Batch Production Planning: 1,200-Unit Example and Record

Batch production makes a defined quantity under one controlled production record before the line changes to another product or batch. A usable batch record connects the approved BOM, input lots, machine, shift, good output, rework, rejection and scrap.

Batch production becomes difficult when the planned batch exists only in a schedule and the factory records output somewhere else. The planner needs one record that follows each batch from approved inputs through completion.

Use this worked example to test whether your system preserves that trail.

Plan the 1,200-unit requirement as three batches

Illustrative requirement: make 1,200 units. The approved production batch is 400 units, so the planner releases three batches. Each batch needs its own identity because setup, input lot, inspection and output can differ even when the product is the same.

A shorter setup on the second run is an observation, not a new standard. Review repeated evidence before changing the routing time.

Reconcile every batch before closure

Suppose B-101 records 386 good units, 8 units sent to rework and 6 rejected. The physical quantity reconciles because 386 + 8 + 6 = 400. If rejected units are scrapped later, keep that later movement linked to the rejection instead of counting the same six units twice.

The ERPNext work-order documentation is a useful primary reference for planned quantities, required materials and manufacturing records. Your test should go further by tracing the actual lot and disposition for each batch.

Record the fields that explain the result

• Production order, product and approved BOM revision
• Input item, lot, issued quantity and return quantity
• Machine, work centre, operator and shift
• Setup start, run start, stop and completion time
• Good, rework, reject and scrap quantities
• Inspection result, hold reason and authorised disposition

Run the workflow in Optiwise

Optiwise connects production orders, multi-level BOMs, routing, material issue, process entries, quality inspections and inventory movement. Item barcodes and movement history keep the material trail attached to the operating records. Smart Suggest can surface material needs against stock and open supply before release.

Use the Optiwise production workflow for the order and execution record, then follow stock in inventory management.

Questions from manufacturing teams

Is a production order the same as a batch record?

The production order authorises the work. The batch record adds the actual input lots, time, output, inspection and disposition evidence for that run.

Should reworked units count as first-pass good output?

No. Keep first-pass good and reworked-good quantities separate so the first-pass result stays visible.

When should a batch close?

Close it after issued material, output, returns, rejection, scrap and pending quality holds reconcile or have an approved exception.

See Batch Production Planning in Optiwise