Batch and lot traceability has gaps in internal genealogy
You can trace one step back and one step forward, but internal transformations (mixing, splitting, rework) are painful to reconstruct.
Today, and with Frontlink.
Paper batch sheets, manual lot logs, and digging through binders during audits and recalls. Timed traceability exercises regularly fail the 4-hour expectation.
- At batch or order start, operators scan or enter the raw material lots being consumed, a quick 'lot used' capture linked to the production order.
- Optional quantity backflush by standard BOM, with quick-adjust for substitutions and partial batches.
- At batch end, the finished goods lot is recorded (or auto-generated) and linked to all consumed material lots.
- Genealogy graph shows the full chain: RM lots → production batch → FG lots → shipments, even if shipment data is uploaded later.
- Recall/audit export generates a one-page report showing all affected lots, quantities, and downstream destinations.
- Time to value
- 2–4 weeks
- Complexity
- Medium
- Works with machine counters
- Partial
The problem
- Who feels it most
QA, compliance officers, and production managers, especially during audits and recall exercises.
- Why ERP / WMS doesn't solve it
ERP and WMS track lots at receiving and shipping, but internal transformations (mixing, splitting, rework, repack) are messy without shopfloor capture at the moment they happen.
- How common is this?
Very common in food and batch industries. FDA FSMA 204 emphasises faster traceability. EU food law requires 'one step back/one step forward' traceability.
Business impact
- Recall scope and time-to-trace measured in hours instead of minutes
- Overly broad recalls when you can't pinpoint affected lots, increasing cost and brand damage
- Audit findings from incomplete internal genealogy documentation
Frequently asked questions.
Who typically feels this problem?
QA, compliance officers, and production managers, especially during audits and recall exercises.
Why doesn't an ERP or WMS system solve this?
ERP and WMS track lots at receiving and shipping, but internal transformations (mixing, splitting, rework, repack) are messy without shopfloor capture at the moment they happen.
How does Frontlink solve this?
Lot capture at batch start, genealogy graph at batch end. At batch or order start, operators scan or enter the raw material lots being consumed, a quick 'lot used' capture linked to the production order. Optional quantity backflush by standard BOM, with quick-adjust for substitutions and partial batches. At batch end, the finished goods lot is recorded (or auto-generated) and linked to all consumed material lots. Genealogy graph shows the full chain: RM lots → production batch → FG lots → shipments, even if shipment data is uploaded later. Recall/audit export generates a one-page report showing all affected lots, quantities, and downstream destinations.
How quickly does it deliver value?
Typical time to value: 2–4 weeks. Implementation complexity: Medium.
Which process takes you the most time?
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