06. Produce the pilot: actual lots, filling, costs and inventory

Lesson 6/18 — Use a Batch for one production run. It records the exact Product/Formula version, physical lots, actual quantities, equipment and packing outcome. This lesson takes the training run through saved Done status.

Before you start

Lessons 1–5 completed. Professional or above for packaging/cost tables; Premium/Enterprise for automatic stock movements. Real production needs its own reviewed process and release decisions.

Create a Batch from the controlled product

1. Open Batches → Add batch. Select DEMO — Body Oil, 50 g and Product Version 1. Confirm that Formula Version 1 is inherited.
2. Set Title to DEMO — Body Oil Pilot 1 kg, Batch index to DEMO-BO-260915-01, and Batch size = 1,000 g. Leave status Draft while preparing the record.
3. The formula calculates 700 g CCT, 290 g sunflower oil and 10 g tocopherol. On each row select CCT-260901, SUN-260902 and TOC-260903, then record the same quantities in Actual weight for this idealised exercise.
4. If you use two physical lots of one material, use + Add lot, record each actual quantity and verify the total. A formula percentage alone does not identify the delivery consumed.
5. Open Equipment and add DEMO — Laboratory balance / DEMO-BAL-01. Real equipment status and calibration evidence must be reviewed; our example asserts no calibration approval. Use Notes and Files for actual measurements, deviations and production documents.

Record filling and packing

1. Open Packaging. Confirm the bottle-and-cap set inherited from the Product.
2. Select Is container and set Net weight (g) = 50. Select packaging lot PACK-260901 and Quantity = 20.
3. Check that 20 × 50 g = 1,000 g, with zero remaining/unpackaged mass. For a real process record actual output, samples and losses; do not force the balance to zero by inventing output.
4. On Premium/Enterprise review Track inventory on every ingredient and packaging lot. This setting is per lot. Only tracked rows should participate in the stock deductions.

Verify costs

Apply stock and complete the record

1. Use Apply inventory now in Ingredient inventory if your process requires stock to be applied while Draft. Review the saved movement history. In the local exercise the ingredient stock became 4,300 g, 1,710 g and 90 g.
2. Return to Formulation and set Batch status → Done after checking the actual record. The local training Product Version was unapproved, so the application showed a warning and offered to continue. We continued only for this fictional software exercise; this is not a product approval.
3. If a PIF document version is selected, it must be Approved to be fixed at Done. Our DEMO selected no PIF document. Done is a production-record state and does not certify a complete PIF or market readiness.
4. Wait for Changes saved automatically. A displayed Done value with “Not saved — fix validation errors” is not a saved completion; open the status error and resolve the actual issue.
5. Open Tracking inventory and search the batch index. Verify four consumption entries: −700 g, −290 g, −10 g and −20 pieces. Packaging stock is now 80 pieces. Previously applied quantities should not be deducted a second time merely because the batch is completed.

Scaling to 500 units

At 50 g per unit, 500 units require 25,000 g net output before process losses. The formula calculation is 17,500 g CCT, 7,250 g sunflower oil and 250 g tocopherol. Our starting demo stock is insufficient for this run. Plan new deliveries and verify process scale, filling accuracy, losses and equipment separately; the app is not a machine integration.

Worked examples in the application

Click any screenshot to read it at full size. All DEMO records are fictional local examples.

Expected result

The saved DEMO Batch is Done, contains the exact lots and 20 filled units, and has four recorded consumption movements. No COA, Product or PIF approval was invented.