Cosmetics Filling Plant

This cookbook walks you through setting up TilliT for a cosmetics filling and packing plant. By the end, you will have a fully configured site with filling and packing lines, shift patterns, GMP-compliant quality activities, batch traceability, material tracking, and a scheduler that can plan and optimise production runs.

The setup is based on a real-world cosmetics facility that fills and packs products such as shampoos, lotions, body washes, and creams across several filling lines. The plant operates with two-shift patterns, follows GMP (Good Manufacturing Practice) procedures, and integrates with an ERP system (e.g. SAP) for production orders and batch management.

All names used in this guide are generic examples. Replace them with your own site, line, and product names.

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Prerequisites

Before you begin, ensure you have:

• A TilliT tenant provisioned for your organisation

• An administrator account with access to Settings

• The Excel Add-in installed (recommended for bulk data loading)

For a general introduction to TilliT setup concepts, see Introduction for New TilliT Customers.

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1

Create the Site

A site represents the physical location of your production plant.

Go to Settings -> Asset Hierarchy -> Sites -> Create

Field	Example Value
Name	Cosmetics Plant
Timezone	Europe/Helsinki
Location Code	CP

For more detail, see Site.

2

Define Asset Classes

Asset classes group similar types of equipment. A cosmetics filling plant typically has the following asset classes:

Asset Class	Description
Cosmetic Lines	The parent filling/packing lines
Cosmetic Fillers	Filling machines (volumetric, piston, or gravimetric) — also cap on combined fill/cap monoblocks
Cosmetic Labellers	Labelling machines — also apply batch/date coding
Cosmetic Case Packers	Case/carton packing machines
Cosmetic Palletisers	Palletising machines or stations
Cosmetic QA	Quality assurance station (shared)

Asset classes are global across the tenant. Prefix yours (e.g. Cosmetic Lines) so the cosmetics plant has its own classes instead of inheriting another site's model (e.g. an existing wine-bottling site that also uses generic Lines/Fillers). This keeps reporting, run-rate templates, and activity assignments scoped to the cosmetics line.

This guide models lines where capping is built into the filler and coding is built into the labeller, and weight verification is an in-process check — so there are no separate Capper, Coding, or Checkweigher asset classes. If your plant runs those as standalone machines, add those classes and the matching assets.

Some plants may also have dedicated asset classes for:

• Bulk Holding - bulk/compounding tanks feeding the filler

• Shrink Wrappers - overwrap or shrink-wrap stations

Go to Settings -> Asset Hierarchy -> Asset Class -> Create

Create one asset class for each type listed above. See Asset Class for details.

3

Build the Asset Hierarchy

Assets represent the individual machines on each line. In a cosmetics plant the hierarchy follows this pattern:

Site
├── Line 1 (class: Cosmetic Lines)
│   ├── Line 1 Filler (class: Cosmetic Fillers)        ← also caps (capping merged into the filler)
│   ├── Line 1 Labeller (class: Cosmetic Labellers)    ← also codes (batch/date coding merged into the labeller)
│   ├── Line 1 Case Packer (class: Cosmetic Case Packers)
│   └── Line 1 Palletiser (class: Cosmetic Palletisers)
├── Line 2 (class: Cosmetic Lines)
│   ├── Line 2 Filler (class: Cosmetic Fillers)
│   ├── Line 2 Labeller (class: Cosmetic Labellers)
│   ├── Line 2 Case Packer (class: Cosmetic Case Packers)
│   └── Line 2 Palletiser (class: Cosmetic Palletisers)
├── ...additional lines...
└── QA (class: Cosmetic QA)  ← shared across all lines

Key points

• Filling lines follow a linear flow: Filler -> Labeller -> Case Packer -> Palletiser.

• On these lines, capping is performed on the filler (combined fill/cap monoblock) and batch/date coding is performed at the labeller, so there are no separate Capper or Coder stations. Weight checks are captured as in-process quality checks rather than a dedicated checkweigher asset.

• Not every line has every station - some may share a palletiser.

• Shared assets like QA sit at the top level, not under a specific line.

• Use Display Order to control the sequence assets appear in the UI (e.g. 100, 200, 300).

• Each line is typically identified by a work centre code from the ERP (e.g. WC-LINE1).

Go to Settings -> Asset Hierarchy -> Assets -> Create

Create each asset, assign it to the correct asset class, and set the parent asset for child equipment. See Asset for details.

For sites with many assets, use the Excel Add-in to create assets in bulk.

4

Configure Shifts

Shift templates define the working hours for each line. A cosmetics plant typically operates two shifts on weekdays:

Shift Template	Start Time	Duration	Description
Morning 8hr	06:00	8 hours	Standard morning shift
Afternoon 8hr	14:00	8 hours	Afternoon shift
Morning 10hr	06:00	10 hours	Extended morning shift
Afternoon 10hr	16:00	10 hours	Extended afternoon shift
16x5	--	--	2-shift coverage (Mon-Fri, 06:00-22:00)

Creating shift schedules

Setting up shifts is a two-step process: first, you define the overall shift pattern (Shift Template and its Items); then, you link that pattern to your equipment using a Shift Calendar.

1

Create and Configure the Shift Template

1. Go to: Settings -> Asset Hierarchy -> Shift Templates -> Create.

2. Create the required shift templates.

3. Within each created template, go to: Items

4. Define the specific shift periods, including their start times and durations.

See Creating a Shift Template for details.

2

Assign Shifts to Assets

Once your templates and items are ready, create calendars to map these schedules to the correct assets.

