🗂️ SOP 04 — Raw Material Separation Zone

SOP Name:         Raw Material Separation Zone
Process Code:     MATERIAL_ZONE_V1
Version:          V1
Owner:            Factory Supervisor
Applies To:       Factory Supervisor, Labour Team, Loader Operator
Frequency:        Daily
Last Updated:     2026-06-25
Review Frequency: Monthly

1. Purpose

Prevent material mixing, spillover and moisture damage.

2. Who Is Responsible

Factory Supervisor — maintains zone discipline.
Loader operator / labour — unload and use material in the correct zone.

3. When To Use This SOP

Daily, and whenever any material is received, moved or consumed.

4. Visual Process Flow

flowchart TD
A[Material arrives] --> B[Identify material type]
B --> C[Unload in marked zone]
C --> D[Maintain separation gap]
D --> E[Cover/protect if needed]
E --> F[Use material batch-wise]

5. Step-by-Step Visual SOP

Keep red soil, m-sand dust, m-sand waste and cement separate. [PHOTO: Material zones]
Mark each area clearly using board/paint/rope/brick boundary.
Maintain a gap between material heaps.
Do not allow loader/labour to push one material into another.
Keep red soil protected from ground moisture as much as possible.
Use old material first unless a quality issue exists.
Keep waste material separately.

6. Do / Don't

✅ Do	❌ Don't
Keep clear marked boundaries	Let heaps spread into each other
Use old stock first (FIFO)	Bury old material under new
Protect cement and soil from moisture	Store cement on wet ground

7. Checklist

[ ] Red soil zone clear
[ ] M-sand dust zone clear
[ ] Waste zone clear
[ ] Cement storage dry
[ ] No spillover between materials
[ ] Wet material separated

8. Records To Update

🔵 Daily housekeeping/zone check note
🔵 Telegram update if a zone issue is found

9. Escalation Rule

Inform management if material is spreading, mixing or absorbing moisture.

10. Common Mistakes

Letting the loader cut across into the next heap.
Storing cement directly on the ground.
Not marking zone boundaries, so labour guesses.

11. Improvement Suggestion

If you find a better way to do this process, add a comment below or submit an improvement request in the SOP Improvement Register.

Automation Readiness

Telegram command: /zone
n8n workflow:     wf_material_zone_check_v1
Odoo object:      stock.location
Approval role:    Factory Supervisor
Supabase table:   material_zone_checks
Status:           Future automation