🧊 SOP 08 — 20-Brick Mini-Stack & Sleeper Method

SOP Name:         20-Brick Mini-Stack & Sleeper Method
Process Code:     STACK20_SLEEPER_V1
Version:          V1
Owner:            Factory Supervisor
Applies To:       Factory Supervisor, Stacking Labour
Frequency:        Every production batch
Last Updated:     2026-06-25
Review Frequency: Monthly

1. Purpose

Standardize stacking, protect bricks from ground moisture and make counting easy.

2. Who Is Responsible

Factory Supervisor — enforces the 20-brick method and batch cards.
Stacking labour — builds mini-stacks and places sleepers.

3. When To Use This SOP

Every time fresh bricks are moved from the machine to the stacking area.

4. Visual Process Flow

flowchart TD
A[Prepare stack area] --> B[Place sleepers/base support]
B --> C[Stack 20 bricks]
C --> D[Keep batch card visible]
D --> E[Maintain gap between batches]
E --> F[Move to curing/stock stage]

5. Step-by-Step Visual SOP

Prepare a clean stacking area. [PHOTO: Work area]
Place rejected bricks/solid supports as sleepers.
Do not allow good bricks to touch wet/dirty ground.
Create mini-stacks of exactly 20 bricks.
Keep batches separate.
Place a batch card in front of each batch island.
Take a photo if required. [PHOTO: Correct stack]

6. Do / Don't (Correct Stack ✅ / Wrong Stack ❌)

✅ Correct	❌ Wrong
20 bricks per mini-stack	Irregular count
Sleepers used below	Good bricks touching ground
Batch card visible	No batch card
Gaps between batches	Mixed batches
Hold/reject separated	Broken bricks mixed with approved bricks

7. Checklist

[ ] Sleeper used
[ ] 20 bricks per mini-stack
[ ] Batch card placed
[ ] Batch separated
[ ] Hold/reject not mixed
[ ] Photo taken if required

8. Records To Update

🔵 Batch card (count, batch ID, date)
🔵 Stock/stacking note

9. Escalation Rule

Inform Ram/Srinivasan if there is not enough space/sleepers to stack correctly, or if batches are getting mixed.

10. Common Mistakes

Mini-stacks with uneven counts (hard to total stock).
Letting fresh bricks sit on bare wet ground.
Forgetting the batch card, losing traceability.

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: /stack
n8n workflow:     wf_stack20_v1
Odoo object:      stock.quant / stock.lot
Approval role:    Factory Supervisor
Supabase table:   stack_batches
Status:           Future automation