Since not every line runs the same schedule, calendars ensure each asset accurately reflects its real-world operating schedule.

1. Go to: Settings -> Asset Hierarchy -> Calendars -> Create.

2. Add your Shift Template as a calendar Item.

3. Select the relevant asset and apply the template.

5

Set Up Units of Measure

Before creating materials and process variables, define the units of measure your site will use.

Unit	Description
PC	Pieces (bottles, caps, labels, cases)
KG	Kilograms (bulk product)
g	Grams (fill weight)
mL	Millilitres (fill volume)
mm	Millimetres (label placement, dimensions)
%	Percentage
EA	Each

Go to Settings -> Configuration -> Unit of Measure -> Create

See Unit of Measure for details.

6

Create Material Groups

Material groups categorise your raw materials, packaging components, and finished goods. For a cosmetics plant:

Group	Description
Finished Goods	Finished packaged cosmetics products (SKUs)
Bulk	Bulk/compounded product (formulations)
BOT	Bottles, tubes, jars, and containers
CAP	Caps, closures, pumps, and applicators
LAB	Labels (front, back, neck, wrap)
CAR	Cartons and cases (shelf-ready, shipper)
PAL	Pallets, slip sheets, stretch wrap, layer pads
BTL	Batch labels (blank and printed)
PKG	Secondary packaging (gift boxes, sleeves, shrink wrap)

Go to Settings -> Material Definition -> Material Groups -> Create

See Material Group for details.

Match your material groups to how your ERP categorises components in the bill of materials. This makes order integration straightforward.

7

Add Materials

Materials represent the specific items consumed or produced. A cosmetics plant typically has hundreds of materials across groups.

Typical material types:

• Bulk products - the compounded formulation (shampoo base, lotion, cream), measured in KG

• Bottles/containers - plastic bottles, tubes, jars, identified by volume and mould code

• Closures - caps, pumps, applicators, flip-tops

• Labels - front labels, back labels, often product-specific

• Cases - carton/shipper boxes, sized to the product (e.g. 6x300mL)

• Batch labels - blank paper labels for batch/lot marking

• Finished goods - the final packaged product (SKU)

Go to Settings -> Material Definition -> Materials -> Create

For bulk loading, use the Excel Add-in to import materials from a spreadsheet.

See Material for details.

8

Define Attributes

Attributes store metadata against orders, materials, and assets. In a cosmetics filling plant, think of them as the product's "Manufacturing Specification Sheet" or identity card. They hold details about a work order, such as fragrance, colour, and package size. TilliT uses them to show relevant fields and calculate changeover times.

Order Number Attributes

These attach to all work orders that share the same Order Number. They are useful when production orders are split into multiple operations but still need shared information. When orders are loaded via the API, these attribute values can be provided in the payload. See Step 14. Group them by purpose:

Product & Batch

Attribute	Data Type	Purpose
MaterialNumber	STRING	ERP material/SKU code
BatchNumber	STRING	Production batch number
BulkBatchNumber	STRING	Bulk/compounding batch number
BulkMaterialCode	STRING	Bulk material code from ERP
BulkLotNumber	STRING	Bulk lot number for traceability
BestBefore	STRING	Best-before / expiry date
ProductionDate	STRING	Date the bulk was produced
StorageConditions	STRING	Storage temperature range (e.g. 10-30 C)

Fill Specifications

Attribute	Data Type	Purpose
NominalFillVolume	NUMBER	Nominal fill volume in mL
NominalFillWeight	NUMBER	Nominal fill weight in g
MinFillWeight	NUMBER	Minimum acceptable fill weight
FillNozzles	NUMBER	Number of filler nozzles/heads in use
ProductViscosity	STRING	Product viscosity category (low, medium, high)

Packaging Configuration

Attribute	Data Type	Purpose
BottleCode	STRING	Bottle/container material code
ClosureCode	STRING	Cap/closure material code
ClosureType	STRING	Closure type (screw cap, pump, flip-top, applicator)
LabelCode	STRING	Label material code
CaseConfig	STRING	Case packing configuration (e.g. 6x300mL)
UnitsPerCase	NUMBER	Number of units per case
CaseDimensions	STRING	Case dimensions (LxWxH in mm)

Palletising

Attribute	Data Type	Purpose
PalletType	STRING	Pallet type (EURO, standard)
CasesPerLayer	NUMBER	Cases per pallet layer
LayersPerPallet	NUMBER	Number of pallet layers
CasesPerPallet	NUMBER	Total cases per pallet
UnitsPerPallet	NUMBER	Total finished units per pallet
LayerPad	BOOLEAN	Layer pad/divider between layers
UnitWeight	NUMBER	Weight of a single packed unit (kg)

General

Attribute	Data Type	Purpose
EANCode	STRING	Consumer package EAN barcode
GS1String	STRING	Full GS1 barcode string for case label
SpecialInstructions	STRING	Special handling or production notes
PreviousProduct	STRING	Previous product on line (for line clearance)
WorkCentre	STRING	ERP work centre code

Material Attributes

Attribute	Data Type	Purpose
ProductCategory	STRING	Product category (shampoo, lotion, cream, body wash, etc.)
Fragrance	STRING	Fragrance family or code
Colour	STRING	Product colour

Go to Settings -> Configuration -> Attributes -> Create

See Attribute for details.

You do not need to create all attributes manually before loading orders. When you use the order upsert API in Step 14, any attribute that does not already exist will be created automatically.

