Is the laboratory system sufficient for the course of quality and traceability?

The laboratory system can handle samples and test results. Batch control also requires knowledge of the materials used and confirmation of stock retention. If existing systems already reliably combine these data, no separate solution is required to develop.

How to combine lab, manufacturing and warehouse data for batch traceability?

Shared batch connections allow to determine which raw materials were used in the product, what studies have been done and where the related stock is located. Existing systems can remain primary sources. When installing, it is checked that data can be linked and that quality solutions reach the warehouse on time.

How should a shorter batch release time be assessed?

Individual measurements are made of how long employees collect data and how much they wait for a decision. The duration of the required investigation is accounted for separately. A faster batch release must be assessed together with the adequacy of the documentation and subsequent non-conformities identified.

What determines how much batch quality control can be automated?

The scope of automation is determined by the reliability of the data and the assessment rules approved by the specialists. Records and discrepancies can be collected more quickly, but the data applied to its specific purpose must be sufficient for the product's suitability decision. Unexplained cases are presented to the specialist responsible with their basis.

Chemicals and plastics quality and traceability system

The quality specialist at the product batch finds raw material data, production records and test results. Once the problem is identified, related stock can be found and the detention solution can be transferred to the warehouse.

The batch sample, laboratory result and process deviation are not always linked to the proper specification and intended use of the product. It takes time to release and it is difficult to determine which part of the quantity available or shipped is covered by the solution.

How the solution works

The batch includes a valid specification and the product's applicable use.
The sample and the laboratory or process result are linked to the verified volume.
In case of non-compliance, the affected quantity, detention and investigative action are determined.
An authorized quality specialist shall confirm the batch decision according to the research and production data.
In the search for affected lots and recipients, registered batch division and processing links are included.

Key challenges

Quality control is disconnected from production
Limited batch and component traceability

Solution capabilities

Sample and control basis

The result is linked to the sample, method, specification version and use.

Relationships between raw materials and manufactured batches

It is recorded what raw materials and recycled materials have been used for each batch. The quality team can trace which output relates to the specific material.

Detention and release

The scope of the decision and its adoption in stock processes are verifiable.

Non-compliance investigation

The identified cause of non-conformity, the results of additional investigations and corrective actions carried out are preserved at the lot.

Determination of affected extent

The investigation restores related stocks, products and recipients by showing unexplained connections.

Business context

Quality control is disconnected from production: The batch sample, laboratory result and process deviation are not always linked to the proper specification and intended use of the product. It takes time to release and it is difficult to determine which part of the quantity available or shipped is covered by the solution.
Limited batch and component traceability: It is not always possible to quickly restore the whole connection: the version of the recipe, the batches of raw materials, process parameters, laboratory results and the final batch. Once the mismatch between the composition or batch is detected, it takes a while to separate the affected products and their recipients.
The customer is explained the quality of a specific batch: It is not enough for the buyer to have a general confirmation that the product conforms to the specification. By linking materials, laboratory tests and the batch produced, data for a specific delivery can be provided. Once the claim is received, it is easier to identify the affected production and discuss the actions without stopping all deliveries without justification.

Core features

Sample and control basis
Relationships between raw materials and manufactured batches
Detention and release
Non-compliance investigation
Determination of affected extent

Key integrations

Chemicals and plastics manufacturing execution system (MES): Production operations data linked to a specific batch or serial product.
Enterprise resource planning system (ERP) / WMS: Materials, Stocks and Detention or Release Statuses.
Laboratories or measurement systems: Laboratory result with a relationship between method, sample and specific batch of production.
Basic Data System: Existing product specification and control criteria.

Potential impact (%)

The ranges indicate an illustrative relative change in the metric under the stated assumptions. Results depend on the starting position and actual use of the solution. Percentages for different metrics must not be added together.

Time of collection of the batch release information

16–42%Decreasing

This illustrative scenario assumes that 40-70% of information searches and repeated cross-checks can be addressed. That share is assumed to fall by 40-60%. Company data is needed to verify both the addressable workload and the resulting change.

Active data matching is separated from laboratory testing and external response waiting.

Time frame for determining affected lots

12–36%Decreasing

This illustrative scenario assumes that 30-60% of manual data entry and handover work can be addressed. That share is assumed to fall by 40-60%. Company data is needed to verify both the addressable workload and the resulting change.

The traceability check measures the time of data collection, checks that all intended relationships have been found, and records an unexplained amount of material.

Conditional calculation scenarios. The assumptions have not been validated against client measurements.

When this solution is relevant

The suitability of the final mixture or packaging is based on the raw material document without verification of application limits.
The detention decision does not reach all the locations of use and dispatch of the material concerned.

Implementation requirements

For quality traceability, the relationship between samples, laboratory results and batches or rolls is compatible. Processing and splitting must maintain the determination of the quantities and recipients affected, and product compliance requirements are approved by the professionals responsible for the intended use.