Protessera

Integrated manufacturing ERP for high-reliability environments (aerospace, defense, precision assembly). Built as a single cohesive Next.js 15 application with full day/night theming (navy/slate night mode, crisp white day mode), teal/amber status accents, shop-floor tablet support, and large-screen information radiators.

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Quick start (one command after install)

npm install
npm run setup      # prisma generate + db push + rich seed
npm run dev        # http://localhost:3000

Optional reset anytime:

npm run db:reset

PostgreSQL path

docker compose up -d
# set DATABASE_URL from .env.postgres.example
# change prisma/schema.prisma datasource provider to "postgresql"
# use @prisma/adapter-pg instead of better-sqlite3 in src/lib/db.ts
npm run setup

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Modules

Navigation is organized into seven domains (sidebar groups are collapsible; state persists per browser). The same structure powers the ⌘K / Ctrl+K command palette, with keyword search (e.g. "8d" → CAR, "rfq" → Quotes).

Overview

Module	Route	Highlights
Command center	/	Cross-module KPIs, EVM strip, quality alerts
My approvals	/approvals	Manager queue: reports' PTO, timesheets, expenses
Production floor	/floor	Color-coded WO tiles, capacity load, sign-off %
Info radiators	/radiators	Large-font wall display, auto-refresh
Value stream	/value-stream	Supplier→Ship live flow + constraints
AI assistant	/ai	Carina settings; optional xAI API

Sales & Customers

Module	Route	Highlights
Quotes	/sales/quotes	Quote → SO conversion
Sales orders	/sales	Order entry, fulfillment planning, ship gate
Customers	/customers	Accounts, credit holds
Shipping	/shipping	Pack/ship, lot & serial trace

Manufacturing

Module	Route	Highlights
Work orders	/work-orders	Production / prototype / task-only + travelers
Work instructions	/work-instructions	CM workflow Draft→Eng→CM→Released
Workcenters	/workcenters	Capacity and cell definitions
Kitting	/kitting	Kit build/complete tied to travelers
Planning & MRP	/planning	Forecasts, material requirements, capacity/workload

Engineering & PLM

Module	Route	Highlights
Engineering	/engineering	JIRA-style board, disciplines, WBS campaigns
Items	/items	Item master + item cards
BOMs	/bom	Multi-rev, prototype banner, certify, where-used
Products (PLM)	/products	Product lifecycle linked to PMO
Config management	/cm	ECR board votes, impact analysis, doc library
UOM master	/uom	Units and conversions

Supply Chain

Module	Route	Highlights
Purchasing	/purchasing	PR→PO→Receive (pass/fail→MRB), PO search
Receiving	/receiving	Dock travelers, partial receipts, GFP intake
Suppliers / ASL	/suppliers	Live scorecards (OTD, PPM, cost)
Inventory	/inventory	Multi-loc, ownership, quarantine, kanban
Virtual assets	/virtual-assets	Licenses and intangibles

Quality & Compliance

Module	Route	Highlights
QA inspection	/qa	Visual / GD&T / first-article queue
Test center	/test-center	Test stations and results
Quality / NCR	/quality	Inspections, NCR trends, yield
MRB / CAR	/mrb	Disposition → inventory + scorecard; corrective actions
Gov property	/government-property	GFP/CAP, UID, DFARS checks

Programs & Business

Module	Route	Highlights
Leadership	/leadership	Executive rollup
PMO	/pmo	Programs, projects, WBS, SPI/CPI, PI planning, alerts
Accounting	/accounting	GL, P&L, BS, TB, AR/AP, WO variance
HR / workforce	/hr	Role-aware: employees see their profile (reviews, goals, PTO, documents), managers see My Team (reviews, goals, approvals), HR sees administration
Permissions	/admin/permissions	Full view + action permission catalog; custom groups per company

Demo identity switcher — the sidebar footer switches the signed-in demo user, so you can experience the app as an executive, HR, a people manager, or a shop-floor employee (permissions and HR views change accordingly).

Day / night mode — toggle in the header; the choice persists and is applied before first paint (no flash). Theming is done centrally in src/app/globals.css by remapping the slate + accent color ramps for html.light, so module pages don't carry per-theme classes.

