KCT Production Floor

Live Warehouse Inventory

Stock = Supplier DO + Returns − DWA Usage − Disposals · updated continuously

● Live

SKUs tracked

86

across 3 warehouses

Low stock

6

below 7-day reorder point

Disposals this week

142 kg

4 QC checkpoints

Batches today

6 / 9

3 remaining on shift

	Item	Warehouse	On hand	7-day usage	Status
▸	Oyster ExtractRM-1042	WH1	1,860 kg	640 kg	Healthy
	+2,400 DO++40 returns−−520 DWA usage−−60 disposal=1,860 kg
▸	Sodium BenzoateRM-1108	WH1	38 kg	22 kg	Reorder soon
	+50 DO++0 returns−−12 DWA usage−−0 disposal=38 kg
▸	PET Bottle 500mlPK-2210	WH2	14,300 pcs	6,200 pcs	Healthy
	+20,000 DO++0 returns−−5,700 DWA usage−−0 disposal=14,300 pcs
▸	Carton — 24pkPK-2311	WH2	410 pcs	380 pcs	Critical
	+800 DO++0 returns−−390 DWA usage−−0 disposal=410 pcs
▸	Oyster Sauce G2 — 500mlFG-3301	WH3	3,240 cs	1,120 cs	Healthy
	+3,600 DO++10 returns−−370 DWA usage−−0 disposal=3,240 cs

Raw Material Disposal

Capture spoiled or expired stock at any QA/QC checkpoint

Log a disposal

Item

Batch / lot

Quantity

Checkpoint

Reason

Notes

Recent disposals

142 kg this week

Oyster Extract — 60 kgLOT-260912-A · Off odor on intake · today, 08:14

Sugar (refined) — 30 kgLOT-260908-C · Damaged packaging · yesterday, 15:40

Corn Starch — 42 kgLOT-260830-B · Expired · 18 Sep, 11:02

Chili (dried) — 10 kgLOT-260901-A · Spoiled, post-cook QC · 17 Sep, 09:20

Production Batches

Today's cook schedule, pulled from DWA · day shift 8:00–17:00

B-0901

G2 Oyster

QC passed

B-0902

Light Soy

QC passed

B-0903

G2 Oyster

QC passed

B-0904

Dark Soy

Pending QC

B-0905

Chili Sauce

Pending QC

B-0906

G2 Oyster

QC passed

B-0907

Light Soy

Cooking

B-0908

G2 Oyster

Queued

B-0909

Dark Soy

Queued

Batch	Product	Cook start	Cook end	Temp	Size	Yield	Export dest.	QC
B-0901	Oyster Sauce G2	08:05	10:20	96°C	1,200 kg	98.4%	MY	Passed
B-0902	Light Soy	08:30	10:05	88°C	900 kg	99.1%	SG	Passed
B-0903	Oyster Sauce G2	10:30	12:40	96°C	1,200 kg	97.8%	HK	Passed
B-0904	Dark Soy	11:00	12:50	90°C	850 kg	—	ID	Pending
B-0907	Light Soy	14:10	—	87°C	900 kg	—	SG	In progress

Order Intake

Normalized from email, WhatsApp, and text into one queue

Order	Customer	Source	Type	Qty	Needed by	Status
ORD-4471	NTUC FairPrice	WhatsApp	Local	400 cs	Tomorrow	Confirmed
ORD-4472	Sheng Siong	Email	Local	260 cs	Tomorrow	Confirmed
ORD-4473	Cold Storage	Text	Local	150 cs	Tomorrow	Awaiting stock check
ORD-4460	Golden Wok Distribution	Email	Overseas	2,400 cs	12 Oct	Planning
ORD-4461	Lion City Exports	Email	OEM	3,600 cs	20 Oct	Material shortfall
ORD-4462	Pacific Harbour Foods	WhatsApp	Overseas	1,100 cs	5 Oct	Planning

Forecasting & Costing

What becomes possible once order, usage, and disposal data are centralized

Oyster Extract — projected requirement

Oct

Nov

Dec

Jan

Forecast requirementCurrent WH1 stock

Top customers by volume — trailing 90 days

Lion City Exports

9,820 cs

Golden Wok Distribution

7,240 cs

NTUC FairPrice

5,760 cs

Pacific Harbour Foods

4,380 cs

Sheng Siong

3,510 cs

Landed cost per case — Oyster Sauce G2

vs. 3-month average

Component	Current batch	3-mo avg	Variance
Raw materials	18.40	17.85	+0.55
Packaging	6.20	6.30	−0.10
Labour & overhead	4.90	4.90	0.00
Total landed cost / case	29.50	29.05	+0.45

Process Map

Oyster Sauce G2 — today's 39-step workflow vs. a centralized system

Today 39 steps

1

Order received via email / WhatsApp

Manually re-typed into Excel order sheet

2

Check stock across 3 separate Excel sheets

No single source of truth

3

Raise hard-copy purchase order

Walked to warehouse for signature

4

DWA entry at cook stage

Batch data isolated from Excel & EB ERP

5

QC sign-off via email notification

Disposal & scrap not captured anywhere

6

Manual weekly stock count

Across 3 warehouses, reconciled by hand

…

+33 more manual touchpoints

Excel, DWA, paper, and WhatsApp handoffs

Centralized ~12 steps

1

Order logged directly into intake queue

Any channel, one record

2

Live stock checked automatically

Real-time across all 3 warehouses

3

PO generated & routed digitally

No paper handoff

4

DWA batch data flows straight into stock

Auto-deducts raw material usage

5

QC sign-off & disposals logged in-system

Every gram accounted for

6

Stock counter always current

Weekly counts become spot-checks