9

Set Up Process Variables

Process variables define the measurements and checks that operators capture during production. In cosmetics, fill weight and label placement are the most critical.

Fill Weight

Process Variable	UoM	Upper Limit	Lower Limit	Notes
Fill Weight	g	NominalFillWeight+5	MinFillWeight	Referenced from order attributes
Tare Weight	g	--	--	Bottle + closure empty weight

Label Placement

Process Variable	UoM	Upper Limit	Lower Limit	Notes
Label Height From Base	mm	13	9	Distance from bottle base to label edge
Label Alignment	mm	2	-2	Front-to-back label alignment offset

Checkweigher

Process Variable	UoM	Upper Limit	Lower Limit	Notes
Checkweigher Weight	g	NominalFillWeight+10	MinFillWeight-5	In-line 100% weight verification

Tolerance settings

Set a target, upper limit and lower limit on each measured process variable. The tolerance lives on the process variable (and can be overridden per order via the order's tolerances — see Step 14), so any activity item that measures it is judged automatically — you don't add a separate "in tolerance?" checkbox. Default tolerances for this plant:

Process Variable	Target	Lower	Upper	UoM
Fill Weight	315	310	320	g
Tare Weight	8	7	9	g
Checkweigher Weight	315	305	325	g
Label Height From Base	11	9	13	mm
Label Alignment	0	-2	2	mm

Go to Settings -> Configuration -> Process Variable -> Create

See Process Variable for details.

Process variables that reference attributes (like NominalFillWeight) will automatically pull the correct spec from the current work order. This means one activity template works for all products.

When an activity item measures a process variable, set the item's tolerance type to Process Variable and link the PV. The operator enters the reading and the item flags out-of-tolerance against the PV's limits — no separate pass/fail field. The fill weight, tare weight, label height, and label alignment checks all work this way.

10

Create Activity Classes

Activity classes group related activity templates in the UI. For a cosmetics filling plant:

Activity Class	Purpose
Line Setup	Line clearance, changeover, and startup checks
Quality	In-process quality checks (weight, label, visual)
Machine Checks	Equipment verification and sensor testing
Data Capture	Material booking, batch logging, consumption records
Sampling	Lab sample collection (start, during, end of batch)
Cleaning	CIP, line cleaning, and sanitation
End of Run	End-of-batch and teardown activities
Palletising	Pallet configuration and label verification

Go to Settings -> Activity Template -> Activity Classes -> Create

See Activity Class for details.

11

Build Activity Templates

Activity templates are the digital forms that replace the paper-based operation system documents used on the production floor. A cosmetics plant typically has a comprehensive set covering GMP requirements.

Core Activity Categories

Pre-Start Preparation (on Order ready, before the order starts)

These fire on the Order ready event — the order is staged and the line prepared so it can start cleanly. "Ready" precedes "start".

Activity	Triggered by	Assigned to (where)
Stage Order Materials	Order ready	Cosmetic Lines
Bulk Product Hook-up	Order ready	Cosmetic Fillers
Change Parts Setup	Order ready	Cosmetic Lines
Label and Coding Reel Load	Order ready	Cosmetic Labellers
Pre-Start Readiness Confirmation	Order ready	Cosmetic Lines

Line Setup & Clearance (before production starts)

Activity	Triggered by	Assigned to
Previous Product Clearance	Order start	operators
Line Inspection & Cleaning	Order start	operators
Wash & Disinfection Confirmation	Order start	operators
Capper Rejection Test	Order start	operators
Rejection Sensor Test	Order start	operators
Case Packer Program Verification	Order start	operators
Checkweigher Setup	Order start	operators
Line Function Confirmation	Order start	operators

Material & Batch Verification

Activity	Triggered by	Assigned to
Work Order Verification	Order start	operators
Material Verification	Order start	operators
Bulk Product Verification	Order start	operators
Printed Material Verification	Order start	operators
EAN Barcode Verification	Order start	operators
Material Booking Confirmation	Order start	operators

In-Process Quality Checks

Activity	Triggered by	Assigned to
Closure Tightness Check	Order start	operators
Closure Leak Test	Interval (hourly)	operators
Reject Lane Inspection	Interval	operators
Visual Quality Check	Interval	operators
Batch Marking Verification	Order start	operators
Fill Weight Check	Interval (hourly)	operators
Tare Verification	Batch change	operators
Label Placement Check	Order start	operators

Sampling

Activity	Triggered by	Assigned to
Start-of-Batch Lab Samples	Order start	operators
Mid-Batch Lab Samples	Interval	operators
End-of-Batch Lab Samples	Order end	operators

Lab sample activities collect physical samples from the line for laboratory testing. Each activity should prompt the operator to record the sample details and confirm the sample has been taken. Below are example form structures for each sampling point.

Start-of-Batch Lab Samples - collected from the first units off the line to confirm the product meets specification before full production begins.

Form Item	Type	Example / Notes
Sample Time	Date/Time	Auto-filled with current timestamp
Batch Number	Text (read-only)	Pulled from order attribute BatchNumber
Bulk Batch Number	Text (read-only)	Pulled from order attribute BulkBatchNumber
Fill Weight Sample 1	Number (g)	Weigh first sample unit
Fill Weight Sample 2	Number (g)	Weigh second sample unit
Fill Weight Sample 3	Number (g)	Weigh third sample unit
Appearance Check	Select	Clear / Cloudy / Off-colour / Contains particles
Fragrance Check	Select	Correct / Incorrect / Weak / Strong
Viscosity Check	Select	Within spec / Too thin / Too thick
pH Reading	Number	Measured with pH meter (e.g. target 5.0-6.5 for shampoo)
Closure Torque Sample	Number (Nm)	Torque test on 3 units (e.g. target 1.2-1.8 Nm)
Label Adhesion OK	Checkbox	Confirm label is firmly adhered, no peeling or bubbling
Sample Sent to Lab	Checkbox	Operator confirms physical sample placed in lab tray
Operator Comments	Text	Free-text field for any observations

Mid-Batch Lab Samples - collected at regular intervals (e.g. every 2 hours or every 3000 units) during the run to monitor ongoing quality.

