A production manager at an international CNC machine manufacturing facility in Jalisco, Mexico, reached out with a critical challenge: “We actually have the problem that operators move pieces without having communication and then we have problems with inventories and tracking.”

Their factory receives precision-machined parts from China that undergo 2-3 additional operations across 14 different machines. With operators frequently switching between machines and no real-time tracking system, parts would go missing, operations would be duplicated, and production schedules would fall behind. The company needed a solution that could track each part’s location, current operation status, and machining times to optimize their production workflow.

The Challenge: Multi-Stage Production Without Visibility

Manufacturing facilities handling complex multi-operation workflows face several interconnected challenges. Parts arrive at the warehouse (designated as station 1009), move through various machining operations, and eventually reach the finished goods warehouse (station 1010). Without proper tracking, several problems emerge:

• Parts disappear between operations when operators move them without logging the transfer
• Production orders lose synchronization with physical inventory
• Machining time data remains uncollected, preventing process optimization
• Quality control becomes difficult when operation history is unknown

The production manager needed a system that could scan QR codes containing both part data and production order information, then automatically log when operations start, complete, and transfer between stations.

Solution Design: Building a Comprehensive Tracking System

Using Barcode to PC’s Output Template system, the manufacturing plant implemented a streamlined tracking workflow. The solution uses a simple four-component template that captures all essential data points without complex programming.

The core tracking template includes:

• BARCODE component to scan QR codes containing part and production order data
• DATE_TIME component to automatically timestamp each scan
• NUMBER component to record machine station numbers
• DEVICE_NAME component to identify which operator performed the scan

This configuration automatically generates CSV output that feeds directly into their existing Excel-based production monitoring system (sheet 1013), providing real-time visibility into part locations and operation status.

How to Track Parts Through Multiple Manufacturing Operations

The facility implemented a three-stage scanning process that captures the complete production lifecycle:

Stage 1: Part Arrival
When parts arrive from China, operators scan the initial QR code containing part specifications. The system logs the arrival timestamp and automatically assigns the part to warehouse station 1009.

Stage 2: Production Order Assignment
When a production order is generated, operators attach a second QR code containing production order details and scan it alongside the original part code. This links the physical part to its production schedule.

Stage 3: Operation Tracking
Throughout the machining process, operators scan codes when:

• Parts arrive at a machine station
• Machining operations begin
• Operations complete and parts transfer to the next station

Each scan automatically captures the machine number, operator identity, and precise timestamp, creating a complete audit trail for every part.

Real-Time Production Monitoring Dashboard

The scanning data flows directly into Excel sheet 1013, which serves as the facility’s production control dashboard. This central monitoring system displays:

• Current location of every part in production
• Which operations have been completed on each part
• Actual machining times versus planned durations
• Operator assignments and productivity metrics
• Parts ready for transfer to finished goods warehouse (station 1010)

The production manager can now identify bottlenecks in real-time, reassign work to balance machine utilization, and prevent parts from getting lost between operations.

Measurable Results: From Chaos to Control

The implementation transformed the facility’s production control capabilities. Operators can no longer move parts without proper documentation, eliminating the inventory discrepancies that previously plagued the workshop. The system provides complete visibility into part locations and operation status across all 14 machines.

Most importantly, the facility now collects accurate machining time data for each operation. This information enables the production manager to identify inefficient processes, optimize operation sequences, and reduce overall production time. The data also supports more accurate production planning and delivery commitments to customers.

The solution integrates seamlessly with existing Excel-based workflows while providing the real-time tracking capabilities needed for modern manufacturing operations. By leveraging CSV output features, the system maintains compatibility with established reporting processes while dramatically improving data accuracy and timeliness.

How to Get Started with Manufacturing Tracking

Manufacturing facilities facing similar production control challenges can implement comparable solutions using Barcode to PC’s flexible template system. The key is starting with a simple tracking workflow that captures essential data points without overwhelming operators with complex procedures.

Begin by identifying your critical tracking points: part arrivals, operation starts, operation completions, and transfers between stations. Design QR codes that contain the minimum necessary information, then use Output Template Generator to create scanning workflows that automatically capture timestamps, operator information, and station details.

For facilities already using Excel-based production tracking, the transition becomes straightforward since Barcode to PC generates standard CSV output that integrates directly with existing spreadsheet systems. This approach allows you to maintain current reporting processes while gaining real-time visibility into production operations.