Production Tracking
Real time traceability and meterage during the production process at high speeds.
Problem Statement
Our Clients experience discrepancies in fabric roll lengths, with significant shortages identified only during the final output measurement. This led to confusion regarding the source of the issue whether rolls were delivered shorter than expected or fabric was lost during production stages. Without a system to track fabric continuously through each process, it was difficult to pinpoint where discrepancies occurred, resulting in inefficiencies, potential loss of material, and challenges in fulfilling customer expectations accurately.
Our Solution:
Upon receiving each fabric roll at input, High Speed barcode scanners scan barcodes automatically to record total meters, creating a digital entry linked to the specific roll using a digital meter counter. This data is used to verify all subsequent fabric usage. As the fabric moves through production, barcode data tracks how much fabric is consumed or wasted, and alerts the team in real-time of any issues, enabling efficient use of materials.
The costing team accesses live data on fabric usage, waste, and roll condition, allowing for accurate cost-per-unit calculation and minimizing over-budget issues. Barcode records also help in making better forecasts based on fabric utilization trends. At the output, barcodes help verify the consistency between the input and output stages. This ensures that the final product meets the requirements and eliminates the need for extensive manual checks.
Advantages of Our System
Accuracy in Fabric Length: High speed auto barcode system and Digital meter capture reduces discrepancies and aligns records with actual fabric received. Efficient Material Use: Real-time tracking enables immediate action on bottlenecks and fabric wastage. Accurate Costing: Continuous usage tracking provides precise cost-per-unit data and helps control budgets. Quick Verification: Consistent tracking from input to output simplifies final checks, ensuring product meets specifications. This high-speed auto barcode-driven process enhances efficiency across teams by providing precise, real-time data to each stakeholder, ensuring alignment, accurate costing, and quality assurance without excessive manual intervention.
