Getting Started & Home

Welcome to ECOAT Core — the single platform your plant and office run on every day. This chapter gets you signed in, gives you the lay of the land on the Home dashboard, and shows you the handful of tools that work the same on every page: the facility selector, the menu, quick search, Help, and the Feedback button.

Signing In

Core uses your my.ecoat.us account — the same login you use for other ecoat.us tools. There's no separate password to remember.

1. Go to the Core web address (bookmark it, or ask IT for the link).
2. Click Sign in with my.ecoat.us.
3. Enter your my.ecoat.us email and password if prompted.
4. You'll land on the Home dashboard.

The Home Dashboard

Home is your morning starting point. It greets you by name, surfaces anything that needs a human right now, and gives you a card for each module you have access to. It refreshes automatically when you switch facilities.

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From top to bottom, Home shows:

• Greeting — "Good morning/afternoon/evening, [your name]."
• Attention rail — the page's headline. A row of numbered call-outs for things that need action: overdue CARs, open NCRs, calibrations overdue or due soon, new QC requests, lab readings out of spec, items below reorder, batches expiring soon, overdue PMs, overdue lots, and more. Red means urgent, amber means soon. Click any item to jump straight to it.
• IT Announcements — messages from IT (see below). Dismiss one with the × and it stays dismissed on that device.
• Your Modules — a card per module (Quality, Inventory, Maintenance, Lab, Production, and so on). Each card shows a few live numbers and links to that module.
• System Status — API health, the current Core version, and running totals like items tracked and equipment count.
• Quick Actions — shortcuts to the things you do most, tailored to your role.

Announcements

Announcements are how IT tells everyone about planned maintenance, outages, or important changes. They appear at the top of Home, colour-coded by type (info, warning, critical, maintenance). Dismissing one only hides it for you — it doesn't remove it for anyone else.

The Facility Selector

Core serves four facilities — Seminole, Tulsa, Cleveland, and Mission — and most screens are scoped to one at a time. The facility dropdown sits in the top bar and is always visible.

• Pick a facility to see only its data.
• If your account covers more than one site, you'll also have an All Facilities option.
• Your choice follows you as you move between pages, and Home re-loads its numbers to match.

Getting Around: the Menu

The Menu button in the top-right corner opens the main navigation. It lists every module you have access to — Home, QMS, Inventory, Maintenance, Lab, Production, and any others. Your signed-in name and the Logout button live here too.

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1. Click Menu (top-right).
2. Pick a module.
3. Inside a module, a sub-navigation bar appears under the header with that module's pages (for example, QMS shows Dashboard, ISO Audits, Calibrations, CAR, NCR, and so on).

Some modules tuck their setup pages into a ⚙ Configure dropdown at the end of the sub-nav to keep the bar tidy. A sub-nav link with an outward arrow (↗) opens in a new tab.

The theme toggle (light / dark / match your system) also lives in the menu on phones, and in the top bar on larger screens.

Jump to Any Page: Quick Search (Ctrl+K)

Core has around 90 pages. Instead of hunting through menus, press Ctrl+K (or ⌘K on a Mac) to jump straight to any of them. You can also click the magnifying-glass icon in the top bar.

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1. Press Ctrl+K.
2. Start typing — a page name, or part of one (e.g. "cycle count", "fai", "calibrations").
3. Use the arrow keys to move up and down the results.
4. Press Enter to go there. Press Esc to close.

Getting Help: Press ?

Every page has built-in help. Press the ? key anytime to open it (or choose Help from the Menu). The Help window has step-by-step guides organized by module, with a search box.

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1. Press ? on your keyboard (this works everywhere except while you're typing in a box).
2. Browse topics in the left sidebar, or type in Search help to filter them.
3. Some topics link to the full written SOP — click View All SOPs at the bottom of the sidebar.

Sending Feedback

The green Feedback button floats in the bottom-right corner of every page. Use it any time you have a question, hit a problem, or have an idea — it's the fastest way to reach the team building Core, and it automatically records which page you were on.

1. Click the 💬 Feedback button.
2. Pick a category: Question, Issue, Idea, Praise, or Other.
3. Type your message. If it's a problem, say what you were trying to do.
4. Click Send.

Seeing replies to your feedback

The team reads every submission and often replies. To see your past feedback and any responses, open the Feedback button and click View my feedback & replies →, or go to /feedback/mine.

Quality (QMS)

The Quality Management System is where the quality team runs the ISO 9001 program and where the whole plant reports quality issues. It covers audits, calibrations, controlled documents, inspections, corrective actions, and the monthly report — all scoped to the facility you pick in the top bar.

Open it from Menu → QMS. The sub-navigation bar lists every page in this chapter: Dashboard, ISO Audits, QC Calendar, Calibrations, Documents, QC Requests, Shop Audits, CAR, NCR, QC Inspection, FAI, and Monthly Report.

QMS Dashboard

The dashboard is the quality team's command center. It pulls the whole facility's quality picture onto one screen and gives you one-click buttons to start the most common actions.

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At the top, action buttons let you jump straight into + NCR, + CAR, the QC Calendar, and the Kiosk. Below that you'll find:

• Attention tiles — overdue calibrations, shop audits pending, calibrations due soon.
• Calibration Health — a snapshot of gauge status across the facility.
• CAR Pipeline — open corrective actions by stage.
• QC Requests inbox — the newest items waiting on the quality team.
• NCR Dispositions (MTD) and Film Thickness Averages (MTD).
• Upcoming on the QC Calendar — the next scheduled audit and events.

ISO Audits

ISO Audits are the yearly ISO 9001 certification audits, run from standardized templates. Each facility completes all five audits every year, and each finishes with a legally binding digital signature.

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Run an audit

1. Go to QMS → ISO Audits and click Start New Audit.
2. Choose an audit template (Quality Management, Production & Shipping, Human Resources, Purchasing & Receiving, or Sales).
3. For each question, read the clause text, then mark Conforming, Non-Conforming, or N/A.
4. Add notes explaining your finding, and upload evidence photos or documents where helpful.
5. When every question is answered, review the summary and click Sign Audit to finish.

The signature captures your name, email, IP address, and timestamp, and is E-SIGN Act compliant.

QC Calendar

The QC Calendar is one month-grid view of everything scheduled — planned ISO audits and general quality events together, colour-coded so you can tell them apart at a glance.

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1. Go to QMS → QC Calendar.
2. Click a day, or the + Add button, to open the chooser.
3. Pick Schedule audit (to plan an ISO audit) or Add event (for any other quality event).
4. Click an existing chip to open its details.

Calibrations

Calibrations is the gauge registry. Every measuring instrument the facility relies on lives here with its calibration due date, and the system colours each one by how close it is to expiring.

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Each gauge shows one of four statuses:

Add a gauge or log a calibration

1. Click Add gauge to register a new instrument.
2. To record a completed calibration, open the gauge and use Log Calibration — this stamps the new date and moves the status back to Current.
3. Filter the list by status (All, Due Soon, Overdue, and so on) or search by name.

Documents

Controlled Documents is the document control library — SOPs, work instructions, forms, and the like, each with revision history and a review interval.

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Documents carry a status of Current, Under Review, Superseded, or Archived. Filter the list by type, applicability, status, or search, and click File on a row to open the attached document.

QC Requests

QC Requests is the quality team's inbox — action items and notifications routed from the floor, such as FAI requests and QC inspections that need attention.

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• Requests are grouped into tabs: New, In Progress, and Resolved, with a red count badge on New.
• Each request shows its type (FAI, QC Inspection, or Other), who it came from, and any notes.
• The quality team moves a request along by changing its status as they work it.

Shop Audits

Shop Audits are the recurring daily and weekly walk-throughs of the shop floor — quick GO / NO GO checks that keep operations honest between the big ISO audits.

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Complete a section

1. Go to QMS → Shop Audits and pick a section that's due (e.g. "Zpex", "Ecoat").
2. For each question, tap GO (green) if it's compliant or NO GO (red) if it isn't.
3. Add notes for every NO GO to explain the issue and what needs to happen.
4. Add section observations and upload evidence photos as needed.
5. Click Submit Section.

You can reopen a completed section to make changes — your previous answers pre-load, and saving updates the existing record rather than creating a duplicate. The Reports tab summarizes total, completed, incomplete, and overdue audits, with PDF download.

CAR — Corrective Action Requests

A CAR is the formal process for fixing a problem at its root, following the 8D methodology with a 5-Why root-cause analysis. It's about correcting the process, and it moves through eight tracked statuses from creation to closure.

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Who creates CARs

The 8-status workflow

(The remaining transitions are re-submit after a rejection, return from verification, and reopen — see below.)