Form Item	Type	Example / Notes
Sample Time	Date/Time	Auto-filled with current timestamp
Units Produced at Sample	Number	Count at time of sampling
Fill Weight Sample 1	Number (g)	Weigh first sample unit
Fill Weight Sample 2	Number (g)	Weigh second sample unit
Fill Weight Sample 3	Number (g)	Weigh third sample unit
Average Fill Weight	Number (g)	Auto-calculated from samples
Appearance Check	Select	Clear / Cloudy / Off-colour / Contains particles
Viscosity Check	Select	Within spec / Too thin / Too thick
pH Reading	Number	pH meter reading
Closure Torque Sample	Number (Nm)	Torque test on 3 units
Label Placement OK	Checkbox	Confirm label height and alignment within spec
Print Quality OK	Checkbox	Batch code, expiry date, and EAN legible
Micro Swab Taken	Checkbox	If required by GMP schedule (e.g. every 4 hours)
Sample Sent to Lab	Checkbox	Operator confirms physical sample placed in lab tray
Operator Comments	Text	Free-text for drift observations or adjustments made

End-of-Batch Lab Samples - collected from the last units off the line to confirm the product remained within specification throughout the run.

Form Item	Type	Example / Notes
Sample Time	Date/Time	Auto-filled with current timestamp
Total Units Produced	Number (read-only)	Final production count
Fill Weight Sample 1	Number (g)	Weigh first sample unit
Fill Weight Sample 2	Number (g)	Weigh second sample unit
Fill Weight Sample 3	Number (g)	Weigh third sample unit
Appearance Check	Select	Clear / Cloudy / Off-colour / Contains particles
Fragrance Check	Select	Correct / Incorrect / Weak / Strong
Viscosity Check	Select	Within spec / Too thin / Too thick
pH Reading	Number	pH meter reading
Closure Torque Sample	Number (Nm)	Torque test on 3 units
Retention Sample Collected	Checkbox	Retain sample stored for shelf-life stability testing
Retention Sample Quantity	Number	Number of units retained (e.g. 6)
Micro Swab Taken	Checkbox	End-of-batch environmental swab if required
Sample Sent to Lab	Checkbox	Operator confirms physical sample placed in lab tray
Batch Release Recommendation	Select	Pass / Conditional / Fail
Operator Comments	Text	Summary observations from the run

Retention samples are a GMP requirement - most cosmetics plants retain 6-12 units per batch for stability and complaint investigation purposes. The retention period is typically equal to the product shelf life plus one year.

Packing & Palletising

Activity	Triggered by	Assigned to
Case Packing Verification	Order start	operators
Case Label Verification	Order start	operators
Pallet Configuration Check	Order start	operators
Transfer Quantity Confirmation	Order end	operators, supervisors

End of Run

Activity	Triggered by	Assigned to
Case Packer Cleaning	Order end	operators
Line Cleaning & Teardown	Order end	operators
Complaint/Reject Sample Collection	Order end	operators
Material Return & Verification	Order end	operators
Run Values Recording	Order end	operators
Deviation Log	Manual	operators, supervisors

Form item types

Each form item has a data type that controls how it is captured and judged. Choose the right one — for a GMP record the difference matters:

Notation	Item data type	Use it for
P/F	Pass / Fail	A quality verdict — the operator records pass or fail, a fail is a recorded non-conformance that can block the order, trigger an event, or require a comment. Use for every GMP check/confirmation.
# → PV	Number with Process-Variable tolerance	A measurement judged automatically against a process variable's target + upper/lower limits (set the item's tolerance type to Process Variable). The reading itself flags in/out of spec — no separate pass/fail item.
#	Number	A plain count or value with no tolerance (e.g. units produced, reject count).
barcode	Barcode	Operator scans a code; validate by length/fields (e.g. EAN-13) or GS1 structure.
material	Material	Scan or select a material; validates the scan against the order's expected material (via the material's barcode reference).
txt	Text	Free text or a reference code (batch number, operator name).
⏱	Date / Time	Timestamps (e.g. sample time).

Pass/Fail, not Boolean. A generic Boolean (true/false) is just data; a Pass/Fail item is a quality verdict that TilliT treats as a check result — it drives compliance status, escalation, and order-blocking. Use Pass/Fail for all checks/confirmations. And never pair a measurement with a "within spec?" Pass/Fail — put the limits on the process variable and let the # → PV measurement decide.

Every activity carries the items operators complete. The three lab sampling activities are detailed in full above (their fill-weight, torque, and pH readings are # → PV measurements); the rest use the concise sets below.

