Every manufacturing or maintenance and repair organization aspires to accomplish efficiency in streamlining processes, maximizing productivity and reducing errors. The success of many businesses comes down to these factors. Some challenges faced by them are related to job and work in progress tracking. As a result they are beginning to make more strategic decisions based on every phase of production process.

The primary concern behind a WIP system is making sure one has the ability to collect and track specific details of each stage in a production process and manage items as they move throughout the facility.

In a WIP system, each item is tracked uniquely as it is fabricated, manufactured or processed in some way. Normally, there are several steps to the process the item goes through, each with a set of data that will have to be captured. This data can vary from details of the nature of the item, location, who is working on it, resources required and control history.

Data gathering, management and updating is done manually. Apart from being a cause of slowdown and errors, these conentional methods do not offer transparency and visibility. Moreover, managers are left dependent on the individual’s whole sole task regarding a particular system. Lack of integration of data also causes isolation. Some results of a conventional tracking system can be: lost orders, incorrect builds and delays.

Our WIP tracking solution combines the strengths of RFID and barcode technology to provide accurate, agile and in-depth view of the state of everything in your facility and that too in real time. It helps improve build accuracy and reduce labour costs by providing your employees with all the information they need with no paperwork and less procedural steps

At each stage of the process the item will be scanned (via. Barcode scanner or rfid reader depending upon the technology used) and whatever actions are done to it will be recorded. This chain of scanning and data provide a very accurate trail of the item’s existence from assembly to a finished product. With this information you also have a line of accountability when there are defects or production issues.

The basic components of the WIP solution are:

  • Custom software – The software drives the entire system and determines how each process is tracked. Depending on the complexity of the data that is being recorded and how detailed of a view you need, different applications will provide varying compatibility with your production process.
  • RFID System:With a network of reader’s setup at different work stations, RFID tracking system tracks parts or assemblies as they pass through a series of steps from creation to completion of processes Work may be tracked in processes independent of each other or sequential steps that have sub steps that must be completed first.

Barcode Scanner - Each item needs to be scanned throughout your process to have a clear account of where it is and what has been done to it. Fixed scanners will allow for a fully automated process while hand held scanners are an easy, cost effective means to get scanned data into your tracking software.

Mobile Computer - In cases where your process requires full mobility, a mobile computer supports your WIP application. With the ability to connect to a wireless network your WIP system can stay up-to-date is real-time regardless of where action takes place.

Wireless infrastructure - The true value of a WIP system is its ability to provide an accurate picture of your process in real-time. Having an adequate wireless network is crucial to supporting your workforce and getting data updated and processed at every stage of your process.

Barcode Printers - Every item that you manufacture or process needs to be identified uniquely to have full traceability. A simple label printer makes sure you are making easy to read barcodes to quickly identify each item.

Having a robust Work in Process (WIP) system in place makes sure you are prepared for any potential recalls or issues and increases efficiency to provide better customer service.

Solution benefits:

A work in process system provides the cost saving benefits of:

  • Efficiency - Automates aspects of your process while eliminating paperwork.
  • Accuracy - Reduces errors from manual or missed input data.
  • Traceability - Know what stage every item is at in your facility with real-time information.
  • Productivity - Accomplish more throughout the day with a streamlined and automated process.