Production Data Tracking App

Below is a comprehensive proposal and plan for an innovative, simple, and practical production data tracking application built on C# .NET Framework, DevExpress UI components, and SQL Server. This solution provides:

1. An input interface (for Operators and Technicians)
2. Configuration interfaces (for Team Leaders to manage resources, machines, and assignments)
3. A dashboard (for Managers to gain insight and validate data)

In this document, you will find:

• System Overview & Goals
• Detailed Workflow (Step-by-Step)
• Interface & Feature Descriptions
• Proposed Database Schema
• SQL Queries and Stored Procedures
• Best Practices & Tools

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1. System Overview & Goals

1.1 Objectives

1. Real-Time Data Capture – Track production starts/stops, downtime, and consumption (materials used) in real time.
2. Simplified Workflows – Provide an easy-to-use interface for Operators, Technicians, and Team Leaders.
3. Role-based Access – Enable Team Leaders to configure their teams and machines. Operators/Technicians should only see machines they are assigned to.
4. Validation & Approval – Each Team Leader checks and validates their team’s data, and the Team Leader Manager (Manager) checks data from the previous day to finalize records.
5. Reporting & Dashboard – Provide real-time dashboards to Managers for production KPIs, downtime reports, and shift summaries.

1.2 Actors

1. Operator – Operates one machine. They start/stop production, declare downtime, and record consumption.
2. Technician – Similar to an operator in data entry, but also in charge of advanced machine aspects (e.g., maintenance).
3. Team Leader – Oversees up to 4 machines (8 Operators + 4 Technicians). Manages resource assignments, sets up production orders, ensures data integrity.
4. Manager – Reviews aggregated data, validates previous day’s data, checks overall performance.

1.3 Shifts & Machines

• The workshop operates 3 shifts (Morning, Day, Night), each of 8 hours.
• Total 8 machines, each shift covered by 2 operators and 1 technician per 2 machines.
• 1 Team Leader covers 4 machines at a time.

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2. Detailed Workflow (Step-by-Step)

Below is a high-level workflow, aligned with your example:

1. Team Leader Login

   • Team Leader starts the day by logging into the application with username/password.
   • Team Leader configures the shift (Morning, Day, or Night).
   • Team Leader sets the assigned personnel (Operators, Technicians) and tools for each machine in the shift.

2. Resource & Manufacturing Order Setup

   • Team Leader selects a Manufacturing Order (MO) and enters:
     • Quantity Launched
     • Theoretical Execution Time
   • System generates a Lot Number for traceability.
   • Team Leader authorizes data entry for the selected machines.

3. Operator/Technician Badge Scan

   • Whenever an Operator/Technician wants to start or stop a production or declare downtime, they must scan their badge (Matricule).
   • The application verifies if the scanned badge belongs to personnel assigned to that machine and shift.

4. Production Start / Stop

   • Operator/Technician selects a machine from their authorized list.
   • Enters the MO, Lot Number, possibly the operation step if required, and taps “Start Production”.
   • The application logs the start time.
   • When production ends or is paused, the Operator/Technician taps “Stop Production”, application logs the stop time and calculates total duration.

5. Downtime Declaration

   • If a machine is idle or has a breakdown, the Operator/Technician declares Downtime by selecting a cause from a predefined list (e.g., Maintenance, Tool Change, Material Shortage, etc.).
   • Enters start time and end time or clicks “Start Downtime” and then “End Downtime” to record automatically.

6. Consumption Declaration

   • Any raw material or component used must be recorded.
   • Operator/Technician selects the machine, the MO, and enters the material used, quantity, and time of usage.

7. Team Leader Shift Validation

   • Before the shift ends, the Team Leader reviews each machine’s record (production times, downtime, consumptions).
   • The Team Leader can correct or validate entries as needed.

8. Manager’s Daily Validation

   • The Manager (or the Team Leader Manager) reviews the previous day’s data (across all shifts).
   • If validated, data gets locked for final reporting and analytics.

9. Dashboard and Reporting

   • Manager checks real-time overview of current shift status, compares planned vs actual production, identifies bottlenecks, etc.

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3. Interface & Feature Descriptions

3.1 Input Interface (Operators/Technicians)

Key Features

1. Badge Scanning: A simple form with a barcode or RFID input field to log in/out quickly or to record actions.
2. Machine Selection: List of assigned machines (Machine 1, 2, 3, 4 …).
3. Production Actions:
   • Start Production: Once pressed, captures time, MO, Lot Number.
   • Stop Production: Captures stop time, calculates production duration.
4. Downtime Actions:
   • Select Cause from a dropdown (DevExpress ComboBox).
   • Start Downtime / Stop Downtime.
5. Consumption:
   • Enter Part Number or select from a dropdown.
   • Enter quantity consumed.