Pre-Start Preparation (Order ready)

Activity	Form items
Stage Order Materials	P/F Bulk Staged, P/F Bottles Staged, P/F Caps Staged, P/F Labels Staged, P/F Cases Staged
Bulk Product Hook-up	Bulk Batch Number, P/F Bulk Connected, P/F Lines Purged
Change Parts Setup	Bottle Size, P/F Change Parts Fitted, Closure Type, P/F Tooling Set
Label and Coding Reel Load	Label Code, P/F Reel Loaded, P/F Coding Ribbon Loaded, P/F Print Verified
Pre-Start Readiness Confirmation	P/F All Materials Staged, P/F Line Set Up, P/F Ready to Start, Confirmed By

Line Setup & Clearance

Activity	Form items
Previous Product Clearance	Previous Product, P/F Line Cleared of Previous Product, Cleared By
Line Inspection & Cleaning	P/F Line Visually Clean, P/F No Foreign Material Present, Inspected By
Wash & Disinfection Confirmation	P/F Wash Completed, Disinfectant Used, P/F Contact Time Met
Capper Rejection Test	P/F Test Cap Rejected, P/F Reject Mechanism OK
Rejection Sensor Test	P/F Sensor Triggered, P/F Reject Confirmed
Case Packer Program Verification	Program Number, P/F Correct Program Loaded
Checkweigher Setup	# Checkweigher Weight → PV (g), P/F Calibration Check Passed
Line Function Confirmation	P/F All Stations Operational, Confirmed By

Material & Batch Verification

Activity	Form items
Work Order Verification	P/F Order Number Correct, P/F Material Matches Order
Material Verification	Material Code, Batch Number, P/F Material Verified
Bulk Product Verification	Bulk Batch Number, Bulk Material Code, P/F Bulk Verified
Printed Material Verification	Label Code, P/F Print Correct
EAN Barcode Verification	barcode Scan EAN (EAN-13), material Verify Material (scan is validated against the order's product)
Material Booking Confirmation	# Quantity Booked, P/F Booking Confirmed

In-Process Quality

Activity	Form items
Closure Tightness Check	# Torque Reading → PV: Closure Torque
Closure Leak Test	# Units Tested, P/F Leak Detected
Reject Lane Inspection	P/F Rejects Present, # Reject Count
Visual Quality Check	P/F Appearance OK, Defects Noted
Batch Marking Verification	P/F Batch Code Legible, P/F Expiry Date Correct
Fill Weight Check	# Fill Weight → PV: Fill Weight (g)
Tare Verification	# Tare Weight → PV: Tare Weight (g)
Label Placement Check	# Label Height → PV (mm), # Label Alignment → PV (mm)

Packing & Palletising

Activity	Form items
Case Packing Verification	# Units Per Case, P/F Case Config Correct
Case Label Verification	P/F Case Label Correct, P/F GS1 Scan OK
Pallet Configuration Check	# Cases Per Layer, # Layers Per Pallet, P/F Config Correct
Transfer Quantity Confirmation	# Quantity Transferred, Confirmed By

End of Run

Activity	Form items
Case Packer Cleaning	P/F Cleaning Completed, Cleaned By
Line Cleaning & Teardown	P/F Teardown Completed, P/F Line Clean
Complaint/Reject Sample Collection	# Samples Collected, P/F Samples Stored
Material Return & Verification	Material Returned, # Quantity Returned, P/F Return Verified
Run Values Recording	# Total Produced, # Total Rejects, # Downtime Minutes
Deviation Log	Deviation Description, Action Taken

These are starter item sets to get each activity functional. Expand them with option lists, barcode scans, and calculated fields as your GMP procedures require.

When and where (triggers and placement)

Each activity needs a When (a trigger / activity starter) and a Where (an assignment to an asset class). For these lines:

When — triggers

Trigger	Event	Activities
Order ready	Order ready	Pre-start prep: Stage Order Materials, Bulk Product Hook-up, Change Parts Setup, Label and Coding Reel Load, Pre-Start Readiness Confirmation
Order start	Order started	All line-setup & clearance, all material/batch verification, Closure Tightness, Batch Marking, Label Placement, Start-of-Batch Lab Samples, Case Packing/Label Verification, Pallet Configuration Check
Hourly	Order started + 60-min interval	Closure Leak Test, Fill Weight Check
Periodic	Order started + 120-min interval	Reject Lane Inspection, Visual Quality Check, Mid-Batch Lab Samples
Batch change	Order changeover started	Tare Verification
Order end	Order completed	End-of-Batch Lab Samples, Transfer Quantity Confirmation, Case Packer Cleaning, Line Cleaning & Teardown, Complaint/Reject Sample Collection, Material Return & Verification, Run Values Recording
Manual	Activity Manual Start	Deviation Log

Where — assigned to asset class

Asset class	Activities
Cosmetic Lines	Clearance/inspection/wash, Line Function, Work Order/Material/Bulk/Booking verification, Reject Lane, Visual Quality, all Lab Samples, Transfer Quantity, all End-of-Run
Cosmetic Fillers	Capper Rejection Test, Rejection Sensor Test, Checkweigher Setup, Closure Tightness, Closure Leak, Fill Weight, Tare Verification (capping + weight live on the filler)
Cosmetic Labellers	Printed Material & EAN Verification, Batch Marking, Label Placement (labelling + coding)
Cosmetic Case Packers	Case Packer Program Verification, Case Packing & Case Label Verification, Case Packer Cleaning
Cosmetic Palletisers	Pallet Configuration Check

When = an Activity Starter (event type, plus an interval for periodic checks). Where = an Activity Assignment binding the template + starter to an asset class. Assigning to a class (e.g. Cosmetic Fillers) applies the activity to that station on every line automatically. Interval checks combine the start event with a repeat interval (e.g. every 60 minutes after the order starts).

