Quad Platform Documentation
Comprehensive guide to every module, page, and feature available in your Quad Platform dashboard. This documentation covers the complete platform hierarchy from plant-level overviews to individual machine reports.
Contents
Platform Overview
The Quad Platform is an end-to-end manufacturing operations platform designed to bring real-time visibility, accountability, and analytics to your factory floor. It covers every aspect of manufacturing operations — from production tracking and downtime management to quality control, maintenance scheduling, and energy monitoring.
Core Capabilities
- Realtime Monitoring — Live machine status, control room bird's-eye view
- Production Tracking — Hourly and periodic reports, machine/station/operation wise
- Downtime Analysis — Categorised downtime logging with shift & machine accountability
- Quality Management — Rejection tracking, PDI reports, process capability analysis
- Maintenance — Preventive maintenance, die/tool health, checksheets
- Performance (OEE) — Machine utilisation, operator efficiency, plant performance
- Human Resource — Operator, helper, supervisor, inspector management & incentives
- Energy Monitoring — Power consumption tracking and historical analysis
Getting Started
Logging In
Navigate to the platform URL and enter your registered email or username along with your password. You can check the "Remember Me" option to keep your credentials saved for future sessions.
| Field | Description |
|---|---|
| Username / Email | Your registered email address or unique username provided by your system administrator |
| Password | Your account password. Contact your system administrator if you need a reset |
| Remember Me | When checked, your email will be auto-filled on your next visit |
Navigation
After logging in, you will see the main dashboard. The left sidebar contains the full navigation menu grouped by module. The top navbar includes your profile, notification bell, language selector, and theme toggler (light/dark mode). The sidebar can be collapsed or expanded by clicking the menu icon.
User Roles
| Role | Access Level |
|---|---|
| Super Admin | Full access across all plants, user management, organisation setup, and system configuration |
| Admin | Plant-level administrative access including master data management and reporting |
| Data Admin | Data entry and reporting access, can manage operational data and generate reports |
| End User | View-only access to dashboards and reports relevant to their assigned scope |
Language & Theme
The platform supports English, Hindi, and Punjabi. Use the language selector in the top navigation bar. You can also switch between light mode and dark mode using the theme toggle.
Organisation Hierarchy
All data in the platform is organised in the following hierarchy. Understanding this structure is essential for navigating reports and filters across the platform.
| Level | Description | Example |
|---|---|---|
| Organisation | The top-level entity representing your company. Contains company info, GSTIN, PAN, and system administrator details | ABC Manufacturing Pvt Ltd |
| Plant | A physical manufacturing facility at a specific location. Each plant has its own shift timings, holiday calendars, and configurations | Faridabad Plant, Noida Plant |
| Division | A functional section within a plant, typically representing a production department or product type | Press Shop, Machining, Assembly |
| Line | A production line within a division, grouping machines that work in sequence or parallel for a manufacturing process | Line 1, Line 2, Line A |
| Machine | Individual equipment on the shop floor. Each machine has a unique profile with type, specifications, and assigned parts/operations | Press #101, CNC Machine #205 |
Organisation Master
The Organisation Master module is your central hub for managing all master data — machines, parts, operations, tools, dies, and plant configuration.
Machine Master
View and manage all machines across your plants. Filter by plant, division, line, machine type, or use the search bar to find specific machines. Clicking on a machine opens its detailed profile with specifications, assigned parts, operation history, and maintenance records.
