Work-in-progress (WIP) monitoring is tracking the progress of production. It allows managers to make informed decisions about resource allocation and scheduling as well as determine the current status of a job or subassembly. Work-in-progress (WIP) monitoring is part of Industry 4.0, the term used to describe the fourth industrial revolution, which use digital technologies to create more efficient and automated production processes.
WIP monitoring saves costs by identifying bottlenecks in the production process, reduces the amount manual tracking and enables proactive decisions. Also, real-time data can be used to optimise production schedules and minimise downtime, reducing the overall cost of production.
Tracking work in progress (WIP) has several advantages for manufacturing and production operations:
- Improved Production Planning: By tracking WIP, manufacturers can better understand how much inventory they have at each stage of production, which can help them plan for future production runs, adjust staffing levels, and optimise production schedules.
- Better Resource Allocation: WIP tracking can help identify areas of the production process where resources are being over-utilised or under-utilised. This information can be used to allocate resources more efficiently, reducing waste and increasing productivity.
- Quality Control: WIP tracking can help identify quality issues earlier in the production process, allowing manufacturers to take corrective action before the product reaches the final assembly stage. This can reduce the amount of rework required and improve overall product quality.
- Reduced Lead Times: By tracking WIP, manufacturers can identify bottlenecks in the production process and take action to resolve them more quickly. This can help reduce lead times and improve on-time delivery to customers.
- Cost Savings: By optimising production schedules and resource allocation, WIP tracking can help manufacturers reduce costs associated with over-production, inventory storage, and waste.
Bluetooth beacons can be used to track WIP by attaching a small, low-power Bluetooth device to each job or unit of production. These beacons transmit a unique signal that can be detected by Bluetooth-enabled gateways located throughout the production line. This allows for real-time tracking of the location and status of each job or unit of production.
Some legacy system use barcodes or RFID for WIP tracking. The problem with these is the information is only as up-to-date as the last scan. Bluetooth beacons transmit all the time allowing for real-time tracking of WIP with no manual scanning. Additionally, Bluetooth beacons can be easily integrated with existing IoT infrastructure, making them a cost-effective solution for WIP monitoring. RFID and barcodes, on the other hand, require specialised equipment to read the tags. Bluetooth beacons can transmit data up to 100 meters or more, also making them more suitable for large spaces such as warehouses and factories.