# Manufacturing Module Enhancement — Scope of Work

**Prepared for:** Habib Cables
**Prepared by:** [Your Company Name]
**Document version:** 1.0 (Draft for approval)
**Date:** [Date]
**Status:** Awaiting client sign-off

---

## 1. Purpose of this document

We have studied how cables are manufactured at your facility and compared it with what the current
ERP system can do today. This document explains, in plain language:

- how we understand your production process,
- what the system supports now and where it falls short,
- what we propose to build to fully support your process, and
- exactly what is included (and not included) in this work.

Because this is a **significant enhancement to the system**, we are sharing this document so that we
can **agree and lock the scope before development begins**. Once you approve it, both sides have a
clear, shared understanding of what will be delivered. Any changes requested after approval will be
handled through a simple change-request process (see Section 10).

---

## 2. Executive summary

Your cable manufacturing is a **multi-stage process**: copper is drawn thinner across several
machines, softened by annealing into coils, combined with PVC to form cable, and finally coiled and
packed. Material changes form at every stage, and some of it is stored between stages (for example,
the annealed copper coils).

The current system treats each production job as a **single step** — raw material goes in, finished
cable comes out — with nothing recorded in between. This means the system cannot see the individual
stages, the machines used, the semi-finished material held between stages, or how much material is
lost (wastage) at each stage.

We propose to upgrade the system so it **mirrors your real production flow stage by stage**, tracks
the **half-finished material between stages**, records **actual output and wastage at each machine**,
and calculates a **more accurate production cost**. This is described as **Approach A** below and is
the option we recommend and that you have chosen.

---

## 3. Our understanding of your current process

This is the process as you described it. We have restated it to confirm we understand it correctly.

| # | Stage | What happens |
|---|-------|--------------|
| 1 | **Material intake & storage** | No. 8 copper and PVC compound arrive and are stored in the main store until issued to production. |
| 2 | **Copper drawing** | Copper is drawn thinner across machines: No. 8 → No. 14, then down to No. 22 and finally No. 26. |
| 3 | **Annealing** | The drawn copper is softened on annealing machines into flexible coils ("goats") of roughly 30–35 kg each. |
| 4 | **Cable forming** | Annealed copper and PVC are formed into cable. **Path A:** lead → twisting (watai) → layering (laying). **Path B:** formed directly into cable, without twisting. |
| 5 | **Coiling & packaging** | Cable is wound into rolls ("adda packing"), then boxed or strapped, and finally shrink-wrapped. |
| 6 | **Storage & dispatch** | Finished cable returns to the store and is issued/dispatched when a customer order is received. |

> If anything in this table is not accurate, please tell us — the whole plan is built on this
> understanding.

---

## 4. What the system does today, and why it is not enough

**What works today**
- Receiving raw material into the store and issuing it (Stage 1 and Stage 6 storage) are already
  well supported.
- The system can record a production job, the finished cable it produces, and track finished cable
  by length and number of pieces.

**Where it falls short for your process**

| Your need | The gap today |
|-----------|---------------|
| See each production stage (drawing, annealing, forming, packing) | The system records only **one combined step** — it cannot see the individual stages. |
| Use a **different machine** at each stage | A job can be linked to only **one machine**. |
| Store and track **half-finished material** between stages (e.g. annealed coils) | The system tracks **nothing between** raw material and finished cable. |
| Know how much material is **lost (wastage)** at each stage | Wastage between stages is **not captured** — it is currently recorded as zero. |
| Handle the **two forming paths** (with or without twisting) | There is **no way to choose a production path**. |
| Consume **packaging materials** (boxes, strap, shrink film) | Packaging is **not represented** as part of production. |
| Accurate cost that reflects **actual material used per stage** | Cost is largely **entered upfront**, not calculated from what was actually consumed. |

In short, the system today sees production as a "black box." Your process needs it to see **inside
the box, stage by stage**.

---

## 5. Proposed solution — Approach A (Full stage-by-stage tracking)

We will upgrade the manufacturing module so it follows your process **exactly as it happens on the
floor**. Three improvements make this possible:

1. **Production stages (routing).**
   Each product will have a defined sequence of stages — drawing, annealing, forming, coiling,
   packing — and each stage will have its **own machine**, its **expected wastage**, and its own
   **unit of measure** (copper measured in kg, cable measured in metres). Where a product can follow
   two routes (with or without twisting), both **Path A and Path B** can be defined and selected.

2. **Half-finished (work-in-progress) material.**
   The material produced between stages — drawn copper, **annealed copper coils**, twisted/laid
   cable — will be treated as **trackable stock held on the shop floor**. Annealed coils can carry a
   **coil/lot reference** so a ~30–35 kg coil can be identified. Each stage **uses up** the previous
   stage's output and **produces** the next.

3. **Stage-by-stage recording during production.**
   As a job runs, staff record, for each stage: the **machine used**, the **quantity that went in**,
   the **quantity that came out**, the **wastage**, the **operator**, and the **time**. This gives
   real visibility of **yield and wastage at every machine**, and feeds an **accurate production
   cost** built up stage by stage.