Page: organisation-machines.php • Profile: organisation-machine-profile.php
Parts & Operations
| Page | Purpose |
|---|---|
| Part Master | Register and manage manufactured parts. View part specifications including standard cycle times and dimensions |
| Operation Master | Define operations (manufacturing steps) for each part. Set standard cycle times, SPM targets, and process parameters |
| Operation Logs | Track all changes made to operations over time |
| Insert Change Logs | View history of insert/tooling changes on machines |
| Assign Operation | Map operations to machines using barcode-based assignment with multiplier support |
| Partwise Production & Cycle Time | View production counts and cycle time performance grouped by part |
Cycle Time Analysis
Assess cycle time variation across operations over the year. The Standard Cycle Time is fetched from the Operation Master. Average cycle time is calculated where an operation has run for 200+ cycles. Use the variance slider to set an acceptable deviation percentage and quickly identify outliers.
| Sub-Page | Purpose |
|---|---|
| Standard Cycle Time | View and manage standard/target cycle times for all operations |
| Cycle Time Analysis | Year-long trend analysis of actual vs standard cycle times with variance highlighting |
| Time Analysis | Detailed time breakdown analysis of manufacturing steps |
| Cost Analysis | Correlate cycle time performance with cost implications |
| Cycle Time Partwise | Cycle time trends grouped by part across a date range |
| Partwise Periodic | Periodic (weekly/monthly) cycle time trends by part |
| Cycle Time Typewise | Analysis grouped by part type classification |
SPM Analysis
Strokes Per Minute (SPM) analysis for press-type machines. Track actual SPM against standard, identify slow-running machines, and analyse daily or min/max trends.
Parameter Analysis
Shift-wise analysis of machine parameters (temperature, pressure, tonnage, etc.). Useful for quality correlation and process stability monitoring.
Tool Management
| Page | Purpose |
|---|---|
| Tool Master | Register tools/inserts with specifications, expected life, and cost |
| Tool Management | Track tool usage, loading/unloading, and remaining life |
| Tool Inventory | Current inventory levels and stock status of all tools |
| Issue Insert | Record insert issuance to machines |
| Operation Wise Insert | View insert consumption grouped by operation |
| Insert Wise Cost | Cost tracking for each insert type |
| Tooling Cost / Consolidated | Aggregated tooling cost reports at line, division, or plant level |
| Tool Life | Track actual vs expected tool life and predict replacement needs |
Die Management
| Page | Purpose |
|---|---|
| Die Master | Register dies with specifications, assigned machines, and expected life |
| Assign Die | Assign dies to specific machines for production |
| Die Logs | Track die loading/unloading events and history |
| Die Life / Life Overview | Monitor die life consumption against expected life. Overview shows fleet-level status |
| Die Maintenance | Schedule and track preventive maintenance for dies |
| Maintenance History | Historical log of all die maintenance activities |
| Health Checksheet | Inspect die health using configured checksheet parameters |
| Health History | View past die health inspection records |
| Repair Request | Submit and track die repair/unloading requests |
| Summary / Summary Info | Consolidated die performance and status summary |
Material Management
Spare Master: Manage spare part inventory with stock levels and specifications.
Material Movement: Track material flow between operations and stations.
Operation Material Movement: Operation-level material tracking.
Material Consumption: Monitor raw material consumption against production output.
Realtime Monitoring
Monitor your factory floor in real-time. Data is pushed via live WebSocket connections and updates automatically without page refresh.
Control Room
The Control Room gives you a bird's-eye view of the entire plant, division, or line, enabling you to identify the status of your factory in a single view. Each machine is displayed as a tile colour-coded by its current status:
Filters: Select Plant → Division → Line. You can also search machines by name or filter by machine type.
Page: control-room-v2.php
Machine Overview
Tabular view of all machines with current production counts, cycle times, SPM, running status, and the current operator assigned. Provides a quick operational snapshot of the shop floor.
Page: machine-overview.php
Cycle Time Variance
Monitors real-time cycle time deviations against standard. Flags machines running outside the acceptable variance band. The Remark Logs page captures operator/supervisor remarks for any flagged variance events.
Pages: ct-variance.php, ct-variance-remark-logs.php
Digital Workstation
The operator-facing kiosk interface (external link) that enables shop-floor operators to view their assigned machine status, log downtime reasons, and interact with the system directly from the workstation.
