Manufacturing Shop Floor Automation
Hourly Production Recording Process
Background – How Production Is Recorded Today (Manual Process)
Today, hourly production details are recorded manually on paper sheets on the shop floor.
Paper Sheets Typically Include:
- Hour-wise time slots
- Production quantity per hour
- Rejection quantity
- Reasons for loss time or defects
- Supervisor checks and signatures
Challenges with Paper Sheets:
- Filled by hand
- Reviewed manually
- Stored physically
- Difficult to track, consolidate, or audit
Objective – What We Are Automating
The goal of this workflow is to transform manual paper-based processes into a fully digital, traceable, and audit-ready system.
- 1Replace manual paper entry with digital hourly entry
- 2Capture the same information, but in a structured system
- 3Automatically generate a digital production report
- 4Ensure traceability, approvals, and audit readiness
People Involved in the Automated Process
Clear role-based responsibilities ensure smooth workflow execution.
Operator
Starts the production record
Shift Person
Enters hourly production details
Supervisor
Reviews and validates data
Manager
Final approval
Admin
User and system setup
End-to-End Process Flow (Real Shop-Floor Story)
A step-by-step journey from production start to automated report generation.
Operator Starts the Digital Production Record
At the start of the shift, the operator opens the system and creates a new production record. The operator enters:
- Date
- Production line / activity (e.g., Cell Sorting)
- Shift (A / B / C)
- Assigned Shift Person
This step replaces the first heading section of the manual paper sheet. Once submitted, the record is opened for hourly updates.
Shift Person Records Hourly Production (Core Activity)
The Shift Person is responsible for recording production for each hour of the shift, just like the manual sheet. For every hourly slot:
- Start time and end time
- Production quantity
- Rejection quantity (numbers only)
- Loss time / rejection remarks (if any)
This step directly replaces the handwritten hourly rows in the paper sheet. The Shift Person continues entering data hour by hour until the shift ends. Once complete, the record is submitted to the Supervisor.
Supervisor Reviews the Digital Entry
The Supervisor receives the completed shift record for review. The Supervisor checks:
- Hour-wise production values
- Rejection quantities
- Remarks and loss reasons
The Supervisor can:
This replaces manual supervisor checking and signatures on paper.
Manager Gives Final Approval
The Manager performs the final review, similar to signing off the paper report. The Manager can:
All approvals and rejections are logged automatically. This replaces manual manager sign-off.
Automated Digital Report Is Generated
Once approved:
- The workflow is closed
- A digital production report is automatically generated
- A unique reference number is assigned
The output is a structured, searchable production report based on the same data that was earlier written manually. This is the automated version of the paper report.
Secure Storage and Easy Access
Approved records are:
Stored Securely
Protected in our RMS with encryption
Version-Controlled
Complete history of all changes
Available Anytime
Ready for audits, reviews, or analysis
No physical files. No missing sheets.
Monitoring and Visibility (For Management)
Managers and Supervisors can see:
- Ongoing shifts
- Pending approvals
- Completed production reports
This visibility is not possible with manual registers.
System Support (Happens in the Background)
User Accounts and Role-Based Access
Users are created with defined roles:
Each role has limited and controlled access.
Standardized Digital Template
The system uses a predefined template that:
- Matches the manual sheet structure
- Enforces mandatory fields
- Prevents incorrect data formats
Audit Trail and Compliance
Every action is recorded:
- Who entered hourly data
- Who reviewed and approved
- Date and time of each action
This provides full audit traceability.
Key Business Benefits
Transform your manufacturing operations with measurable improvements.
No paper handling
Eliminate physical forms and manual data entry with digital document management
No missing or damaged records
All data stored securely in the system
Accurate hourly tracking
Real-time production data capture
Faster approvals
Streamlined digital approval workflow
Easy audits
Complete audit trail with timestamps
One-click reports
Automated report generation on demand
Ready to Automate Your Shop Floor?
Transform your manual paper-based production recording into a streamlined digital workflow. Contact us to schedule a demo and see how our shop floor automation solution can benefit your manufacturing operations.
Schedule Consultation