Responding to a CAR (assigned department)

1. Open the CAR and click Start Work.
2. Complete the 8D sections. D3 Containment, D4 Root Cause (the 5-Why), and D5 Corrective Actions are required; D6 Validation, D7 Prevent Recurrence, and D8 Closure Notes are optional.
3. Your work auto-saves every 60 seconds, and you can click Save Draft anytime — a draft does not submit the CAR.
4. When it's complete, click Submit to QC.

Extensions, verification, and reopening

• Need more time? Click Request Extension, pick a new date, and give a specific reason. Request it before the due date passes — Quality approves or denies it.
• Quality review: Quality accepts a submitted 8D (moving it to a 30-day verification period) or rejects it back with feedback. After verification, Verify & Close closes the CAR.
• Reopen: Quality can reopen a closed CAR if the issue recurs; it returns to Open-In Progress with a fresh due date.

Overdue CARs escalate automatically — a manager is notified at 7 days overdue, a director at 14. CAR numbers look like CAR#001-FAC-2026 (sequence-facility-year).

NCR — Non-Conformance Reports

An NCR documents non-conforming material and decides what to do with it. Where a CAR fixes the process, an NCR handles the physical parts — return, scrap, or rework — and records the cost.

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The workflow

Open → Disposition → Closed. Anyone can open an NCR; Quality decides the disposition; the system closes it with the cost recorded.

Create an NCR

1. Go to QMS → NCR and click + Create NCR.
2. Search for and select the affected lot number.
3. Fill in the defect type, reason, quantity affected, and a description.
4. Attach evidence photos and click Submit NCR.

Disposition types

Adding photos after creation

You don't have to attach everything up front. Open an existing NCR and use the evidence upload on the detail page to add photos later. Core can even run an AI defect-classification pass on uploaded photos to suggest the defect type.

NCR numbers look like NCR-SEMINOLE-2026-0015 (facility-year-sequence).

QC Inspection

A QC Inspection is a formal quality check on coated parts, driven by a template that carries the parameters for each coating type. It replaces the old Cognito Forms workflow, flags out-of-spec readings live, and can open an NCR automatically when an inspection fails.

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Run an inspection

1. Go to QMS → QC Inspection and click New Inspection.
2. Choose the inspection template (coating type) and enter the lot, part number, customer, and quantity.
3. Enter each reading. Numeric fields show a green border within spec and a red border out of spec; you'll also see Yes/No and free-text parameters.
4. Choose an overall result — Pass, Fail, or Conditional — add notes, and click Complete Inspection.

A Failed inspection automatically creates a linked NCR. The quality team can fully edit past inspections (this closed an ISO 9001 finding). Inspection IDs look like QCI-SEM-2026-0001.

In-process vs. final inspections

Each inspection carries a Final inspection toggle, and the list shows a badge for it:

• Final (indigo badge) — on a Pass, the lot is finished and its on-time-delivery (OTD) is calculated.
• In-Process (grey badge) — results are recorded and the lot can advance, but it stays open for OTD.

FAI — First Article Inspection

An FAI is the up-front inspection you do on the first article of a part to confirm the process is set up correctly before a full run. Core builds it as a short wizard and includes a risk assessment.

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Create an FAI

1. Go to QMS → FAI and click New Inspection. (The Parts needing FAI list, at FAI → Needed, flags parts that don't have one yet — click Create FAI next to any of them.)
2. Step 1 — Part & Product: search for the part number. If it's brand new, click to enter new-product mode and set its product type (Coil, ZPEX, Powder, Gen. Industrial, CARC, ZPEX II) plus a customer.
3. Step 2 — Design: build the process across its stages (substrate, pre-treatment, coating, masking, preservation).
4. Step 3 — Risk: complete the risk assessment and sign off. Any area flagged high risk requires a mitigation before the FAI can be completed.
5. Click Mark Complete — enabled once every checklist item is done.

A completed FAI can be reopened with Reopen to Edit if you need to change something.

Monthly Report

The Monthly Quality Report pulls the month's quality metrics into one document with a bit of manual narrative, then generates the finished report in one click.

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1. Go to QMS → Monthly Report and choose the period (month) at the top.
2. Write the Quality Statement — a short summary of the month.
3. Choose which metrics to include and fill in the Quality Costs.
4. Click Save & Generate to produce the report.

Past reports live under Monthly Report → Archive.

Inventory

The Inventory module is where you track everything ECOAT buys, stores, and consumes — from paint and pretreatment chemicals to shop supplies. It keeps on-hand quantities accurate across all four facilities (Seminole, Tulsa, Cleveland, and Mission), tracks material batches for traceability, and drives purchasing so you never run out of a critical item.

Almost every screen respects the facility selector in the top-right corner. Set it to the plant you work at and the lists, counts, and reports below will scope themselves to that location.

Inventory Dashboard

The dashboard is your at-a-glance health check for the current facility. Open it from Inventory in the main menu (it is the default view).

It surfaces the numbers you care about most: how many items are below their reorder point, batches expiring soon, and quick links into the busiest screens (Receive, Items, Purchase Orders). Use it as your morning landing page, then jump to the specific task from there.

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Items

The Items screen is the working list of every stocked item at the selected facility. Open it from Inventory > Items.

Each row shows the part number, description, vendor, on-hand quantity, a facility badge (so you always know which plant the item belongs to), and the manufacturer part number (MFG Part#) for cross-referencing vendor paperwork. A colored stock indicator tells you the situation at a glance.

View and search items

1. Go to Inventory > Items
2. Search by part number, description, or vendor
3. Click any row to open the item detail

Edit an item

1. Click an item row to open its detail panel
2. Click Edit
3. Update the fields you need — description, vendor, code, location, unit price, UOM, reorder point, reorder quantity, lead time, or notes
4. Save

Quick actions from an item

From the item detail you can jump straight into related work:

• Receive Product — opens Receiving with this item pre-loaded
• Make Transaction — create an adjustment or issue for this item
• View Batches — see every batch for this item
• View Transactions — see the full movement history

Stock indicators:

Item Master

The Item Master groups the same product across all four facilities so you can compare and manage them together. Open it from Inventory > Item Master.

Products are grouped by MFG Part#, with a canonical (standardized) name and a facility matrix showing on-hand quantity at Seminole, Tulsa, Cleveland, and Mission side by side. A warning icon (⚠️) flags products whose names differ between facilities so you can clean up inconsistent naming.

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Compare and edit a product across facilities

1. Go to Inventory > Item Master
2. Click a product row to expand its per-facility breakdown
3. Click any facility row (it has a pencil icon) to edit just that facility's copy
4. Update description, vendor, category, location, pricing, or reorder settings
5. Save

Add a new item across facilities

1. Click + Add Item in the Item Master header
2. Step 1 — Common fields: enter part number and description (required), plus vendor, UOM, and unit price. Flag Hazardous Material (enables an SDS link) or Critical Item if relevant, then tick the facilities to create the item at
3. Click Next
4. Step 2 — Per-facility settings: set location, category, reorder point, reorder quantity, qty-to-keep, lead time, inventory interval, and notes — each facility can differ
5. Click Create Items

Purchase Orders

Purchase Orders (POs) track what you have ordered from vendors and what is still expected. Open the list from Inventory > Orders.

Create and submit a PO

1. Go to Inventory > Orders and click New Purchase Order
2. Select the Vendor and set an Expected Delivery date
3. Click Add Item to search and add items, entering a quantity for each
4. Review the total, then Save Draft or Submit

PO status flow:

Xero — POs are entered twice (on purpose)

Automatic Xero sync is currently turned off. When you submit a PO in Core, it does not flow into Xero by itself. Core reminds you of this right after you submit:

So the honest procedure today is: submit the PO in Core, then create the same PO by hand in Xero. The Buyer Worklist (below) exists specifically to make that second step reliable so nothing slips through.

Buyer Worklist

The Buyer Worklist is the checklist that keeps Core and Xero in step while auto-sync is off. Open it from Inventory > Orders > Xero Worklist. Its header reads "Buyer Worklist — Enter in Xero."

It lists every submitted PO that has not yet been entered in Xero, with columns for PO #, Vendor, Facility, Total, and Submitted date. As you enter each one into Xero, mark it here and it drops off the list.

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Clear a PO off the worklist

1. Open Inventory > Orders > Xero Worklist
2. For each PO, create the matching Purchase Order in Xero
3. Optionally type the Xero PO# into the reference box so both systems cross-reference
4. Upload a copy of the PO so everyone can see what was ordered
5. Mark it entered — the row disappears from the worklist

When the list is empty you will see "Nothing waiting — all submitted POs have been entered in Xero. ✓"

Receiving

Receiving records incoming shipments and creates the batch records that give you traceability. Open it from Inventory > Receive Inventory.