Quad Eye — Role-Based Dashboards
Quad Eye provides role-specific dashboards tailored to different levels of the manufacturing hierarchy. Each dashboard is pre-configured with the metrics and views most relevant to the role.
| Dashboard | Intended For | Key Metrics |
|---|---|---|
| Line Supervisor | Shop-floor supervisors responsible for a specific line | Machine status, hourly production, current shift output, operator assignments, downtime events on their line |
| Production Head | Production managers overseeing multiple lines/divisions | Division-level production summary, shift-wise output, downtime breakdown, target vs actual comparison |
| Plant Head | Plant managers with full plant responsibility | Plant-wide KPIs, division comparisons, OEE summary, downtime Pareto, production trends across shifts |
| Material Head | Material/supply chain managers | Material movement status, consumption tracking, inventory levels |
| Quality Head | Quality managers and QA leads | Rejection summary, quality trends, inspection compliance, top defect categories |
Pages: qe-supervisor.php, qe-production-head.php, qe-plant-head.php, qe-material-head.php, qe-quality-head.php
Production Module
Track production output at granular and aggregated levels. The module is divided into Hourly (shift-level, live) and Periodic (daily/weekly/monthly) reporting.
Hourly Production
Live production data for the ongoing shift. Automatically refreshes to show real-time hourly output.
| View | Description |
|---|---|
| Machine Wise | Hourly production breakdown per machine for the current shift. Includes toggles for Cavity/Multiplier, Show Decimal, and Is Quality flags. Chart view available |
| Station Wise | Production output grouped by manufacturing stations within a line |
| Final Station | End-of-line (EOL) production station output — the last station count representing finished output |
Periodic Production
Historical production data across date ranges with weekly and monthly aggregation options.
| View | Description |
|---|---|
| Machine Wise | Periodic production per machine with report type (Weekly/Monthly), target toggles, efficiency %, and bottleneck machine identification |
| Station Wise | Station-level periodic output |
| Final Station | EOL station periodic output |
| Operation Wise | Production grouped by manufacturing operation |
| Operation/Machine Wise | Cross-tabulated view of operations across machines |
| Final Goods Report | Finished goods production report with dispatch-ready quantities |
| Stroke Summary Report | Total strokes/shots summary (for press machines) |
| Production Summary | High-level production summary with key aggregate metrics |
Downtime Module
The Downtime Module (DTE — Downtime Engine v2) provides comprehensive tracking, categorisation, and accountability of all non-productive time on machines.
Downtime Formula
| Page | Purpose | Key Features |
|---|---|---|
| Downtime Categories | Configure L1 (primary) and L2 (secondary) downtime reason categories | Hierarchical category management |
| Downtime Groups | Group related downtime categories for consolidated analysis | Group-level reporting |
| State Analysis | Visual timeline of machine states (running, idle, downtime) over a shift | State charts, filters by plant/division/line/date |
| Shift Accountability | Complete breakup of shift time for every machine showing runtime, idle, loading/unloading, and downtime by category | View in minutes or percentage, export data |
| Consolidated Accountability | Aggregated downtime accountability across a period (daily/weekly/monthly) | Period comparison, trend analysis |
| Machine Consolidated | Machine-level consolidated downtime report | Per-machine downtime trends |
| Downtime Logs | Searchable, detailed log of every downtime event with machine, reason, start/end time, and duration | Search, filter by reason, export, columns: Machine Name, Reason, Start Time, End Time, Total Minutes |
| Downtime Details | Machine-wise downtime breakdown with reason filtering | Day's total statistics card, reason-level drill-down |
| Downtime Counter | Count of downtime events (frequency analysis, not just duration) | Identify recurring issues |
| Activity Update | Log and update activities related to downtime resolution | Action tracking |
| All Plant Overview | Cross-plant downtime comparison (daily/monthly/yearly) | Multi-plant view with Highcharts drilldown |
| Plant Information | Plant-level downtime KPI dashboard | Summary metrics and trends |
| Overview | High-level downtime overview across all divisions | Summary cards and charts |
Human Resource
Manage shop-floor personnel across four categories: Helpers, Operators, Supervisors, and Quality Inspectors. Each category has a Master (registry), Change Log, Incentive tracking, and Attendance view.
