Shop-floor execution

This page describes what a worker does with a production order on the floor. The worker logs in at the workstation, brings and takes the material, starts the order, reports how much was made and closes the order. The finished goods then go from the workstation to a warehouse. Workers can do this in three places: in the browser, on a point of sale (POS) terminal in the hall (a shared screen, also called a kiosk), and in the Complaia mobile app.

Where to find it: in the browser, Production → Planning, then Details → Produce on a workstation's card. On the floor, the Production module of a POS terminal, or the Production section of the mobile app.

When you'll use it

• A worker is about to begin a job and needs the order in front of them.
• The start button is disabled and you need to know what blocks it.
• You want to understand when material stock goes down and when finished goods appear in stock.
• Goods were made, but nobody can find them in the warehouse.
• Work has to stop for a while, or the order has to close with fewer pieces than planned.

Key concepts

Presence: who is at the workstation

Presence is the record of who is logged in at which workstation right now. It matters because an order cannot start while fewer people are logged in than the workstation needs.

• People needed to start is a workstation setting. A new workstation needs 1 person. 0 means the workstation runs without people, for example an automatic machine.
• Most logged in at once caps how many people can be logged in at the workstation. Without a limit, any number can log in.
• A person is at one workstation at a time. Logging in at another workstation moves them there.

What blocks a start

An order that has not started shows one label that says whether it can start. Complaia checks the same rules when you press start, so the label always matches what will happen. Three things can block a start:

What blocks the start	What clears it
Sub-orders are not finished.	Finish them, or bring what they made to this workstation and take it for this order.
Not all material from the recipe was taken for this order.	Bring the material and take it for the order. See Bring and take the material.
Too few people are logged in at the workstation.	Log in at the workstation. If it runs without people, set People needed to start to 0 on the workstation.

In the browser the labels are Ready to start, Sub-assemblies with a count such as 1/3 (ready of all), Material with a count such as 2/5 (missing of all lines), and No crew.

Start, report, pause, finish

• Start opens the order for work and moves it to the status Started. After the start, the order cannot change its workstation.

• Report adds pieces to the order's produced quantity. You cannot report more than what is left to reach the planned quantity. A report cannot be reduced later.

• Pause and resume cover interruptions. A pause can have a note. A paused order shows who paused it.

• Finish happens in one of two ways:

  • the reported quantity reaches the planned quantity, and the order closes by itself;
  • the worker closes the order early with fewer pieces, in the browser or in the mobile app.

  Either way the order moves to the status Completed.

You do not change the status of an order by hand. The work on the floor sets it.

What happens to material

Material moves in two steps, and only the second step lowers your stock:

Step	What it does to stock
Bring the material to the workstation	The quantity moves from a warehouse into the workstation buffer. It is still yours and still counted.
Take the material for the order	The quantity leaves the workstation buffer and is recorded on the order as used.

Undo on a taken line puts that line back into the workstation buffer. It works only before the order starts.

When you bring material, Complaia looks for it in this order:

1. what this order's own sub-orders made, in the buffers of other workstations of the same site;
2. stock already reserved for this order in the warehouses of the site;
3. available stock in the warehouses the order takes material from. For products, the finished goods warehouse of the workstation's area comes first.

Material that was brought to this workstation for this order only needs to be taken.

Where finished goods land

Finished goods are booked when the order finishes, not with each report. The quantity booked is the produced quantity.

The goods go into the workstation buffer: a place that belongs to the workstation and keeps goods separate for each production order. Complaia creates the buffer automatically. On warehouse screens, for example Stock levels, the buffer is shown as Workstation followed by the workstation's name.

Goods in the buffer are real and counted, but they are work in progress (WIP). Nobody can reserve, pack or ship them until they are moved to a warehouse. See Move finished output into a warehouse.

An order for a recipe element adds to that element's stock. An order for a product adds to the product's stock.

The screens

In the browser

The floor screen in the browser opens from Production → Planning: click Details on a workstation's card, then Produce. It has three views.

1. Select a production workstation — one tile per active workstation, with a search box when there are many. This view appears when you click Change workstation at the top.

2. The workstation's orders:

   • At the top, a panel says whether you are logged in at this workstation, with a button to log in or log out.
   • Under it is the list of the workstation's orders, in the order of work. Each order shows the product, the order number, the customer, the production day, the deadline, the quantity, a progress bar and the start label.
   • At the bottom, At the workstation shows what lies in the workstation buffer.

   The list refreshes every 15 seconds. Print list at the top opens the workstation's production list as a PDF file.

3. One order, from the top:

   • What is being made — the picture, the name, the production day, the deadline and the workstation;
   • Before you start — the material and sub-order lines, with a What now hint;
   • the reporting block, after the start;
   • one main button at the bottom.

📷 Screenshot to add: the single-order view in the browser with "Before you start" showing one line taken and one line missing

On the kiosk

The Production module of a POS terminal shows:

• Workstation tiles for the workstations attached to this terminal. Each tile shows how many people are logged in.
• Order cards for the open orders of those workstations. Each card shows the product, the quantity, the workstation, the production day and the deadline.
  • Before the start, or while the order is paused, the card has a Start button.
  • After the start, the card shows the produced quantity with Report production and, once something is produced, Print product labels.
• A round button at the top that opens the Work in progress screen, where finished goods go to a warehouse.

