Background & results
Picking, reporting, outsourced processing and inspection were logged on paper with manual reporting and handwriting — accuracy could not be assured, it was slow and laborious, and progress data was already out of date by the time it appeared.
Products had to be traced unit by unit by serial number, and paper could not compile a single unit’s material, production and inspection history quickly or accurately.
The ERP had no work-order WIP module, leaving in-process quantities and progress per operation invisible.
Outsourced work was despatched and received on paper — stock never matched the books, and too many documents had to be keyed into ERP.
SCOPE
Product traceability, process management, purchasing & receiving
ERP integration, mobile document execution, mobile lookup, label printing, eSOP
In-process measurements fed back live and bound to the product serial number
Give every unit an identity before it moves
Before production starts, the routing and operation sequence are set and the product serial numbers imported.
Routing setup + serial-number import
Print the serial labels in one go, not by hand
Select the work order and print the serial-number labels imported earlier, in one action.
Serial label printing
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 picking
Report fast — and see the drawing while doing it
Scanning the work-order voucher brings up its detail and logs the start time on report-in; the system jumps straight to the eSOP, and on completion the operator enters completed, scrapped and defective quantities while transfer and reporting documents generate automatically.
In-house reporting + eSOP digital drawing
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 generates automatically.
Outsourcing transfer (completed / scrap / defect)
Bind measurements to the exact unit
Scanning the serial label brings up the unit’s detail, and IIoT feeds the measurement data straight back, bound to that specific product.
In-process inspection (scan serial, bind readings)
One serial, three histories — material, work and inspection
Once picking, production and inspection are done, the material, inspection and production histories are all presented together.
Product history (material / inspection / production)
See work-order progress and what is short, at a glance
A work-order progress board, a shortage list, mobile receiving and inspection, and a shortage breakdown for work orders still in process.
Progress board + shortage list + mobile receiving / inspection
RESULTS
- With the serial number at its core, every unit carries a traceable material, production and inspection history — a step change in quality traceability.
- Outsourced despatch and receipt go digital — stock matches the books and outsourcing progress is visible in real time.
- Progress and shortages are visible per operation for every work order, and the production data collected feeds further analysis.