Twelve modules built for food manufacturing. Not adapted from a generic ERP.
Each module is designed around the real workflows of quality managers, production teams, warehouse supervisors, and factory management — with HACCP compliance built into every step.
Lot Traceability
Digital CCP Monitoring & Batch Records
Smart HACCP Navigator
Monitoring Module
Supplier & COA Management
Production Planning & Work Orders
Work Centers & Labour Costs
Verified Goods Receiving
Inventory Stock Balance & Expiry Management
Customer & Finished Goods Management
Recipe Scaling & Allergen Compliance
Management Review Analytics
Lot Traceability
Recall-ready · Forward & backward · Under 5 minutes
When a customer complaint, a supplier recall, or an auditor request arrives, you need to answer one question immediately: which lots are affected? RYLOTRACE gives you a complete lot trace — forward from raw material to every finished good and customer it reached, or backward from a finished lot to every raw material input, supplier, and CCP reading that produced it.
Capability callouts
- Forward trace: raw material lot → all batches produced → all finished goods → all customer shipments
- Backward trace: finished lot → all production inputs → all raw material lots → all supplier COAs
- Lot disposition: Released · Quarantined · Recalled · Consumed — with full audit trail
- Recall scope report: automatically identify the minimum set of lots affected by a supplier or CCP issue
- CCP history per lot: every CCP reading from every batch that used a given lot — searchable, exportable
Without this
A recall scoping exercise without lot traceability takes 2–5 days of manual cross-referencing across production records, warehouse logs, and delivery dockets. BRCGS Food Safety Issue 9 requires manufacturers to demonstrate full lot traceability within a 4-hour exercise. RYLOTRACE completes this trace in under 5 minutes.
Digital CCP Monitoring & Batch Records
Real-time · Deviation alerts · No paper forms
Your HACCP plan defines your Critical Control Points. RYLOTRACE makes monitoring them part of your production team's daily workflow — not a separate documentation exercise done after the shift ends.
Capability callouts
- Digital CCP log: readings entered on-screen, timestamped and operator-signed automatically
- Critical limit validation: every reading validated in real time; out-of-limit values flagged immediately
- Deviation alert: CCP breach triggers an immediate alert to the designated quality contact
- Corrective action linkage: every deviation spawns a corrective action record, pre-populated with CCP, batch, operator, and timestamp
- Batch record compilation: ingredients, CCPs monitored, yield, operator — compiled automatically
- Yield variance tracking: actual vs. planned yield, per batch, per work center
Without this
Paper CCP logs filled in retrospectively are the most common HACCP audit finding in food manufacturing facilities. A CCP log with uniform handwriting and no corrections raises questions with any trained auditor.
Smart HACCP Navigator
Hazard & allergen flagging · Team-reviewed, always current
Building and maintaining a HACCP plan is a team responsibility. The Smart HACCP Navigator makes it faster and harder to get wrong. RYLOTRACE structures your HACCP documentation from your product, recipe, and process data, flags potential hazards, allergens, and sensitive materials based on your formulation, and drafts CCP placement points, critical limits, and monitoring procedures for your HACCP team to review, adjust, and approve.
Capability callouts
- Hazard and allergen flagging: biological, chemical, physical, and allergen risks identified from your recipe and ingredient data — for your team to assess and confirm
- CCP/OPRP placement suggestions: based on your process flow; your HACCP team validates and finalizes
- Drafted critical limits and monitoring procedures: structured from your process parameters, reviewed and approved by your team
- Corrective action log: Correction, Root Cause Analysis, Corrective Action, and Verification of Effectiveness — tracked as distinct steps
- Version control: every HACCP plan change timestamped; auditors see the plan exactly as it stood on any production date
- One-click audit package: HACCP plan + CCP logs + corrective actions + verification summary, exported in under 60 seconds
Scope note
RYLOTRACE structures and drafts your HACCP documentation for your team's review. Hazard significance determination, CCP validation, and final sign-off remain the responsibility of your qualified HACCP team, consistent with Codex, ISO 22000, and MS 1480:2019 requirements.