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Receive a shipment

1. Go to Inventory > Receive Inventory
2. Enter the PO Number from the packing slip and click Search
3. For each item, enter the Quantity received
4. Enter the MFG Batch Number from the product label
5. Enter the MFG Expiration Date if the label or Certificate of Analysis shows one (optional)
6. Click Complete Receiving

You can add the same item more than once to receive different batches with different batch numbers or expiration dates.

About the MFG Batch Number

This is critical for traceability. Find it on the product label (e.g. LOT 123456 or BATCH XYZ789). If it is missing, contact the vendor before receiving.

Certificate check while receiving

Core tracks certificates by vendor + MFG batch/lot number, so you only ever request a cert once per batch:

• Green "Cert on file" — nothing to do; a cert already exists for this vendor + batch
• Amber "Cert needed" — click Register Cert to create the cert record

If a Certificate of Conformance is missing, mark the batch Quarantined until it arrives.

Special cases

• Partial receipt: receive only what physically arrived; the PO stays Partial
• Over-shipment: stop and notify the Materials Manager — do not receive the excess
• Wrong item: stop, take a photo, notify the Materials Manager, set it aside for return
• Customer-supplied (no PO): use a PO number in the format CUSTOMER-YYYY-NNN and unit cost $0.00

Batches

A batch is a uniquely identified quantity of material — the backbone of ISO 9001 traceability and expiration control. Open the list from Inventory > Batches.

Each batch carries a unique Batch ID (BATCH-YYYY-NNNNNN), the vendor's MFG batch/lot number, quantity, received date, expiration date, PO link, and storage location.

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How batches get created (Material Type matters)

You normally don't create batches manually — Receiving does it for you, but only for the right kind of item. When you receive an item whose Material Type is "Paint," Core automatically creates a batch and sets an expiration date (the manufacturer's date if you entered one, otherwise one year from today). Items with any other Material Type are not batch-tracked unless you supply an MFG batch number during receiving.

This is why Material Type is a load-bearing field: it decides whether paint batches and expirations get created at all. If a paint product isn't generating batches, check that its Material Type is set to Paint.

View and filter batches

Go to Inventory > Batches and filter by facility, item, status, or "expiring soon" (next 30 days).

Batch statuses:

Use the oldest stock first (FEFO/FIFO)

The policy is FEFO — First Expired, First Out. Core recommends the batch with the earliest expiration date first. For items without expiration dates it falls back to FIFO (oldest received first). The batch detail shows a "use first" recommendation — pull that batch, and if you use a different one you'll be asked for an override reason.

Check out (issue) material from a batch

When you consume material, record it against the batch so on-hand stays accurate:

1. Open a batch and click Checkout
2. On the Checkout Material screen, review the Available Quantity
3. Under Issue Material, enter the Quantity to Issue
4. Submit

If you try to issue from a batch that isn't the FEFO-recommended one, Core flags a FEFO violation and asks you to enter an Override Reason before it will proceed.

Print a batch label

From the batch detail, click Print Label. Labels include a scannable QR code, the Batch ID and MFG batch number, part number and description, expiration date, and location.

Transactions

The Transactions screen is the audit trail of every inventory movement. Open it from Inventory > Transactions.

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Common transaction types:

Make an adjustment

The simplest correction is to edit the item directly:

1. Go to Inventory > Items and open the item
2. Click Edit and update the On Hand quantity
3. Add a note explaining the change (e.g. Spill - 2026-07-07 - 2 gal lost - J. Smith)
4. Save

Receiving vs. Transfers

Receiving brings material in from vendors. Transfers move material between ECOAT facilities with a full audit trail. Open the list from Inventory > Transfers.

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Transfer statuses: Draft → In Transit → Received (or Cancelled while still Draft).

Create, ship, and receive a transfer

1. Create: Go to Inventory > Transfers > New Transfer, pick the Source and Destination facilities, add items with quantities, and click Create Transfer (starts as Draft)
2. Ship: Open the Draft and click Ship Transfer — Core verifies stock and deducts inventory from the source immediately, moving it to In Transit
3. Receive: Open the In Transit transfer, click Receive Transfer, confirm the quantities, enter your name as Received By, and Complete Receiving — inventory is added to the destination

Certificate Registry

The Certificate Registry tracks which vendor batches already have certificates (CofC/CofA) on file, so you never request the same cert twice. Open it from Inventory > Certs.

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Search by vendor name or MFG batch/lot number. Each record shows the Cert ID, vendor, batch/lot, status (Active or Superseded), who uploaded it, and when. Certs are usually registered during Receiving (via the Register Cert button); the actual cert file is attached in Baserow on the matching record.

Cycle Count

Cycle counting keeps inventory accurate by counting a slice of items regularly, without shutting operations down. Open it from Inventory > Cycle Count.

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Items are scheduled by their ABC classification and inventory interval — Class A (critical) counted most often, Class C least often. Each row shows the item's facility badge and manufacturer part number alongside a color-coded due status: red (overdue), yellow (due soon, within 3 days), green (current).

Record a count

1. Go to Inventory > Cycle Count
2. Narrow the list with the filter bar — search text, ABC class, status, or "include current"
3. Click an item row to open the Record Count modal
4. Physically count the item and enter the Counted Quantity
5. Core shows the variance versus on-hand; if it exceeds the ABC threshold you'll see a warning
6. Add a note explaining any variance and click Submit Count

Submitting creates a COUNT transaction, updates on-hand, stamps the last-count date, and moves the item to "Current."

Variance thresholds: Class A < 2%, Class B < 5%, Class C < 10%.

Reports

The Reports hub collects the standard inventory reports plus the custom Report Builder. Open it from Inventory > Reports.

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From here you can reach:

• Order List / Low Stock — every item where on-hand ≤ reorder point, color-coded by urgency (red = out of stock, orange = below 50% of reorder point, yellow = at or below reorder point). Filter by facility, page through results, and Export to CSV. Quick actions let you jump to Receiving, bulk-create a PO, or view the item.
• Variance Report — discrepancies found during cycle counts (see below)
• Report Builder — build your own custom report (see below)

Variance Report

Open it from Inventory > Reports > Variance Report. Summary cards show Total Counts, Over, Short, Exact Match, Alerts, and Total Variance for the period. Filter by date range and minimum variance percentage, and Export CSV for analysis in Excel. High-variance rows are highlighted.

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Report Builder

Report Builder lets you build your own report from live Core data — pick a dataset, choose columns, filter, group, and export. Open it from Inventory > Reports > Report Builder.

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Build a report

1. Go to Inventory > Reports > Report Builder
2. Pick a dataset (your data source — see the list below)
3. Choose the columns you want and add filters to narrow the rows
4. Optionally group by a column and add an aggregation (sum, count, etc.) to summarize
5. Review the results table
6. Export as CSV, XLSX, or PDF — or save the report to reuse it

Datasets you can report on

Report Builder reads from a shared library of datasets across the whole system, not just inventory:

Charts

Report Builder charts your results automatically when you group by a single column and add a numeric aggregation. If you group by a date column you get a line chart; otherwise you get a bar chart. Without grouping, you simply get the results table. There is no separate "pick a chart type" step — grouping is what turns the table into a chart.

Save, share, and schedule

• Save a report to reuse its dataset, columns, filters, and grouping later
• Share a saved report so colleagues can open it
• Subscribe to have a saved report emailed on a schedule — daily, weekly, monthly, or quarterly — as PDF, XLSX, or CSV

Lab

The Lab module is where technicians record chemical test readings for each processing line, watch bath conditions in real time, and prove the process stays in control. It turns shift-by-shift measurements into out-of-spec alerts, SPC control charts, and audit-ready capability reports.

Like the rest of Core, Lab respects the facility selector in the top-right corner — set it to your plant so lines, stages, and specs match where you work.

Lab Dashboard

The dashboard is your overview of testing activity for the selected facility. Open it from Lab in the main menu (it is the default view).

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At a glance it shows entry counts (today, this week, this month), pending drafts, how many specs are configured, and out-of-spec counts for today and the week. A Quick Entry by Line section lets you start a new entry pre-set to a line, and a Recent Entries table lists the last 10 with status and out-of-spec (OOS) badges. An SPC Health Summary rates each parameter as Capable (Cpk ≥ 1.33), Marginal (1.0–1.33), or Not Capable (< 1.0).

Monitor

Lab Monitor is a full-screen, live gauge display built for shop-floor TVs. Open it from Lab > Monitor, or click Lab Monitor on the dashboard.

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Each parameter shows as a gauge with its current value, min/max limits, target marker, and last-updated time. The color tells you the status instantly:

Use the line selector at the top to switch processing lines, and the summary bar to see total OK / Warning / Out-of-Spec counts. Click any gauge to jump into its SPC chart.

