add_styles_page(); $date_time = date("Y-m-d H:i", strtotime("+2 Hours")); if (isset($_GET['record_id'])) { $lop_res = $db->query("cracking_jobcard", "SELECT * FROM cracking_jobcard WHERE record_id = '" . $_GET['record_id'] . "' "); $cracking = $lop_res->fetch_assoc(); $cracking_record_id = $cracking['record_id']; } else { $lop_res = $db->query("cracking_jobcard", "SELECT jobcard_no FROM cracking_jobcard ORDER BY record_id DESC LIMIT 1"); if ($lop_res->num_rows == 0) { $jobcard_no = 1; } else { $cracking = $lop_res->fetch_assoc(); $jobcard_no = $cracking['jobcard_no'] + 1; } $cracking_record_id = $db->query("cracking_jobcard", "INSERT INTO cracking_jobcard (jobcard_no) VALUES ('" . $jobcard_no . "')"); echo ""; } $product_id_label = new label(); $product_id_label->for("product_id_label"); $product_id_label->value("Product Identification"); $product_id = new select(); $product_id->name("product_id"); $product_id->id("product_id"); $product_id->style("width: 20%"); $product_id->fill_from_db("variety", "record_id", "name"); $product_id->value_from_db("cracking_jobcard", "product_id", "record_id = $cracking_record_id"); $cracking_id = new input(); $cracking_id->type("hidden"); $cracking_id->name("cracking_id"); $cracking_id->id("cracking_id"); $cracking_id->placeholder("LOP JC NO"); $cracking_id->value($cracking_record_id); $record_id = new input(); $record_id->type("hidden"); $record_id->name("record_id"); $record_id->id("record_id"); $record_id->placeholder(""); $record_id->value($cracking_record_id); $jobcard_date_opened_label = new label(); $jobcard_date_opened_label->for("date_opened_label"); $jobcard_date_opened_label->value("Date Jobcard Opened"); $jobcard_date_opened = new input(); $jobcard_date_opened->type("datetime-local"); $jobcard_date_opened->name("jobcard_date_opened"); $jobcard_date_opened->id("jobcard_date_opened"); $jobcard_date_opened->value($cracking['jobcard_date_opened']); $checked_by_production_label = new label(); $checked_by_production_label->for("checked_by_label"); $checked_by_production_label->value("Checked By (Production)"); $checked_by_production = new input(); $checked_by_production->type("text"); $checked_by_production->name("production_checked_by"); $checked_by_production->id("production_checked_by"); $checked_by_production->placeholder("Checked By (Production)"); $checked_by_production->style("width: 40%"); $checked_by_production->value($cracking['production_checked_by']); $checked_by_quality_control_label = new label(); $checked_by_quality_control_label->for("checked_by_label"); $checked_by_quality_control_label->value("Checked By (Quality Control)"); $user_id = $_SESSION['user_id']; $username_res = $db->query("users", "SELECT username FROM users WHERE record_id = $user_id"); $username = $username_res->fetch_assoc(); $checked_by_quality_control = new input(); $checked_by_quality_control->type("text"); $checked_by_quality_control->name("quality_control_checked_by"); $checked_by_quality_control->id("quality_control_checked_by"); $checked_by_quality_control->placeholder("Checked By (Quality Control)"); $checked_by_quality_control->value($username['username']); $checked_by_quality_control->style("width: 40%"); $batch_no_label = new label(); $batch_no_label->for("batch_no_label"); $batch_no_label->value("Batch No"); $batch_no = new input(); $batch_no->type("text"); $batch_no->name("batch_no"); $batch_no->id("batch_no"); $batch_no->placeholder("Batch No"); $batch_no->value($_GET['batch_no']); $batch_no->style("width: 20%"); $batch_no->value($cracking['batch_no']); // EQUIPMENT SECTION $equipment_label = new label(); $equipment_label->for("equipment_label"); $equipment_label->value("Equipment"); $equipment_settings_label = new label(); $equipment_settings_label->for("equipment_settings_label"); $equipment_settings_label->value("Equipment Settings & Line-speed specifications"); $accurate_label = new label(); $accurate_label->for("accurate_label"); $accurate_label->value("Accurate (YES/NO)"); $equipment = new input(); $equipment->name("equipment_0"); $equipment->id("equipment_0"); $equipment->placeholder("Equipment"); $equipment->style("width: 90%"); $varify_settings = new input(); $varify_settings->type("text"); $varify_settings->name("verify_settings_0"); $varify_settings->id("varify_settings_0"); $varify_settings->placeholder("List of settings to be verified before start-up"); $varify_settings->style("width: 90%"); $accurate = new select(); $accurate->name("accurate_0"); $accurate->id("accurate_0"); $accurate->add_option("", "SELECT ACCURATE"); $accurate->add_option("YES", "YES"); $accurate->add_option("NO", "NO"); $accurate->style("width: 90%"); $submit_btn = new button(); $submit_btn->class("submit_btn"); $submit_btn->value("Submit"); $submit_btn->id("submit_btn"); $submit_btn->onclick("validateForm()"); ?>