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Architecture overview

flowchart TB
  subgraph UI["Next.js 15 App Router"]
    RSC[Server Components]
    SA[Server Actions]
    Client[Client charts / cmdk / AI chat]
  end

  subgraph Domain["Domain services"]
    SC[supply-chain.ts]
    WO[work-orders.ts]
    BOM[bom.ts]
    AI[ai.ts]
    AUDIT[audit.ts]
  end

  subgraph Data["Prisma + SQLite / PostgreSQL"]
    DB[(Protessera DB)]
  end

  RSC --> Domain
  SA --> Domain
  Domain --> AUDIT
  Domain --> DB
  Client --> SA

flowchart LR
  PR[Purchase Request] --> PO[Purchase Order]
  PO --> RCV[Receipt]
  RCV --> INV[Inventory]
  RCV --> INSP[Incoming Inspection]
  INSP -->|PASS| AVAIL[Available stock]
  INSP -->|FAIL| NCR[NCR]
  NCR --> MRB[MRB Case]
  MRB --> Q[Quarantine hold]
  MRB --> DISP[Disposition]
  DISP --> INV
  DISP --> SC[Supplier Scorecard]
  SC --> CAR[CAR optional]

flowchart LR
  BOMR[BOM Rev] -->|PROTOTYPE| FAI[Prototype WO]
  FAI --> CERT[Certify BOM]
  CERT --> PROD[Production WO]
  WI[Work Instruction Released] --> PROD
  PROD --> STEPS[Step sign-offs]
  STEPS --> FLOOR[Floor board %]
  STEPS -->|FAIL test| NCR2[NCR + Hold]
  PROD --> COST[Actual cost → Projects / GL]

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How major integrations work

1. Purchasing → Receipt → Inspection → MRB → Inventory → Scorecard

Implemented in src/lib/services/supply-chain.ts and wired from Purchasing UI:

1. PR submitted → approved → Convert to PO
2. Receive (Pass QA) or Receive (Fail → MRB) on open POs
3. Receipt updates PO line qty + PO status (PARTIAL_RECEIPT / RECEIVED)
4. Stock posts to Receiving location; material transaction RECEIPT logged
5. Incoming inspection auto-created with characteristics
6. On FAIL: NCR + MRB case, inventory moved to QUARANTINE, available qty → 0, mrbCaseId set
7. MRB disposition (USE_AS_IS / REWORK / SCRAP / RETURN_TO_SUPPLIER / REPAIR) releases or scraps stock and may open a CAR
8. updateSupplierScorecard recomputes OTD (receipt vs promise), quality PPM (NCR qty / received), overall rating A–F and writes scorecard history

2. BOM → Work Instruction → Work Order → Floor sign-offs

• BOMs: DRAFT / PROTOTYPE / IN_REVIEW / CERTIFIED / OBSOLETE
• Production WOs may only attach CERTIFIED BOMs; prototype builds use type PROTOTYPE
• Certify locks the rev, clears prototype flag, and obsoletes prior certified revs for that part
• Released Work Instructions (CM path: Draft → Engineering → CM → Released) attach to WOs; steps become WorkOrderStepCompletion rows
• Operator Sign Off (incl. test pass/fail + measured values) writes sign-off records, audit log, updates floor progress; FAIL opens NCR and can hold the WO

3. Projects / EVM and accounting

• Projects store PV / EV / AC; UI computes SPI = EV/PV, CPI = EV/AC
• WOs link to project + WBS; actual cost feeds program and Accounting cost variance (actual vs standard)
• Seed includes journal entries, AR/AP, chart of accounts, budgets

4. Government property

• Assets with UID, contract, custodial code, DFARS flag, and compliance checklist events
• Linked inventory rows use ownership: GOVERNMENT (visual violet strip)

5. AI assistant

• Default: context-aware local responses over live DB metrics (src/lib/services/ai.ts)
• Upgrade: set XAI_API_KEY → calls xAI Chat Completions with plant JSON context (tool-calling ready)

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Tech stack

• Next.js 15 App Router, Server Components, Server Actions
• TypeScript strict
• Prisma 7 + SQLite (better-sqlite3 adapter) / Docker PostgreSQL
• Tailwind CSS 4 + shadcn-style Radix primitives
• TanStack Table, Recharts, date-fns, lucide-react, jsPDF, xlsx, fuse.js, sonner, cmdk, zod, react-hook-form, framer-motion, dnd-kit