Kiosk mode (for a wall display)

Monitor is designed to run unattended on a shop-floor screen:

1. Click the Fullscreen (expand) button
2. Data auto-refreshes every 60 seconds — the refresh toggle in the header turns this on or off
3. Press Escape to leave fullscreen

New Entry

The entry form is where technicians record readings for a shift. Open it from Lab > New Entry.

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Start and fill an entry

1. Go to Lab > New Entry
2. Select the Line (e.g. "Ecoat Zero")
3. Select the Shift (1st, 2nd, 3rd, or N/A)
4. The date defaults to today — change it if you're back-entering
5. The form loads organized by Stage (each chemical tank/process step is a collapsible section)

Expand a stage to see its parameters, then enter only the values you actually measured — sparse data is normal; a 10–15% fill rate per shift is typical.

• Numeric parameters: type the value. A green border means in spec; a red border means out of spec.
• Yes/No parameters (e.g. Tank Dumped, Filter Changed): tick the checkbox.
• Text parameters: free-form notes.

Some parameters show a Method note beneath the input describing how to run that titration — follow it exactly.

Out-of-spec detection

Core flags out-of-spec readings automatically: a red border on the input, an "X OOS" badge in the stage header, and an email alert to the lab team. Review any OOS reading before submitting to confirm it's real.

Save vs. Submit

• Save as Draft keeps your progress editable (status "Draft")
• Submit finalizes the entry (status "Submitted"), fires any OOS alerts, and locks it — after submission, contact IT for corrections

% Paint Solids calculator (Cleveland)

On stages set up for it (currently Cleveland Ecoat 5, Stage 11), the % Solids parameter appears as an interactive 3-tin calculator instead of a plain box:

1. For each of 3 tins, enter three weights in grams — Baked (dried residue), Empty Tin, and Liquid (wet sample)
2. Each row's % Solids computes live as (Baked − Empty) ÷ Liquid × 100
3. The bottom box shows the Average % Solids — this is the value saved
4. A red border on the average means it's outside the 13–17% range

Click Enter manually to switch to a plain box (type the final % directly), or Use calculator to switch back. In calculator mode all 9 raw weights and the average are saved as readings; in manual mode only the final % is saved. Other facilities show a plain box unless an admin has seeded the tin-weight specs.

Entries

The Entries list shows every lab entry with its status. Open it from Lab > Entries.

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Each row shows the entry ID (LAB-NNNN), line, facility, technician, date, a status badge, and an OOS indicator. Filter by line, status, date range, or "out of spec only." Results are paginated (100 per page).

• Draft entries have an Edit button — continue and submit them
• Submitted entries open read-only via View

SPC Charts

SPC (Statistical Process Control) charts show whether a single parameter is stable over time, with control limits and capability indices. Open it from Lab > SPC Analysis.

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Read a control chart

1. Choose Line, Stage, and Parameter
2. Pick a date range (7, 30, 60, or 90 days)

The chart plots your readings against:

Red dots mark out-of-spec readings. A statistics panel shows Cp (potential capability) and Cpk (actual, centered capability) — 1.33 or higher is capable; below 1.0 is not. Parameters without defined limits may show "N/A."

Control limits are usually calculated from your data (dashed lines) but a lab admin can set fixed limits for parameters with known process bounds (solid lines, labeled "Fixed").

Capability Reports

Capability Reports are the formal, printable, branded PDF for a whole processing line — the version you hand to management, customers, or an ISO auditor. Open it from Lab > Capability Reports. For live monitoring use Monitor or SPC instead; this is the signed-record view.

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Generate a report on demand

1. Go to Lab > Capability Reports (facility is locked to your current facility selector)
2. Pick a Processing Line (e.g. "Ecoat 5")
3. Pick a Period (the most recent 12 months are listed)
4. Click Preview to see cover-page metrics quickly (~1 second)
5. Click Download PDF to generate the full report (~30–60 seconds)

The PDF is built from current submitted readings; drafts are excluded. It includes a cover page with the capability headline and sign-off block, a line-level summary table, per-parameter detail pages (control chart, histogram, trend), and methodology and stats appendices.

Scheduled monthly delivery

If your email is in the Report Subscriptions table, the previous month's report is generated and emailed to you automatically at 07:00 UTC on the 1st of each month. Use the on-demand download for anything between scheduled runs.

Mechanical Checklist

The Mechanical Checklist is the daily visual/mechanical equipment inspection. Open it from Lab > Mechanical Checklist.

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Complete a checklist

1. Go to Lab > Mechanical Checklist
2. Click Start Checklist (or continue today's)
3. For each check point, set OK, NOT OK, or N/A - If NOT OK, add notes explaining the issue - If the check point takes a reading, enter the numeric value
4. Click Complete when every item is reviewed

Check points are grouped into sections (Pumps, Filters, Mixers, Tanks, Heaters). Any NOT OK item automatically alerts maintenance.

Configuration (Supervisor / Admin)

The pages in this section define how the Lab module behaves — the stages, the specifications, how tank additions draw down inventory, who gets scheduled reports, and the mechanical checklist templates. They are supervisor and lab-admin territory; most technicians never need to open them. Changes here affect everyone at the facility, so make them deliberately.

Stages

Configure the processing stages (chemical tanks/steps) for each line. Open it from Lab > Stages.

Create a stage with a stage number, name, facility, and line. Optionally enter tank dimensions so Core can calculate tank volume, and define a chemical bath mix (each chemical with a ratio and unit) so the bath-mix calculator can work out required quantities for a target volume.

Specs

Configure the test parameters and their limits. Open it from Lab > Specs.

For each specification set the parameter name, type (numeric, boolean, or text), and the stage it belongs to, plus Min / Max / Target limits. You can also add a Method (titration instructions shown to technicians during entry), UCL/LCL overrides (fixed SPC limits for parameters with known bounds), a test frequency (informational), and — for derived values — a Calculator such as the % Solids 3-tin average (which needs 9 named child specs on the same stage).

Additions → Inventory link

This page maps a lab "tank-add" parameter to the inventory item it consumes, so recording an addition automatically draws that material down from stock. Open it from Lab > Additions Mapping (Tank-Add → Inventory Mapping).

Each row pairs an Add parameter on a stage with the inventory item it deducts and a conversion factor (lab unit → inventory unit). When a lab entry is submitted, each Confirmed add deducts its mapped item (quantity × factor) from inventory. To set one up, click Edit on a row, search inventory by name or MFG part number, set the factor, and tick Confirmed so it deducts on submit. Rows can be marked Active/Inactive, and unmapped rows are flagged "— not mapped —."

Report Subscriptions

Manage who receives the scheduled monthly Capability Reports by email. Open it from Lab > Report Subscriptions.

Click + Add Subscription, then enter the recipient's email, facility, and the Line name exactly as it appears in Lab (e.g. Ecoat 5), and a report type (monthly is the only one currently wired). If several people subscribe to the same facility + line, Core generates one PDF and emails it to all of them. Prefer toggling a subscription inactive over deleting it when someone steps away temporarily — the row stays as an audit trail.

Mechanical Templates

Build and maintain the mechanical checklist templates. Open it from Lab > Mechanical > Admin.

Admins create a template per facility, add and edit check points grouped by section, set numeric reading limits (min/max/unit) per point, clone a template to another facility, and deactivate check points no longer needed.

Production

The Production module follows a job from the moment it lands on the floor to the moment it leaves on a truck. You create a lot, route it through your shop's process stages, clear the quality gates, print the paperwork that travels with it, and ship it on a Bill of Lading. Along the way the module keeps score — on-time delivery, bottlenecks, paint usage — so supervisors can see where work is piling up.

Everything lives under the Production tab in the top navigation. This chapter walks through each part roughly in the order a lot moves through it.

Production Dashboard

The dashboard is your live view of everything on the floor. It's the first thing you see when you open the Production tab.

What you'll see

• Active lots — everything currently in production at this facility
• Overdue lots — anything past its due date
• Shipped this month — a running count of completed work
• A Kanban board that lays out lots as cards grouped by their department stage

Find a lot

1. Use the search box to look up a lot by lot number, customer, PO, or part number.
2. Filter by status to narrow the board down.
3. Click any card to open the lot's detail page.

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Lots

A lot is one production job — a quantity of one part, for one customer, against one PO. The Lots page is the full searchable list behind the dashboard's board.

Create a new lot

1. Click New Lot.
2. Search for a product by part number or description and select it.
3. Fill in the job details: - Customer, PO #, Quantity, Due Date - Optional: Skids, Expedite level
4. For coil products, the # of Clamps field appears and is calculated for you from the product's coil dimensions. It applies to coils only — you won't see it on other parts.
5. Click Create.

The lot gets a unique lot number and starts in the first department stage.

Move a lot through the shop (transitions)

Drag a lot card between columns on the Kanban board, or open the lot and click Move to Next Stage, then confirm.

