in the batch and how many copies or how much quantity

Step-by-Step: Creating a Transfer Lot

1. Finish your work on the current step (or finish a partial batch).
2. Open the Production Order.
3. Click Create Transfer Lot, or use Handoff on the Kanban card.
4. The window shows available quantity per output and fields for transfer copies and transfer quantity.
5. Enter what you are sending. The system can convert between copies and quantity using the output’s unit area.
6. Click Confirm.

The system creates the lot and its lines. The next operation appears on the Kanban (released for work).

⚠️ Warning:

• You cannot transfer from the last operation (there is no next step).
• Rejected work is not available to transfer.
• For non-nested steps, you must transfer at least 20% of what is available (no tiny partial moves).

💡 Role Tip: You can send several lots — for example half now and half later. Each lot gets its own card on the next step’s board.

Understanding Voided Lots

Sometimes a lot is voided during rejection with remake:

1. You transferred 50 copies from Printing to Lamination.
2. Lamination rejects 10 and requests a remake.
3. The original lot is voided (kept for history, hidden from the floor).
4. A new lot carries the remaining 40 plus the 10 remake copies.

For you on the floor:

• Voided lots do not show on the Kanban.
• Voided lots do not count toward progress.
• You can still see them in the transfer history on the order if you need to trace what happened.

💡 Role Tip: A "voided lot" notice is normal after a rejection — follow the new lot on the board.

3. Handling Errors & Rejections

💡 Role Tip: Rejections happen in every shop. Follow the steps below so the system stays aligned with what actually happened on the floor.

3.1 The Rejection Protocol: Logging a Rejection

When to Reject

Reject when:

• Quality is bad (color, print defects, damage)
• The piece does not meet spec
• Material was ruined during processing

Step-by-Step: Logging a Rejection

1. Open the Production Order.
2. Go to Outputs on the order page.
3. Find the defective output.
4. Click Log Rejection.
5. Fill in:
   • Operation — where the defect was found
   • Rejection reason — pick from the list (for example Color mismatch, Print error)
   • Rejected copies and rejected quantity
   • Create remake — should the system add a replacement output?
   • Machine (optional)
   • Notes
6. Click Confirm.

Remake vs In-Place Shrink

Option 1: Create remake (recommended)

• The system adds a new output to replace the rejected work.
• Downstream steps plan for the rejected amount to be redone.
• The remake goes through all operations again.

Option 2: In-place shrink (use with care)

• Planned quantities on the original output are reduced.
• No replacement output is created.
• The order may finish with fewer copies than originally planned.

💡 Role Tip: Use Create remake when the customer still wants the full quantity. Use in-place shrink when fewer good copies are acceptable.

Tile Rejection

For tiled outputs:

1. Click Log Tile Rejection (only on outputs that have tiles).
2. Choose the specific tile.
3. Only that tile is affected; parent and sibling tiles continue.

💡 Role Tip: Tile rejection targets one piece of a large job, not the whole banner at once.

3.2 The Locked Rejection: When the Next Step Has Already Started

What Is the Block?

If you reject with Create remake checked, and that work was already transferred forward, the system asks: Has the next operation already started on this batch?

• Yes: Rejection is blocked with a message that the destination has already started.
• No: Rejection proceeds; the old transfer lot is voided and a new one is created.

Why It Exists

Analogy: You printed 50 posters and sent them to lamination. They already started on 20. You cannot recall all 50 for a full reprint without losing work already done on those 20.

The block protects floor work and inventory from conflicting changes.

What to Do When Blocked

1. Talk to the next operator — how much did they already process?
2. Options:
   • A: They finish what they started; you reject only what they have not touched.
   • B: They reject their work too (cascade), then you can reject yours.
   • C: Accept fewer copies (in-place shrink) instead of a full remake.

⚠️ Warning: This block cannot be overridden on the floor. It is there to prevent mismatched quantities and stock.

🛠️ Troubleshooting: "Why can't I reject this output?" — It was transferred forward and the next step already started. Coordinate with the next operator or your production manager.

4. Managerial Completion & Inventory

💡 Role Tip: Production managers oversee the full job, resolve rejections, watch KPIs, and post finished goods. Many actions are permanent — verify before you confirm.

4.1 The Final Audit: Verifying Completion

Before completing an order, check:

1. All operations are COMPLETED — Kanban or the order’s operations list.
2. All tiles are done (if tiled) — every child tile has produced quantity greater than zero.
3. At least one output has produced quantity — something was actually made.

Step-by-Step: Checking Completion

1. Open the Production Order.
2. In Operations, confirm each step shows COMPLETED.
3. In Outputs, confirm produced quantities look correct.
4. For tiled jobs, confirm each child tile shows progress.

🛠️ Troubleshooting: "Why can't I complete this order?" — All operations must be COMPLETED, at least one output must show production, and the order must use the normal routing workflow (not a legacy order without operations).

Auto-Completion

When the last routing step completes, the system often:

1. Checks that every operation is complete.
2. Sets the order to COMPLETED.
3. Posts finished goods to inventory.
4. Updates the linked sales order to READY_TO_SHIP when applicable.
5. Notifies production managers.

💡 Role Tip: You usually do not need to complete the order by hand. You can still complete manually when needed (see §4.2).

4.2 Posting Finished Goods: The Permanent Click

What Is Posting Finished Goods?

Post Finished Goods is the final inventory step. It:

1. Moves produced items from work-in-progress into finished goods stock
2. Deducts raw materials using oldest stock first (FIFO) costing
3. Works out the unit cost of the finished product
4. Records stock movements for audit
5. Locks the order — no further edits

⚠️ Warning: This is irreversible. After posting:

• Finished goods are in inventory
• The order cannot be changed or reopened

Double-check before you confirm.

Step-by-Step: Posting Finished Goods

1. Confirm all operations are COMPLETED (§4.1).
2. Confirm output produced quantities are correct.
3. Open the Production Order.
4. Click Post Finished Goods (or rely on auto-completion when the last step finishes).
5. Read the confirmation warning.
6. Click Confirm.

The system rolls up material, labor, and overhead into a unit cost, adds finished goods to stock, deducts consumed materials (oldest layers used first), marks the order as posted, and may set the sales order to READY_TO_SHIP. Managers receive a notification.

💡 Role Tip: FIFO here means raw materials are taken from the oldest stock on hand first, which keeps inventory valuation consistent with how goods were received.

What Happens to Raw Materials?

Raw materials are consumed when the order is completed and finished goods are posted, not after each intermediate operation. Only the final completion triggers the bulk material deduction. If you need material tied to a specific rejection scenario, use the rejection and consumption tools your administrator configured.

⚠️ Warning: Intermediate steps do not deduct BOM materials by themselves. Plan purchasing and floor checks around order completion, not per machine stop.

4.3 Monitoring KPIs

Production Overview Table

The Production Overview table summarizes all production orders:

Filters

• Status — Pending, Queued, In progress, Paused, Completed, or all non-cancelled
• Work center — Orders that have a step at a chosen work center

💡 Role Tip: Use this view for daily standups and shift handovers — one snapshot of the whole floor.

5. Quick Reference: Buttons & Fields

Production order actions

Operation actions

Requirement actions

6. Glossary

If buttons, menus, or workflows on your screen do not match this guide, contact your administrator.