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Project layout

prisma/
  schema.prisma      # Full manufacturing domain model
  seed.ts            # Rich integrated demo data
src/
  app/               # Routes per module + server actions
  components/        # UI, layout, charts, shared
  lib/
    db.ts            # Prisma client (SQLite adapter)
    audit.ts         # Audit logging
    auth.ts          # Demo role-based user
    services/        # Supply chain, WO, BOM, AI
    pdf.ts           # Branded PDF helpers
    utils.ts         # cn, formatters, status colors, EVM
docker-compose.yml

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Order-to-ship fulfillment flow

Sales Order (required date)
    → Stock check finished goods  (or Bypass stock → order full demand / full BOM)
        → allocate if available
        → else Work Order (BOM + WI digital traveler, due date schedule)
            → BOM material check
                → short (or bypass)? auto Purchase Request
                → PR multi-step approval (threshold policy) → Convert to PO
                → Receiving traveler on PO issue
                → Receive: per-line qty (partial OK) + photos + putaway location
                    → partial? child traveler for remainder
                    → all lines received → Close PO from receiving
            → Ready to kit → Kit order (travels with WO)
            → Kit complete → Start production → step sign-offs
            → Complete → FG to stock
    → READY_TO_SHIP (respects allowEarlyShip / shipNotBefore)
    → Shipping pull & ship (inventory + lot/serial trace)

Route	Role in flow
/sales	Create SO, plan fulfillment (optional bypass stock), ship gate
/purchasing	PR multi-step approve → PO; keyword search all POs past/present
/purchasing/approvals	Configure PR threshold approvers / steps
/receiving	Dock travelers; partial receive, photos, putaway area, child remainders
/inventory	Stock by location · lot/serial trace · quarantine
/kitting	Create / complete kit for traveler
/work-orders/[id]	Digital traveler, material (bypass BOM stock), kit, sign-off, complete
/shipping	Pull queue & confirm ship

Every step writes TraceEvent + material transactions for genealogy.

PR approval (configurable)

Default policy (seeded, editable at /purchasing/approvals):

1. Buyer review — all PRs (role PURCHASING)
2. Finance / controller — estimate ≥ $5,000 (ACCOUNTING)
3. Operations admin — estimate ≥ $25,000 (ADMIN)

Steps below a PR’s dollar amount are skipped. Switch DEMO_USER_ROLE to walk steps as different roles; ADMIN can always approve.

Receiving partials

On the traveler, enter only the qty that arrived, attach dock photos, and must select a stock location. Material inspects then putaways there. Open remainder spawns a child traveler. Close PO is enabled only when every line is fully received.

Seed scenarios to click through

1. Sales SO-00002 → Plan fulfillment → WO + shortage PR → approve/convert/receive → Put away on Inventory → Kitting → start production → complete → ship
2. BOM ASM-1000 Rev C PROTOTYPE → create Prototype WO → Certify after FAI story
3. WO-00001 traveler → sign remaining test steps on the floor
4. PO-00003 → Receive (Fail → MRB) → dispose on MRB page → watch supplier score move
5. Value Stream — MRB stage shows constraint while holds open
6. Projects PRJ-AERO-01 — SPI/CPI and linked WOs
7. CM ECR-00001 — cast board votes
8. Radiators — full-screen plant board
9. AI — “Summarize open MRB cases”

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Production roadmap

Phase	Focus
Auth	NextAuth / Clerk / SSO; enforce RBAC matrix in auth.ts on every action
Jobs	Queue (BullMQ / Inngest) for scorecard recompute, email, PDF batch, MRP
Files	S3-compatible storage for drawings, inspection photos, traveler attachments
DB	PostgreSQL primary; read replicas; row-level security for multi-site
Realtime	WebSockets / SSE for floor & radiators instead of poll refresh
AI	Grok tool calling: receivePo, dispositionMrb, listOpenHolds, etc.
MES	Barcode/RFID scan endpoints, device auth, offline tablet sync
Compliance	Electronic signature 21 CFR Part 11-style, export packages for DCMA
Observability	OpenTelemetry, structured audit export, SIEM sink
Hardening	Rate limits, CSRF on actions, secrets manager, backup/DR drills

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Scripts

Command	Description
npm run setup	Generate client, push schema, seed
npm run db:reset	Wipe DB + reseed
npm run db:studio	Prisma Studio
npm run dev	Dev server (Turbopack)
npm run build	Production build

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License

Proprietary demo / prototype — adapt for your organization.