Job Card / Production Order · Standard Operating Procedure

Step 3 of 8 · the master shop-floor document for a release-to-floor batch

APPROVED

SOP-JC-003

v1.0 · Last reviewed 2026-05-08

← Previous: Material Req · Index · Next: WIP Report →

Lifecycle step

Step 3 of 8

Module owner

Production Floor · Supervisors

Trigger event

Batch → IN_PROGRESS (start)

Approval matrix

Planner + Supervisor + QC Inspector

1. Purpose

The Job Card (also called Production Order or Work Order in other ERPs) is the master shop-floor document for a single batch. It travels with the kit from the storeroom door, sits on the machine clipboard for the duration of the run, and is signed off when the run completes. It carries the BOM consumption record, the routing (Setup → Run → QC → Pack), the labour assignment for the shift, an inline QC inspection checklist (Visual / Dimensional / Weight / Packaging / Label), an hourly tally grid, and a 3-signature block.

The Job Card mirrors the Sage X3 "Manufacturing Order Tracking", Syspro "Job Slip", SAP S/4HANA "Production Order Confirmation" and NetSuite "Manufacturing Work Order Traveler". It is the single most data-rich document in the production lifecycle — everything from cycle time and yield to scrap and downtime ties back to it.

Once a batch transitions to IN_PROGRESS via POST /api/production-batches/:id/start, the system snapshots all dimensions, builds a default 4-stage routing, and the floor has a printable Job Card available within 5 seconds.

2. When to use

Production batch transitions from PLANNED → IN_PROGRESS when the supervisor releases the run to the floor.
Re-issue mid-run if the batch crosses a shift boundary (Day → Night) and a fresh paper trail is required.
Re-print of a damaged / illegible card — reissue carries a "REPRINT" watermark via the status meta field.
Trial / engineering build where the routing is non-standard and supervisor must annotate alternative steps.
Customer-witness build — the customer rep is on-site and signs against the QC inspection block as a witness.
QC re-inspection after a FAIL line on the original Job Card — second card carries a "REWORK" stamp.
Workshop-tied production where a machine breakdown was repaired immediately before run; the Job Card carries the breakdown ref for traceability.
Batch split — planner divides a single PO into two physical runs on two machines; each gets its own Job Card with parent batch ref noted.

3. Data sources

The JobCard spec (frontend/js/erp-templates/job-card.js) is built from the live batch row + its line snapshot + labour assignments + machine register. Each row is wired into a real column.

Field on document	API endpoint	DB table.column	Example value
Job Card / PO Ref	`POST /api/production-batches`	`production_batches.batch_ref`	PO-BATCH-2026-0481
FG product code & name	`GET /api/products`	`products.code` & `products.name`	A4_72PG_FM · A4 72-page FM
Planned qty	`POST /api/production-batches`	`production_batches.planned_qty`	5 000
Actual qty	`POST /api/production-batches/:id/complete`	`production_batches.actual_qty`	4 940
BOM version	`GET /api/bom/:id`	`bom_headers.version`	v3
Machine code & name	`GET /api/machines`	`machines.code` & `machines.name`	RUL_4 · Ruling 4
Department	via FK	`departments.code` via `machines.department_id`	RULING
Shift	`POST /api/production-batches`	`production_batches.shift`	DAY / NIGHT
Planned / actual start & end	auto-stamped	`production_batches.started_at`, `completed_at`	2026-05-08 06:30 / 14:10
Status	state machine	`production_batches.status`	IN_PROGRESS
Customer / SO ref	`GET /api/sales-orders`	`sales_orders.order_no`	SO-2026-1142
BOM consumption row · required	snapshot	`production_batch_lines.required_qty`	217.350
BOM consumption row · issued	posted on start	`production_batch_lines.consumed_qty`	217.450
BOM consumption row · variance	derived	computed in `JobCard._bomRows()`	+0.100
Issued from WH	`GET /api/warehouses`	`warehouses.code`	RM-MAIN / PSTAT
Issued by clock	captured on MR	`employees.clock_no`	1042
Routing (Setup / Run / QC / Pack)	default routing	generated client-side via `_defaultRouting(batch)`	30 / 60+ / 20 / 25 min
Labour assignments · Operator / Assistant / Setter / Packer	`GET /api/labour`	`labour_assignments.employee_clock_no` × `role_on_floor`	OPERATOR · clock 1042
Operator name	via FK	`employees.first_name` + `last_name`	P. Mokoena
QC checklist (5 points)	printed blank	captured on paper, then digitised at FGRN	VIS / DIM / WGT / PKG / LBL
Hourly output grid (8 slots)	printed blank	captured on paper · digitised on Tally Sheet	H+1 … H+8
Created by	`req.user`	`users.email` via `created_by`	planner@palmstat.co.za