Building an activity template

For each activity, you need to:

1. Create the template with a name and activity key.

2. Assign it to an activity class.

3. Set the "Claimable By" field to define who can see and claim the activity.

4. Configure the trigger to define when it fires.

5. Build the form items that operators fill in.

Go to Settings -> Activity Template -> Activity Template -> Create

See Creating an Activity for a complete walkthrough.

For trigger types, see When and Where.

Start with the line setup and clearance activities first. These are the GMP-critical checks that must happen before every production run. Expand to in-process and end-of-run activities once the team is comfortable.

12

Configure Order Templates

Order templates define how a work order is executed across a line. They specify which machines within the line participate in the order and the operation type for each stage.

Filling Line (Line 1 example)

Order Template	Operation	From Asset	To Asset
Line 1 Filler	FILLER	Line 1	Line 1 Filler
Line 1 Labeller	LABELLER	Line 1	Line 1 Labeller
Line 1 Case Packer	CASE_PACKER	Line 1	Line 1 Case Packer
Line 1 Palletiser	PALLETISER	Line 1	Line 1 Palletiser
QA	QA	Line 1	QA

Repeat this pattern for each line. (No separate Capper/Coder/Checkweigher templates — capping runs on the filler and coding on the labeller.)

Order template components

Each order template can declare the material groups it consumes, so the bill of materials cascades to the right station when an order is created. For these combined lines:

Order Template	Consumes (material groups)
Filler	Bulk, BOT (bottles), CAP (closures — capping is on the filler)
Labeller	LAB (labels)
Case Packer	CAR (cases), BTL (batch labels)
Palletiser	PAL (pallets)
QA	—

Go to Settings -> Asset Hierarchy -> Order Templates -> Create

See Order Template for details.

13

Set Up the Scheduler

Once Digital Operations is configured, you can set up the Scheduler to plan and optimise production runs.

1

Create the Data Template

The Default Data Template links the Scheduler to the Digital Operations site and connects scheduler equipment to live production data.

In newly provisioned environments, sections such as Equipment, Availability, Optimisation, and Changeovers may not be available until a Data Template has been created.

Go to Scheduler -> Data Templates -> Create

Create the Default Data Template.

See Data Templates for details.

2

Create Scheduler Equipment

Each filling line becomes a piece of equipment in the Scheduler:

Equipment (Name)	External ID (Code)	Display Order
Line 1	Line 1	1
Line 2	Line 2	2
Line 3	Line 3	3

See Equipment for details.

3

Create Availability Templates

Typical availability patterns for a cosmetics plant:

Template (Code)	Name	Description	Days
16x5	16 Hours Mon-Fri	Mon-Fri, 06:00-22:00 (2 shifts)	Mon-Fri
8x5	8 Hours Mon-Fri	Mon-Fri, 06:00-14:00 (day shift only)	Mon-Fri

After creating the templates, assign one to each line - a line with no availability has no working calendar and the scheduler can't place work on it. Assign 16x5 to all three lines for two-shift coverage (or 8x5 for a day-shift-only line).

When you assign an availability to equipment you give it a calendar date range. Keep this to the scheduling horizon you actually need (e.g. one year) - do not use an open-ended far-future end date. The scheduler materialises every shift in the range when it loads the line, so a multi-decade window generates tens of thousands of periods per line and the schedule view will fail to load. A one-year window is plenty and can be rolled forward later.

See Availability for details.

4

Define Optimisation Properties

Optimisation properties are the characteristics the scheduler uses to sequence orders and calculate changeover times. For cosmetics filling:

Property (Name)	Example Values	Description
Product Category	Shampoo, Lotion, Cream, Body Wash, Conditioner	Drives cleaning requirements between categories
Fragrance	Unscented, Floral, Citrus, Fresh Mint...	Fragrance changes may require line flush
Colour	Clear, White, Pink, Blue...	Dark-to-light transitions need more cleaning
Bottle Size	100mL, 200mL, 300mL, 500mL	Size changes require filler head and packer adjustments
Closure Type	Screw Cap, Pump, Flip-Top, Applicator	Closure changes require capper changeover

A property only affects sequencing if your finished-good materials carry its value. Each finished good should be tagged with all five properties (e.g. Moisturising Shampoo 300mL = Product Category Shampoo, Fragrance Floral, Colour Clear, Bottle Size 300mL, Closure Type Screw Cap). The scheduler reads these values off the order's product and applies the matching changeover rule. Components (bottles, caps, labels) don't need optimisation properties.

See Optimisation for details.

5

Configure Changeover Rules

Changeovers define the downtime required to clean or mechanically reconfigure a line when switching between products. In cosmetics, changeovers are driven by cleaning and mechanical adjustments.

Key changeover rules for cosmetics filling:

• Same product category, same fragrance - 15-30 minutes (mechanical changeover only)

• Same category, different fragrance - 30-60 minutes (partial line flush)

• Different product category - 60-120 minutes (full wash and disinfection)

• Colour change (dark to light) - additional 30-60 minutes for cleaning

• Bottle size change - 20-40 minutes (filler, capper, labeller, case packer adjustments)

• Closure type change - 15-30 minutes (capper changeover)

Changeover times are entered as a matrix of from-value to to-value for each optimisation property.

These rules are grouped into a changeover set (e.g. Cosmetics Filling). Remember to assign that changeover set to each line - a line not linked to a set won't apply any changeover times when sequencing.

See Changeovers for details.

