Operational Vision Portal
v3.6 ⢠Brick Factory ERP Architecture
THE COLOUR GROUP â FACTORY OPERATIONS BLUEPRINT
đŻ Future Operational Vision
Welcome! This blueprint represents the **future operational model** for The Colour Group, built around Brick Factory ERP as our central intelligence platform.
đ§ How to Explore This Blueprint
- ⢠Click Departments below to expand dedicated workflows.
- ⢠Hover over purple automation nodes for sample JSON payloads.
- ⢠Toggle Developer Mode (top right) to inspect backend schemas.
đ¤ Collaborative Discussion
This specification is a **living conversation starter**. We actively welcome feedback, improvements, and alternative ideas from the software development team to build the best platform together.
đť DEVELOPER ARCHITECTURE: RELATIONAL SCHEMA & STATE MACHINE
FOR SOFTWARE TEAM
1. RELATIONAL DATA HIERARCHY (ONE-TO-MANY)
⢠MasterOrder (
order_id: "CT-10542")âââş ShipmentGroup (
shipment_group: "A", status: "IN_PROD")âââş ProductionTraveller (
traveller_id: "CT-10542-A-01")
2. TRAVELLER STATE MACHINE LIFECYCLE
1. CREATED âââş Generated at RIP hot-folder / PO intake
2. PRINTED âââş 570mm strip printed at end of manufacturing run
3. STAGED âââş đ˘ Scanned at exit âââş ERP assigns
STAGING-BIN-A074. DISPATCHED âââş đŁ Group scanned at pack table âââş Courier API label
⥠MASTER MANUFACTURING LEAD TIME CONFIGURATION MATRIX
ERP PARTIAL DISPATCH THRESHOLD: ⼠24 HOURS (1 DAY)
FAST-TRACK CELL (SAME-DAY CUTOFF 12:00 PM)
- ⢠DTF Transfers (Roll/Cut): Same Day (< 12pm) [lead_time_hrs: 0]
- ⢠UV DTF Transfers: Same Day (< 12pm) [lead_time_hrs: 0]
- ⢠Vinyl Decals (Standard): Same Day (< 12pm) [lead_time_hrs: 0]
- ⢠Sublimation Rolls: Same Day (< 12pm) [lead_time_hrs: 0]
MID-TIER CELL (24 HOURS â 5 DAYS)
- ⢠Laminated Decals: +1 Day (Cold Roll) [lead_time_hrs: 24]
- ⢠UV TPU Patches: 48 Hours [lead_time_hrs: 48]
- ⢠Sublimated Goods: 3â5 Days [lead_time_hrs: 96]
- ⢠Screen Transfers (Outsourced): 4â5 Days [lead_time_hrs: 120]
EXTENDED MANUFACTURING CELL (3â7 DAYS)
- ⢠In-House Garments: 3â5 Days [lead_time_hrs: 96]
- ⢠Supplier-Ordered Garments: 5â7 Days [lead_time_hrs: 144]
- ⢠Multi-Position Garments: 5â7 Days [lead_time_hrs: 144]
đ Production Traveller Standard (570mm Roll-Fed Strip with Lead-Time Due Date)
Zero-box lean print layout. Black ink only on substrate (No white backing). Height: 32mm.
MASTER: CT-10542
GROUP: A
ACME WORKWEAR
DPD NEXT DAY
GROUP MATRIX:
[A-01]
A-02
| B-01
B-02
DEPT: DTF TRANSFERS
MACH: DTF-02
SPEC: 500mm x 3.2m Gang Sheet (Matte Film)
QTY: 1 ROLL
PACK: Tube + End Caps
STAGING TARGET:
BIN-A07
DUE: TODAY (SAME DAY)
PRIORITY: EXPRESS PARTIAL
QC: [ ]
*CT-10542-A-01*
CT-10542-A-01
LIVE ERP
1. Order Intake & Intelligent Checkout Evaluation
Shopify Store
Brick Factory Portal
Sales / Phone
Trade Account
API Order
CHECKOUT LEAD-TIME EVALUATOR: Do Basket Lead Times Delta ⼠24 Hours (1 Day)?
YES âââş OFFER EXPRESS PARTIAL DISPATCH
e.g., DTF Roll (Same-Day) vs Garments (5-7 Days). Offer Express Partial Dispatch at checkout.
e.g., DTF Roll (Same-Day) vs Garments (5-7 Days). Offer Express Partial Dispatch at checkout.
NO âââş STANDARD SINGLE SHIPMENT
All products share similar lead times. Route under single Shipment Group A.
All products share similar lead times. Route under single Shipment Group A.
Master Order Decomposition (e.g., CT-10542) [POST /api/v1/orders/decompose]
Decomposes into Group A (`A-01 Same-Day`) & Group B (`B-01 5-7 Days`)
Are Artwork Files & Specifications Valid?
