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Food & Process Manufacturing

Contain the bad lot and the late ingredient before they cost you the batch.

Lab results and supplier delays arrive by email and PDF. The ERP batch schedule doesn't know yet. LevelOneAI connects each one to the batches, lots and shipments it affects, so QA and planning act before it turns into a dump, a recall or an idle line.

Where the work gets stuck

A COA fails spec, and nobody knows which batches already used the lot

QA digs through emails, lab reports and batch records to trace a single lot

An ingredient is ten days late, and the line is staged before anyone finds out

Short-shelf-life ingredients expire while the batch waits for a late one

Quality Exception & Batch Impact Workbench

Contain a bad lot in minutes, not a day.

A COA fails a moisture spec, a lab retest comes back out of range, or a supplier sends a contamination notice. QA spends hours in emails, lab reports and batch records working out which batches used the lot, where it's staged and what's already shipped. The workbench maps the whole blast radius as soon as the result arrives.

Doesn't the LIMS or QMS handle this? They hold the test results and the procedures. The workbench connects a result to the batches, inventory and shipments in the ERP, and follows each one until it's contained.

Raw lot 9021 · Lecithin · Northfield Ingredients · out of spec

Pulled from Supplier COA Lab email ERP batches and inventory Shipping schedule
  • Batch ticket 10492 · Vessel 3 · 10,000 gal sauce cook

    Hold required

    Supplier COA (PDF)

    Moisture 14.2% · spec max 12%

    ERP batch record

    Lot 9021 charged at 7:40 AM

    Place quality hold
  • Raw lot 9021 · Warehouse A · 40 drums

    Quarantine

    Lab email · retest

    Confirms out of spec

    ERP inventory

    Status: available

    Quarantine the lot
  • Finished lot 8810 · packed yesterday

    Shipment block

    ERP lot trace

    Made with lot 9021

    Shipping schedule

    Leaves today, 2 PM

    Block the shipment
  • Batch 10492 · rework or dump?

    QA decides

    Rework

    6 hours · about $3,800

    Dump (ERP batch cost)

    About $42,000

1 batch, 1 lot and 1 shipment affected

Approve containment

Illustrative example · sample company and data

What comes in

  • Supplier certificates of analysis (PDF)
  • Lab test results by email
  • Supplier quality alerts

What the workbench does

  • Reads the lot code, the failing parameter and the expiry
  • Traces every batch, staged lot and shipment that used it
  • Shows rework against dump cost, for QA to decide

What goes into the ERP, after approval

  • Quality hold on the batch ticket
  • Lot status changed to quarantined
  • Supplier non-conformance report drafted for the debit

The metrics it moves

MetricBeforeWith the workbenchWhat it means
Batch scrap and dumps2–5% of production volumeUnder 0.4%Recovered straight to EBITDA
Time to contain a quality exception4 to 24 hoursUnder 10 minutesOut-of-spec batches stopped before packing or shipping
Tracing one lot for an audit or recall3–5 days of diggingMinutesLower recall and regulatory exposure
Out-of-spec batches saved by reworkAbout 30%75%+Fewer batches scrapped

Targets, not published results. We agree your baseline before setup and measure against it.

What it's worth: a $50M plant

  • $50Mannual revenue, a food, beverage or chemical plant
  • $1.5Ma year in batch scrap and dumps at 3% of production
  • $450,000of it from quality exceptions contained too late, if that's 30%
  • ~$360,000back to EBITDA every year by containing 80% of those in time

At that rate, a setup from $20,000 pays back in about a month. Example assumptions. Use your own scrap rate and share caused by late containment.

For the QA director, plant manager and VP of Operations. Holds, quarantines and supplier reports happen only after approval. Rework decisions stay with QA.

Ingredient & Material Disruption Workbench

Know which batch will stall, before the line is staged.

A supplier emails that the lecithin is ten days late, or delivers 200 gallons instead of 1,000. The ERP schedule doesn't change, so the team stages the line on Monday and finds out halfway through. The workbench reads supplier updates, checks them against the batch schedule and shelf life, and recommends a fix before the line sits idle.

Doesn't MRP do this? MRP plans on the dates in the ERP. The delay is in the buyer's email, days before anyone updates it.

Disruption queue · this week

Pulled from Supplier email and tickets ERP POs and inventory Batch schedule
  • Organic lecithin · Harlan Ingredients

    Batch will stall

    Supplier email

    Delayed 10 days

    ERP PO 5502

    Due Friday

    Batch schedule

    Batch 3021 cooks Monday · needs 500 kg

    Advance Batch 3045 (all ingredients in stock)
  • Glycerin · PO 5518 · Calder Chemical

    Partial

    Delivery ticket

    200 gal, not 1,000

    ERP PO

    1,000 gal due Oct 22

    Batch schedule

    Batches 3030–3033 need 900 gal

    Re-sequence Line 2
  • Strawberry purée · lot 7740

    Spoilage risk

    ERP inventory

    Expires Oct 31

    Batch schedule

    Batch 3040 moved to Nov 2

    Pull Batch 3040 forward

3 batches at risk

Approve fixes

Illustrative example · sample company and data

What comes in

  • Supplier acknowledgments and delay notes (email, PDF)
  • Partial delivery tickets
  • Revised delivery dates for raw ingredients

What the workbench does

  • Reads the ingredient, quantity and new arrival date
  • Checks it against the batch schedule and shelf life
  • Recommends a fix, like advancing a batch that has everything in stock

What goes into the ERP, after approval

  • Batch sequence changed on the dispatch board
  • PO dates and expected inventory updated
  • Request to suppliers for unconfirmed shipments

The metrics it moves

MetricBeforeWith the workbenchWhat it means
Unplanned line downtime8–14% of operating hoursUnder 2%10–15% more capacity, no capital spend
Spoilage and expiry scrap1.5–3% of raw inventoryUnder 0.3%Ingredients used before they expire
On-time in-full delivery78–85%95–98%Fewer missed delivery windows and retail penalties
Emergency sourcing premium$100,000–$350,000 a yearUnder $30,000 a yearLess spot buying and rush freight

Targets, not published results. We agree your baseline before setup and measure against it.

What it's worth: a $50M plant

  • $50Mannual revenue, about $8M a year in raw ingredients
  • 8%more operating hours back by cutting unplanned downtime from 10% to 2%
  • ~$170,000saved each year by cutting emergency sourcing from $200,000 to $30,000
  • ~$135,000saved each year by cutting spoilage from 2% to 0.3% of raw ingredients

Example assumptions. Use your own downtime, sourcing premium and spoilage rate.

For the plant scheduler, supply chain manager and VP of Operations. Schedule changes, PO updates and supplier requests happen only after approval.

How every workbench works

1

Work

The commitment: one record for each order, PO, deal or invoice, and what was promised for it.

Matches the same work across email and systems.

2

Context

The promise versus the evidence: what the systems say against what just arrived.

Labels each fact confirmed, conflicting, inferred or unknown, with its source.

3

Decision

The exposure: what the mismatch puts at risk, and who needs to decide.

Works out the impact downstream and recommends the next step.

4

Action

The resolution: owned, approved and tracked until the promise is confirmed or replaced.

Assigns owners and dates, drafts follow-ups for review, and records every approval.

Until it's resolved: the issue stays open until the promise is confirmed or replaced, not when a follow-up is sent.

How the Operations Engine works

Start with one workflow.

Pick the workflow that costs you the most. We'll show you a workbench on work like yours.

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