1. Iwoscan
  2. Solutions
  3. Applications
  4. Manufacturing Efficiency
When plan and reality start to diverge

Shop-floor data for manufacturing efficiency analysis

Iwoscan helps show where shift capacity turns into waiting, small stops, unclear states or work that is recorded too late or too roughly.

Circle green checkmark Odoo ERP friendly
Circle green checkmark Built-in task splitting and merging
Circle green checkmark Raw data without distortion
iwoscan manufacturing efficiency

Efficiency is visible through states

Manufacturing efficiency is not just about higher speed. It is often lost between task release, preparation, work start, stops, transfer to the next stage and final system update.


iwoscan manufacturing assistant

Workstation state

- The system records whether a workstation is working, waiting, preparing, stopped or finishing a task.

- This separates real work from time that only looks like production.

iwoscan packaging assistant

Small time losses

- Efficiency is often lost through many short interruptions, not one large problem.

- Iwoscan collects them into a visible data picture.

iwoscan manufacturing assistant

Planned and actual flow

- A task may be planned one way, but its route on the shop floor changes.

- Event data shows where the process starts to drift from the plan.

iwoscan packaging assistant

Work-center load

- One work center may wait for material while another has a queue of tasks.

- State data shows not only output, but also where flow is constrained.

iwoscan manufacturing assistant

Data collected at the process

- Efficiency analysis should begin where the work happens.

- The operator, machine, scanner or sensor can provide different parts of the same process fact.

iwoscan packaging assistant

Clearer shift picture

- The supervisor sees not only the daily result, but how it was formed.

- This supports discussion about specific causes instead of a general feeling that the shift was weak.

How manufacturing efficiency is evaluated

Here, efficiency is understood practically: how much planned working time becomes real, recorded work, and where that time is lost between process states.

  • 1

    Define the states

    First, the relevant workstation states are agreed for the process: work, waiting, preparation, stop, changeover or transfer.

  • 2

    Record events at the workstation

    The operator, machine, scanner or sensor records events when they happen, not at the end of the shift.

  • 3

    Link time to the task

    Event duration is assigned to a specific task, operation, work center or product.

  • 4

    Separate work from waiting

    The analysis shows how much time was active work and how much was waiting for material, a decision, transfer or another reason.

  • 5

    Check improvement impact

    After changing the process, state durations, queues, task delays and real workstation utilization can be compared.

Efficiency loss often hides between events

When workstation states are not recorded, lost time disappears into the shift result. Iwoscan helps turn those small events into data that can be analyzed.

Iwoscan for efficiency analysis

This solution complements planning with factual shop-floor data: states, events, durations, tasks and links to the production process.

iwoscan manufacturing assistant

State model

Workstation events are classified into clear states: work, waiting, preparation, stop and completion.

iwoscan manufacturing assistant

Event timestamps

Each event has a timestamp, so durations can be calculated instead of only total output.

iwoscan manufacturing assistant

Task context

Data is linked to the task, product, operation, operator or work center.

iwoscan manufacturing assistant

Automatic reading

QR codes, barcodes or other signals can reduce manual entry errors.

iwoscan manufacturing assistant

Sensor events

When needed, machine counters or sensor signals can add another source of shop-floor fact.

iwoscan manufacturing assistant

Shift comparison

Shifts can be compared not only by output, but by time structure.

iwoscan manufacturing assistant

Queue visibility

States help show where tasks wait for transfer, material, approval or the next stage.

iwoscan manufacturing assistant

Report foundation

Reports are based on events, not assumptions recreated later.

iwoscan manufacturing assistant

ERP complement

Iwoscan can add execution facts from the shop floor to the planning system.

iwoscan manufacturing assistant

Change validation

After a process change, it is possible to see whether waiting, stops or task queues decreased.

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

Frequently Asked Questions

How is this different from takt time or Lean?

This page is not about the takt formula or Lean methodology. It focuses on recording actual workstation states: where time disappears between plan and result.

Do we need to connect every machine?

Not necessarily. Some events can be recorded by the operator, some through QR or barcode reading, and some from machines or sensors.

Which data matters most for efficiency?

The most useful data is the task, workstation, state, event time and reason when the process stops or waits.

Does this replace ERP?

No. ERP usually holds the plan and accounting objects, while Iwoscan adds execution facts from the workstation.

When does this data become useful?

When the result is worse than the plan, but it is not clear whether the cause is waiting, task queues, preparation, stops or inaccurate registration.

; ;