Development of an IoT-Integrated Manufacturing Monitoring and Reporting System

Despite utilizing modern machinery, the manufacturing facility relies on manual data collection through pen and paper, leading to delayed reporting, limited visibility into ongoing production, quality issues, and difficulty in managing inventory and task prioritization. This hampers decision-making, causes inaccuracies, and impacts overall productivity and product quality management.

A medium to large manufacturing company specializing in footwear production, seeking to digitalize production tracking, quality control, and reporting processes to enhance operational visibility and efficiency.

• Implement a real-time production monitoring system accessible across devices to enhance operational visibility.
• Reduce the time spent on manual data collection and reporting by automating data entry and aggregation processes.
• Minimize data entry errors and false inputs through digital validation and standardized data entry protocols.
• Improve quality tracking by monitoring defects at each production stage and providing instant alerts for deviations.
• Standardize product naming and documentation to streamline inventory management and seasonal balance audits.
• Visualize bottlenecks and downtime instantly to enable prompt corrective actions.

• Enterprise dashboard displaying overall production metrics, inventory levels, and task statuses.
• Administrative interface for managing product models, user access rights, and receiving operational alerts.
• Shop manager interface for assigning, prioritizing, pausing, and tracking tasks at each machine or production line.
• Worker interface for viewing assigned tasks and reporting completed units with data validation.
• Sales interface to monitor product availability in real-time and track in-production items for pre-sales and order acceptance.
• Warehouse interface for reporting shipped and shipped-out products, maintaining accurate stock levels.
• Real-time defect and quality monitoring at each production stage with instantaneous notifications for deviations.

• Manufacturing equipment data feeds or APIs for automated real-time data collection
• Inventory management systems for current stock levels
• Quality control systems for defect reporting
• Order management or CRM systems for sales forecasting and pre-order tracking

• Scalability to support multiple production lines with minimal latency
• High system availability and real-time performance to facilitate instant decision-making
• Robust security measures for sensitive production and business data
• User role-based access control and audit logging

The implementation of the integrated manufacturing monitoring system is expected to significantly decrease reporting and data collection time, reduce input errors, and improve inventory accuracy. This will lead to enhanced visibility into production bottlenecks, quicker response times, and better quality control, ultimately increasing overall productivity and operational efficiency with measurable reductions in seasonal inventory discrepancies and defect rates.