What happens in the plant
- Piece counts are entered manually after production has moved on
- Good count, reject count, and rework count are not separated clearly
- Counters, PLC values, operator sheets, and ERP numbers do not match
- Supervisors cannot tell whether a count mismatch is mechanical, procedural, or reporting-related
- Production status is reported with totals but without count confidence
Why it matters
Count accuracy affects OEE, inventory, scrap, shipment confidence, and production scheduling. If the plant cannot trust the count, every downstream decision becomes slower: whether the order is complete, whether material is missing, whether quality loss occurred, or whether the line actually met its target.
What teams need to see
Teams need to see good count, reject count, rework count, counter source, manual adjustments, order context, shift context, and count mismatch reasons in one operational view.
Decisions this problem affects
- Is the order actually complete or only reported complete?
- Which count source should be treated as the operational reference?
- Which line or shift is producing repeated count mismatches?
- Which mismatch requires quality, maintenance, or supervisor follow-up?
- Which count issue will affect inventory or shipment planning?