**How your process maps to the new system:**

| Stage | Machine | Goes in | Comes out |
|-------|---------|---------|-----------|
| 1. Drawing | Drawing machine 1 | No. 8 copper (kg) | No. 14 copper (kg) |
| 2. Drawing | Drawing machines 2 & 3 | No. 14 copper | No. 26 copper (kg) |
| 3. Annealing | Annealing machines | No. 26 copper | Annealed coil (kg, ~30–35 kg per coil) |
| 4. Forming | Extruder / forming | Annealed coil + PVC | Cable (metres) — Path A or Path B |
| 5. Coiling | Adda | Cable | Rolls |
| 6. Packaging | — | Rolls + boxes/strap/film | Packed finished cable |

---

## 6. Delivery phases

To reduce risk and give you working improvements sooner, the work will be delivered in **stages**.
Each phase builds on the previous one.

| Phase | What you get | Outcome for you |
|-------|--------------|-----------------|
| **Phase 0 — Foundation & clean-up** | Fix underlying issues that would block the new features; allow more than one machine; start recording real wastage; make raw-material issuing reliable. | A stable, corrected base to build on. |
| **Phase 1 — Half-finished materials** | Set up drawn copper, annealed coils and other in-between materials as trackable stock, held in a shop-floor location. | You can see and store work-in-progress. |
| **Phase 2 — Production stages (routing)** | Define the stages, machines, and the two forming paths for each product, including where PVC and packaging materials are used. | Your products are set up the way you actually make them. |
| **Phase 3 — Stage-by-stage production** | Run a job stage by stage, recording input, output, wastage, operator and machine at each step. | Full shop-floor visibility and real yield/wastage. |
| **Phase 4 — Packaging & costing** | Consume packaging materials; calculate finished-cable cost from what was actually used across all stages; stage/machine wastage reports. | Accurate costing and management reports. |

> **Indicative timeline and effort:** [to be confirmed after the decisions in Section 8 are
> finalised]. Phases are delivered in sequence and each will be demonstrated to you before moving on.

---

## 7. Scope — what is included and what is not

### 7.1 Included in this work (in scope)
- Defining production **stages, machines, expected wastage, and units** per product.
- Support for the **two forming paths** (Path A with twisting / Path B direct).
- **Work-in-progress (half-finished) material** tracking between stages, including a coil/lot
  reference for annealed coils.
- **Stage-by-stage recording** of machine, input, output, wastage, operator and time during a job.
- **Packaging materials** consumed as part of production.
- **Cost of production** calculated from actual stage-by-stage consumption.
- **Reports** for production output, yield, and wastage by stage/machine.
- Necessary **clean-up and corrections** to the existing manufacturing area so the new features work
  reliably.

### 7.2 Not included in this work (out of scope)
The following are **not** part of this engagement unless agreed separately in writing:
- Changes to **Sales, Purchasing, or Accounting** beyond the connections needed for manufacturing.
- **Automatic machine data capture** (sensors/IoT/PLC integration) — data is entered by staff.
- A **mobile or tablet app** (the system is used through its existing web screens).
- **Migration of old/historical production records** into the new stage format.
- **New hardware, barcode/RFID equipment,** or shop-floor devices.
- **Staff training material** beyond a standard handover walkthrough. *(Can be added on request.)*
- Any process, product type, or stage **not described in this document**.

---

## 8. Decisions we need from you

These choices affect what is built, so we need them confirmed before development starts:

1. **Which half-finished materials do you physically store and weigh?** Only annealed coils, or also
   the drawn copper (No. 14 / No. 22 / No. 26)?
2. **Are drawing machines 2 and 3 one stage or two?** i.e. do you store No. 22 copper separately, or
   does it go straight through to No. 26?
3. **Do you need operator/labour tracking per stage** (for payroll or incentives), or is recording
   the machine and output enough?
4. **How should production cost be calculated** — from the actual material used in each job, or kept
   as a monthly average?
5. **Should packaging materials** (boxes, strap, shrink film) be **tracked as inventory**, or treated
   as general consumables?

---

## 9. Benefits / outcomes

Once complete, you will be able to:
- **See production as it really happens** — every stage, machine, and half-finished material.
- **Measure wastage and yield at each machine**, so copper losses can be controlled.
- **Know exactly how much finished cable costs to make**, based on real consumption.
- **Track annealed coils and work-in-progress** held on the floor.
- **Report** on output and efficiency by stage, machine, and product.

---

## 10. Change control

This document defines the agreed scope. After sign-off, any new requirement or change to what is
described here will be handled as a **change request**: we will assess its impact on time and cost,
share it with you, and proceed only once you approve it. This keeps the project predictable for both
sides.

---

## 11. Approval & sign-off

By signing below, both parties confirm they understand and agree to the scope described in this
document, and authorise development to begin on this basis.

| | Client — Habib Cables | Service provider — [Your Company Name] |
|---|---|---|
| **Name** | ____________________ | ____________________ |
| **Designation** | ____________________ | ____________________ |
| **Signature** | ____________________ | ____________________ |
| **Date** | ____________________ | ____________________ |

---

## Appendix — Glossary (plain-language terms)

| Term | Meaning |
|------|---------|
| **Stage / operation** | One step in making the product (e.g. drawing, annealing, packing). |
| **Routing** | The full sequence of stages a product goes through. |
| **Path A / Path B** | Two ways to form the cable — with twisting (A) or directly (B). |
| **Work-in-progress (WIP) / half-finished material** | Material that is partly made — not raw, not yet finished (e.g. annealed coils). |
| **Wastage** | Material lost or scrapped during a stage. |
| **Yield** | How much good output you get from what went in. |
| **Coil / lot reference** | An identifier for a specific coil of annealed copper (~30–35 kg). |
| **Cost of production** | The total cost to make the finished cable, built up from each stage. |
