The Complexities of Tracking Manufacturing Products from Raw Materials to Shipping

Tracking manufacturing products from raw materials to shipping is a multifaceted process that requires meticulous planning, robust systems, and seamless coordination across various departments. This blog will delve into the complexities involved, the systems that facilitate this process, their costs and maintenance, and popular system brands used in the USA. Additionally, we'll explore use cases by different company departments.

Remember when the world shut down due to COVID-19. Supply chain issues worldwide were created and consumers were left to search for goods. Small and Medium sized businesses were equally hurt with inventory issues and logistical nightmare.

Every consumer wants to know when they purchase goods from your company, the transaction fulfillment process is a pleasurable experience. How does your company track fullfilment?

The Tracking Process

1. Raw Materials Management:

• Inventory Tracking: Ensuring that raw materials are available when needed is crucial. This involves real-time tracking of inventory levels, reordering points, and supplier lead times.

• Quality Control: Raw materials must meet quality standards before entering the production process. This requires rigorous testing and documentation.

2. Production Tracking:

• Work-in-Progress (WIP) Tracking: Monitoring the status of products as they move through various stages of production helps identify bottlenecks and optimize workflows.

• Batch and Lot Tracking: Assigning batch or lot numbers to products ensures traceability, which is essential for quality control and regulatory compliance.

3. Finished Goods Tracking:

• Inventory Management: Finished products must be tracked in real-time to manage stock levels, prevent overproduction, and ensure timely fulfillment of orders.

• Shipping and Logistics: Coordinating the shipping process involves tracking products from the warehouse to the customer or distributor, ensuring timely and accurate deliveries.

  
  

Systems That Help with the Process

Several systems are designed to streamline the tracking process in manufacturing:

1. Manufacturing Execution Systems (MES):

• Functionality: MES systems manage and monitor work-in-progress on the factory floor. They provide real-time data on production activities, machine performance, and labor utilization.

• Popular Brands: FactoryTalk, ShopVue, ShiftWorx

2. Enterprise Resource Planning (ERP) Systems:

• Functionality: ERP systems integrate various business processes, including inventory management, production planning, and order fulfillment. They provide a unified view of operations.

• Popular Brands: SAP, Oracle, Microsoft Dynamics

3. Inventory Management Systems:

• Functionality: These systems track inventory levels, manage reordering, and ensure optimal stock levels. They often integrate with MES and ERP systems.

• Popular Brands: Katana, Fishbowl, NetSuite

4. Barcode and RFID Systems:

• Functionality: These systems use barcodes and RFID tags to track materials and products throughout the supply chain. They provide real-time data on location and status.

• Popular Brands: Zebra Technologies, Honeywell, Avery Dennison

System Costs and Maintenance Processes

1. Initial Costs:

• Software Licenses: The cost of software licenses can vary significantly based on the system's complexity and the number of users.

• Hardware: This includes servers, barcode scanners, RFID readers, and other necessary equipment.

2. Ongoing Costs:

• Subscription Fees: Many systems operate on a subscription basis, with monthly or annual fees.

• Maintenance and Support: Regular maintenance is essential to ensure system reliability. This includes software updates, hardware repairs, and technical support.

3. Implementation Costs:

• Customization: Tailoring the system to meet specific business needs can incur additional costs.

• Training: Employees need training to effectively use the new systems, which can involve both time and financial investment.

Use Cases by Company Departments

1. Production Department:

• Use Case: The production department uses MES systems to monitor real-time production data, identify bottlenecks, and optimize workflows. This ensures efficient use of resources and timely completion of production orders.

2. Quality Control Department:

• Use Case: Quality control relies on batch and lot tracking to trace the history of raw materials and finished products. This helps in identifying and addressing quality issues promptly.

3. Inventory Management Department:

• Use Case: Inventory management systems help maintain optimal stock levels, manage reordering processes, and prevent stockouts or overstock situations. This ensures that production runs smoothly without interruptions.

4. Shipping and Logistics Department:

• Use Case: Barcode and RFID systems are used to track products from the warehouse to the customer. This ensures accurate and timely deliveries, enhancing customer satisfaction.

Conclusion

Tracking manufacturing products from raw materials to shipping is a complex but essential process for ensuring efficiency, quality, and customer satisfaction. By leveraging advanced systems like MES, ERP, and inventory management, companies can streamline their operations, reduce costs, and maintain high standards of quality. Understanding the costs and maintenance involved, along with the specific use cases for different departments, can help businesses implement these systems effectively and reap their full benefits. As your company grows you need systems that grow as well. Contact us for how we can improve your current technologies via AI Enablement or optimization upgrades.