Without this
A HACCP plan built once and filed away goes stale the moment a recipe, supplier, or process changes — and gaps only surface during an audit or recall. The Smart HACCP Navigator keeps your HACCP documentation structured, versioned, and continuously ready for review, so every product change flows into an updated plan your team approves — not a document you rebuild from scratch before the next audit.
Monitoring Module
Configurable forms · Scheduled tasks · Verified responses
Powered by Smart Form ArchitectEvery food safety program outside your CCPs still needs to be scheduled, executed, recorded, and verified — cleaning and sanitation, pest control, environmental swabbing, equipment calibration, lab testing, and customer complaint handling. The Monitoring Module — powered by the Smart Form Architect — lets you build a custom form for any recurring or ad-hoc check, assign it to a team member or role, schedule its frequency, and route completed responses for verification. Overdue tasks are flagged automatically, and every record links to the relevant lot, work order, or production date.
Capability callouts
- Prerequisite Programs (PRPs): cleaning and sanitation, pest control, waste management, and personnel hygiene forms — scheduled, tracked, and alerted on non-completion
- Environmental Monitoring Program (EMP): swab testing schedules across your production environment; pathogen results logged, positive findings trended, corrective actions triggered — linked to affected lots and production dates
- Good Hygiene Practices (GHP): hygiene inspection checklists aligned to Codex General Principles of Food Hygiene (CAC/RCP 1-1969) and Malaysian GMP audit expectations
- Calibration Management: instrument calibration scheduling (thermometers, pH meters, metal detectors); overdue calibration triggers an alert on any linked CCP reading
- Laboratory & Test Results: log test requests, upload results, record pass/fail decisions, link results to lot disposition
- Customer Complaints: log complaint details, trigger a linked lot trace, assign investigation, route through the corrective action log to closure
- Verification workflow: every submitted form routes to a designated verifier, with full audit trail of verified, rejected, and pending responses
Without this
Cleaning schedules on whiteboards, calibration records in a drawer, and complaint logs in someone's inbox are among the most common root causes of GMP and HACCP audit findings. The Monitoring Module puts every recurring food safety task on a single schedule, with every response verified and time-stamped.
Supplier & COA Management
Approved vendor list · COA expiry · No surprises at audit
Capability callouts
- Approved vendor list: qualification status, product scope, approval expiry per supplier
- COA tracking: upload and track Certificate of Analysis documents per supplier per material; expiry alerts before lapse
- COA-to-lot linkage: every incoming lot linked to the COA verified at receiving
- Supplier suspension: block new PO creation automatically for suspended suppliers
- Audit evidence package: export a supplier quality file — qualification records, COA history, inspection records
Production Planning & Work Orders
Plan-to-floor · WO tracking · Linked to compliance
A production plan that isn't connected to your batch records, CCP logs, and lot traceability is just a spreadsheet. RYLOTRACE converts production plans into work orders that carry compliance requirements with them — CCP checkpoints, allergen alerts, approved material lists — so your production team executes with the right information at hand.
Capability callouts
- Production planning: schedule runs against finished goods demand, raw material stock, and work center capacity
- Work order creation: recipe, lot assignments, work center, operator, and CCP requirements pre-populated
- WO-to-FG transfer: closing a work order transfers finished goods to the warehouse, generating stock cards, lot numbers, and FIFO tags automatically
- Allergen alert on WO: work orders for allergen-containing products flag the production team before the run begins
- WO history: every work order linked to its lot trace, batch record, and corrective actions — permanently
Work Centers & Labour Costs
Line efficiency · Cost per batch · No separate ERP
Capability callouts
- Work center definition: production lines with capacity, operating hours, and CCP station assignments
- Labour assignment: assign operators to work orders; track hours per batch per work center
- Labour cost per batch: calculate actual labour cost per batch — useful for costing accuracy and contract manufacturer pricing
- Output efficiency: actual vs. planned output per work center, per period
- Work center CCP mapping: operators assigned to a work center see their CCP monitoring responsibilities automatically
Verified Goods Receiving
PO to stock card · 5-step verification · No uninspected stock
Every non-conforming raw material that enters your production floor is a future audit finding, a potential recall, and a preventable quality failure. RYLOTRACE's verified goods receiving workflow closes the gap between what you ordered, what arrived, and what's actually cleared for production — through a mandatory 5-step verification sequence that generates a permanent compliance record for every incoming lot.