The kiosk has no buttons for material, pausing or closing an order early. Do those in the browser or in the mobile app.

On the kiosk, the status on an order card is shown in Polish in every language: Oczekujące means Pending and Rozpoczęte means Started.

How to pair a kiosk and check in on it is described in POS terminals. The kiosk's other modules, such as Stock reservation, Packing and Loading, are warehouse work, not production steps.

📷 Screenshot to add: the kiosk Production module with workstation tiles and one started order card

In the mobile app

The Production section of the app has two tiles. Both stay locked until you are on a workstation.

• Production list — the orders of your workstation, each with a label that says whether it can start. Inside an order you see the material list, and you can start, report, pause and close the order.
• Workstation buffer — what lies in your workstation's buffer, with To warehouse on each item.

For an order that has not started, the list shows its status in Polish in every language: Oczekujące means Pending.

The app is described in The mobile app.

Common tasks

Log in at a workstation

In the browser

1. Open the workstation's floor screen from Planning (Details → Produce).
2. Click Log in at the workstation. The panel turns green and shows how many people are logged in.
3. To leave, click Log out of the workstation.

On the kiosk

1. Check in on the terminal first. See Check in on a kiosk.
2. In Production, tap your workstation's tile.
3. Tap your name in the list of people checked in at the terminal. The tile's counter goes up.

In the mobile app

1. Tap the round button in the header of the app and scan the QR code on the kiosk's screen. This checks you in at the terminal.
2. Choose your workstation from the list. A full workstation is greyed out.

You can only choose a workstation in the app after scanning a kiosk's code. Every hour the app asks whether you are still working. If you answer no, you leave the workstation. To stop work, open your workstation in the header and tap End work.

Bring and take the material

In the browser, on the order:

1. Read Before you start. Each line shows what is needed and where it is: at the workstation, in a warehouse, at the workstation of a sub-order, or missing.
2. If material has to be brought, fetch it. Then click Brought from the warehouse. When everything comes from the workstations of sub-orders, the button says Brought to the workstation.
3. In the window Did you bring the material?, check the list of what will be recorded and from where. Click Yes, I have it here. Complaia records the material at your workstation and takes it for the order straight away.
4. If material is already lying at the workstation, click Take material.
5. If you took something by mistake, click Undo on that line.

When every line is taken, the block says Everything is ready. The result of each action is shown inside the block, with what is still missing.

An order without a recipe and without sub-orders has no such block. You can start it straight away.

In the mobile app the steps are the same. The main button changes to a take or bring action until the material is ready.

Start an order and report what you make

In the browser

1. Open the order and click Start working.
2. Under Completed quantity, set the number: with − and +, by typing it, or with a quick button such as 1, 5, 10 or everything that is left.
3. Click the main button Report with the quantity, and confirm. The confirmation reminds you that a report cannot be reduced later.
4. Repeat as you work.

On the kiosk

1. Tap Start on the order's card. If the button is disabled, the reason is written under it.
2. Tap Report production and choose the quantity.
3. In Confirm it’s you, choose your name and enter your PIN. Only people logged in at the order's workstation are listed.

When the reported quantity reaches the planned quantity, the order finishes by itself. The kiosk has no separate finish button.

In the mobile app

1. Open the order from Production list and tap Start work.
2. Tap Done, choose how many pieces are done and confirm.

For goods counted in metres, kilograms, litres or grams, you can enter a decimal quantity on the kiosk and in the mobile app.

Finish an order

In the browser, the main button changes to Report … and finish as soon as the quantity you entered covers everything that is left.

1. Click that button. The Finish the order window opens.
2. Check Quantity produced. To close the order with fewer pieces than planned, lower this number. Enter only good pieces. There is no separate field for scrap.
3. Leave Print product labels ticked if you want the PRO- labels now. They open as a PDF file in a new tab.
4. Click Report and finish.

The order shows Order finished., and the goods are booked into the workstation buffer. See Where finished goods land.

In the mobile app, report a quantity that covers what is left. The app then asks for the produced quantity, which you can lower, and asks you to confirm before it closes the order.

Pause and resume

1. In the browser, on a started order, click Pause.
2. Optionally type the reason, then click Pause work.
3. To continue, click Resume work.

The mobile app has the same buttons. On the kiosk, a paused order shows Start, which continues the work.

Move finished output into a warehouse

Goods stay in the workstation buffer until somebody moves them to a warehouse. There are three ways.

Scan the labels on the kiosk

1. Stick the PRO- labels on the goods. Print them on the kiosk with Print product labels, or in the browser when you finish the order.
2. After the order is finished, tap the round button at the top of Production to open Work in progress.
3. Scan each label, or type its code and tap Reconcile.

Each scan moves the label's quantity from the workstation buffer to a warehouse. The message says where the goods went. The list To put away in the warehouse shows what is still waiting. If the terminal has several workstations, you can filter the list by workstation.