6

Define Operations and Production Routes

Equipment, availability, and changeovers tell the scheduler where and when it can work. Operations tell it what the work is and how long it takes.

The model is a small hierarchy:

Operation (one per finished good - code = the product's material code)
  └── Route
        └── Segment "Fill and Pack"
              ├── Consumed materials  - the bill of materials (bulk, bottle, cap, label, case, batch label)
              ├── Produced material   - the one finished good this operation makes
              └── Run rate            - throughput in units per second

For each finished good, create an operation with a single Fill and Pack segment that:

• consumes its components - e.g. Moisturising Shampoo 300mL consumes the shampoo bulk, a 300mL bottle, a screw cap, the 300mL front label, a 6x300mL case, and a batch label;

• produces the one finished good (the SKU); and

• declares a run rate in units per second. The scheduler derives an order's duration from quantity ÷ run rate (e.g. 10,000 units at 2 units/s ≈ 1.4 hours of run time, before changeovers). Smaller bottles typically run faster (2.0-2.5 u/s) than larger ones (≈1.5 u/s); and

• declares an equipment requirement. Match the segment to an equipment class (e.g. Lines) rather than a single line, so the scheduler can place the order on any line in that class. Without an equipment requirement the scheduler has nowhere to run the order.

The run rate replaces a fixed duration: a segment is timed either by a fixed duration or by a throughput rate. For filling lines, the per-product run rate is what you want, since duration then scales with order quantity.

See Operations for details.

7

Load Scheduler Data

For bulk loading of scheduler master data, including equipment properties, availability calendars, and changeover matrices, use the Excel Add-in.

See Loading data with Excel Add-in for details.

14

Integrate Order Loading from ERP

In most cosmetics plants, production orders originate in an ERP system such as SAP and need to flow into TilliT automatically. Use the POST:/core/order-instances/upsert endpoint to load orders with all their attributes, tolerances, and components.

Order Payload Structure

The upsert endpoint accepts an array of orders. Below is an example based on a typical cosmetics production order for a 300mL shampoo:

[
  {
    "orderNumber": "WO-20260428-001",
    "orderDate": "2026-04-21",
    "dueDate": "2026-04-29",
    "scheduledStart": "2026-04-28T06:00:00",
    "scheduledEnd": "2026-04-29T14:00:00",
    "quantityTarget": 9500,
    "defaultRunRate": 120,
    "status": "NEW",
    "name": "Moisturising Shampoo 300mL",
    "asset": "Line 1",
    "batchNumber": "B26041",
    "material": {
      "externalId": "FG-SH-300",
      "name": "Moisturising Shampoo 300mL"
    },
    "attributes": [
      { "attributeName": "MaterialNumber", "value": "FG-SH-300" },
      { "attributeName": "BatchNumber", "value": "B26041" },
      { "attributeName": "BulkMaterialCode", "value": "BLK-SH-001" },
      { "attributeName": "BulkBatchNumber", "value": "B26040" },
      { "attributeName": "BulkLotNumber", "value": "LOT-2026-04-001" },
      { "attributeName": "ProductionDate", "value": "2026-04-22" },
      { "attributeName": "BestBefore", "value": "2029-04" },
      { "attributeName": "StorageConditions", "value": "10-30 C" },
      { "attributeName": "NominalFillVolume", "value": "300" },
      { "attributeName": "NominalFillWeight", "value": "315" },
      { "attributeName": "MinFillWeight", "value": "310" },
      { "attributeName": "BottleCode", "value": "BOT-300-RND" },
      { "attributeName": "ClosureCode", "value": "CAP-SC-28" },
      { "attributeName": "ClosureType", "value": "Screw Cap" },
      { "attributeName": "LabelCode", "value": "LAB-SH-300" },
      { "attributeName": "CaseConfig", "value": "6x300mL" },
      { "attributeName": "UnitsPerCase", "value": "6" },
      { "attributeName": "PalletType", "value": "EURO" },
      { "attributeName": "CasesPerLayer", "value": "55" },
      { "attributeName": "LayersPerPallet", "value": "4" },
      { "attributeName": "CasesPerPallet", "value": "220" },
      { "attributeName": "UnitsPerPallet", "value": "1320" },
      { "attributeName": "LayerPad", "value": "true" },
      { "attributeName": "UnitWeight", "value": "1.8" },
      { "attributeName": "EANCode", "value": "5901234123457" },
      { "attributeName": "WorkCentre", "value": "WC-LINE1" },
      { "attributeName": "SpecialInstructions", "value": "" }
    ],
    "tolerances": [
      { "processVariableName": "Fill Weight", "target": 315, "lowerLimit": 310, "upperLimit": 320 },
      { "processVariableName": "Checkweigher Weight", "target": 315, "lowerLimit": 305, "upperLimit": 325 },
      { "processVariableName": "Label Height From Base", "target": 11, "lowerLimit": 9, "upperLimit": 13 }
    ],
    "orderComponents": [
      { "componentExternalId": "BOT-300-RND", "componentGroup": "BOT", "componentName": "300mL Round Bottle", "target": 9785 },
      { "componentExternalId": "CAP-SC-28", "componentGroup": "CAP", "componentName": "28mm Screw Cap", "target": 9785 },
      { "componentExternalId": "LAB-SH-300", "componentGroup": "LAB", "componentName": "Shampoo Front Label 300mL", "target": 10450 },
      { "componentExternalId": "CAR-6x300", "componentGroup": "CAR", "componentName": "Case 6x300mL", "target": 1635 },
      { "componentExternalId": "BTL-100x74", "componentGroup": "BTL", "componentName": "Batch Label 100x74mm", "target": 1666 },
      { "componentExternalId": "BLK-SH-001", "componentGroup": "Bulk", "componentName": "Moisturising Shampoo Bulk", "target": 2994 }
    ]
  }
]

Key points

• asset - set to the parent line name. If order templates are configured in Step 12, the order automatically cascades to child assets.

