Material Verification and Consumption

One of the biggest risks in production is starting with the wrong materials, even if you follow the correct procedure. A wrong part number, wrong serial number, wrong quantity, or wrong timing can directly impact quality and traceability. The Material Validation and Usage module controls materials used in production at the batch level; it validates, records, and makes consumption traceable.

With this module, material usage moves from ‘declaration’ to ‘system control’. Operators use the correct materials at the correct steps; validations are automated; consumption records are a natural part of batch records. Result: fewer errors, stronger traceability, cleaner audit trails, and faster investigations.

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Material Verification and Consumption

Material Verification and Consumption links the materials to be used in manufacturing steps with the batch, verifies the correct material, correct batch number or serial number and correct quantity, records consumption, and initiates controlled processes when deviations occur. All records are…

Material Planning and Listing

Identity and Batch Validation

Batch and Quantity Control

Consumption Record and Inventory Impact

Alternative Material and Deviation Management

Traceability and Compliance Validation

Material Planning and Listing

You specify which materials will be used for which steps in the production process. Operators can see the answer to ‘What is needed?’ before production starts; the setup process speeds up.

Features

Batch-based Material List
Step-based material requirements
Required material control
Batch preparation and missing material visibility

Batch-based Material List
Plans for all materials to be used in the batch are provided in one place.

Step-based material requirements
Specifies which step for which material to use to reduce confusion on-site.

Required material control
Defines critical materials to reduce the risk of progress with missing or wrong materials.

Batch preparation and missing material visibility
Highlights missing materials in advance; makes it easier to take action before production starts.

Identity and Batch Validation

Verifies that the material is correct for the product and the correct batch number/serial number is used. This prevents incorrect material usage from the start; traceability is strengthened.

Features

Barcode/Serial/Batch number validation
Approval of the material list
Validity and suitability checks
Preventing unauthorized material usage

Barcode/Serial/Batch number validation
Reduces the risk of incorrect usage by matching the correct material with the correct identity.

Approval of the material list
Allows only authorized materials for the batch to control access.

Validity and suitability checks
Reduces risk by automatic control when usage requirements are met.

Preventing unauthorized material usage
Prevents the start of incorrect material usage by stopping approvals for incorrect materials.

Batch and Quantity Control

Controls the quantities to be used, target values, and tolerances. Batch and quantity steps are recorded and can be strengthened with second-party validation when needed.

Features

Target quantity and tolerance control
Batch control and measurement unit standard
Automated calculations and totals
Second Party Validation

Target quantity and tolerance control
Issues a warning if the quantity goes outside the acceptance range and ensures correct progress.

Batch control and measurement unit standard
Improves the consistency of measurement units with measurement unit standards.

Automated calculations and totals
Reduces manual errors in total consumption and difference calculations by system processing.

Second Party Validation
Strengthens reliability in critical batch controls with second-party validation and strengthens audit trail documentation.

Consumption Record and Inventory Impact

Usage records are captured, detailing how much and in which batches the material was consumed. This record is an integral part of the batch record and can be linked to stock movements for traceability.

Features

Create Usage Record
Step-Material-Batch Association
Manage Partial Consumption and Returns
Alignment with Stock Movements

Create Usage Record
Record material usage in a sequential manner to enhance traceability.

Step-Material-Batch Association
Link usage to relevant steps and batches for enhanced traceability.

Manage Partial Consumption and Returns
Ensure consistency with partial consumption and returns in batches that were not fully consumed.

Alignment with Stock Movements
Support alignment with corporate systems through batch records linked to stock processes.

Alternative Material and Deviation Management

Unexpected events can occur on-site: alternative lot usage, quantity deviations, material changes, etc. This step manages these changes in a controlled manner; it includes justification and approval mechanisms.

Features

Alternative Lot/Series Usage
Quantity Deviations and Justification
Approval Required Situations
Initiate Deviation Initiation

Alternative Lot/Series Usage
Manage alternative lot usage within the scope of defined rules to provide flexibility on-site.

Quantity Deviations and Justification
Enhance the meaning of the record with a requirement for explanations in off-target consumption.

Approval Required Situations
Integrate the approval process for critical changes to increase control.

Initiate Deviation Initiation
Initiate and track deviation processes in policy-driven situations.

Traceability and Compliance Validation

Record material usage, which is one of the most frequently questioned topics: 'Which material was used in which batch?' This step strengthens traceability and makes the record more reportable.

Features

Material Usage History
Batch-Based Material Reports
Enhance traceability and visibility with batch and series information.
Audit-Ready Evidence Set

Material Usage History
Net the batches where the material was used to ensure strong traceability.

Batch-Based Material Reports
Report all materials used in batches with lot/series and quantity information to simplify monitoring.

Enhance traceability and visibility with batch and series information.
Show the material-batch-step relationship; speed up inspection and troubleshooting processes.

Audit-Ready Evidence Set
Comprehensive audit trail, including justifications and approvals, forms a robust quality assurance package.