The plan ignores the blueprint.
The whiteboard says the batch runs Tuesday. It does not know the mixer is booked, the raw material is not released, or an exhibit batch is still on the line.
ProductsMES
• Manufacturing Execution System
Guide the floor. Finish the record.
Plan on your product and control masters, run every batch on an enforced EBR, prove new formulations on exhibit orders before they scale, and see yield, OEE and planned versus actual for every run.
Runs on its own. Connects when you’re ready.
PRODUCTION PLAN · LINE 01
Capacity meets the batch.
B-2281
B-2282
B-2283
Material readyReleased lots on the plan
Capacity checkedRooms and equipment available
Master approvedCurrent product and control masters
A plan the floor can run.
Schedule against capacity, released material and equipment readiness.
The problem
A paper batch record is checked
after the batch is made.
By the time QA reads it, the step was skipped, the machine was out of calibration and the batch is already in the bin. Review becomes the place mistakes are found, not the place they are prevented.
Every deviation starts from zero.
The same binder problem returns every month. The investigation begins with a blank form because nobody can see the last occurrence and its closed fix.
The batch waits. Then it waits again.
Finished product sits in quarantine while QA chases missing entries and rebuilds the story. Deviations stretch release by days, sometimes weeks.
From plan to finished batch
Make the batch.
Not a second job out of its paperwork.
01 / Capacity planning on product and control masters
Plan every step of the blueprint, not just the batch.
Your product and control masters define every stage of the batch. Factro builds plans from sales orders and checks each stage against real capacity before release.
- 01Plan on the approved master.
Build plans from sales orders, pinned to the approved master version.
- 02Catch double bookings.
See rooms and equipment booked twice, before the plan is released.
- 03Check material early.
Check shortages and lead times against every stage of the plan.
02 / Execution that enforces itself
No clearance, no start. No calibration, no machine. No training, no task.
The EBR runs the batch step by step, and every gate is part of execution. The system holds the work instead of asking someone to remember a rule.
- 01Enforce every step.
Enforce step order, peer verification and minimum and maximum time, with a signed line clearance on every changeover.
- 02Check quality where it gates.
Run IPQC at the stage it gates, and FPT before the batch leaves the floor.
- 03Assign only what is ready.
Block equipment overdue for calibration or cleaning. With QMS connected, assign tasks only to operators trained on the current SOP.
03 / Exhibit orders for formulations
Prove the formulation before it reaches production.
Development batches run on their own orders and record. Each trial runs like a real batch, and a formulation is proven only by three passing trials in a row.
- 01Run trials like batches.
Run trials with a timer, stages in order and the same stage window as work orders.
- 02Prove it three in a row.
Any failed trial resets the count, so proof means three passes in a row.
- 03Approve together.
Head QA and Head R&D approve jointly, and the formulation moves into the Library.
04 / Deviation history & genealogy
Every deviation arrives with its past, and its reach.
A new deviation arrives with the history for the same equipment, product and stage, and the genealogy of the lots involved. Your team starts from evidence.
- 01See the history.
See past occurrences and how each was resolved, beside the open deviation.
- 02Trace the lots.
Trace the material lots behind the batch, and the batches that share them.
- 03Keep it connected.
Keep the investigation, actions and release evidence on one record.
05 / Yield, OEE & planned vs actual
See where every batch gains and loses.
Every run records planned versus actual quantity, time and yield, stage by stage, and every machine feeds OEE. No spreadsheet needed.
- 01Analyse yield.
Break yield down by batch, product and stage.
- 02Compare plan and actual.
Compare planned and actual quantity, time and yield for every run.
- 03Track OEE.
Track OEE for every machine from runtime, downtime and output.
Under the hood
Everything MES runs,
module by module.
Planning, execution, equipment and exhibit orders, all on the batch record.
MES
Planning
Plans from sales orders, checked against material and capacity.
- Masters
- Plans board
- Timeline
- Sales order demand
- Materials and lead time
- Work centre availability
- Calibration checks
- Approvals
- Capacity Planning
- Schedule Collision
- Material Shortage
- Operator Assignment
MES
Work orders
Approved plans, run step by step on the electronic batch record.