YES âââş Select Department
NO âââş Hold & Sync CS
đ´ Contact Customer (CS Portal Alert)
Receive Revised File âââş Re-flight
2. Department Production Workflows (Click Tabs To Explore)
đ Click any tab to switch view
DEPARTMENT 1: DTF TRANSFERS (SAME DAY IF ORDERED BEFORE 12:00 PM)
Artwork Pre-flight Check âââş Queue Job in Digital Factory RIP
Select DTF Production Queue
STANDARD COLOUR QUEUE (Printers 1, 2 & 3)
WHITE / METALLIC QUEUE (Printers 4 & 5)
Main 9-Colour Production Printers
White-Only / Gold Metallic / Silver Metallic Film
âď¸ DTF PRODUCTION CELL (CONTINUOUS AUTOMATED PROCESS)
1. DTF Printer Pass
2. Powder Application
3. Tunnel Oven Cure
đ INLINE PRODUCTION TRAVELLER STRIP: Printed at END OF JOB (Group ID: CT-10542-A-01)
đ˘ PRODUCTION SCAN: Operator Scans Sub-Task Traveller Barcode (`CT-10542-A-01`) âââş ERP Status: "Production Complete / Moved to Finishing"
What Product Was Ordered?
ROLL PRODUCT
CUT PRODUCT
Metres / Half Metres / Quarter Metres / Full Roll
Individual Sheets or Precision Cut Transfers
ROLL PRODUCT FINISHING
Measure Roll Length
Re-roll Product (Attach Production Traveller Strip to Outer Roll)
Route to Group Staging Bay âââş
CUT PRODUCT FINISHING METHOD
Large Volume Run?
YES âââş Slicer
NO âââş Flatbed
âď¸ Semi-Auto Slicer
Set Vertical Blades
Program Cut Length
Auto Feed & Chop
Basket Collection
đ Flatbed Cutter 1 / 2
Scan Optical Marks
Auto Precision Cut
Individual Pieces
đ Quality Check Inspection Pass?
YES âââş Attach Production Traveller Strip & Route to Group Staging Bay
NO âââş Log Scrap Reason & Trigger Sub-Task Reprint
đ˘ STAGING SCAN: Scan Traveller Barcode at Production Staging âââş ERP Assigns Group A Bin (`STAGING-BIN-A07`)
DEPARTMENT 2: UV DTF TRANSFERS (SAME DAY IF ORDERED BEFORE 12:00 PM)
Artwork Check (Spot White & Gloss Varnish Layers)
đ¨ď¸ UV DTF Roll Printer (Single Pass: CMYK + White + Gloss Varnish)
Continuous Inline A/B Film Laminator (Prints Production Traveller Strip `A-02` at End of Run)
đ˘ PRODUCTION SCAN: Operator Scans Traveller Barcode (`CT-10542-A-02`)
Sheet Trim & Manual Cut-Down Separations
đ Quality Check âââş Board Sleeve Pack âââş Route to Group A Staging Bay (`BIN-A07`)
DEPARTMENT 3: VINYL DECALS (SAME DAY < 12PM / LAMINATED +1 DAY)
Artwork & Cut Vector Line Check
đ¨ď¸ Large Format Print-and-Cut Roll Printer (Prints Production Traveller Strip at End of Run)
Require Laminate?
YES âââş Cold Roll Laminator (+1 Day Curing)
NO âââş Skip Lamination
âď¸ Graphtec Plotter Cutter (Optical Registration Mark Scan)
Cut Format Type?
KISS CUT âââş Cut Vinyl Layer Only âââş Weed Excess Vinyl
DIE CUT âââş Cut Through Vinyl + Backing Paper
đ Quality Check & Count âââş Pack Decals (Attach Traveller) âââş Route to Group Staging Bay
DEPARTMENT 4: UV TPU / RAISED PATCHES (48 HOURS PRODUCTION)
Manual Artwork Check âââş Prepare Base & Raised Texture Layers
đ¨ď¸ Print Directly onto Thick TPU Media (Prints Production Traveller Strip at End of Run)
Inline UV LED Cure Engine
đ Flatbed Cutter (Cut Out Patch Outline Shapes)
đ Quality Check âââş Pack Patches (Attach Traveller Strip) âââş Route to Group Staging Bay
DEPARTMENT 5: DECORATED GARMENTS (IN-HOUSE 3-5 DAYS / SUPPLIER 5-7 DAYS)
LANE A: STOCK TASK
Stock In-House?
YES (3-5 Days) âââş Pick Shelf
NO (5-7 Days) âââş Order Supplier
Receive Delivery âââş Check QC âââş Allocate Garments into Labelled Job Tote (`TOTE-882`)
LANE B: DECORATION TASK
Method Required?
DTF TRANSFERS
EMBROIDERY
DTF: Print Cell & Cut Transfers (Production Traveller Attached)
Embroidery: Digitise File âââş Frame âââş Stitch Machine
Embroidery: Digitise File âââş Frame âââş Stitch Machine
MATCHING / STAGING VALIDATION SCAN
đľ VALIDATION SCAN: Scan Tote Barcode + Scan Production Traveller Barcode
VALIDATION MATCH âââş Unlock Heat Press Screen
MISMATCH âââş LOCK TASK & Flag CS Holding Bay
đĽ Heat Press First Position (e.g. Left Chest) âââş Scan Position Complete
Another Position / Method Required? (e.g. Back Print)
YES âââş Press / Stitch Next Position
NO âââş Move to Final Garment QC
đ Final Garment QC âââş Fold âââş Bag âââş Attach Production Traveller Strip (`CT-10542-B-01`)
DEPARTMENT 6: SUBLIMATION (PAPER ROLLS SAME DAY < 12PM / GOODS 3-5 DAYS)
What Product Type Was Ordered?