Real-time Feedback

• Display running timers, color-coded machine status (Green = In Production, Red = Stopped, Orange = Downtime, etc.).
• Confirmation messages or warnings (e.g., “Production stop recorded successfully!” or “Downtime reason required.”).

3.2 Configuration Interface (Team Leaders)

Key Features

1. Shift Management
   • Select current shift (Morning/Day/Night).
   • Set start/end times.
2. Resource Assignments
   • Assign Operators/Technicians to machines (drag-and-drop or simple dropdown).
   • View a summary of assigned personnel.
3. Manufacturing Order Setup
   • Enter MO details (MO Number, planned qty, theoretical time, lot number).
   • Decide which machines will run this MO.
   • Authorize data entry (toggle on/off).
4. Data Validation
   • Review logs for each machine.
   • Edit incorrect entries or add missing data.
   • Mark data as validated at shift close.

3.3 Manager Dashboard

Key Features

1. Shift Performance Overview
   • Production quantity vs target, time spent in production vs downtime, throughput.
2. Downtime Analysis
   • Graphical charts of downtime by cause, machine, shift.
3. Consumption Reports
   • Material usage vs planned usage.
4. Daily/Weekly/Monthly Summaries
   • Filter by date range, shift, machine group.
5. Data Locking/Final Validation
   • Manager reviews data from the previous day and, if acceptable, marks it final for official reporting.

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4. Proposed Database Schema

Here is a simplified schema in SQL Server. (Tables can be expanded or normalized further as needed.)

text
-- Table: Users
CREATE TABLE Users (
    UserID INT IDENTITY(1,1) PRIMARY KEY,
    BadgeNumber VARCHAR(50) NOT NULL,
    UserName VARCHAR(100),
    PasswordHash VARCHAR(200),
    Role VARCHAR(50),           -- e.g. 'Operator', 'Technician', 'TeamLeader', 'Manager'
    TeamLeaderID INT NULL       -- if applicable, who they report to
);

-- Table: Shifts
CREATE TABLE Shifts (
    ShiftID INT IDENTITY(1,1) PRIMARY KEY,
    ShiftName VARCHAR(50),      -- e.g. 'Morning', 'Day', 'Night'
    StartTime DATETIME,
    EndTime DATETIME
);

-- Table: Machines
CREATE TABLE Machines (
    MachineID INT IDENTITY(1,1) PRIMARY KEY,
    MachineName VARCHAR(100),   -- e.g. 'Machine 1'
    IsActive BIT
);

-- Table: ManufacturingOrders
CREATE TABLE ManufacturingOrders (
    MOID INT IDENTITY(1,1) PRIMARY KEY,
    MONumber VARCHAR(50) NOT NULL,
    PlannedQty INT,
    TheoreticalTime DECIMAL(5,2), -- in hours or minutes
    LotNumber VARCHAR(50),
    CreatedDate DATETIME DEFAULT GETDATE()
);

-- Table: Assignments (Who is assigned to which machine for each shift)
CREATE TABLE Assignments (
    AssignmentID INT IDENTITY(1,1) PRIMARY KEY,
    ShiftID INT NOT NULL,
    MachineID INT NOT NULL,
    UserID INT NOT NULL,
    CONSTRAINT FK_Assignment_ShiftID FOREIGN KEY (ShiftID) REFERENCES Shifts(ShiftID),
    CONSTRAINT FK_Assignment_MachineID FOREIGN KEY (MachineID) REFERENCES Machines(MachineID),
    CONSTRAINT FK_Assignment_UserID FOREIGN KEY (UserID) REFERENCES Users(UserID)
);

-- Table: ProductionRecords
CREATE TABLE ProductionRecords (
    ProductionID INT IDENTITY(1,1) PRIMARY KEY,
    MOID INT NOT NULL,
    MachineID INT NOT NULL,
    StartTime DATETIME,
    EndTime DATETIME,
    UserID INT, 
    ShiftID INT NOT NULL,
    IsValidated BIT DEFAULT 0,
    CONSTRAINT FK_PR_MOID FOREIGN KEY (MOID) REFERENCES ManufacturingOrders(MOID),
    CONSTRAINT FK_PR_MachineID FOREIGN KEY (MachineID) REFERENCES Machines(MachineID),
    CONSTRAINT FK_PR_UserID FOREIGN KEY (UserID) REFERENCES Users(UserID),
    CONSTRAINT FK_PR_ShiftID FOREIGN KEY (ShiftID) REFERENCES Shifts(ShiftID)
);

