Make, pack and release

Who does what (0:00) In this video, we make the tablets, pack them into boxes, and release them for sale. It has three chapters: make, pack, and test and release. Ali, the operator, does the work. Bilal, the supervisor, checks every step. Hamid and Faisal test in the lab. And Usman, the head of quality, decides.

Weigh the powders (0:26) Chapter one: make the tablets. Ali opens batch B-0001 and presses Continue. The first task: weigh 100 kilograms of paracetamol. The app picks the lot that expires first. Ali weighs it, and types what the scale shows: 100.05. That's inside the allowed difference, so he presses Weigh. It comes off the stock straight away.

Weighed too much? (0:55) What if he weighs too much? Here, 9.2 kilograms of maize starch, when the recipe needs 9. The app says it's outside the allowed difference, and offers to open a deviation. Ali takes some out, and weighs again: 9.02. He weighs the other three powders the same way.

Sign the weighing (1:17) When everything is weighed, Ali signs that weighing is finished. First he records a reading: the scale was checked with a test weight. Then the yield: what went in, and what came out. Here, nothing was lost. And he presses Sign as done.

Bilal checks (1:35) Now Bilal checks Ali's work. For each weighing, he reads the label on the container, and presses Sign as checked. Then he checks the weighing step itself. Weighing is done.

Blend (1:48) Next, blending. Ali presses Start this stage, and types each reading as it happens. The blend time must be between 18 and 22 minutes. If a reading is outside its limits, the app says so straight away. Here, it's 20 minutes. He saves the yield, signs as done, and Bilal checks it.

Press the tablets (2:11) Then the tablet press. Two readings: the average weight of 20 tablets, 601 milligrams, and the hardness, 8. Both are inside their limits. Ali signs, and Bilal checks. Making is done.

Close the batch (2:27) Now Bilal closes the batch. He counts the good tablets: 196,000. That's a yield of 98 percent, inside the range. The app also shows the costs it adds: workers, machines and factory overhead. He presses Complete batch. The tablets become lot B-0001, and wait in quarantine.

Quality reviews the record (2:53) Usman, from quality, reads the batch record. Every weighing, reading and signature sits beside its check. All six checks pass. He signs it as reviewed.

Release the tablets for packing (3:05) These tablets have no lab tests of their own here: the lab tests the finished boxes. So Usman releases the tablets for packing. In Inventory, Lots, he opens B-0001, presses Change status, and picks Release without tests. He writes why, and saves. If you want the lab to test the tablets too, give them their own test list, as in set-up video 6.

Open a packing batch (3:36) Chapter two: pack into boxes. Packing is its own small batch, with its own recipe. Open a batch, and pick the boxes: 1,950 of them. The app works out everything for that size: 195,000 tablets, the plastic film, the foil, the printed cartons, the leaflets, and the shipper cartons. Bilal is the supervisor again, and the batch opens as B-0002.

Take out the packing (4:06) Ali counts out the tablets, and Bilal checks them. Then he takes the packing to the line. The film and foil go by weight. The printed cartons and the leaflets are counted. He takes 2,000 of each: a few more than needed, in case some get spoiled.

Clear the line (4:24) Before packing, Ali clears the packing line. He ticks each item: nothing left from the last product, the printer set to this batch, the leak tester checked today, and the reject bin emptied and sealed. He signs, and Bilal checks the line too.

Pack (4:41) Now Ali runs the packing stage. Two readings: the blisters pass the leak test, and the batch number and expiry are printed clearly. The yield: 194,000 tablets packed, out of 195,000. He signs as done.

Check the print (5:00) Next, the print check. The app shows what the pack should read: batch B-0002, and the expiry, September 2029. The expiry is never later than the tablets inside. Ali types what the first carton actually shows. Both match, and he saves the check. Then Bilal checks the packing stage.

Count the cartons back (5:24) Now Bilal counts the printed cartons back. 2,000 were taken out: 1,940 used, and 15 spoiled. That leaves 45 missing. They are unused and intact, so he returns them to the store. Now it adds up. He does the same for the leaflets. A missing printed carton is a real risk: it could end up on a fake medicine.

Complete: 1,940 boxes (5:49) Then Bilal completes the batch: 1,940 good boxes. The app checks that the counts add up, and the print check matches. The boxes become lot B-0002, and wait in quarantine.

Take the samples (6:07) Chapter three: test and release. Hamid takes two samples from the boxes. A test sample: 3 boxes, for the lab. And a kept sample: 4 boxes, sealed in the retention room until after expiry, in case someone asks questions later.

Record the tests (6:25) He records the four tests: the assay, 100.2 percent; the appearance; the identification; and the dissolution, 92 percent. Faisal checks each result. Then he issues the certificate of analysis: the lab's report, to give your customers.

Decide and release (6:45) Usman reads the packing batch's record, and signs it as reviewed. Then he presses Decide on this lot. Every test passed and was checked. No problems are open. The certificate is issued, and the record is reviewed. He picks Release, and presses Sign as released.

Ready to sell (7:05) Lot B-0002 is released: 1,933 boxes, ready to sell. On the factory map, both lots show as released this month. From powders to boxes, every step was done by one person, and checked by another. In the next video, we sell it.