Move goods without labels

• In the browser, on the workstation's floor screen, find the item under At the workstation and click To warehouse.
• In the mobile app, open Workstation buffer and tap To warehouse on the item.
• On the kiosk, on the Work in progress screen, tap Return to warehouse on the item, then choose your name and enter your PIN.

In the window that opens:

1. Keep the whole quantity selected, or enter a smaller quantity. In the browser the whole quantity is the Hand over everything switch.
2. If more than one warehouse can take the goods, you can choose the Target warehouse. In the browser, in advanced warehouse mode, you can also choose a Segment.
3. Read the preview. It says where the goods will go and how much of it the orders on this workstation still need.
4. Confirm the move.

This also works for material that was brought to the workstation and not used.

Where the goods go

Unless you choose another warehouse, Complaia uses these rules:

• A product goes to the finished goods warehouse of the workstation's production area. Without one, it goes to the site's main warehouse for products.
• An element or material goes to the first material warehouse of the area. Without one, it goes to the site's main warehouse for materials.
• In simple warehouse mode, everything goes to your one main warehouse.

When goods made for a customer order enter that order's warehouse, Complaia sets them aside for the order. Goods made by a sub-order are set aside for the main production order that waits for them. The message tells you when this happens.

If the main order waits for the goods at another workstation, do not scan them into a warehouse. Take them to that workstation instead. The screens show a hint such as Take the finished pieces to workstation …, where order … is waiting for them. The worker there brings them in like any other material.

Take somebody off a workstation

On the kiosk:

1. Tap the workstation's tile, or the people button on it.
2. Tap the name of the person to remove and confirm.

The person leaves the workstation and the terminal. They have to check in again before they can work. Only an operator whose role has Workstations: Edit can remove other people. See the Signed in menu for who is the operator.

When it doesn't work

What you see	Why	What to do
The sub-orders are not finished yet. Finish them or take their materials for this order, then start production.	A sub-order is still open, and what it makes has not been taken for this order.	Finish the sub-order, or bring its output and take it for this order.
Not all materials from the recipe have been taken for this order yet…	At least one recipe line has not been taken.	Bring and take the material.
Not enough people are logged in at the workstation to start the order…	Fewer people are logged in than People needed to start.	Log in at the workstation, or set People needed to start to 0 if it runs without people.
Not enough material in stock.	There is not enough available stock to bring. The material is missing or reserved for other orders.	Receive the material, or release a reservation that holds it, then try again.
This material is not in the workstation buffer.	You clicked Take material before the material was brought.	Bring the material first.
The order has no workstation assigned.	The order is not on a workstation.	Assign it in Planning.
This employee is not checked in at a POS terminal…	On the kiosk, the person has not checked in at the terminal.	Check in on the kiosk first.
This workstation has already reached its limit of logged-in people…	Most logged in at once is reached.	Wait until somebody leaves, or raise the limit on the workstation.
This order has already reached its planned quantity…	Everything was already reported.	Nothing to do. The order is done.
On the kiosk, This item is not in the workstation buffer yet… after a label scan	The order is not finished yet. Goods enter the buffer only when the order finishes.	Finish the order, then scan the label again.
On the kiosk, The main order is waiting for this item at another workstation…	The goods belong to a sub-order whose main order needs them.	Take the goods to the main order's workstation and bring them in there.
No active warehouse accepts this item…, or a message that no active warehouse accepts these goods	No active warehouse of the site accepts this kind of goods.	Add such a warehouse or switch one on, see Warehouses.
An order disappeared from the list with a message that it is cancelled	Somebody cancelled the order.	Nothing to do on the floor. Its material and output are settled on the order page, see Production orders.
The whole kiosk is covered by Stocktake in progress	A stocktaking session is running. The kiosk is locked until the count is finished.	Wait, or tap Go to counting to help with the count.
Failed to load the workstation. in the browser	Your role cannot open workstation settings.	Ask for Workstations: View to be added to your role.
Everything was reported, but stock shows nothing	The goods are in the workstation buffer.	Move them into a warehouse.

Permissions

To do this	You need
See a workstation's orders, the material list and the workstation buffer	Production: View
Bring, take and undo material; start, pause, resume, report and finish	Production: Reporting
Print the workstation's production list or product labels	Production: View
Move goods from the workstation buffer to a warehouse	Production: Reporting or Warehouse: Stock movements
Scan a label into a warehouse on the kiosk, or in the mobile app	Warehouse: Stock movements
Log in and out at a workstation	No permission. Any signed-in user can.
Remove another person from a workstation on the kiosk	Workstations: Edit

On a kiosk, a person is identified by checking in and, for reports and returns, by their PIN. A kiosk where nobody is signed in as the operator can scan labels and return goods to a warehouse.

The mobile app shows the Production section only to people with Production: View.

Related

• Planning — getting orders onto a workstation
• Workstations — people needed to start, people limit, allowed items
• Production areas — the warehouses that finished goods and material go to
• POS terminals — pairing a kiosk, checking in and the PIN
• Production orders — creating orders and following their status
• Stock levels · Stocktaking — the warehouse side
• Glossary — PRO- label, reconcile, presence, worker PIN