Real-Time Manufacturing Intelligence
Automate Order Tracking, Improve On-Time Delivery and Shop-Floor Operational Efficiency
Real-time Work-in-Process (WIP) visibility has become a critical requirement in today's manufacturing and maintenance & repair operations (MRO). The shop-floor has transformed in to a virtual operations environment of collaborating business partners. Although, these partners improve quality and costs for tasks performed, they increase the complexity for coordination and on-time delivery. Omnitrol Smart Infrastructure's™ solutions were designed from the "get-go" to transform asset traceability (TaaS™) in to process based operational intelligence.
Omnitrol Smart Infrastructure's™ for WIP tracking means making smart decisions about production issues as they happen. Our WIP tracking solution enables our customers to automatically monitor work-orders and associated sub-work-orders through each task, both within their operations and also across their partners operations. Our Manufacturing Intelligence solution provides complete end-to-end work-order traceability, automatically reconciles multiple orders, alerts on deviations with complete visibility on your customer orders from kitting/disassembly through finished goods/final assembly and delivery.
Omnitrol WIP Smart Infrastructure™ Benefits
- Achieve over 97% on-time delivery
- Track each work-order by task, status, location and staff
- Monitor each customer order with all associated work-orders
- Substantial improvement in employee productivity through scorecards on vital information
- Reduce errors on tasks performed while ensuring compliance and quality
- Real-time monitoring, measuring, with accurate reporting of work-in-progress across complex shop-floors
- Confgiurable real-time alerts, analytics and dashboards for optimal decision making
Omnitrol WIP Smart Infrastructure's™ allow manufacturing and repair operations to run leaner and smarter, improving operating margins while simultaneously increasing customer and employee satisfaction with near perfect on-time delivery.
- Over 90% overall equipment and materials effectiveness
- Over 20% improvement year over year in customer satisfaction
- Over 10% year over year improvement on operating margins
Omnitrol WIP Smart Infrastructure™ Features
Omnitrol's WIP visibility brings valuable real-time operational intelligence to any customer operation that needs to monitor jobs/work-orders through one or multiple assembly lines by task. Information is captured automatically and in real-time through sensors, RFID, SCADA and mobile handheld devices and displayed in visual dashboards that are accesible throguh secure web-portals anytime, anywhere. Furthemore, information can be captured from remote sites through mobile handhelds or smart storage shelves or portals that reconcile receipt of goods. All orders tracked by (TaaS™) keep complete historical trace information and generate alerts based on age/shelf-life thresholds, dwell time, or unauthorized movements and operations.
Although, the Omnitrol WIP Smart Infrastructure™ solution provides a complete end-to-end solution to track WIP, the system also has open interfaces to easily integrate with existing ERP systems. Our open architecture allows customers to extend their existing manufacturing operations systems in to a real-time WIP Smart Infrastructure™.
- Create work-orders and task lists (routes) by product
- Automatically generates expected work-time by task and product
- Automatically generates traveller that can be delivered to any site or partner for execution
- Support for split work-order, rework order tracking and reconiliation
- Alerts and automatically adjusts required operational work time due to reworks
- Cost analysis and tracking of employee earned time and actual work time by task
- Product, task and employee performance analytics to monitor productivity issues by job
- Automatically generate employee scorecards based on performance and quality of work
- Open architecure allows for seamless integration with existing ERP, MRP and Asset Management Systems
- Track tasks and employee activity through RFID (automated) and barcode input devices
- Powerful EASE-V8™ platform allows for extensible reporting
- User configurable web-based visual dashboards that can be viewed on mobile tablets at anytime, anywhere
- Cost effective and incrementally scalable from single to multiple locations worldwide
The Omnitrol WIP Smart Infrastructure™ solution provides powerful and highly intuitive real-time dashboards and reports for managing and tracking work-orders through each stage. The solution automatically highlights orders that are at risk to on-time delivery of the associated customer order. As an integrated (TaaS™) solution, you are always in the know of stock availability, which reduces the need for high "safety" stock levels. Operations will automatically be notified on production bottlenecks, work-order delivery errors and delays.
- Confirmation of each work order as it moves from one stage to the next
- Track on-time delivery risk for all customer orders by specific product and quantity
- Role-based secure access to specific customer reports and employee performance
- Open web-based access to allow your partners and/or customers access to their order information
- Instant alerts on errors, bottlenecks and delays via email, text and voice messages
- Complete order traceability with over 10+ years historical data
Real-Time Supplier Collaboration
TaaS™ WIP visibility Smart Infrastructure's™ has pioneered manufacturers to automatically and securely collaborate in real-time with both their shop-floor operations and with their supplier partners to track order status directly from their operations-floor. Our WIP visibility truly enables Supplier Collaboration through real-time web reports eliminating the overhead of manual spreadsheet based daily operating reports. Furthermore, since our WIP tracking is based on high integrity and accurate order information directly from the operations-floor, customers gain the true benefits from supplier collaboration.
Ready to learn more about how OMNITROL Real-Time WIP Visibility can satisfy your business needs? Please contact us!
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It mitigates technology investment risk by minimizing integration with existing legacy systems; enabling customers to migrate at their own pace while still being future-proofed.
Omnitrol’s cutting-edge solution suite automatically collects information from a large variety of sensors and, through predictive analytics, delivers real-time visibility with accurate forecasting between business partner operations. Potentially, any control system or middleware may help an end-user integrate back-end and shop-floor but Omnitrol infrastructure extends business intelligence directly from the operations-floor without the complexity of multiple software layers, thereby minimizing total investment and improving ROI.
