Glass Manufacturing
Glass Manufacturing: production orders and BOM, stock and warehouse, quality and reporting.
Challenges
- Melting-furnace energy is never allocated to product cost, so the real cost stays unknown.
- The annealing cycle is not linked to the batch, so breakage complaints never reach a root cause.
- Second-quality goods are held in the same stock item as first quality.
- Cullet feedback is not measured, so raw-material consumption looks higher than it is.
Workflows
From melting to forming
- The batch recipe is defined with sand, soda ash and cullet ratios.
- A furnace melting batch is opened and its energy consumption is posted to the batch.
- The forming work order is run with its mould set.
From annealing to quality sorting
- The annealing cycle is recorded on the batch with its time and temperature.
- Output is stocked separately as first quality and second quality.
- Broken glass goes into the feedback stock and returns to the batch recipe.
Documents
- Batch recipe
- Furnace batch record
- Annealing cycle form
- Quality sorting slip (1st/2nd)
Reports
- Energy consumption by batch
- Quality grade distribution
- Cullet feedback ratio
- Scrap and breakage report
Metrics
- Energy cost per tonne
- First-quality rate
- Cullet usage rate
- Scrap rate
Compliance
- Food-contact glass packaging regulations
- Industrial emissions and flue-gas permit
- Packaging waste and recovery declaration
Glossary
- Batch
- The bill of materials for the glass raw-material mix
- Annealing
- An operation whose time and temperature are kept on the batch record
- Cullet
- Broken glass tracked as a feedback stock item
- Second quality
- A quality grade held in its own stock item and price list
FAQ
Can I reflect furnace energy in product cost?
Yes — energy consumption per batch is posted as an expense on the work order and spreads into unit cost.
Can I record the annealing cycle?
Yes — time and temperature are kept on the batch record, and the relevant cycle is pulled up when a complaint arrives.
Can I manage second quality separately?
Yes — the quality grade is defined as its own stock item and price list.
Can I feed broken glass back into production?
Yes — cullet is its own stock item, and its share is stated in the batch recipe.
Can I monitor the first-quality rate?
Yes — the sorting slip feeds a grade-distribution report broken down by batch.
