Customer Overview
A motor manufacturer required a connected system to manage production activities, track individual units and monitor output across the shop floor. The solution covers serial number generation, station-wise scanning, production stages, packing, planning and reporting.
The Challenge
The manufacturer needed to maintain accurate records for every unit, from production to packing. Key requirements included serial number generation, barcode verification at each station, tracking of pressing, testing and packing, and recording of rejections, retests, scrap and defect codes.
The manufacturer also needed carton-level traceability, production plan monitoring, stage-wise backlog reports, live shop-floor displays and controlled label reprinting.
The Solution
A' Niche Solutions implemented a barcode-based production tracking system with the following capabilities.
- Serial Numbers and Labels
Serial numbers are generated by plant, line and model, with monthly or yearly resets. Product and carton labels are created using a template designer with print preview.
- Network Scanners at Production Stations
Fixed network barcode readers scan each unit as it passes through every station. Each scan is recorded in a scan log for traceability and audit purposes.
- Stage-Wise Unit Tracking
Units are tracked through pressing, testing and packing. Rejections, retests and scrap are recorded with defect codes.
- Carton Packing by Scan
Units are scanned into cartons. When a carton reaches its required capacity, the carton label prints automatically.
- Production Planning and Shift Reports
The system provides monthly and daily plans, hourly output, shift progress with supervisor remarks, stage-wise backlog reports and plan-versus-actual reports by category and customer.
- Live Displays and Automated Reports
Large TV screens display live plan-versus-actual production figures on the shop floor. Reports are sent by email on a schedule, while every label reprint requires approval and is logged.
Facing a similar problem in your production line tracking? See how this solution would work with your process and ERP.
Book a FREE DemoImproving Production Visibility
The system provides real-time visibility into unit movement, production output and stage-wise progress. Scan logs support traceability, while defect records help teams monitor rejections, retests and scrap. Live displays and scheduled reports help supervisors review production performance and identify pending work.
Results
The digitised workflow connects serialisation, scanning, production tracking, packing and reporting. It supports unit-level traceability, carton-level packing records, structured production reporting and better visibility into plan-versus-actual performance.
- Serial number generation by plant, line and model
- Product and carton label design with print preview
- Fixed network scanners and auditable scan logs
- Pressing, testing and packing stage tracking
- Rejection, retest and scrap recording with defect codes
- Automatic carton label printing when full
- Monthly and daily plans, hourly output and shift reports
- Stage-wise backlog and plan-versus-actual reports by category and customer
- Live TV displays and scheduled email reports
- Approved and logged label reprints
Business Impact
The solution gives the manufacturer a structured way to monitor production activities throughout every shift. Automated label printing, stage-wise tracking, live production displays and controlled reprints support consistent operations, traceability and production monitoring.