Quality gates can block a transition until the lot is clean:

If a gate stops you, the lot detail page tells you which one and what's outstanding.

Print the traveler

The traveler is the paper packet that rides with the lot through the shop.

1. Open the lot's detail page.
2. Click View Traveler to open the PDF on screen, or Print Traveler to email it straight to that facility's Epson printer.

The traveler carries:

• Page 1 — lot details, barcodes (Code 128 + QR), the risk gauge, and FAI photos. For coil products it also prints the coil square footage and the number of clamps so the floor sets up correctly.
• Page 2 — the step-by-step process routing for that product.

Each reprint bumps the revision number, and the button shows the current one (e.g. "View Traveler · rev 2") so everyone knows which copy is the latest.

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BOLs (Bill of Lading)

A BOL is the shipping document that closes out one or more lots. Building one confirms the shipment and moves those lots to "Shipped."

Create and confirm a BOL

1. Go to Production > BOLs and click Create BOL.
2. Add lot line items by searching for lot numbers.
3. Enter the carrier and tracking details.
4. Click Confirm shipment — this runs the quality gates against every lot on the BOL. If any lot fails a gate, fix it before confirming.
5. Capture the signature.
6. Download the BOL PDF for the driver.

Confirming a BOL automatically transitions all its lots to "Shipped" status, so you don't have to move them one by one.

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Master Label

Master Label prints the customer-specific shipping label (currently the Modine master label format) for a finished shipment.

1. Go to Production > Master Label.
2. If you launch it from a BOL (via a ?bol= link), it opens in Auto mode and fills the header for you. Otherwise it opens in Manual mode.
3. Confirm or enter the header fields: From / To block, Modine part number, description, lot number, ship date, ASN.
4. Add a row per pallet with its piece count.
5. Generate and print the label PDF.

Ship Verify

Ship Verify is the last check before a truck leaves — a photographed, signed confirmation that what's on the BOL is what's on the dock.

1. Go to Production > Ship Verify.
2. Find the BOL awaiting verification (status Pending verification).
3. Review the customer, invoice, and line items.
4. Take photos of the loaded shipment (up to 10).
5. Have the production supervisor sign.
6. Submit — the status flips to Verified, stamped with who verified it and when.

A verification can later be Voided if something was wrong, which is recorded too.

Reports

Reports turn the floor's activity into trends so you can see where time is being lost.

Go to Production > Reports for:

• On-Time Delivery (OTD) — the percentage of lots shipped on or before their due date, month by month.
• Active Lot Aging — how long current lots have been open.
• Department Bottleneck Analysis — the average days lots spend in each department, so you can spot the slow stage.
• Rework Events — Strip, Recoat, and other rework, grouped by cause.

Everything is scoped to the facility selected in the top bar. Empty charts ("No data available") just mean nothing matched for that facility and period.

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Batching

Batching groups your unshipped lots by paint colour and process so the floor can rack jobs by paint changeover instead of purely by due date.

1. Go to Production > Batching.
2. Lots are grouped by (process, colour). Each group shows its lot count, total quantity, and the earliest due date.
3. The colour chip on each group matches the identity stripe on the traveler, so a rack of the same colour is easy to spot.

This page is read-only — it's a planning aid, not a place to move lots. Batch the racks it suggests, then move the lots through their stages as usual.

Paint Log

The Paint Log is the office window into what the paint kiosk recorded on the floor. Painters log their mix sessions at the shop-floor kiosk; this page lets office staff review them.

1. Go to Production > Paint Log.
2. Browse the list of paint-mix sessions.
3. Click a session to open its detail, including material genealogy (which containers went in) and lot chain-of-custody (which lots the paint went to).

This is a read surface — you review here; the mixing itself happens at the kiosk.

Paint Dashboard

The Paint Dashboard reports paint usage and waste per facility, month by month.

1. Go to Production > Paint Dashboard.
2. Pick a month; the facility comes from the top-bar selector.
3. Review the KPI row, the paint-by-product breakdown, the daily paint vs waste trend, and operator activity.

It combines the new Core paint log with the older legacy paint log. A source-split badge shows how much of the data is new vs legacy, and there's an always-on link to the read-only Legacy Paint Log archive for older entries.

Processes

Processes are the routing recipes — the ordered steps a given product follows through the shop, which print on page 2 of the traveler.

1. Go to Production > Processes (Process Management).
2. Filter by department or type.
3. Click a process to see its steps — each with a step number, detail, the responsible department, whether testing is required, and any linked documentation.
4. A process can be marked Use as FAI Process Template so new First Article Inspections start from a known-good routing.

QC Queue TV

The QC Queue TV is a wall-mounted dashboard for the quality team — a dark, distance-readable screen showing every lot waiting for QC inspection, oldest first, with time-in-stage and SLA colouring.

• It runs full-screen with no login on a shop TV, opened at core.ecoat.us/production/qc-queue-tv with the display key in the address.
• It refreshes every 30 seconds and shows a DISCONNECTED indicator if it loses the server.
• When there's nothing waiting, it reads QC queue clear.

Motor Line

The Motor Line module runs the Danfoss hydraulic-motor coating work at Seminole. It tracks a motor from the dock to the truck: you print pack labels, receive boxes of motors, pack and QC them at the shop-floor kiosk, then load them onto a truck and record the shipment. Planners flag rush jobs as Hot Orders, dashboards and floor TVs keep everyone pointed at the right work, and a customer portal lets Danfoss look up anything we've shipped.

Everything lives under the Motor Line tab in the top navigation. This chapter follows a box of motors through the line, then covers the screens managers and admins use.

Motor Line Dashboard

The dashboard is the internal scoreboard for the line — the production team and management view. It replaces the old public Metabase dashboard.

Go to Motor Line > Dashboard for live tiles including:

• Motors In House and Orders In House — received but not yet packed out
• Oldest In-House and Avg Days In-House — how long work is sitting
• Completed Today — motors packed out today
• QC Overrides Today — supervisor overrides logged at the kiosk

It refreshes every 30 seconds. Numbers are click-through where it helps — a tile drills into the underlying orders or inspections.

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Hot Orders

Hot Orders are the rush jobs — orders a planner has flagged as expedited (and usually upcharged). Flagging an order makes it shout across the whole line.

Flag an order as hot

1. Go to Motor Line > Hot Orders.
2. Click Add Hot Order.
3. Enter the PO number, Part #, and set a Priority (Standard or Critical).
4. Save.

A hot order then:

• shows on the Floor TV and the e-ink Hot List devices at the tables,
• fires a takeover alert at the packing kiosk when that order is scanned, and
• auto-completes (drops off the board) once the order finishes packing.

Completed and cancelled hot orders stay retrievable as the upcharge record — sort by Completed to find them.

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Reports / Investigate

Reports is where you search scans and pull motor-line trends. The old standalone Investigate page was folded in here as the Motors tab, so scan-search links still land in the right place.

1. Go to Motor Line > Reports.
2. Use the Motors tab to look up scans by PO, part number, serial, or date.
3. Use the reporting tabs for throughput and QC trends.

Print Pack Labels

Pack labels are the QR labels on each box — one QR per box, carrying the Pack UUID, PO, Line, Box, and Qty so Receiving and Packing can scan instead of type. They print on Avery 5160 sheets (30 labels a sheet).

The fastest path — upload the Danfoss PO PDF

1. Go to Motor Line > Print Pack Labels.
2. Click Upload Danfoss PO and pick the PDF Danfoss emailed (e.g. 4413179217.pdf).
3. Review the parsed lines in the preview, then click Apply to matrix. The PO number and one row per line item (with the right quantity) fill in for you.
4. Set Boxes per line — the PO doesn't say how to split a line into boxes. It defaults to one box of the full quantity; use Duplicate to split a row, or Quick Set to apply the same boxes/qty across many rows.
5. Click Generate PDF and print on Avery 5160 at 100% scale (no fit-to-page).

Enter it manually instead

Add one row per PO line with PO, Line #, Boxes, and Qty per box. Use Duplicate to copy a row and Quick Set to fill across rows.

If the upload fails: "Could not find a Purchase order number" means it isn't a Danfoss PO or it's a scanned image (only text PDFs read); re-export from the email as PDF if you get "Expected a PDF."

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Receiving

Receiving logs each box of motors as it hits the dock. Scanning the pack QR fills in the box's identity so you only add what the QR can't carry.

1. Open Motor Line > Receiving on an iPad or a PC with a scanner.
2. Tap Scan Pack QR — a green chip confirms PO, Line, and Qty are pre-filled.
3. Scan or type the Work Order (focus jumps here automatically).
4. Scan or type the Part Number.
5. Confirm the Paint Spec — it's a dropdown of every spec on record, and it auto-fills from the part number's history when there's a strong match. An amber note ("verify before submitting") warns when that part sometimes uses a different spec.
6. Tap Submit — the box is added to Inbound and ready for packing.