Frost & Sullivan
Omnitrol Networks has become a major force in the industry.
President & CTO,
RFID Global Solutions
The OMNITROL appliance's network and business application convergence, compounded by its dramatic economic value proposition, is rapidly transforming the landscape of the real-time enterprise network and appliance-based service delivery.
Successfully deploying asset tracking solutions in the enterprise requires an integrated platform that reduces costs, risks and complexity. Omnitrol's scalable open platform is enhanced by adding Wi-Fi RTLS functionality using Ekahau's RTLS and its open XML/HTTP software interface.
President & CEO,
Business leaders should care about the benefits that a solution like Omnitrol's could bring to the inherently complex manufacturing models that automotive, aerospace and other large discrete manufacturers face.
Our current focus is on lean manufacturing, common systems, and ergonomics. To prepare for the next step function improvement in aircraft manufacturing, the Advanced Manufacturing Research & Development organization is exploring network enabled manufacturing, Omnitrol Networks helps us create such an environment by providing the capability to collect, analyze, correlate, and act upon edge device and applications data in a highly adaptive, real-time environment.
Senior Manager, Aerostructures Manufacturing,
The PCB tracking solution combines Texas Instruments’ experience in electronics manufacturing along with our core competency in RFID with Omnitrol Networks' Work-In-Process application appliance.
Director of Asset Tracking,
Texas Instruments RFID Systems
I can view the complete status of my shop-floor and quickly identify at-risk orders from my desktop. Instead of discovering late orders through missed delivery dates, thanks to the OMNITROL solution I am always in the know.
Vice President of Manufacturing,
Bay Creek Manufacturing
Working with Omnitrol Networks to add UWB capability to their best-in-class WIP visibility solution will offer customers the solution they are seeking to improve their work-in-process operations.
Vice President of Worldwide Sales and Marketing,
The OMNITROL appliance has developed a powerful new paradigm in real-time Work-In-Process visibility and traceability. By combining all the computing, networking, and software resources into a single physical device, Omnitrol Networks is going to be a catalyst of the IT transformation that will support the proliferation of intelligent edge networks.
Joseph Robin Mathews,
With OMNITROL, end users will not have to upgrade their entire infrastructure to adapt to the latest technology change or workflow improvement. The OMNITROL encapsulates complete business services intelligence on the work-floor where business operations happen.
Frost & Sullivan
Omnitrol Networks' offering combines middleware, device management and networking functions that reduce costs and time-to-market for real-time RFID-based edge services. We look forward to continued collaboration with Omnitrol to bring the benefits of RFID to our customers.
Director of Channel Development,
Alien Technology Corporation
Omnitrol's ability to automatically monitor and track what is happening on the factory floor without user intervention is a unique differentiator. It eliminates inconsistent or inaccurate reports of work in process.
The aerospace and defense industries are constantly looking for better ways to manage complexity. Among their goals are the creation of ‘sense and respond’ supply chains that help warfighters increase availability of their weapons systems to ensure mission readiness. Omnitrol Networks’ award-winning track and trace infrastructure solution is a proven, scalable and elegant approach to help existing ERP, MRO, and logistical systems achieve these goals in the aerospace and defense sectors.
The OMNITROL solution provides Hobart’s manufacturing team with real-time visibility on all our customer orders without any impact on our operations. The solution eliminates the tasks of order tracking and manual entry. More importantly, the solution makes us a better partner to our customers by automatically sharing critical order information with them 24x7.
Hobart Machined Products
Most middleware is limited, requires extensive customization making it difficult for use to integrators like us.The OMNITROL supports not only all types of wireless, barcode and RFID technologies, but also sensors and PLC systems simplifying integration with our customers installed infrastructure while providing the flexibility to expand, improve and scale their business processes without incurring high costs.
Vice-President and General Manager,
Ahearn & Soper
Omnitrol’s web-based in-production dashboard provides us with a unique Work-In-Process solution that is expected to deliver the next level of process innovation and change order management.
SVP and General Manager,
Endwave Defense Systems
This low cost solution can help to transform the business relationship between customers and their key suppliers and deliver better and faster product.
We are delighted to be working with Omnitrol as it will strengthen our existing capabilities within BT Supply Chain Solutions and enable us to better address our customers’ requirements to improve the operational efficiency of their supply chains. The versatile OMNITROL platform allows BT Supply Chain Solutions to quickly customize solutions, and to meet individual customer needs.
BT Supply Chain Solutions
The OMNITROL solution delivers a new generation network appliance encapsulating all RFID processing and management, thereby eliminating back-end development, reducing setup and support costs for edge deployments.
Director of VDC's Automatic Identification and Data Collection (AIDC) Practice,
VDC Automatic Identification
I was extremely impressed with the capabilities of the OMNITROL appliance approach, and its ability to rapidly create and deploy intelligent edge manufacturing services, which led me to select Omnitrol Networks' solution for my laboratory. The new OMNITROL-based network gives us more flexibility than today's approach, making our research more timely and applicable. In addition, the OMNITROL's capability to integrate with all devices on the shop floor, including PLCs and new sensor technologies like RFID, is giving our students and industry partners access to the latest leading edge technologies.
Director of the MSA and Associate Professor of Mechanical Engineering,
The OMNITROL PCB tracking solution using TI’s RFID chips allows us to automatically maintain traceability on each component that goes into the products we build. We have been able to replace tedious manual scanning with a completely automated process.