Helpers
- Helper Master — Register and manage helper profiles with personal details and photo
- Change Log — Track assignment and status changes over time
- Incentives — View helper incentive calculations with detailed breakdowns
- Attendance Details — Daily attendance records and shift assignment history
Operators
- Operator Master — Full operator registry with profile, skills, and machine assignments
- Change Log — Track operator assignment changes
- Incentives — Performance-based incentive with Alpha/Beta/Gamma range calculations
- Incentive Daily / Analysis — Day-wise incentive details and trend analysis
- Performance Analysis — Multi-month performance comparison across all operators
- Attendance Details — Attendance and shift records
Supervisors
- Supervisor Master — Register supervisors with profile photo upload and personal details
- Change Log — Track changes to supervisor records
- Incentives — Supervisor incentive tracking with work time correlation
- Attendance Details — Shift-wise attendance records
Quality Inspectors
- Inspector Master — Register QA inspectors with certifications and assignments
- Incentives — Inspector incentive calculations
- Attendance Details — Inspector attendance tracking
Quality Module
End-to-end quality management covering rejection tracking, process inspections, PDI reports, and statistical process control (SPC).
Rejection Reports
| Page | Purpose |
|---|---|
| Add Final Rejections | Record rejection data filtered by plant, date, shift, machine, part, and operator |
| Accountability | Rejection accountability by plant/division/line/machine/part with drill-down to individual reasons |
| Consolidated Accountability | Aggregated rejection accountability across a time period |
| Consolidated Overview | High-level rejection overview with total counts and trends |
| Final Rejection L1 Accountability | Primary (L1) reason-level rejection accountability grouped by part |
| Final Rejection L2 Accountability | Secondary (L2) sub-reason level rejection accountability |
| Inprocess Rejection Update | Record and update rejections detected during in-process inspection |
| Die Rejection Accountability | Rejections tracked and attributed to specific dies |
Rejection Report (Multi-Stage)
View rejection counts across manufacturing stages: Casting → Fettling → FIC → Machining → FIM → FIA → Quality Wall. Available in daily/monthly report types with part-level and date range filtering.
Control Plan (SPC)
| Page | Purpose |
|---|---|
| Process Capability Analysis (Cpk) | Calculate Cpk values from measured data to assess process capability |
| x̄ and R Chart | X-bar and Range control charts for statistical process monitoring |
| Process Capability Charts | Visual capability charts with USL/LSL lines and distribution curves |
PDI & Inspection Reports
| Page | Purpose |
|---|---|
| PDI Report | Pre-Delivery Inspection logs — final inspection records before dispatch, filterable by plant, part, and date |
| Process Flow | Visual process flow mapping showing operation sequences and quality gates |
| Process Inspection Checksheet | Configure and fill in-process inspection checksheets for operations |
| Process Inspection Analysis | Analyse inspection data trends and compliance rates |
| Process Inspection Details | Line-wise inspection detail view |
| Process Inspection Report | Consolidated process inspection compliance report |
| Inprocess Rejection Accountability | Accountability for in-process rejections with hierarchical filtering (Plant → Division → Line → Machine → Part → Operation) |
| FOLO & Inprocess Inspections | First-Off / Last-Off and in-process inspection readings |
Maintenance Module
Manage preventive and corrective maintenance activities for machines and dies. Track maintenance schedules, checksheets, and history.
| Page | Purpose |
|---|---|
| Maintenance Calendar | Calendar view showing scheduled maintenance activities across machines. Helps plan and avoid conflicts with production schedules |
| Maintenance Check Sheet | Fill and submit preventive maintenance checksheets. Create custom checklists with configurable parameters |
| Machine Maintenance History | Historical log of all maintenance activities performed on each machine |
| Machine 5S Checksheet | 5S (Sort, Set, Shine, Standardise, Sustain) compliance checksheets for machines |
| Machine 5S History | Historical 5S inspection records — available in summary and daily views |
Performance Module
Comprehensive performance analytics covering machine utilisation, plant performance, OEE, and personnel efficiency.