After a successful submit, click Receive next box on same PO to keep PO, vendor, and paint spec on the form for the next box on the same pallet.

If you see "This pack label has already been received as Inbound #N," the QR was scanned before. Don't re-scan; check Inbound #N with QA.

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The Packing Kiosk

The Packing Kiosk is a separate full-screen page that runs on the tables in the pack area (portrait TVs with barcode scanners). It has no login and no navigation chrome — it's built for one job: scanning every motor against its box and recording QC. Operators reach it at core.ecoat.us/motor-line/packing.

Operator flow

1. Pick your table. Confirm the Table 1–5 badge in the top-right. If the picker shows instead, tap your table number (or press 1–5 on the keyboard). Tap Change Table in the header if you moved kiosks.
2. Scan the pack label. Tap Scan Pack Label and point the scanner at the box's QR. The kiosk loads that box's PO, line, part number, and quantity.
3. Pack the motors. The kiosk picks the mode from the inspection record and shows it at the top: - Bulk — scan the box label once; the packed count jumps by the box quantity. Used when a box holds several motors of the same part. - Individual — scan each motor label, then the box. Used when traceability matters (active CAPA parts, customer requirement, first article).
4. Watch and listen for the result. A short high beep + green flash means the scan was accepted; a low double-beep + red flash means it was rejected (wrong part, wrong table, or a duplicate).
5. Record QC readings when prompted — Film Build (mils), Pencil Hardness, and Meets Customer Requirements — for the inspection record.
6. Finish the session. When the packed count reaches the quantity, a Final QC strip appears at the bottom. Walk the checklist (visual, packing slip, pallet count), tap each green check, then tap Complete Session to save the inspection.

To stop early, tap Cancel and confirm — the session is marked Abandoned, no finished-goods record is written, but the scans are kept for traceability.

Part-number mismatch and supervisor override

If a scanned motor's part number doesn't match the box, the kiosk hard-blocks and opens the Supervisor Override panel:

1. A QC supervisor enters their 5-digit PIN.
2. Press Enter to approve, or Esc / tap outside to cancel.
3. The override is logged (supervisor, time, motor, box).
4. Three wrong PINs in a row locks the kiosk for 60 seconds.

Load Truck

Load Truck is the dock app for loading a finished shipment. A dock worker scans each packed box's pack-ticket QR as it goes on the truck, then the driver signs.

1. Open Motor Line > Load Truck on an enrolled dock tablet (or signed in as a supervisor).
2. Open the shipment you're loading.
3. Scan each box's pack ticket as it's loaded. Progress is saved server-side per scan, so a mid-load refresh loses nothing.
4. When the truck is loaded, have the driver sign to record the shipment.

Shipments

Shipments is the management record of every truck that left.

1. Go to Motor Line > Shipments.
2. Browse the list of truck loads; click one to drill into its contents, the driver, and the signature.
3. A supervisor can Void a shipment if it was recorded in error.

It's read-only otherwise — full traceability for operations.

In-House Orders

In-House Orders are motors that have been received but not yet packed out. It's the working list behind the "Motors In House" dashboard number.

1. Go to Motor Line > In-House Orders.
2. Search and filter by part, paint spec, or how many days a box has been sitting.
3. Motor-line supervisors (and admins) can edit an order's identity fields — those changes sync back to the receiving record so the kiosk and dashboards stay consistent — or Remove an order from the in-house list.

Everyone with Motor Line access can view and search; only supervisors/admins can change anything, and every change is audited.

Floor TV

The Floor TV is the wall display in the production area — a dark, distance-readable board that shows the day's work and hot orders. A Linux box auto-opens it full-screen at core.ecoat.us/motor-line/floor with the display key in the address; there's no login. It refreshes every 30 seconds and shows a disconnected indicator if it loses the server. There's also a public dashboard variant (/motor-line/public-dashboard) for a lobby or open-floor kiosk.

e-ink Device Labels (Hot List)

The e-ink devices are small battery screens at the tables (Xteink X4) that show the current Hot List — the hot orders the floor needs to jump on. They update over the air from the same hot-order data, so what a planner flags in Hot Orders shows up on the tables without anyone printing anything.

Admins check the fleet's health at Motor Line > e-ink Devices: station, battery level, last check-in, and firmware. The page is read-only — provisioning and token minting are done through the device-setup flow, not here.

Admin corner

These pages are admin-only and live under Motor Line > Admin (the Admin tile page links to them). Most people never need them — they're for fixing data, managing supervisors, and auditing what happened.

Maintenance

The Maintenance module keeps your equipment running. It's where you track every machine, log and assign repair jobs, schedule the routine servicing that prevents breakdowns, and let shop-floor workers report problems the moment they spot them.

Everything lives under the Maintenance tab in the top navigation. This chapter walks through each part in the order you'll usually use it.

Maintenance Dashboard

The dashboard is your at-a-glance health check for equipment across your facility. It's the first thing you see when you open the Maintenance tab.

What you'll see

Four headline numbers sit at the top:

Below the KPIs, an Equipment Condition breakdown shows progress bars by condition — Good (green), Fair (yellow), Poor (orange), and Critical (red). Click the Poor or Critical count to jump straight to the equipment that needs attention.

The Work Order Analytics section groups your jobs by type, status, and priority, and charts how many were created each day.

Two reliability numbers help you tune your maintenance schedule:

• MTTR (Mean Time To Repair) — average hours to close a work order. Lower is better.
• MTBF (Mean Time Between Failures) — average days a machine runs between breakdowns. Higher is better.

How to change the reporting period

1. Use the period selector to choose Last 7 days, 30 days, 60 days, or 90 days.
2. The analytics and trend charts refresh to match.

Use 7 or 30 days for day-to-day operations and 60 or 90 days when you're looking for longer trends.

Equipment

Equipment is your master registry of every machine, tool, and asset you maintain. This is where each item gets a permanent record, a criticality rating, and a running service history.

Find a piece of equipment

1. Go to Maintenance > Equipment.
2. Filter by category, criticality (A/B/C), condition, or active status.
3. Or search by name, Asset ID, or serial number.

Add a new piece of equipment

1. Click + Add Equipment.
2. Fill in the required fields: - Name — a clear, descriptive name - Asset ID — the unique tag (see format below) - Facility — where it lives - Category — the equipment type - Criticality — its ABC rating
3. Add any optional details you have: manufacturer, model, serial number, install date.
4. Click Create Equipment.

ABC criticality — how important is this machine?

Asset ID format

Asset IDs follow EQ-{FACILITY}-{NUMBER}:

Condition ratings

Print QR labels for the shop floor

Every piece of equipment can carry a QR label that jumps straight to the reporting kiosk when scanned.

1. Open the equipment's detail page (click it in the list).
2. Click the purple Print Labels button.
3. A PDF downloads with the QR code label.

The label carries the QR code, Asset ID, name, location, category, and a "SCAN FOR SERVICE" prompt.

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Work Orders

Work orders are the individual repair and service jobs. Each one moves through a simple lifecycle from the moment it's raised to the moment it's finished.

OPEN → ASSIGNED → IN PROGRESS → COMPLETED
              ↓
         (or CANCELLED)

Create a work order

1. Click + New Work Order.
2. Fill in the required fields: - Title — a brief description of the job - Equipment — pick it from the dropdown - Type — Breakdown, Preventive, Safety, or Other - Priority — Emergency, High, Medium, or Low
3. Add a description, an assignee, or a scheduled date if you have them.
4. Click Create Work Order.

Set the right priority

Complete a work order

1. Open the work order's detail page.
2. Click Complete Work Order.
3. Fill in the required fields: - Actual Hours — time spent - Work Performed — what you did
4. Optionally add parts used and any follow-up notes.
5. Click Complete.

Finishing a work order automatically writes a service record and updates the equipment's history for you.

Kanban view

Click the Kanban (board) toggle for a visual workflow. Jobs appear as cards in columns — Open, Assigned, In Progress, Completed — colour-coded by priority. Drag a card between columns to change its status.

Work order numbers

Numbers follow WO-YYYY-NNNN, for example WO-2026-0001 (the first of 2026) or WO-2026-0150.

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PM Tasks

PM (preventive maintenance) tasks are the recurring servicing schedules that keep machines healthy before they break. Set a task up once, and the system generates the work orders for you on schedule.

Choose a frequency

Create a PM task

1. Click + New PM Task.
2. Fill in the required fields: - Name — what the task covers - Equipment — pick the machine - Frequency — how often it runs - Priority — the priority of the work orders it will create
3. Add instructions, safety notes, and an estimated time if useful.
4. Click Create Task.