Capability callouts
- Step 1 — Purchase Order: raise and approve a PO against your approved vendor list. Only approved suppliers with current COAs can receive a PO.
- Step 2 — Delivery Notification: log the incoming delivery against the open PO before physical unloading begins.
- Step 3 — Goods Receipt: confirm quantities received vs. ordered; record delivery vehicle details, temperature (for cold chain), and condition on arrival.
- Step 4 — Incoming Quality Inspection: record COA verification, sensory evaluation, sampling results, and inspection decision: Released · Quarantined · Rejected.
- Step 5 — Stock Card Generation: released lots are automatically assigned a lot number, expiry date, FIFO tag, and stock card entry — available for production and fully traceable.
Without this
A raw material lot that enters your production floor without an inspection record is untraceable. If that lot later becomes a recall subject, you have no documented evidence of its condition on arrival, no COA on file, and no way to demonstrate your receiving control was effective — a critical nonconformance in any HACCP, GMP, or Halal audit.
Inventory Stock Balance & Expiry Management
Real-time balance · FIFO enforcement · Expiry before GMP finds it
Capability callouts
- Real-time stock balance: current on-hand quantities updated with every receipt, consumption, and transfer
- FIFO enforcement: material issue to production guided by FIFO, with override requiring a documented reason
- Expiry date tracking: alerts at configurable lead times (30, 14, 7 days before expiry)
- Lot disposition management: Released · Quarantined · Expired · Recalled — quarantined and expired lots locked from production automatically
- Stock movement history: full movement log per lot — received, issued, returned, disposed
Customer & Finished Goods Management
Customer-linked lots · Recall notification ready
Capability callouts
- Customer database: delivery addresses, product approvals, allergen requirements
- FG-to-customer linkage: every finished goods lot linked to the customer it was shipped to
- Recall notification scope: list of affected customers with shipment dates and quantities for any recalled lot
- Customer product history: full shipment history per customer
Recipe Scaling & Allergen Compliance
Scale without errors · Auto allergen declarations
Capability callouts
- Recipe management: formulations with ingredient quantities, processing steps, CCP assignments
- Scaling with compliance validation: allergen declarations, additive usage levels, and label claims recalculated automatically when scaling
- Allergen profile: work orders for allergen-containing products alert production before the run
- Ingredient compliance check: flag ingredients exceeding permitted additive levels at scaled quantity
- Recipe version control: every recipe change versioned and timestamped
Management Review Analytics
Automated reporting · Trend analysis · Decision-ready
Your management review shouldn't require a week of manually compiling data from ten different systems. RYLOTRACE aggregates CCP deviation trends, corrective action status, Monitoring Module completion rates, supplier performance, customer complaints, and lot traceability metrics into a single management review report — generated on demand or on a scheduled interval.
Capability callouts
- Automated management review report: CCP trends, CA status, Monitoring completion rates, supplier performance, complaint summary
- Trend flagging: patterns across deviations, corrective actions, and supplier risk surfaced for leadership review
- Scheduled reporting: monthly, quarterly, or custom interval report generation and distribution
- Historical comparison: track food safety performance trends across review periods
The next time a lot is questioned, how fast will you have the answer?
RYLOTRACE gives your quality, production, warehouse, and management teams the answer in minutes — not days.