1. Iwoscan
  2. Applications
  3. Manufacturing Defects
MANUFACTURING DEFECT AND SCRAP MANAGEMENT AT THE WORKSTATION

Record manufacturing defects where they occur

Iwoscan enables operators to record a manufacturing defect immediately, select its cause and pass accurate data to the people responsible. Defect and scrap management takes place in real time: the system links each event to a workstation, job, product and operator, and can automatically add the replacement quantity to the production plan.

Circle green checkmark Odoo ERP friendly
Circle green checkmark Built-in task splitting and merging
Circle green checkmark Raw data without distortion
Manufacturing defect recording with Iwoscan

How Iwoscan manages manufacturing defects

The system collects data directly at the workstation. A manufacturing defect becomes a traceable event that can be assessed and used to eliminate recurring causes of scrap and rework.


Recording a manufacturing defect at the workstation

Defects are recorded immediately

The operator records a manufacturing defect using a physical button panel, a workstation terminal or a tablet. There is no need to leave the workstation or complete a paper log at the end of the shift.

Manufacturing defect cause data

Know where and why the defect occurred

Each record can include the workstation, time, operator, job, product and selected cause. Manufacturing defect analysis is therefore based on actual production data rather than reconstructed information.

Replacement production quantity

Replacement quantity is added to production

When a defective unit is recorded, the system can immediately increase the quantity that still needs to be produced. This reduces the risk of final assembly or packing stopping because a single component is missing.

Real-time scrap quantity and cost

Scrap quantity and cost are visible in real time

Managers can see the number of manufacturing defects and the cost of scrap without waiting for a stocktake. Data can be filtered by product, workstation, shift, operator or defect cause.

Recurring manufacturing defect analysis

Recurring manufacturing defects become visible

The manufacturing defect history shows which products, operations or workstations repeatedly generate the same problem. After a change is made, periods can be compared to verify whether scrap has actually decreased.

Iwoscan integration with production systems

Data is passed to other systems

Iwoscan can be integrated with an ERP, MRP or another production management system. Data can also be exported in CSV, JSON or binary format.

From a manufacturing defect to a specific action

Scrap management starts with an accurate production event, not with a report completed at the end of the month.

  • 1

    The operator records a manufacturing defect

    When a defective product, component or material is found, the operator selects the defect type. Buttons and cause lists are configured for the actual production process.

  • 2

    The system retains the production context

    The defect is linked to the active job, product, workstation, operator and exact time. If required, the equipment, supplier or material batch can also be recorded.

  • 3

    The required quantity is updated

    If the defective unit must be replaced, an additional unit is added to the production requirement automatically. Production does not have to wait until the shortage is discovered during final assembly.

  • 4

    Relevant staff see the issue immediately

    Managers can see the number, causes and locations of manufacturing defects in real time, together with the related jobs. Supplier claims and internal investigations can be supported by the event history.

  • 5

    The result of corrective action is verified

    After changing a process, tool, material or instruction, the actual manufacturing defect data is compared between periods. This shows whether the action reduced scrap.

Is Iwoscan suitable for your production process?

Leave your name, email address and phone number. We will contact you to discuss how manufacturing defects are currently recorded, what data is needed and whether integration with an ERP or MRP system is required.

What the production team gets

Iwoscan does not decide whether a product meets quality requirements. It helps record manufacturing defects on time, manage their effect on production flow and collect reliable data for root-cause analysis.

Manufacturing defect recording

Simple recording for operators

A defect is recorded with one selection, without taking the operator away from production for longer than necessary.

Scrap history

Accurate scrap history

Every record includes its time, location and production context, so events do not have to be reconstructed from memory.

Production batch management

Lower risk of incomplete production batches

Defective units are accounted for during production, and replacement quantities can be planned before the final stage.

Manufacturing defect analysis

Data for eliminating defect causes

Reports identify recurring manufacturing defects and help verify whether corrective actions produced a measurable result.

Local production data storage

Operation during network interruptions

The recorder stores data at the workstation first, so production events can still be recorded during temporary network interruptions.

ERP and MRP integration

Integration with the existing process

Manufacturing defect data can supplement the ERP, MRP or quality management process already used by the company.

Show us one production workstation

Briefly describe the process, equipment and data that is currently missing.

We will explain what can be recorded, which Iwoscan set is suitable and how the data can reach your systems.

Discuss your process

Key questions before implementing Iwoscan

Does Iwoscan automatically detect manufacturing defects?

Iwoscan records a defect event submitted by an operator, quality inspector or connected system. If measurement, machine vision or other inspection equipment provides a suitable data interface, its signals can be incorporated into the overall defect and scrap management process.

How does an operator record scrap?

The operator selects the defect type using a physical button panel, terminal or tablet. The system adds the active job, product, workstation, operator and time automatically, so information that is already known does not have to be entered again.

What happens after a defective unit is recorded?

The event appears in the manufacturing defect history immediately. Depending on the configured process, the system can increase the required production quantity, notify the responsible employee and update the connected production management system.

Do we need to replace our existing ERP, MRP or quality management system?

Not necessarily. Iwoscan can collect data at workstations and pass the required information to the ERP, MRP or other system already in use. The integration scope is defined after reviewing the existing software and its data interfaces.

What is needed to start an implementation?

The first step is to choose one process or workstation and define the manufacturing defects to be recorded and the actions required after each event. The input method, equipment and integration can then be selected. Implementation can start with a limited scope and expand after the process has been verified in production.

; ;