Turn tasks into work orders

• One task: open its detail page and click Generate Work Order.
• In bulk: click Generate PM Work Orders, choose how many days ahead to look (7, 14, or 30), and click Generate. The system creates work orders for every task due in that window.

PM Calendar

The calendar shows what's due and when, laid out month by month.

1. Go to Maintenance > Calendar.
2. Navigate between months with the arrows.
3. Each day shows the PM tasks due and any scheduled work orders, colour-coded by priority.
4. Click a day to see its details.

Task colours tell you the schedule at a glance:

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QR Kiosk — reporting issues from the floor

The Maintenance Kiosk is a big-button, touch-friendly screen for shop-floor workers to report an equipment problem in seconds — no login gymnastics, no digging through menus.

Open the kiosk

• From the dashboard: click the Kiosk Mode button (top right).
• By QR code: scan the label on a machine — the kiosk opens with that equipment already selected.
• Direct link: core.ecoat.us/maintenance/kiosk.

Find the equipment

Scan its QR code: 1. Tap Scan Equipment. 2. Allow camera access. 3. Point at the machine's QR code — its details appear.

Or enter the Asset ID: 1. Tap Enter Asset ID. 2. Type the ID (e.g., EQ-SEM-0001). 3. Tap Search.

Report the issue (3-step wizard)

1. Issue type — Breakdown (stopped working), Preventive (service needed), Safety (a hazard), or Other.
2. Priority — Emergency (red, production stopped), High (orange, needs attention today), Medium (yellow, within 24 hours), or Low (green, can wait).
3. Details (optional) — a short description of the problem and your name.

When you submit, a green checkmark confirms it and shows the new work order number (e.g., WO-2026-0001). The kiosk returns home automatically after 10 seconds, or tap Done to go back right away.

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Safety

The Safety module runs your monthly PPE (personal protective equipment) audits. Each month you walk the floor, record whether people are wearing the gear their area requires, and the system tallies up whether the facility passes. It also keeps a running history so you can see how compliance trends over time.

Everything lives under the Safety tab. This chapter covers the dashboard, recording observations, the area and history views, and the configuration screen.

PPE Audit Dashboard

The dashboard is the home base for the current month's audit at your facility. It shows where you stand and gives you one-tap access to start recording.

What you'll see

• Facility compliance cards with the overall compliance percentage
• Area progress bars showing how many observations you've recorded versus the minimum required
• Pass/Fail indicators for each area and for the facility as a whole
• Quick actions to start recording observations or complete the audit period

Run a monthly audit

1. Select your facility from the header dropdown.
2. Click Open Audit Period to start the current month.
3. The dashboard lists every configured area with its minimum sample requirement.
4. Record observations throughout the month until every area meets its minimum.
5. When you're done, click Complete Audit to finalize the month.

What counts as passing

A facility passes the monthly PPE audit only when all three of these are true:

• Overall compliance is 95% or higher
• Every area is at 95% or higher
• Every area has met its minimum sample size

The minimum sample size scales with how many people work in an area:

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Record Observations

This is the mobile-first form you use on the floor to log each person's PPE compliance. It's built for phones and tablets and stays put on your selected area so you can log people one after another.

Record a single observation

1. Select your facility and area.
2. The required PPE items fill in automatically from that area's configuration.
3. Tap Compliant or Non-Compliant for the person you're observing.
4. If non-compliant, tap the PPE items they're missing.
5. Optionally add the person's name and any corrective action taken.
6. Tap Save and move to the next person.

Batch mode — logging several people quickly

The form keeps your facility and area selected after each save, so you don't re-pick them every time:

1. Choose the facility and area once.
2. Record the first person.
3. After you save, the form resets for the next person.
4. Keep going until you've hit the area's minimum sample size.

Filling in non-compliance details

When you mark someone Non-Compliant:

• Missing Items — tick each PPE item not being worn (e.g., Safety Glasses, Steel Toes)
• Corrective Action — toggle on if you fixed it on the spot
• Coaching Completed — toggle on if you coached the person on the requirement
• Person Name — optional, but it helps you spot repeat offenders
• Comments — any extra notes

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Area Summary

The Area Summary breaks a month down area by area so you can see exactly which spots are dragging compliance down.

For a chosen facility and month it shows, per area:

• Headcount and the minimum required observations
• Observed count and progress toward that minimum
• Compliance percentage, colour-coded — green at 95%+, yellow 90–94%, red below 90%
• Pass/Fail status

Click any area row to expand it and see the individual observations behind the numbers.

History

The History page shows compliance trends month over month so you can spot patterns instead of just reacting to the current month.

• A monthly results table lists total observations, compliance percentage, and pass/fail for each month.
• A bar chart visualizes the trend.
• Click any month to drill into that period's Area Summary.

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Configuration

The Config screen defines what each area requires — its headcount, its required PPE, and its supervisor. Getting these right is what makes every audit accurate.

Each area has these settings:

• Headcount — number of employees in the area (this sets the minimum sample size)
• Default Requirements — the PPE items required, comma-separated (e.g., "Safety Glasses, Steel Toes, Gloves")
• Area Supervisor — the supervisor's name, filled in automatically on observations
• Active — toggle to include or exclude the area from audits

ZNET

ZNET is the production-intelligence side of ECOAT Core — it turns your coating-line data into dashboards you can actually use. Every time a bar of parts runs through the line, the line records how much square footage it coated, how many amp-hours it drew, how efficient it was, how the anodes behaved, and more. ZNET collects all of that and shows you production totals, run histories, line diagnostics, statistical process-control charts, anode health, and printable reports.

If you've used the standalone "ZStats" app before, ZNET is that same intelligence, now built into Core.

You'll find it under the ZNET tab (its icon is the ⚡ lightning bolt).

What ZNET is watching

ZNET is built around the electrocoat line. The data it shows comes straight off each run:

• Runs — every bar of parts that goes through the line, with its customer, part number, operator, square footage, amp-hours, and cycle time.
• Efficiency — how much coating you get per amp-hour (sqft/Ah) and per paint-hour (throughput).
• Anodes — the health of the anodes in the tank, scored over time so you can replace them before they fail.
• SPC (Statistical Process Control) — control charts that flag when the process drifts out of its normal range.
• Reports — printable PDF/CSV summaries you can file or email.

Fleet Overview (Global)

If you have fleet access, ZNET opens on the Global ZNET Operations view — a single screen comparing every plant. The heading reads Global ZNET Operations, with month arrows to step back and forward.

You'll see:

• Fleet Totals — combined production across all plants for the month.
• Efficiency Comparison — a table ranking plants by Amp-Hr Eff (sqft/AH), Throughput (sqft/paint-hr), Paint Hrs, Amp Hrs, and Runs, plus a Data Quality indicator (a "Data OK" flag warns when a plant is missing cycle-time data).
• Anode Health — a fleet-wide roll-up of healthy / warning / critical anodes.
• Per-plant cards — each plant shows its Today and MTD (month-to-date) numbers and a live status line. When a line is mid-run, the card shows Running, the elapsed time, the active anode count, and the current amperage; otherwise it shows idle or offline.

Click any plant to drill into its per-facility view.

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A single plant's view

Single-facility users land straight on their own plant. However you get here, a plant's data is organized into six tabs across the top:

Dashboard

The plant Dashboard shows the current month's Monthly Production totals with month arrows to move between periods. Headline figures include Today, This Week, Runs, Avg / Run, Avg Cycle Time, Amp-Hours, Amp-Hr Eff, Throughput Eff, and Rework Rate, along with a daily production trend.

Run Log

The Run Log lists every run for the month in a sortable table. Columns are Run #, Date, Customer, Part #, SqFt, Amp-Hrs, and Operator. Use Search runs… to find a specific run, customer, or part, and click a column header to sort. Runs pulled automatically from the line are tagged "Auto-logged run from ZNET Web."

Diagnostics

Diagnostics digs into why the numbers look the way they do. It shows a Coating Efficiency trend and an Operator Performance table with each operator's Total SqFt, Runs, Avg SqFt/Run, Avg Cycle, and Rework %.

SPC (Statistical Process Control)

The SPC Control Charts tab tells you whether the process is behaving. Pick a metric — Efficiency or Current Imbalance — a time window (7, 30, or 90 days), and a chart type (EWMA or CUSUM). The chart plots each run against calculated control limits and flags any points that break the control rules, so a drift shows up before it becomes scrap. A Cpk capability badge summarizes how well the process is holding to spec.

Anodes

The Anodes tab shows the health of every anode in the tank. Each anode gets a health score and a status — Healthy, Warning, Critical, or Inactive (never fired). A Range selector lets you score anodes over a specific date range. Click any anode to open its detail page, which shows its cumulative amp-hours, percent of life remaining, an estimated replacement date, and its recent cycle history.