-- Table: DowntimeRecords
CREATE TABLE DowntimeRecords (
    DowntimeID INT IDENTITY(1,1) PRIMARY KEY,
    MachineID INT NOT NULL,
    ShiftID INT NOT NULL,
    UserID INT,
    DowntimeCause VARCHAR(100),
    StartTime DATETIME,
    EndTime DATETIME,
    IsValidated BIT DEFAULT 0,
    CONSTRAINT FK_DR_MachineID FOREIGN KEY (MachineID) REFERENCES Machines(MachineID),
    CONSTRAINT FK_DR_ShiftID FOREIGN KEY (ShiftID) REFERENCES Shifts(ShiftID),
    CONSTRAINT FK_DR_UserID FOREIGN KEY (UserID) REFERENCES Users(UserID)
);

-- Table: ConsumptionRecords
CREATE TABLE ConsumptionRecords (
    ConsumptionID INT IDENTITY(1,1) PRIMARY KEY,
    MOID INT NOT NULL,
    MachineID INT NOT NULL,
    UserID INT,
    MaterialCode VARCHAR(50),
    QuantityUsed DECIMAL(10,2),
    RecordTime DATETIME DEFAULT GETDATE(),
    ShiftID INT NOT NULL,
    IsValidated BIT DEFAULT 0,
    CONSTRAINT FK_CR_MOID FOREIGN KEY (MOID) REFERENCES ManufacturingOrders(MOID),
    CONSTRAINT FK_CR_MachineID FOREIGN KEY (MachineID) REFERENCES Machines(MachineID),
    CONSTRAINT FK_CR_UserID FOREIGN KEY (UserID) REFERENCES Users(UserID),
    CONSTRAINT FK_CR_ShiftID FOREIGN KEY (ShiftID) REFERENCES Shifts(ShiftID)
);

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5. SQL Queries and Stored Procedures

Below are example Stored Procedures for key operations. In a production environment, you’ll add more error handling, validations, and auditing as needed.

5.1. Creating a Shift Record (Team Leader)

sql
CREATE PROCEDURE spCreateShift
    @ShiftName VARCHAR(50),
    @StartTime DATETIME,
    @EndTime DATETIME
AS
BEGIN
    INSERT INTO Shifts (ShiftName, StartTime, EndTime)
    VALUES (@ShiftName, @StartTime, @EndTime);

    SELECT SCOPE_IDENTITY() AS NewShiftID;
END

5.2. Assigning a User to a Machine in a Shift

sql
CREATE PROCEDURE spAssignUserToMachine
    @ShiftID INT,
    @MachineID INT,
    @UserID INT
AS
BEGIN
    INSERT INTO Assignments (ShiftID, MachineID, UserID)
    VALUES (@ShiftID, @MachineID, @UserID);
END

5.3. Creating a Manufacturing Order

sql
CREATE PROCEDURE spCreateMO
    @MONumber VARCHAR(50),
    @PlannedQty INT,
    @TheoreticalTime DECIMAL(5,2),
    @LotNumber VARCHAR(50)
AS
BEGIN
    INSERT INTO ManufacturingOrders (MONumber, PlannedQty, TheoreticalTime, LotNumber)
    VALUES (@MONumber, @PlannedQty, @TheoreticalTime, @LotNumber);

    SELECT SCOPE_IDENTITY() AS NewMOID;
END

5.4. Starting Production

sql
CREATE PROCEDURE spStartProduction
    @MOID INT,
    @MachineID INT,
    @UserID INT,
    @ShiftID INT
AS
BEGIN
    INSERT INTO ProductionRecords (MOID, MachineID, StartTime, UserID, ShiftID)
    VALUES (@MOID, @MachineID, GETDATE(), @UserID, @ShiftID);

    SELECT SCOPE_IDENTITY() AS NewProductionID;
END

5.5. Stopping Production

sql
CREATE PROCEDURE spStopProduction
    @ProductionID INT
AS
BEGIN
    UPDATE ProductionRecords
    SET EndTime = GETDATE()
    WHERE ProductionID = @ProductionID;
END

5.6. Declaring Downtime

sql
CREATE PROCEDURE spStartDowntime
    @MachineID INT,
    @ShiftID INT,
    @UserID INT,
    @DowntimeCause VARCHAR(100)
AS
BEGIN
    INSERT INTO DowntimeRecords (MachineID, ShiftID, UserID, DowntimeCause, StartTime)
    VALUES (@MachineID, @ShiftID, @UserID, @DowntimeCause, GETDATE());

    SELECT SCOPE_IDENTITY() AS NewDowntimeID;
END

sql
CREATE PROCEDURE spStopDowntime
    @DowntimeID INT
AS
BEGIN
    UPDATE DowntimeRecords
    SET EndTime = GETDATE()
    WHERE DowntimeID = @DowntimeID;
END

