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Add end-to-end process flow document and diagram; floor loading criterion

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- docs/process-flow.md: mermaid chart plus stage table of every check and
  the three artist approval gates, from audio intake to fulfillment
- docs/process-flow.drawio with PNG and PDF exports
- pressing-line.md: floor must carry multiple tons per m2 in machine areas
- README: process-flow entry in document index and layout tree
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grabowski committed 2026-07-17 15:48:48 +07:00
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README.md
+4
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@@ -78,6 +78,9 @@ The detail lives in dedicated documents:
(Keyence-class confocal, profiler, XRF), layered pressed-record QC (100%
optical inspection, per-cycle press telemetry, sampled automated audio
comparison), and how it feeds traceability
- [Process flow](docs/process-flow.md): the whole chain from audio file to
delivered record as a chart and stage table, with every check and the
three artist approval gates (printable diagram alongside)
## Repository Layout
@@ -91,6 +94,7 @@ docs/
├── finance/ Project cost overviews
├── suppliers/ Supplier contacts, vendor landscape, supplier map
├── facility-security.md Security, HVAC, fire and life safety, compliance
├── process-flow.md Audio file to delivered record, with all checks
├── quality-automation.md Stamper metrology and layered record QC
├── sustainability.md Energy, water, materials commitments
├── traceability.md Process logging and per-order traceability
docs/equipment/pressing-line.md
+9
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@@ -40,5 +40,14 @@ electrical load, saturated steam at 10 bar, and compressed air and cooling
water circuits, plus side rooms for materials, compressor, chiller, and
finished goods.
**Floor loading is a building-selection criterion**: the slab must carry
multiple tons per m² in the machine areas. A Newbilt press weighs 1,350 kg
on a footprint under 1 m², and the boiler, chiller, hydraulic aggregate,
battery stack, and stacked material storage all concentrate weight the same
way. The floor must also be flat but not slippery (machine levelling pads
need grip) and resistant to the solvents used in production. Dynamic loads
from press cycles come on top of the static figures, so the structural
engineer gets the vendor data sheets, not just the totals.
Source documents live in [`newbilt/`](newbilt/): the budgetary offer, the
Duplex site requirements, the process schematic, and the service rate card.
docs/process-flow.drawio
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@@ -0,0 +1,238 @@
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docs/process-flow.md
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# Production Process Flow: Audio File to Delivered Record
The complete chain with every check and approval gate. Three gates involve
the artist or label directly (marked as approval gates); everything else is
internal QC. Every step writes to the [traceability
database](traceability.md); the instruments behind the checks are specified
in [quality automation](quality-automation.md).
A printable diagram of this flow lives alongside this document:
[process-flow.drawio](process-flow.drawio) (editable),
[process-flow.png](process-flow.png), and
[process-flow.pdf](process-flow.pdf).
```mermaid
flowchart TD
A[1. Audio intake] --> G1{Artist gate:<br/>master plan approved}
G1 --> B[2. Vinyl mastering]
B --> G2{Artist gate:<br/>master approved}
G2 --> C[3. Lathe cutting<br/>lacquer]
C --> D[4. Silvering and<br/>electroforming<br/>father, mother, stampers]
D --> E[5. Stamper prep<br/>punch, back-finish, coin]
E --> F[6. Pressing]
PVC[PVC compound intake] --> LAB[Material lab gate] --> F
REG[Regrind stream] --> LAB
F --> G3{Artist gate:<br/>test pressing approved}
G3 --> F2[Production run]
F2 --> H[7. Finishing<br/>trim, label, shrink]
H --> I[8. Packaging<br/>and assembly]
CART[Cartons and sleeves<br/>from local partners] --> PQC[Packaging incoming QC] --> I
I --> J[9. Fulfillment<br/>warehouse, bulk, dropshipping]
A -.-> QA1[Checksums, format,<br/>technical QA]
C -.-> QA3[Groove microscope,<br/>test cut, dead-wax<br/>scribe and fiducial]
D -.-> QA4[Bath logs, XRF thickness,<br/>metrology on sampled zones,<br/>mother listening check,<br/>laser back marks]
E -.-> QA5[Concentricity,<br/>dimensional, visual]
F2 -.-> QA6[Press telemetry per cycle,<br/>100% optical inspection,<br/>sampled audio comparison]
I -.-> QA8[Matrix code vs jacket<br/>barcode scan, barcode<br/>verification]
```
## Stage by stage
| # | Stage | Internal checks | Approval gate |
|---|---|---|---|
| 1 | Audio intake | File checksums and format verification; technical QA (levels, clipping, side length vs format) | Artist/label confirms the master plan |
| 2 | Vinyl mastering | Engineer QA of the vinyl master | Artist/label approves the master |
| 3 | Lathe cutting | Groove inspection under microscope; test cut evaluation; dead-wax matrix scribe and angular fiducial applied (cold mechanical scribe, never laser) | |
| 4 | Silvering and electroforming | Bath chemistry logs per batch; XRF nickel thickness per part; confocal/profiler groove metrology on sampled radial zones; mother listening check (mothers are playable); laser Data Matrix marks on part backs | |
| 5 | Stamper prep | Concentricity and dimensional checks after punch, back-finish, and coining; visual inspection | |
| M | PVC intake (parallel input) | Material lab gate per lot: certificate of analysis, moisture, heat stability, color, density, granulate physicals; new lots released only by test pressing; regrind stream passes its own contamination gate before joining the 80/20 mix | |
| 6 | Pressing | Press telemetry logged every cycle; then per record: 100% inline optical inspection; sampled automated audio comparison against the source master | Artist/label approves the test pressing before the production run |
| 7 | Finishing | Trimming quality; label print inspection (labels pre-dried in the oven); shrink wrap on sampling basis | |
| 8 | Packaging | Incoming carton QC per delivery (dimensions, print Delta E against approved proof, seam strength, inner sleeve scuff check); assembly verification by scanning the runout matrix code against the jacket barcode; barcode verification on every unit | |
| 9 | Fulfillment | Consignment assembly against the order's bill of materials; carrier tracking recorded per shipment or per dropshipped end customer | |
## Reading the chain
- **The three artist gates** are the customer-facing milestones: master plan,
approved master, approved test pressing. Nothing proceeds past a gate
without a recorded approval, and the approvals live in the same
traceability record as the physical process data.
- **Identity travels with the product**: the dead-wax scribe from stage 3
propagates through every metal generation and appears on every pressed
record, which is what lets stage 9 verify that the right record is in the
right jacket.
- **Materials join the chain with their own gates**: PVC lots and regrind
batches enter at pressing, cartons and sleeves at packaging, and their lot
IDs attach to every record and order they touch.
- **A complaint resolves backwards**: any single record traces to its
stamper, press, cycle, operator, compound lot, and packaging lot, and from
the stamper back through mother and father to the lacquer and the approved
master it came from.
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