Complete Garment Factory Automation — All 12 Modules Included

QR Code Bundle Tracking & WIP Monitoring

• Every bundle gets a unique QR code at cutting — JSON format scans 42% faster
• 3-decoder pipeline (jsQR + BarcodeDetector + ZXing) for multi-decoder QR scanning
• Real-time WIP tracking across all sewing lines with color-size heatmaps
• Full traceability: which operator sewed which piece, when, on which machine

Zero-Dispute Piece-Rate Payments

• Every QR scan = automatic, tamper-proof diary entry (deterministic ID prevents duplicates)
• Smart rates: piece rate × skill level (novice 0.8x to expert 1.3x) × machine type
• Deductions, restorations, advances — full monthly salary sheet with net payable
• Operators see earnings on their phone instantly — no 3-day end-of-month reconciliation

Factory Floor Live Monitor & TV Display

• Zero-click TV display: active operators, pending work, bottlenecks, earnings leaderboard
• Auto-detects bottlenecks in 30 seconds (CRITICAL/HIGH/MEDIUM severity scoring)
• Production velocity projections — see if you'll hit the daily target before it's too late
• Audio notifications: distinct tones for work started, completed, alerts, and milestones

Operator Self-Service Mobile App

• Operators scan QR, see earnings, check attendance, view work history — all on their phone
• "I Am Free" smart button — AI-scored work suggestions based on skill, machine, and priority
• Real-time earnings counter with peer leaderboard to drive competition
• Bilingual interface (English/Nepali) with voice feedback for semi-literate operators

Fabric & Accessory Inventory

• Immutable stock ledger with full audit trail — kg for knits, meters for wovens
• Auto-deduction on cutting — transaction-safe with instant roll-by-roll breakdown
• Low stock alerts with velocity calculation: "7 days until stock-out" based on last 30 days
• Size-aware consumption analysis from Optitex marker data, GSM analysis, and aging reports

Cut & Sew Management — Cutting Room to Assembly

• Multi-size, multi-color cutting sheets with auto bundle generation and QR labels
• Bundle handoff: scan bundles → scan operator badge → handoff confirmed. Zero-paperwork physical transfer
• Marriage tracking — ensures all components (Front, Back, Sleeve, Collar) converge before assembly
• Visual template builder with drag-drop dependency chains that auto-unlock operations

Dispatch, Compliance & Supply Chain Traceability

• SAC receipts with A/B quality grading, atomic numbering (SAC-2082-0001), and QR labels
• Challan management with picking lists, packing lists, and printed dispatch documents
• Lot pipeline ledger: balance-sheet view of CUT → RECEIVED → DISPATCHED with running A/B-grade balances per lot
• Every bundle traced through cutting, operator, machine and operation timestamps up to finishing; lot-and-article tracking through packing and dispatch

Quality, Compliance & Dispatch Modules

Quality Control & Damage Management

• Damage reports with photo evidence, severity classification, and payment hold rules
• Bundle splitting: damaged pieces separated into repair bundles — repairs pay 1.5× the operation rate
• B-grade inventory with defect-type tracking (stain, tear, size issue, stitching defect)
• Finishing receipt scanner: big green/red confirmation on every scan, auto-announced over the factory PA

Operator Skill & Machine Management

• 4-level skill tracking (Basic/Intermediate/Advanced/Expert) per machine type
• Skills affect payment multipliers, work eligibility, and smart work suggestions
• Machine library with 7+ types (Overlock, Flatlock, Single Needle, Buttonhole, Kansai...)
• Operator-machine compatibility matrix for supervisor work assignment

Workforce & Operations Modules

Biometric Attendance & Salary

• ZKTeco fingerprint integration — auto check-in/out with ADMS protocol
• Late detection (15-min grace), overtime (1.5x after 8 hours), half-day rules
• Full attendance bonus (Rs 500 for zero absent/late), 3 free late days per month
• Monthly salary: piece-rate + attendance + overtime + bonuses - deductions = net payable

Analytics, Reports & Excel Export

• Supervisor dashboard: color-size heatmaps, lot pipeline, bottleneck summary, idle operators
• Production velocity with hourly breakdown and daily projection
• Machine utilization rates, weekly comparison, and consumption variance analysis
• Daily work reports, payment sheets, and lot pipeline ledger — all exportable to Excel/PDF

Floor Map & Vendor Management

• Cinema-style factory floor map: drag-and-drop seat layout with real-time operator status
• Self-service vendor portal — vendors enter stock deliveries directly, no phone calls needed
• Entry pass management for fabric/accessory receipts with QR labels and godown tracking
• Production planner with capacity planning, lot pipeline, and timeline visualization