• batchNumber - the production batch number from the ERP. This is critical for GMP traceability.

• attributes - all values are strings, even for BOOLEAN and NUMBER types.

• tolerances - override the default process variable limits for this specific order.

• orderComponents - the bill of materials for the order. Quantities can include overages.

• Upsert behaviour - if you send a work order that matches an existing combination of orderNumber, operation, and asset, TilliT updates the existing order instead of creating a duplicate.

• Auto-creation - materials, attributes, UoMs, and tolerances that do not already exist will be created automatically.

Typical attribute categories in the payload

Category	Attributes	Purpose
Product & batch	MaterialNumber, BatchNumber, BulkBatchNumber, BulkMaterialCode, BulkLotNumber, BestBefore	GMP traceability
Fill specs	NominalFillVolume, NominalFillWeight, MinFillWeight, FillNozzles, ProductViscosity	Filler setup and weight checks
Packaging	BottleCode, ClosureCode, ClosureType, LabelCode, CaseConfig, UnitsPerCase	Line setup and material verification
Palletising	PalletType, CasesPerLayer, LayersPerPallet, CasesPerPallet, UnitsPerPallet, LayerPad	Pallet build configuration
Barcoding	EANCode, GS1String	Barcode verification and case labels
General	SpecialInstructions, WorkCentre, PreviousProduct	Operator notes and line clearance

For the full API reference, see Upload Production Schedule.

15

Create Your First Work Order

With all master data in place, you can test by creating a work order manually:

1. Navigate to the line where you want to run the order.

2. Click Create Order.

3. Select the material to produce.

4. Enter the quantity and batch number.

5. Fill in the order number attributes.

6. Start the order.

When the order starts, TilliT automatically triggers the configured activities and the order flows through each machine according to the order template.

See Create adhoc Order and Start an Order for details.

16

Schedule Production (Scheduler)

With the scheduler configured, you can now plan production:

1. Open the Scheduler.

2. Import orders from your ERP or create them manually.

3. Assign orders to lines.

4. Let the scheduler optimise the sequence based on changeover rules.

5. Publish the schedule to Digital Operations.

Scheduler orders

A scheduler order is lighter than a Digital Operations work order - it tells the optimiser what to make and by when, and references the operation (the finished good) rather than carrying the full BOM and attributes:

Field	Example	Notes
Order code	WO-2606-001	Unique key (upserts match on it)
Operation	FG-SH-300	The finished good's operation (defines BOM + run rate)
Quantity	10000	In finished units; duration = quantity ÷ run rate
Earliest start / Due date	2026-06-01 / 2026-06-05	The window the optimiser must fit the run into
Priority	1-5	Relative importance when sequencing
Status	Planned	Load new orders as Planned - the optimiser plans these. (Released is for orders already committed/locked.)

New orders should be created with status Planned so the scheduler is free to place and sequence them. Scheduler orders are scoped to the location, not the data template - so a site whose lines share one location shares one order pool.

To load a backlog (e.g. two weeks of orders) in bulk, upsert them via the scheduler order API or the Excel Add-in, then optimise.

See How to Schedule and Scheduler to Digital Operations integration for details.

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Summary Checklist

Use this checklist to track your progress:

• Site created with correct timezone

• Asset classes defined, Cosmetic-prefixed so they don't inherit another site's model (Cosmetic Lines, Cosmetic Fillers, Cosmetic Labellers, Cosmetic Case Packers, Cosmetic Palletisers, Cosmetic QA — capping on filler, coding on labeller)

• Assets created with correct parent-child hierarchy

• Shift templates configured (morning, afternoon, 16x5 patterns)

• Units of measure defined (PC, KG, g, mL, mm, %)

• Material groups created (Finished Goods, Bulk, BOT, CAP, LAB, CAR, PAL, BTL)

• Materials loaded (bulk products, bottles, caps, labels, cases, finished goods)

• Attributes defined (product & batch, fill specs, packaging, palletising, barcoding)

• Process variables configured (fill weight, label placement, checkweigher)

• Activity classes created (Line Setup, Quality, Machine Checks, Sampling, End of Run, etc.)

• Activity templates built for GMP-critical checks (line clearance, material verification, quality)

• Each activity given a When (trigger/starter) and Where (assignment to an asset class)

• Order templates mapped for each line

• Scheduler equipment created

• Availability templates configured and assigned to each line (bounded date range, ~1 year)

• Optimisation properties defined (Product Category, Fragrance, Colour, Bottle Size, Closure Type)

• Finished-good materials tagged with their optimisation property values

• Changeover rules entered and the changeover set assigned to each line

• Operations created (one per finished good: Fill and Pack segment with consumed BOM, produced finished good, run rate in units/sec, and an equipment-class requirement so any line can run it)

• Scheduler orders loaded as Planned (operation, quantity, start/due, priority)

• Order integration configured and payload tested

• First work order tested end-to-end

• Production scheduled and optimised end-to-end

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Related Articles

• Planning Overview

• Data Gathering Checklist

• Upload Production Schedule (API)

• Entity Data Source