From Paper to Automation: Rethinking Shop Floor Reporting

Traditionally, manufacturers have relied heavily on manual shop floor reporting methods involving paper logs, spreadsheets, chalkboards, and color-coded tracking systems to record critical information.

Today, Microsoft Dynamics 365 Finance and Supply Chain Management (D365 F&SCM) helps manufacturers streamline shop floor reporting and leverage their data more effectively.

Why Better Shop Floor Reporting Matters

Shop floor reporting refers to collecting and analyzing data to optimize manufacturing processes.

This can include:

• Tracking materials
• Monitoring product quality
• Scheduling
• Machine utilization
• Maintenance
• Overall equipment effectiveness (OEE)

Historically, teams have manually collected and entered this data, leaving a wide margin for error. For example, machine operators might manually record pick tickets and work times on paper. A shift supervisor then collects and verifies the hand-written logs, manually entering the data into an ERP or MES system. The final step would be an Excel or other report generated by hand from a manager.

However, manual reporting has several limitations:

• Inefficiency and errors: Paper-based methods are notoriously inefficient, inconsistent and error-prone. These outdated practices increase the likelihood of data inaccuracies which misinform production decisions and encumber the need for near real-time transactions.
• Data silos: When storing data manually, it often fragments across different formats, records or departments, blocking a comprehensive view of what’s happening on the shop floor.

Many manufacturers are turning to automation to address these challenges. By shifting from manual processes to digital reporting tools, manufacturers can streamline data collection that leads to smoother, more efficient production workflows.

Transforming Manual Processes into Automated Solutions

We’ve seen powerful examples of the benefits of automation when manufacturers upgrade from manual material management to automated barcoding and labeling. A simple scan allows the manufacturer to track the item through every stage of the production process. Digitization and automation reduce errors, improve reporting accuracy, and enable real-time inventory updates, leading to better controls on the shop floor.

The shift from manual to automated reporting provides several benefits:

• Enhanced efficiency: Automated systems capture data quickly and accurately, reducing the time spent on administrative tasks.
• Error reduction: Digital systems minimize the risk of human error, providing more accurate and consistent data across the shop floor.
• Improved decision-making: Automation allows instant data access and analysis, so manufacturers make real-time adjustments that impact output quality and efficiency.
• Reduced downtime: Manufacturers can quickly spot production bottlenecks or quality issues.
• Better inventory and item management: Automated tracking keeps inventory under control and reduces waste.
• Foundation for the future: Implementing automated reporting lays the groundwork for incorporating more advanced AI and analytics, positioning manufacturers to better scale with the latest evolving, innovative technology.

Automation isn’t just about swapping out paper for screens; it’s about transforming how data is gathered, shared, and used to drive improvements.

Leveraging AI

D365 F&SCM can help facilitate, along with other connected IOT devices to help enhance manufacturing processes. These tools enable predictive maintenance, demand forecasting, and real-time anomaly detection—all tailored to optimize production and streamline operations without additional integrations.

For example, employees with deep knowledge of equipment might detect issues based on intuition or experience, such as a sound or vibration. AI tools can enhance this intuition, providing data-driven predictions that complement the expertise of experienced staff and spot potential breakdowns before they happen. 

This reduces unexpected downtime while ensuring machinery operates at peak efficiency. It also significantly increases productivity.

Transitioning from a traditional reporting system to automation is a significant change, particularly for manufacturers that have operated manually for decades. However, the long-term gains far outweigh the initial investment and inevitable learning curve. With automation, production floor data is no longer scattered across notebooks and boards but is centrally available, enhancing visibility and control.

Ultimately, automating shop floor reporting helps manufacturers stay competitive by empowering them with data-driven insights into more streamlined processes that boost the bottom line.

Sikich: Your Microsoft Partner

Sikich can help you modernize shop floor reporting and harness real-time insights across your production environment. As a trusted Microsoft partner, Sikich offers expertise in implementing and optimizing D365 solutions tailored to your unique needs, ensuring you get the most value from your automation journey. Contact us to find out more.