Background & results
Picking, production reporting, outsourced processing and in-process inspection were all recorded by hand on paper, leaving management with no live view of material, production or quality on the floor.
Machine operation, utilisation and faults were known only when someone walked the floor and reported back — utilisation stalled and fault response lagged.
Production data was transcribed line by line on paper, then compiled and keyed into ERP by planning — stock never matched, information lagged, entry errors crept in, and labour and management costs rose.
SCOPE
Product traceability, process management, purchasing & receiving
ERP integration, mobile document execution, mobile lookup, label printing, eSOP
Collects machine operation and measurement data live, feeds it back to MES, and drives the dashboards and Line fault alerts
Report fast — and see the drawing while doing it
ERP issues the work order and planning sets the routing to generate a voucher; operators scan its QR code to report in seconds, and the system logs start and finish times and generates the transfer and reporting documents automatically.
Mobile reporting + eSOP digital drawing
Stop keying picks into ERP line by line
Pick against a selected work order in one action, instead of keying each line into ERP.
Work-order quick picking
Check outsourced work back in properly
When outsourced work returns, receiving staff select the vendor and record completed, scrapped and defective quantities; the transfer document is generated automatically.
Outsourcing receipt (completed / scrap / defect)
Bind measurements to the exact unit
Scan the serial-number label and IIoT feeds the measurement data straight back, bound to that specific product.
In-process inspection (scan serial, bind readings)
See work-order progress and what is short, at a glance
A work-order progress board alongside a shortage list.
Work-order progress board + shortage list
Finish receiving and inspection on the floor
Receiving and incoming inspection both run on a mobile device.
Mobile receiving + mobile inspection
Know about a fault before someone walks past it
Machine output, production trend charts and fault lookups — with an instant Line alert when something goes wrong.
Machine dashboard (output / trend / fault) + Line alert
RESULTS
- An IIoT dashboard gives a live read on utilisation and production for every machine, with Line pushing faults out proactively — cutting response time sharply.
- An automated production planning system removes the transcription errors of manual records, keeps product information traceable, and produces a complete production history.
- Production and machine data keep accumulating into a broad database, strengthening the quality of both engineering and management decisions.