5.7. Recording Consumption

sql
CREATE PROCEDURE spRecordConsumption
    @MOID INT,
    @MachineID INT,
    @UserID INT,
    @MaterialCode VARCHAR(50),
    @QuantityUsed DECIMAL(10,2),
    @ShiftID INT
AS
BEGIN
    INSERT INTO ConsumptionRecords (
        MOID, MachineID, UserID, MaterialCode, QuantityUsed, ShiftID, RecordTime
    )
    VALUES (
        @MOID, @MachineID, @UserID, @MaterialCode, @QuantityUsed, @ShiftID, GETDATE()
    );
    
    SELECT SCOPE_IDENTITY() AS NewConsumptionID;
END

5.8. Validating Production Data (Team Leader)

sql
CREATE PROCEDURE spValidateProduction
    @ProductionID INT
AS
BEGIN
    UPDATE ProductionRecords
    SET IsValidated = 1
    WHERE ProductionID = @ProductionID;
END

5.9. Validating Downtime Data (Team Leader)

sql
CREATE PROCEDURE spValidateDowntime
    @DowntimeID INT
AS
BEGIN
    UPDATE DowntimeRecords
    SET IsValidated = 1
    WHERE DowntimeID = @DowntimeID;
END

5.10. Validating Consumption Data (Team Leader)

sql
CREATE PROCEDURE spValidateConsumption
    @ConsumptionID INT
AS
BEGIN
    UPDATE ConsumptionRecords
    SET IsValidated = 1
    WHERE ConsumptionID = @ConsumptionID;
END

5.11. Manager’s Final Validation (Previous Day)

You could have a single stored procedure to finalize all data of the previous day.

sql
CREATE PROCEDURE spFinalizePreviousDayData
AS
BEGIN
    UPDATE ProductionRecords
    SET IsValidated = 1
    WHERE CAST(StartTime as DATE) = CAST(DATEADD(DAY, -1, GETDATE()) as DATE);

    UPDATE DowntimeRecords
    SET IsValidated = 1
    WHERE CAST(StartTime as DATE) = CAST(DATEADD(DAY, -1, GETDATE()) as DATE);

    UPDATE ConsumptionRecords
    SET IsValidated = 1
    WHERE CAST(RecordTime as DATE) = CAST(DATEADD(DAY, -1, GETDATE()) as DATE);
END

5.12. Reporting & Dashboard Queries

Example: Get total production by shift and machine for a specific date range.

sql
CREATE PROCEDURE spGetProductionSummary
    @StartDate DATETIME,
    @EndDate DATETIME
AS
BEGIN
    SELECT 
        M.MachineName,
        S.ShiftName,
        COUNT(PR.ProductionID) AS TotalRuns,
        SUM(DATEDIFF(MINUTE, PR.StartTime, PR.EndTime)) AS TotalProductionMinutes
    FROM ProductionRecords PR
        INNER JOIN Machines M ON PR.MachineID = M.MachineID
        INNER JOIN Shifts S ON PR.ShiftID = S.ShiftID
    WHERE PR.StartTime BETWEEN @StartDate AND @EndDate
    GROUP BY M.MachineName, S.ShiftName;
END

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6. Best Practices & Tools

1. Development Environment

   • Visual Studio (for C# .NET) with DevExpress UI controls.
   • SQL Server Management Studio for database design and administration.
   • Version Control with Git or Azure DevOps for team collaboration.

2. UI/UX Simplification

   • Minimize clicks: Provide large buttons for “Start Production,” “Stop Production.”
   • Use DevExpress Grid controls for data validation screens (Team Leader) and dashboards (Manager).
   • Use color coding to quickly identify machine status.

3. Security & Role Management

   • Secure login with hashed passwords.
   • Use stored procedures to avoid SQL injection.
   • Implement role-based access at the application layer to control who can see or update each screen.

4. Data Validation

   • Team Leader validation at the end of each shift.
   • Manager final validation the next day.
   • Lock records after final validation for auditing integrity.

5. Scalability

   • Consider archiving older records for performance.
   • Index frequently queried columns (e.g., StartTime, EndTime, ShiftID, MachineID).

6. Monitoring & Alerting

   • Optionally implement automated notifications for prolonged downtime or deviation from planned production.

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7. Conclusion

This proposal provides a solid foundation for a Windows application in a manufacturing environment, focusing on ease of use, real-time data capture, and role-based data validation. By leveraging C# .NET, DevExpress for the user interface, and SQL Server for data storage, you ensure a robust, scalable solution that delivers immediate benefits:

• Streamlined data entry for Operators and Technicians with real-time feedback.
• Clear configuration and validation tools for Team Leaders.
• High-level monitoring and approval workflows for Managers.

With the workflow steps, database schema, stored procedures, and best practices outlined above, you can begin developing the application to effectively track production data across shifts, machines, and manufacturing orders—ultimately driving better decision-making and improving manufacturing performance.