CRAKING JOBCARD

add(); $jobcard_date_opened_label->add(); $jobcard_date_opened->add(); $batch_no_label->add(); $batch_no->add(); $product_id_label->add(); $product_id->add(); $checked_by_quality_control_label->add(); $checked_by_quality_control->add(); $checked_by_production_label->add(); $checked_by_production->add(); ?>


EQUIPMENT CHECKLIST


query("cracking_equipment_check_list", "SELECT * FROM cracking_equipment_check_list WHERE cracking_id = '" . $cracking_record_id . "' ORDER BY record_id, equipment_id ASC"); if ($equipment_check_res->num_rows > 0) { while ($equipment_check = $equipment_check_res->fetch_assoc()) { // check if equipment is already checked $show = 0; ?> query("equipment_list", "SELECT * FROM equipment_list WHERE 1 ORDER BY record_id ASC"); while ($equipment = $equipment_res->fetch_assoc()) { $show = 1; // check if equipment is already checked ?> "> []" value="Equipment appears clean and free from damage">
EQUIPMENT QUESTION ANSWER DATE USER
get_equipment($equipment_check["equipment_id"]); ?> get_username($equipment_check["user_id"]); ?>
Equipment appears clean and free from damage
[]" value="No signs of excessive wear, rust, or corrosion"> No signs of excessive wear, rust, or corrosion
[]" value="All guards, covers, and shields are securely fitted"> All guards, covers, and shields are securely fitted
[]" value="Moving parts operate smoothly without obstruction"> Moving parts operate smoothly without obstruction
[]" value="Power cables and plugs are intact and undamaged"> Power cables and plugs are intact and undamaged
>



query("cracking_food_safety_inspections", "SELECT * FROM cracking_food_safety_inspections WHERE cracking_jobcard_id = '" . $cracking_record_id . "' ORDER BY record_id ASC"); if ($safety_res->num_rows > 0) { $safety = $safety_res->fetch_assoc(); $safety_comments_res = $db->query("cracking_food_safety_comments", "SELECT * FROM cracking_food_safety_comments WHERE food_safety_id = '" . $cracking_record_id . "' ORDER BY record_id ASC"); if ($safety_comments_res->num_rows > 0) { $safety_comments = $safety_comments_res->fetch_assoc(); } } else { $safety = array(); $safety_comments = array(); } ?>
Food Safety Inspections
Food safety Inspection criteria/ points: Select/ complete: Comment:
Equipment Clean & sanitized
Magnet 1 (Initial) Clean?
Magnet 2 (Initial) Clean?
Oxyacid Concentration verification (Add in spec after validation):
Cracking equipment inspected (rollers, blades, hopper)? Yes/ No
No signs of rust, oil leaks, or foreign objects
Shell separator & sieves clean
Air filtration/dust control working properly
Personal hygiene (hands, gloves, PPE) checked?
Tools sanitized and labelled?



Standard Operating procedure: Sampling of nuts for evaluation
Step 1 Take a random sample of cracked nuts (e.g., 100–200 kernels) per batch or hourly from the cracking output
Step 2 Look for signs of over-cracking, broken pieces, or stuck kernels
Step 3 Count how many are: whole, half, broken, crushed, or with shell fragments
Step 4 % of whole + half kernels vs. total
Step 5 If breakage is high (>10–15%), adjust cracker pressure, roller gap, or shell moisture- consult operations manager
Step 6 For the inspection of the magnets at end of shift- please indicate the number of the magnet, and then if metal was detected


QUALIITY CONTROL HISTORY

query("cracking_quality_process_control", "SELECT * FROM cracking_quality_process_control WHERE cracking_id = '" . $cracking_record_id . "' ORDER BY record_id ASC"); if ($quality_res->num_rows > 0) { while ($quality = $quality_res->fetch_assoc()) { ?>
≥ 85–90% (for premium grade) <= 10 - 15% < 1% < 1-2%
Wholes Halves Dust Shells Broken/ Chipped Shell in kernel (adhering) Un-cracked Nuts (shell in tact)
0%(rework required) 1.5 - 3.5% 18 -24°C 45 - 55 RH Metal Fragments-Capture on FO library
Crushed/ missing kernel Moisture % Env. Temperature Env. Humidity Magnet inspection, end of shift Person Inspecting Signature
query("users", "SELECT * FROM users WHERE record_id = '" . $quality['person_inspection'] . "'"); $user = $user_res->fetch_assoc()['username']; ?> signature

×

QUALITY & PROCESS CONTROL TRACK INFORMATION:

add(); $datetime = new label(); $datetime->for("datetime_label"); $datetime->value("Date & time"); $datetime->add(); ?>
for("shift_label"); $shift_label->value("Shift (Day / Night)"); $shift_label->add(); ?>
for("sample_size_label"); $sample_size_label->value("Sample Size (Kg)"); $sample_size_label->add(); ?>