Machine Utilisation
Analyse how effectively machines are being used. Filter by plant/division/line/machine and view daily, weekly, or monthly reports. Key statistics include:
Machine Utilisation %
Ratio of actual runtime to available shift timeIdle Time
Time when machine was available but not runningEffective Machines
Count of machines above utilisation thresholdPage: machine-utilisation-v2.php
Plant Performance
Plant-wide performance overview with live data from the ongoing shift. Shows machine status, production metrics, and bottleneck identification. Use the Bottleneck Machines toggle to highlight underperforming machines.
Page: plant-performance-overview-v2.php
Management Review
Bird's-eye view dashboard for plant heads and senior management. Shows plant-wide metrics across selected date ranges (weekly/monthly) including: Plant Utilisation, Machine Utilisation, Operator Efficiency, Idle Time, Late Start (LS), Early Stop (ES), Average SPM, and Run SPM. Supports PDF export for sharing.
Page: management-dashboard.php
OEE (Overall Equipment Effectiveness)
OEE analysis with two reporting modes:
- Shift Accountability: OEE breakdown per shift showing availability, performance, and quality components
- Consolidated Accountability: Aggregated OEE report across date ranges. Supports Daily/Weekly/Monthly views in both minutes and percentage formats. Filterable down to individual machine level
Pages: oee-accountability-v2.php, oee-consolidated-v2.php
Personnel Efficiency
| Category | Views Available |
|---|---|
| Operator Efficiency | Monthly efficiency overview with configurable Alpha/Beta ranges and utilisation thresholds. Daily view available for day-level drill-down |
| Line Supervisor | Monthly and daily supervisor efficiency, plus daily accountability reports |
| Quality Inspector | Daily and monthly inspector efficiency metrics |
Condition Based Monitoring
Monitor machine health conditions and set up automated alerts and interlocking mechanisms.
| Feature | Description | Status |
|---|---|---|
| Notification | View and manage system notifications triggered by threshold breaches, maintenance due dates, and other configured alerts | Active |
| Poka Yoke | Error-proofing system that monitors process parameters and flags deviations from standard conditions to prevent defects | Active |
| Watchdogs | Automated monitoring agents that continuously watch machine parameters and trigger alerts on anomalies | Coming Soon |
| Parameter Monitoring | Continuous monitoring of critical machine parameters (temperature, vibration, pressure) with trend analysis | Coming Soon |
| Interlocking | Automated machine interlocking based on parameter thresholds to prevent out-of-spec production | Coming Soon |
Energy Monitoring
Track and analyse electrical energy consumption across your manufacturing operations.
| Page | Description | Status |
|---|---|---|
| Consumption | Monitor energy consumption by plant, division, and line over a selected date range. Includes export functionality | Active |
| Historical Analysis | View historical energy usage trends and patterns over extended periods | Active |
| Power Quality Analysis | Analyse power quality parameters (voltage, frequency, harmonics, power factor) | Coming Soon |
| Fluctuations & Trends | Detect power fluctuations and identify energy consumption trends for optimisation | Coming Soon |
Pages: energy-consumption.php, energy-logs.php
User Management
Central administration hub for managing platform users. Available to Super Admins and Admins.