SUBLIMATION TRANSFERS ONLY (SAME DAY < 12PM)
SUBLIMATED GOODS (Mugs/Mats: 3-5 Days)
Sold Exclusively as Roll Product (1/4m, 1/2m, 1m Gang Sheets)
Requires Blank Substrate Stock + Precision Paper Wrap Trimming
OPTION A: ROLL TRANSFERS ONLY
Artwork & Colour Profile Verification
đ¨ď¸ Print onto Sublimation Transfer Paper Roll (Prints Production Traveller Strip at End)
đ˘ PRODUCTION SCAN: Scan Production Traveller Barcode
Measure Roll Length (1/4m, 1/2m, 1m Gang Sheet)
Re-roll Product (Attach Traveller Strip to Roll)
Quality Check âââş Roll Wrap Pack
Route to Group Staging Bay âââş
OPTION B: SUBLIMATED GOODS WORKFLOW
BLANK STOCK TASK
Pick Blank Items (Mugs, Tumblers, Mats)
Allocate Stock into Job Tote (Bin Tagged)
PAPER WRAP TASK
đ¨ď¸ Print Sublimation Paper Roll
đ DTF Flatbed Cutter (Trim Wraps + Traveller)
MATCHING STAGING STATION
đľ VALIDATION SCAN: Scan Tote Barcode + Scan Production Traveller Barcode
Wrap & Tape Paper onto Item âââş Mug Press / Rotary Oven / Heat Press
Cooling Station âââş Final Inspection âââş Box Pack (Attach Traveller Strip)
đ˘ STAGING SCAN: Route Output to Group Staging Bay (`STAGING-BIN`)
DEPARTMENT 7: SCREEN-PRINTED TRANSFERS (100% OUTSOURCED: 4-5 DAYS)
Create Supplier Purchase Order in Brick Factory âââş Send Approved Artwork & Specification
Await Supplier Production âââş Receive Delivery & Check Quantities
đ˘ PRODUCTION SCAN: Receiving Inspection Complete (Production Traveller Strip Printed & Attached)
đ Final Quantity & Quality Check âââş Pack âââş Route to Group Staging Bay
3. Production Staging, Group Consolidation & Partial Dispatch Gateway
đŚ GROUP CONSOLIDATION STAGING BAY (SHIPMENT GROUP A)
LOCATION: STAGING-BIN-A07
Are all sub-task Production Travellers for SHIPMENT GROUP A present? (`A-01` + `A-02`)
YES âââş UNLOCK SHIPMENT GROUP A PACKING
All Group A components present. Release to Packing Table for immediate courier label generation.
All Group A components present. Release to Packing Table for immediate courier label generation.
NO âââş HOLD IN GROUP STAGING (`BIN-A07`)
Hold completed Group A outputs until remaining Group A travellers arrive. Group B stays in production.
Hold completed Group A outputs until remaining Group A travellers arrive. Group B stays in production.
đľ GROUP CONSOLIDATION INTERLOCK SCAN: Scan ALL Group A Production Travellers (`CT-10542-A-01`, `CT-10542-A-02`)
Brick Factory validates Group A completeness and unlocks DPD/DHL label generation for Shipment Group A.
đŁ GROUP A DISPATCH READY SCAN: SCAN GROUP A TRAVELLERS AT PACKING TABLE
Brick Factory Automatically: Generates DPD/DHL Label for Group A âââş Syncs Group A Tracking Code to Shopify âââş Customer Email Issued ("Shipment 1 of 2 Dispatched")
ERP PARTIAL DISPATCH PAYLOAD:
POST /api/v1/orders/dispatch-group
{ "parent_order_id": "CT-10542", "shipment_group": "A", "scanned_travellers": ["CT-10542-A-01", "CT-10542-A-02"], "status": "PARTIALLY_DISPATCHED", "issue_carrier_label": true }
POST /api/v1/orders/dispatch-group
{ "parent_order_id": "CT-10542", "shipment_group": "A", "scanned_travellers": ["CT-10542-A-01", "CT-10542-A-02"], "status": "PARTIALLY_DISPATCHED", "issue_carrier_label": true }
OPTION A: COURIER DELIVERY
1. Apply Courier Label (Generated at Group Dispatch Ready Scan)
2. Hand Off Box to Courier Pick Area
3. Group A Tracking Code Synced to Shopify Store
OPTION B: FACTORY PICKUP
1. Customer Receives Collection QR Email for Group A
2. Move Group A Box to Pickup Bay Slot
3. Scan QR Code at Counter Bay to Close Shipment Group