SPECIFICATION / GUIDANCE ON ELEVATION

for("product_samples_point_label"); $product_samples_point_label->value("Product samples point"); $product_samples_point_label->add(); ?>
name("product_samples_point"); $product_samples_point->id("product_samples_point"); $product_samples_point->class("inputs"); $product_samples_point->style("width: 20vw;"); $product_samples_point->fill_from_db("product_sample_point", "record_id", "name"); $product_samples_point->add(); ?>


≥ 85–90% (for premium grade) <= 10 - 15% < 1% < 1-2%
Wholes Halves Dust Shells Broken/ Chipped Shell in kernel (adhering) Un-cracked Nuts (shell in tact)


0%(rework required) 1.5 - 3.5% 18 -24°C 45 - 55 RH Metal Fragments-Capture on FO library
Crushed/ missing kernel Moisture % Env. Temperature Env. Humidity Magnet inspection, end of shift Person Inspecting
name("person_inspecting"); $person_inspecting->id("person_inspecting"); $person_inspecting->class("inputs"); $person_inspecting->style("margin: 0vw;width: 100%;"); $person_inspecting->fill_from_db("users", "record_id", "username"); $person_inspecting->add(); ?>

SIGNATURE






×

GUIDANCE/ SPECIFICATION & DEFINATION

Please consult the maintenance artisan or the operations manager when out of specification
results are recorded in order for the process and equipment to be altered.

PROBLEM LIKELY CAUSE CORRECTION
Too many broken kernels Cracking force too high Reduce roller pressure or adjust spacing
Shell not cracking open Shell too dry or cracker not aligned Adjust moisture (~10–13% ideal) or realign machine
Shell fragments in kernel Poor shell separation Check air classifier or vibrating sieve settings
Crushed + discolored kernels Old nuts or over-dried product Recheck drying specs, avoid over-dehydration

GOOD CRACK POOR CRACK
Shell is cleanly split open Over-cracked: Kernel is crushed, broken, or bruised
Kernel is intact (whole) or minimally damaged Under-cracked: Shell not fully broken, kernel stuck
Minimal adhering shell or husk on the kernel Adhering shell pieces: Risk of contamination
No deep gouges, crushing, or bruising on kernel Multiple fractures in kernel: Reduces grading value
query("cracking_batch_summary", "SELECT * FROM cracking_batch_summary WHERE cracking_jobcard_id = '$cracking_record_id'"); if ($summary_res->num_rows > 0) { $summary = $summary_res->fetch_assoc(); } else { $summary['whole_kernal'] = 0; $summary['halves'] = 0; $summary['broken'] = 0; $summary['crushed'] = 0; $summary['waste'] = 0; $summary['kernal_breakage_rate'] = 0; $summary['dust_summary'] = 0; $summary['moisture_in_shell'] = 0; $summary['shell_summary'] = 0; $summary['whole_kernal_recovery'] = 0; $summary['shell_in_kernal_contamination'] = 0; $summary['shell_in_kernal_summary'] = 0; $summary['kernal_stuck_in_shell'] = 0; $summary['uncracked_nuts_summary'] = 0; $summary['crushed_missing_kernal_summary'] = 0; $summary['actions_taken'] = 0; $summary['chips_broken'] = 0; } ?>
Batch Output Calculation Summary
Whole Kernel Waste
Halves Kernal Breakage rate (≤ 10–15%)
Dust Moisture (in-shell 1.5–3.0%)
Shells Whole kernel recovery (≥ 85%)
Chips/Broken Shell in kernel contamination (0%)
Shell in kernal Kernel stuck in shell (< 1–2%)
Uncracked nuts
Crushed/ missing kernel Actions taken for NC product:


for("date_jobcard_closed"); $date_jobcard_closed_label->value("Date Jobcard Closed"); $date_jobcard_closed_label->add(); $date_jobcard_closed = new input(); $date_jobcard_closed->type("datetime-local"); $date_jobcard_closed->id("jobcard_closed"); $date_jobcard_closed->name("jobcard_closed"); $date_jobcard_closed->value($cracking['jobcard_closed']); $date_jobcard_closed->add(); ?>
for("product_supervisor_signature_label"); $product_supervisor_label->value("Product Supervisor"); $product_supervisor_label->add(); $production_supervisor = new select(); $production_supervisor->name("production_supervisor"); $production_supervisor->id("production_supervisor"); $production_supervisor->class("inputs"); $production_supervisor->value_from_db("cracking_jobcard", "production_supervisor", "record_id = '" . $cracking_record_id . "'"); $production_supervisor->style("width: 20vw;"); $production_supervisor->fill_from_db("users", "record_id", "username"); $production_supervisor->add(); ?>
for("quality_control_signature_label"); $quality_control__label->value("Quality Control"); $quality_control__label->add(); $quality_control_name = new select(); $quality_control_name->name("quality_control_name"); $quality_control_name->id("quality_control_name"); $quality_control_name->class("inputs"); $quality_control_name->value_from_db("cracking_jobcard", "quality_control", "record_id = '" . $cracking_record_id . "'"); $quality_control_name->style("width: 20vw;"); $quality_control_name->fill_from_db("users", "record_id", "username"); $quality_control_name->add(); ?>