- Work orders
- EBR execution
- Weighing and dispensing
- Line clearance
- IPQC
- FPT
- Reconciliation
- Audit log
- Enforced EBR
- Line Clearance Gates
- Peer Verification
- Early Start Warnings
- Batch Genealogy
- Yield & Planned vs Actual
MES
Shop floor
Work centres and equipment, with runtime, calibration and cleaning.
- Units
- Work centres
- Equipment
- Instruments
- Calibration
- Cleaning records
- Upkeep
- Layout designer
- OEE
- Calibration Gates
- Unit Qualification
MES
Exhibit orders
Formulation trials, proven by three passing runs in a row.
- Orders
- Timeline
- Trials
- Stage execution
- Results
- Deviations
- Decision
- Win-streak-rules
- Acceptance Criteria
- Trial Timers
- Joint QA & R&D Approval
Industry packs
Controls for each regulated category, on the same records and workflows.
Moments that matter
The shifts that
decide release.
Five situations every plant meets. Here is what happens in Factro.
01
Sales wants a rush batch on Thursday.
The planner builds it from the sales order and sees every stage against actual work centre and material readiness. The clash is visible before the customer gets a promise.
02
Line 2 changes over from one product to another.
The next batch cannot run until the clearance is signed. The record knows who cleaned it and when, on the changeover before its first step.
03
The third exhibit trial fails.
The successful-run counter resets. The formulation stays in trials until three consecutive runs pass, and the joint QA and R&D approval is on the record.
04
An IPQC check fails mid-batch.
The next stage stays held. The deviation opens with the stage, readings and history already attached, so QA starts from facts instead of a phone call.
05
Yield on one product dropped 3% this month.
Planned versus actual by stage shows where it went. Production traces it back to a machine, shift or material lot without reconstructing the run.
Who it is for
Built for the people who
make the batch.
Each role opens Factro on its own screen, with the evidence it needs to act.
01 / Who it is for
Production planner
Plans from sales orders, with real capacity and shortage checks before release.
- 01
Plans from sales orders on the approved masters
- 02
Clashes and shortages caught before release
- 03
Exhibit and commercial work on one plan
02 / Who it is for
Shift supervisor
Run the shift without chasing signatures.
- 01
Open IPQC checks and pending sign-offs
- 02
Competency checked before every assignment
- 03
A handover with the whole batch history
03 / Who it is for
Weighing operator
The right lot and quantity, independently verified.
- 01
Released material only
- 02
Checked quantities and weighing tolerances
- 03
Second-person verification before the batch moves
04 / Who it is for
Manufacturing operator
The approved instruction at the step you are on.
- 01
Stage order and time windows enforced
- 02
Current SOP from QMS, and equipment standing
- 03
Readings recorded directly against the batch
05 / Who it is for
Formulation scientist
Prove the process before the production run.
- 01
Dedicated exhibit orders
- 02
Three successful consecutive trials
- 03
Joint QA and R&D approval
06 / Who it is for
Head R&D
Review the trial evidence, not a summary spreadsheet.
- 01
Formulation versions on the record
- 02
Trial results and deviations together
- 03
Approved masters move into the Library
07 / Who it is for
Plant head
See the losses and the delays while there is time to act.
- 01
OEE by machine and line
- 02
Planned versus actual for every stage
- 03
Yield and delay trends with source records
Before you start
Questions
plants ask us.
Start with the operation you have. Agree the controls and connections you need.
Talk to our teamWhat is an exhibit order?
A separate order for trials and development batches of new formulations. It runs on the same floor and capacity plan as commercial work, but keeps its own record and approvals.
What happens if the master changes during a batch?
A work order is pinned to its approved master version. A later revision applies to future batches; the record of what the operator actually followed remains intact.
Can a batch skip a required check?
Not with the controls on. Line clearance is mandatory on changeover, IPQC checks gate the relevant stage, FPT must pass before the batch can go to release, and training and equipment standing are checked before the work starts.
Can someone untrained be assigned a task?
No. Assignment checks the competency matrix. A task only goes to people trained on its current SOP.
Where does the EBR come from?
It is generated from your approved master and completed as work happens. Operators record readings and signatures at the step, rather than assembling a separate record at the end.
When do we start paying?
When you start using it. Your team works with its own masters and batches during onboarding, before the subscription begins.
Make it your workflow
Bring a master record.
Watch it become a plan.
Walk through your planning, people and equipment with our team. See the plan against your blueprint, the gates hold, and a deviation arrive with its history and genealogy.