User Statistics Dashboard
The User Management page displays real-time counts for each user category:
Features
- Search Users — Search by name, username, email, or mobile number
- Filter by Role — Filter user list by role (Super Admin, Admin, Data Admin, End User)
- Add Users — Create new platform users with role assignment and plant access configuration
- Edit Users — Modify user details, role, and access permissions
- Activate / Deactivate — Enable or disable user accounts without deleting them
Page: user-management.php
Common Filters & Controls
Most pages across the platform share a common filter pattern. Understanding these controls will help you navigate any report efficiently.
| Control | Description | Found On |
|---|---|---|
| Select Plant | Choose which plant's data to view. Changing this reloads division options downstream | All pages |
| Select Division | Filter to a specific division within the selected plant. Updates line options | Most report pages |
| Select Line | Filter to a specific production line. Updates machine options | Most report pages |
| Select Machine | Filter to a specific machine for machine-level reports | Machine-specific pages |
| Select Date | Date picker for selecting a specific date or date range. Format: YYYY-MM-DD | All report pages |
| Report Type | Choose between Daily, Weekly, or Monthly aggregation for periodic reports | Periodic report pages |
| Select Machine Type | Filter machines by type (e.g., Press, CNC, Assembly) | Control Room, Machine lists |
| Generate Report | Click this button after setting your filters to load/refresh the report data | All report pages |
| Export / Share Data | Download the current report as a file (CSV/Excel) or generate a PDF for sharing | Most report pages |
| Percentage / Minutes Toggle | Switch between viewing data as percentages or absolute minutes | Downtime, OEE pages |
| Bottleneck Machines | Toggle to highlight machines that are underperforming or limiting throughput | Production, Plant Performance |
| Search | Free-text search to quickly find machines, operations, logs, or users | Control Room, Downtime Logs, User Management |
Glossary
| Term | Definition |
|---|---|
| OEE | Overall Equipment Effectiveness — a composite metric measuring Availability × Performance × Quality. The gold standard for measuring manufacturing productivity |
| SPM | Strokes Per Minute — the speed at which a press machine operates. Standard SPM is set in the operation master; actual SPM is measured in real-time |
| Cycle Time | The time taken to complete one production cycle (one part or one stroke). Measured in seconds. Lower is generally better, as long as quality is maintained |
| DTE | Downtime Engine — the platform's downtime tracking and analysis system (currently on version 2) |
| Shift | A defined working period (e.g., Day Shift: 6:00 AM – 2:00 PM). Configurable per plant. All reports are shift-segmented |
| L1 / L2 Reasons | Level 1 (primary category) and Level 2 (sub-category) classifications for downtime and rejection reasons |
| PDI | Pre-Delivery Inspection — the final quality inspection performed before parts are dispatched to the customer |
| Cpk | Process Capability Index — a statistical measure of how well a process meets specification limits. Cpk ≥ 1.33 is generally considered capable |
| x̄ and R Chart | X-bar (mean) and Range control charts — statistical tools for monitoring process stability over time |
| 5S | A workplace organisation methodology: Sort, Set in Order, Shine, Standardise, Sustain |
| FOLO | First-Off / Last-Off — inspection of the first and last parts produced in a batch to verify process setup and consistency |
| Poka Yoke | Error-proofing mechanisms that prevent defects by detecting abnormal conditions and stopping the process |
| EOL | End of Line — the last station in a production line where finished parts exit |
| Idle Time | Time when a machine is available but not producing — no active downtime reason logged, but no production occurring |
| Late Start (LS) | The delay between shift start time and when the machine actually begins producing |
| Early Stop (ES) | The gap between when the machine stops producing and the shift end time |
| Prehistoric Data | Historical/past data (as opposed to live/current shift data). Many pages have a "Prehistoric" tab for historical lookback |
| Cavity / Multiplier | Number of parts produced per stroke/cycle. A machine with a 4-cavity die produces 4 parts per stroke |
Quad Platform Documentation
For additional support or training, please contact your system administrator or use the FAQ page. You can also request a training session via the Request Training option in the sidebar.