INT-CZB40, Ca/Zn base pre-blend, one-pack platform. 16,000 kg planned, started 08 Sep 2025, due 10 Sep 2025, operator Malcolm Rees.
Materials issued
$77,198
4 components out of 1310
Labour & plant recovered
$2,244
6.6 hours across 1 work centres
Overhead applied
$942
42% of recovery
Carried in 1320 WIP
$80,385
$5.06/kg made
Formulation Rev 6 approved 14 Oct 2025 by Amir Haddad
Issued against this works order, with the supplier lot recorded on every line, which is the backward half of a trace.
| Raw material | kg / tonne | Required | Lot | Cost /kg | Value |
|---|---|---|---|---|---|
| INT-CAST70 Calcium stearate, own manufacture, blending grade · Own calcium stearate, made on the stearate line | 457 | 7,312 | RED-2405470 | $3.40 | $24,861 |
| RM-5010 Polyethylene wax, 100 mPa·s · External lubricant | 253 | 4,048 | SAS-2412462 | $4.26 | $17,244 |
| RM-3010 Hydrotalcite, synthetic, Mg-Al · HCl scavenger | 164 | 2,624 | KIS-2610129 | $9.64 | $25,295 |
| RM-2020 Zinc oxide, French process, 99.7% · Zinc source, early colour | 126 | 2,016 | ZIB-2509871 | $4.86 | $9,798 |
| Material cost | $77,198 | ||||
Routing
Each step recovers its work centre's rate for the hours run, and overhead is applied on top. That is the conversion cost inside WIP.
| Seq | Work centre | Operation | Hours | Rate /hr | Recovered |
|---|---|---|---|---|---|
| 10 | BL-01 High-speed Blender 1 (one packs) | Charge and blend to a homogeneous base, held in silo | 6.6 | $340.00 | $2,244 |
Quality release · One-pack stabiliser release
Recorded 10 Sep 2025 by Karen Doust. Run at the end of manufacture, before the goods can be receipted into finished goods.
| Test | Result | Specification | Outcome |
|---|---|---|---|
| Yield | 99.69 % | 97.5-100 % | Within spec |
| Peak temperature | 133.5 °C | 128-142 °C | Within spec |
| Fusion time | 54.4 s | 52.4-55.6 s | Within spec |
| Torque, peak | 41.6 Nm | 40.7-43.3 Nm | Within spec |
| Colour, initial ΔE | 1.32 ΔE | 0-3.5 ΔE | Within spec |
| Bulk density | 309 g/L | 260-400 g/L | Within spec |
| Moisture | 0.54 % | 0-1.5 % | Within spec |
| Texture, visual | 1 | pass | Within spec |
Standard cost
Computed from the formulation and the routing, not typed in. It is what the finished goods control account is debited at.
- Material /kg
- $4.82
- Conversion /kg
- $0.20
- Standard /kg
- $5.02
Yield
- Planned
- 16,000 kg
- Made
- 15,879 kg
- Formulation standard
- 99.7%
- Actual
- 99.24%
- Variance to 5400
- $672
Released as batch B25-0798
15,879 kg made, 4,558 kg still on the floor at the Main Store. Best before 09 Sep 2027.
Full trace →Ledger effect
DR 1320 Work in Process Control, as material is issued and hours are booked
CR 1310 Raw Materials Control
DR 1330 Finished Goods Control, on a quality release, at standard
DR/CR 5400 Yield Variance, the difference
DR 1350 Quarantined Stock, on a failure, instead of 1330
Each line posts at the moment of the transaction it belongs to.
SUNACE
Australia · Leading through quality
Sun Ace Australia Pty Ltd
32-38 Remington Drive, Dandenong South VIC 3175
ABN 52 006 388 102 · +61 3 9702 9444 · sunace@sunace.com.au
Batch manufacturing record
WO-2025-0798
- Grade
- INT-CZB40
- Batch
- B25-0798
- Made
- 09 Sep 2025
| Raw material | Lot | kg issued | Cost |
|---|---|---|---|
| INT-CAST70, Calcium stearate, own manufacture, blending grade | RED-2405470 | 7,312 | $24,861 |
| RM-5010, Polyethylene wax, 100 mPa·s | SAS-2412462 | 4,048 | $17,244 |
| RM-3010, Hydrotalcite, synthetic, Mg-Al | KIS-2610129 | 2,624 | $25,295 |
| RM-2020, Zinc oxide, French process, 99.7% | ZIB-2509871 | 2,016 | $9,798 |
| Quality test | Result | Specification |
|---|---|---|
| Yield | 99.69 % | 97.5-100 |
| Peak temperature | 133.5 °C | 128-142 |
| Fusion time | 54.4 s | 52.4-55.6 |
| Torque, peak | 41.6 Nm | 40.7-43.3 |
| Colour, initial ΔE | 1.32 ΔE | 0-3.5 |
| Bulk density | 309 g/L | 260-400 |
| Moisture | 0.54 % | 0-1.5 |
| Texture, visual | 1 | pass |
Manufactured by Malcolm Rees
Released by Quality Manager