The operating problem
Piece counts often come from multiple sources that do not agree: PLC counters, operator entries, quality records, and ERP adjustments.
What happens without this system
- Good count, reject count, and rework count are mixed or reconciled manually.
- PLC counters, operator records, and ERP quantities do not match.
- Teams cannot quickly tell whether the order is actually complete.
- Count uncertainty slows inventory, quality, and shipment decisions.
What the system makes visible
- Good count, reject count, and rework count by order and line
- Count source and manual adjustment history
- Count mismatch between PLC, operator, quality, and planning records
- Shift-level production quantity confidence
- Downstream inventory or shipment risk caused by count uncertainty
Decisions it supports
- Is the order actually complete?
- Which count source should be trusted for this line?
- Which mismatch needs supervisor or quality review?
- Which count issue will affect inventory or shipment planning?
What this is not
This is not a generic dashboard template. Innovomind shapes each system around the operating problem, the information teams need to trust, and the decision the plant needs to improve.