Reports

The Reports tab generates printable production reports you can save or email. Choose a Report Type:

• Monthly Summary — a full monthly production report with the KPI summary, daily breakdown, operator performance, and run statistics. Available as PDF or CSV.
• Anode Heat-Map — a date-range snapshot of anode health as a colour-coded grid, with per-anode scores and amp-hours and a worst-first ranking table. PDF only.

Pick the month (or date range for the heat-map), choose the format, and click Generate Production Report. The file downloads to your device.

The Home-page ZNET card

Your Home dashboard carries a ZNET card (⚡) so you get the headline without opening the module. What it shows follows your scope:

• Single-facility users see their plant name, its MTD sqft and Today totals, MTD runs, and an Anode alerts line counting critical and warning anodes.
• Fleet users see "Fleet production intelligence" with the fleet totals plus a one-line-per-plant breakdown, each showing MTD sqft and any anode alerts.

Click the card to jump straight into ZNET — to your plant if you're single-facility, or to the Global view if you have fleet access. If the data is briefly unavailable, the card says so rather than showing stale numbers.

IT

The IT module is your help desk. When something's broken — a login won't work, a printer's offline, an app is misbehaving — this is where you file a ticket and track it to resolution. It also holds a searchable FAQ of answers to common questions, and (for IT staff) a Devices registry of the company's enrolled machines.

You'll find it under the IT tab. Opening it drops you on the Help Desk by default. Everything here is available to any signed-in user; a few staff and admin screens are noted along the way.

Getting help fastest

Before you file a ticket, it's worth a 10-second look at the FAQ — if the answer's already there, you're unblocked immediately. If it isn't, filing a ticket takes under a minute. Here's the quick path:

1. Open the IT tab.
2. Check the FAQ for your issue.
3. If it's not answered, click Submit an IT request and describe the problem — the more detail, the faster it gets solved.

Help Desk — the ticket queue

The Help Desk (/it/helpdesk) lists IT tickets so you can see what's open and what's been done.

• Search by subject or requester with the search box ("Search subject, requester…").
• Filter by status (Open, In Progress, Waiting on User, Resolved, Closed — plus All statuses) and by priority (All priorities, or Low/Medium/High/Urgent).
• Each row shows the Ticket, Subject, Status, Priority, and whether it's Assigned or Unassigned.

Click any ticket to open its detail page.

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Create a ticket

Click "Submit an IT request" (/it/helpdesk/new) to file a new ticket. The form is short:

1. Subject — a short summary of the problem.
2. Category — pick the area it falls under from the dropdown.
3. Priority — Low, Medium, High, or Urgent (defaults to Medium).
4. Description — the details. The prompt asks: "What happened? Any error messages, and which device/app?"
5. Submit.

Below the form, Your recent tickets shows what you've filed lately (or "You haven't filed any tickets yet." if you're new), so you can jump back into an existing conversation instead of opening a duplicate.

Track a ticket

Open any ticket to see its full detail and conversation. The page shows the subject, current Status, Priority, and who it's Assigned to.

• The Conversation section is the running thread. Add a reply in the "Add a reply…" box to ask a question or give more information.
• You'll see updates as IT works the ticket, right through to Resolved and Closed.

FAQ

The IT FAQ (/it/faq) collects answers to common IT questions so you can self-serve.

1. Browse the list, or use Search the FAQ… to find a topic.
2. Filter by category if you like.
3. Click an article to read it.

At the bottom of each article, tell IT whether it helped with the Helpful / Not helpful buttons. That feedback helps them improve the answers over time.

Devices

The Devices registry (/it/devices) is IT's inventory of enrolled company machines — laptops, workstations, and kiosks across the fleet.

• The list shows each machine's Hostname, Owner, Location, Status, and Last seen, with filters for location and status.
• Click a device to open its detail page, which shows its operating system, kernel, uptime, memory, disk, pending updates, Tailscale IP, agent/service heartbeat, and a full Audit trail of actions taken on it.

Enrolling a new device

Enrollment (/it/devices/enroll) is admin-only. It works by generating a one-time command you run on the machine being added:

1. Open Devices and choose Enroll a Device.
2. Fill in the Owner name, Owner email, and Location.
3. Click Generate enrollment command.
4. Copy the generated command and run it on the target machine — it registers the device and it then appears in the Devices list.

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Admin & Feedback

This chapter has two halves. The first is for everyone — what happens to the feedback you send about CORE. The second is the admin corner: a set of behind-the-scenes settings screens that only administrators can open. If you're not an admin, the admin section won't appear for you, and that's fine — you can skip to whatever you need.

What happens to the feedback you send (for everyone)

CORE has a built-in "Send feedback" button so you can tell the team what's working, what's broken, and what you'd like to see. You'll find it available throughout the app.

Send feedback

1. Click Send feedback.
2. Pick a category — Question, Issue, Idea, Praise, or Other.
3. Type your message. If it's a problem, say what you were trying to do (the prompt reads: "What's on your mind? If it's an issue, what were you trying to do?").
4. Send it. CORE automatically notes which page you were on, so you don't have to explain where you were.

What happens next

Your feedback goes into a triage queue that admins work through. When an admin replies or changes the status of your submission, you're notified — the reply lands in your email and in the app.

To see the whole conversation, open My Feedback (/feedback/mine). It lists everything you've submitted along with any replies, and you can keep the thread going with the "Add to the conversation…" box. The notification bell links you straight here.

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The admin corner (for admins)

The following screens live under the Admin menu and require administrator access (an @ecoat.us admin account). They control the option lists, mappings, and integrations that the rest of CORE depends on. Changes here ripple across every user, so go carefully.

Feedback triage

Route: /admin/feedback · Admin only

This is the other end of the feedback flow above. The User Feedback page lets you "Triage feedback, reply to users, and update status. Users are notified of replies and status changes."

• Filter the queue by status and category. A count of new items helps you see the backlog at a glance.
• Each item carries a status: New, Reviewed, or Resolved. Change it as you work the item.
• Reply to the submitter in the "Write a reply to the user…" box. Your reply is added to the thread and emailed to the person who submitted it — this is the threaded, two-way conversation they see in My Feedback.

Announcements

Route: /admin/announcements · Admin only

Create the IT announcements that appear on everyone's dashboard — the banners for outages, maintenance windows, and company notices. You set a title, message, type (Info, Warning, Critical, Maintenance), priority, optional start/expiry dates, and which facilities see it. This module is covered in full in its own help topic; the short version is that higher-priority announcements show first, and setting an expiry date keeps the dashboard tidy.

CAR Departments

Route: /admin/car-departments · Admin only

Maintains the list of departments that a Corrective Action Request (CAR) can be assigned to. Add, rename, or remove departments here. A department that has active CARs against it can't be deleted.

NCR Reasons

Route: /admin/ncr-reasons · Admin only

Maintains the reason codes for Non-Conformance Reports (NCRs). Add or edit reason codes and toggle them active or inactive — an inactive reason simply drops out of the dropdown when someone creates an NCR, without affecting past records.

Vendor Mapping

Route: /admin/vendor-mapping · Admin only

Links a vendor name in CORE inventory to its matching Xero contact, per facility. This mapping is what lets a purchase order sync to Xero automatically: when a PO is submitted, CORE looks up the vendor here, and if a mapping exists it creates a draft PO in the right facility's Xero organization. No mapping means the PO still saves locally but won't reach Xero. This module has its own detailed help topic.

GL Codes

Route: /admin/gl-codes · Admin only

Manages the general-ledger (GL) codes that CORE offers when you assign an item to an accounting bucket. The page shows an overview of your codes broken down by cost category, plus the full catalog. Each code carries a GL Number (e.g., 121110), a Description (e.g., "Ecoat Inventory"), an Account Group, an Account Type, and optional Notes.

• Search by GL number, description, or group.
• Add or edit a code and set its group, type, and description.
• Only assigned codes appear in the Items dropdown; the page also flags codes that still need assignment ("Other/Do Not Know plus empty rows").

Xero Sync

Route: /admin/xero-sync · Admin only

Sync to Xero by E-PN is a manual tool for pushing specific inventory items to Xero on demand. As the page explains: "Push specific items to Xero by ECOAT part number. Each E-PN is pushed at every facility it exists at, to that facility's Xero organization. Safe to re-run — it updates the existing Xero item if one already exists."

1. Paste one or more ECOAT part numbers (E-PNs) into the box — commas, spaces, or new lines all work (e.g., E000035, E000036, E000362).
2. Optionally leave Refresh last-purchase price before pushing checked (recommended).
3. Click Push to Xero.
4. A results table shows each part's Status — a green ✓ Synced, or the Xero item / error if something went wrong.