Using Digital WIP Manufacturing Solutions to Streamline Operations

Manufacturers are increasingly investing in Manufacturing Execution Systems (MES) to automate tasks, maintain high quality, and gain real-time insights into their operations. A Digital Work Order Progress Tracking system is designed to address these needs by offering a comprehensive, automated WIP manufacturing solution for tracking production workflows, ensuring consistency, and improving operational efficiency. 

Why a Digital Work in Process Solution?

Implementing an automated Work in Progress (WIP) solution offers significant benefits to employees, managers, and customers in manufacturing:

• For employees, real-time tracking of products and materials allows them to monitor progress and ensure processes are consistently followed, while automated alerts reduce human errors and minimize downtime, keeping production smooth and efficient. This digital tool also lightens their manual workload, enabling them to focus on more critical tasks.
• Managers benefit from built-in safety checks and improved communication across teams, ensuring alignment between production, quality control, and logistics. The software aids in regulatory compliance, simplifies training for new staff through standardized processes, and allows for tracking employee performance metrics.
• For customers, WIP manufacturing software guarantees consistency in manufacturing, with real-time monitoring identifying defects early and reducing delays. Streamlined production results in faster shipping, and the system’s flexibility supports custom orders and faster response to customer feedback, enhancing overall satisfaction.

How Automated Work in Progress Tracking Works

In an automated Work in Progress system, data is organized and connected to ensure seamless production workflows and real-time tracking of tasks. At the heart of this system are Work Orders, which act as the central unit that links all relevant production data—such as checklists, tests, and other critical information—together. Each work order represents a unique product or batch and serves as the primary reference point throughout the manufacturing process.

To streamline operations, Part Numbers are used to filter and assign the appropriate checklists to work orders and stations. Each part number corresponds to a specific product type or recipe, ensuring that operators only see the instructions and tasks that are relevant to the item they are producing. This filtering process helps reduce errors and keeps production focused on the right steps for each product.

Stations represent the physical production cells or lines where tasks are completed. At each station, operators can access specific checklists related to the current work order. Additionally, Standard Operating Procedures (SOPs) are available at these stations, providing operators with real-time guidance to ensure that each task is performed correctly and consistently, further supporting quality and efficiency in the production process.

Together, work orders, part numbers, and stations with SOPs create an interconnected system that drives consistency, traceability, and operational accuracy in automated manufacturing environments.

The technical infrastructure needed to support an automated work order solution is both scalable and customizable, utilizing Ignition by Inductive Automation and a database for tracking. 

Features of Automated WIP Manufacturing Tracking

An automated WIP tracking solution offers versatile tools for collecting and tracking production steps, including: 

• Checklist Progress Retention: This feature allows operators to pause their work and resume checklists exactly where they left off, ensuring smooth transitions and minimal disruption.
• Customizable Checklists: The system supports multiple checklists per station, automatically filtering them to show only those relevant to the part number or work order. This helps streamline operations and ensure accuracy.
• User-Friendly Interface: Intuitive applications make it easy to create and modify checklists, accepting various input methods while retaining previous data even after edits.
• Comprehensive Manager Access: Managers have the ability to retrieve and review entire work orders, giving them full visibility into all recorded checklists at any time.

Core Applications and User Roles

Within the WIP manufacturing solution, the flexibility allows for different applications based on user roles:

• Checklist Operator: The app used by operators to complete checklists at various stations. With this app operators select their workstation from the navigation tree and they choose the relevant work order from a list of active options. The system filters the available checklists based on the work order and part number, presenting either a fresh checklist or a previously saved one. Operators can also view relevant documents through the “Documents” tab, providing further support during production.
• Checklist Manager: This app allows managers to monitor checklist progress and control work orders. They can easily manage work orders by adding descriptions and part numbers, stopping, restarting, or deleting orders as needed. Managers can also search work orders and access comprehensive reports, which can be exported for analysis. This feature is crucial for maintaining production transparency and addressing any discrepancies quickly.
• Checklist Editor: An app designed for editing checklists and assigning documents to stations, giving managers more control over the production process. Managers can reorder tasks, edit items, and insert new tasks. These changes can be applied immediately without losing previously entered data. Additionally, SOP documents can be assigned to stations, ensuring operators always have access to the most up-to-date instructions.

Adopting a Digital Work in Progress Solution  

With real-time tracking, automated checklists, and streamlined processes, an automated work order solution ensures consistency, enhances communication, and reduces errors across the production floor. Employees benefit from simplified workflows and reduced manual tasks, while managers gain complete visibility into production and can make informed decisions quickly. For customers, this results in higher quality products, faster delivery times, and better responsiveness to custom requests. 

By investing in a scalable and customizable WIP solution like NeoMatrix’s, manufacturers can improve efficiency, maintain high quality standards, and stay ahead in an increasingly competitive market.