Carton Audit

The Carton Audit Module is designed to ensure accuracy and compliance in the packing and shipping process.

It provides a systematic process for verifying packed carton contents and then accepting or rejecting the carton.

This module helps reduce shipping errors, improves traceability, and supports quality assurance by maintaining detailed audit trails for every carton leaving the facility.

Pre-Requisites

For a pre-pack to be available for audit, the following conditions must be met:

1. It’s Pack Job must be finished

   • In [Packing].[PackJob], JobStatus must be Completed

2. The logged-in user must have the required permissions

3. Packing list should not have passed audit already

   • In [Packing].[PrePackingList], PackStatus must be PackingCompleted

4. There is no audit in progress

   • In [Packing].[CartonAuditSession], there is no audit against the pre-pack with AuditStatus of Pending

5. Packing list must not be shipped

   • In [Packing].[PrePackingList], PackStatus must not be PackingCompleted
   • Doesn’t actually need to be checked since check #3 already checks for this

Flow

1. Select a Pre-pack to audit.

   • All existing audits will be listed
   • User can explore existing audit details
   • In-progress audits can be updated
   • New audits can be created if there is no in-progress or successful audit

2. Click the new audit button.

   • In CartonAuditSession, A new empty audit will be created
     • SessionName will be set to AUDIT-{AuditNo}__{PrePackingListName}
     • AuditStatus will be set to Pending
   • In CartonAuditSessionDetail, an entry will be created for each size
     • Default SampleSizeQuantity will be calculated for each size
   • Default DefectedQuantity will be set to 0
   • In CartonAuditLog
     • cartons will be auto selected based on required audits for each size
     • Entries will be created for each carton with default Pass status and without any faults or defects

3. Add and update audit details. (Audit detail can be saved at any time)

   1. (Optional) Update SampleSizeQuantity can be updated for each size
   2. Select the required number of cartons to audit for each size
      • In CartonAuditLog, an entry is created for each carton
   3. (Optional) Set the defected piece quantity for each carton
      • In CartonAuditLog, DefectedQuantity is updated
      • In CartonAuditSessionDetail, DefectedQuantity is updated
   4. (Optional) Select one or more fault found for each carton
      • In CartonAuditFaultLog, an entry is made for each fault
   5. (Optional) Add additional remarks for each carton
      • In CartonAuditLog, Remarks is updated
   6. Set audit result status for each carton
      • Result must not be Pending for any carton for the audit to finish
      • In CartonAuditLog, AuditStatus is updated

4. When all cartons are reviewed, click the Finish Audit button

   • The finish carton audit dialog will open
   • The dialog will show the sample size, defected pieces, and DHU % to help the auditor make a decision

5. Select the carton audit status

6. (Optional) Add additional remarks for the audit

7. Click Submit to finish the audit

   • In CartonAuditSession, Auditor will be set to the logged-in user
   • In CartonAuditSession, AuditStatus will be set to the selected status
   • In CartonAuditSession, AuditDate will be set to the current time stamp
   • In CartonAuditSession, Remarks will be set to the provided remarks
   • If the audit is successful, In PrePackingList, PackStatus will be set to PackingAudited

Note

When an audit Pre-pack’s carton is transferred to another Pre-pack, the audit will be cancelled. The pre-pack will need to be re-audited.

Technical Details

Available to

• admin
• erp
• carton audit

Required Roles

• packing:pre_pack:get
• packing:pack_job:get
• packing:carton_audit:get
• packing:carton_audit:post

Audit Status Enum

Pass and FailButRelease represent successful audits

• Pass - Pre-Pack is ready to ship
• FailButRelease (FBR) - Pre-Pack is ready to ship
• Recheck - Needs further auditing, and/or repacking
• Hold - Re-audit is required without repacking
• Fail - Needs a re-audit and/or repacking

Defects per Hundred Units (DHU) Calculation

DHU is crucial for deciding the result of the audit.

DHU Formula:

DHU = DefectPieces / TotalPieces * 100

Sample Size Calculation

Sample Size is used to calculate the number of cartons that need to be audited for each size.

Sample Size Formula:

if          (prePackQty < 16)          sampleSize = 2
else if     (prePackQty < 26)          sampleSize = 3
else if     (prePackQty < 91)          sampleSize = 5
else if     (prePackQty < 151)         sampleSize = 8
else if     (prePackQty < 281)         sampleSize = 13
else if     (prePackQty < 501)         sampleSize = 20
else if     (prePackQty < 1201)        sampleSize = 32
else if     (prePackQty < 3201)        sampleSize = 50
else if     (prePackQty < 10001)       sampleSize = 80
else if     (prePackQty < 35001)       sampleSize = 125
else if     (prePackQty < 150001)      sampleSize = 200
else if     (prePackQty < 500001)      sampleSize = 315
else                                   sampleSize = 500

The number of cartons that need to be audited for each size is calculated by te following formula:

cartonsToAudit = ((sampleSize / prePackQty) * sizePackQty) / 3;

The value is rounded to the nearest integer.

For example:

• Size XXL sizePackQty: 150
• Size L sizePackQty: 200
• prePackQty: 150 + 200 = 350
• sampleSize: 13
• Size XXL cartonsToAudit: ((13 / 350) * 150) / 3 = 1.85 = 2
• Size L cartonsToAudit: ((13 / 350) * 200) / 3 = 2.47 = 2
• Total cartonsToAudit: 2 + 2 = 4

ERD

The following columns are shared by all tables and are therefore excluded: CreatedAt, UpdatedAt, CreatedBy, UpdatedBy

Screenshots