4. Step-by-step workflow

Batch released to floor — supervisor calls POST /api/production-batches/:id/start. The endpoint loops over production_batch_lines and posts txn_type=ISSUE rows; status flips to IN_PROGRESS and started_at stamps.
Print Job Card — from the batch detail view, supervisor clicks Print Job Card. The frontend calls JobCard.build(batch, bomLines, labourAssignments).print(). Output: a single A4 page with header, BOM consumption table, routing, labour grid, QC checklist, hourly tally grid, signatures.
Setter prepares machine — setter performs the SETUP routing step (30 min). First-off check is made; if dimensions OK, the run is released. Setter signs the SETUP row of the routing table.
Operator runs the line — primary operator monitors output, scrap and rework. Hourly grid is filled in by hand each hour (count, scrap, rework, operator initials).
QC in-line inspection — QC inspector samples 1-of-100 (per QC matrix) and ticks PASS / FAIL / N/A on each of the 5 checklist points: Visual, Dimensional, Weight, Packaging, Label. Any FAIL triggers a Non-Conformance Report (NCR) and a hold on the line.
Packer wraps & palletises — per the dispatch spec on products. Packer signs the PACK row of the routing.
Run completes — the supervisor closes the run via the Tally Sheet (Step 5). When tally is CONFIRMED and all 3 Job Card signatures are captured, the supervisor calls POST /api/production-batches/:id/complete with actual_qty.
Posting to FG — the complete endpoint posts a PROD_IN inventory transaction for the FG product against the target FG warehouse and computes yield_pct, wastage_pct, shortfall_qty. Status → COMPLETED.
3-way sign-off — Production Planner signs the planning section (often before release), Supervisor signs the start & end stamps, QC Inspector signs the QC checklist. All three names are stamped on production_batches via req.user.
Archive — the printed Job Card is scanned and uploaded; document_links ties the PDF to entity_type='production_batch', entity_id=batch.id. Retention 7 years.

5. Roles & permissions

Action	Admin	Planner	Supervisor	Operator	QC / Maintenance
Generate this doc	✓	✓	✓	–	✓ (read)
Start the batch (POST ·/start)	✓	–	✓	–	–
Sign QC checklist	✓	–	–	–	✓ (QC)
Complete the batch (POST ·/complete)	✓	–	✓	–	–
Reprint after archive	✓	✓	✓	✓	✓
Cancel batch	✓	–	–	–	–

Permission gate enforced by requireRole('admin','planner','supervisor') on the start / complete endpoints. Cancellation is admin-only.

6. Common scenarios

Scenario A · Clean run, on plan

Happy path: Planned 5 000 units, achieved 4 940 with 60 units of scrap. Yield 98.8%. QC passes all 5 checklist items, supervisor signs, FGRN posts cleanly. Cycle time within +5% of plan.

Scenario B · Mid-run machine breakdown

Happy path: Ruling shaft fails at H+3. Maintenance logs a machine_breakdowns row with the bd_ref. Supervisor pauses the line, downtime is captured. Once repaired, run resumes; Job Card carries a hand-written note "Breakdown BD-ref · 45 min". WIP variance flag fires (+20% over plan).

Sad path: Breakdown is not logged. Cycle-time variance shows +30% but no explanation; OEE for the machine is unfairly hit. Recovery: back-fill machine_breakdowns after the fact.

Scenario C · QC fails inspection

Happy path: QC inspector ticks FAIL on Dimensional check. Line halts immediately. NCR raised, root cause identified (folder offset), batch routed to rework. A REWORK Job Card is reprinted; original is filed with the NCR.

Sad path: FAIL is overlooked, batch makes it to FGRN and dispatch. Customer returns goods. Recovery: customer return triggers a reverse PROD_OUT + scrap, NCR opens with a CAPA and the original QC inspector is retrained.

Scenario D · Shift change mid-batch

Happy path: Batch crosses Day → Night boundary. Day operator signs the H+1 to H+6 grid, Night operator picks up at H+7 with a fresh row of initials. Supervisor at handover countersigns the labour grid to confirm the swap.

7. Related documents

Upstream · STEP 1: GRN (RM in stock)
Upstream · STEP 2: Material Requisition (kit prepared)
Upstream · Production batch header (PLANNED)
→ STEP 3: Job Card · this document
Downstream · STEP 4: WIP Report (live floor view)
Downstream · STEP 5: Tally Sheet (digitises the hourly grid)
Downstream · STEP 6: FGRN (closes the loop)
Cross-ref · machine_breakdowns for any pause events

8. Approval signatures

Document Owner

Production Planner — ____________

Signed: ____ / ____ / ______

Quality Lead

QC Inspector — ____________

Signed: ____ / ____ / ______

Operations Director

Production Supervisor — ____________

Signed: ____ / ____ / ______

9. SLA & escalation

Stage	Target	Owner	Escalation
Setup → First-off OK	30 min	Setter	Maintenance + Supervisor
QC inline sample	1-of-100 units	QC Inspector	Quality Manager · raise NCR
Cycle time vs plan	+/- 10%	Supervisor	WIP Report variance flag at +20%
Sign-off (3 roles)	Within 60 min of complete	Planner / Sup / QC	Production Manager
Scan & archive	End of shift	Supervisor	Operations Director

10. Glossary

Job Card / Production Order / Work Order — All three names refer to the same document in different ERPs. PalmStat uses "Job Card" on the floor and "Production Order" in finance reports.
Routing — The ordered list of operation steps a batch follows. PalmStat default is SETUP → RUN → QC → PACK.
NCR — Non-Conformance Report. Raised when QC stamps a FAIL.
OEE — Overall Equipment Effectiveness. Calculated downstream from Job Card start/end stamps + scrap %.
First-off — The first unit produced after setup; QC verifies it before the run is released.