Real-Time Control, Full Traceability and Maximum Efficiency in Production

Production is the heart of modern businesses. Proper planning, fast reaction, traceability and error-free process management have become essential to surviving in today’s competitive markets. While traditional production methods still matter, modern industrial environments now require real-time data flow, software that can communicate with automation and a fully transparent shop floor.

IQ Production – Production Management Module sits at the center of this transformation, providing both traditional and Industry 4.0-ready production capabilities on a single platform. It is a powerful production ecosystem that digitalizes, accelerates and optimizes every step of the production line.

From Traditional Production Methods to Full Industry 4.0 Support

IQ Production manages all conventional production processes end-to-end, from classic work orders to operation-based production recording:

• Work order creation,
• Operation tracking
• Production in/out recording,
• Quantity-based and time-based production,
• Fully integrated progress with the production planning module.

This infrastructure supports production models that companies are accustomed to, while delivering a hybrid production experience powered by modern automation technologies.

API-Ready for Machine and Automation Integrations

IQ Production provides a flexible API layer that can seamlessly communicate with the automation world:

• Real-time reading of PLC, SCADA, sensor and machine data,
• Automatic calculation of cycle times,
• Capturing and triggering machine downtime reasons directly from the system,
• Continuous monitoring of performance metrics such as capacity, speed and efficiency.

As a result, the production line is no longer dependent solely on manual input; it becomes an intelligent system constantly fed by real-time machine data.

Operator Tracking: Full Visibility on the Shop Floor

One of the strongest components of the production module is the operator/employee traceability system:

• Which operator is working at which station,
• Clock-in/clock-out times,
• Operation start and end times,
• End-of-shift production performance,
• Analysis of stoppages, breaks and lost time.

This system enables productivity graphs for each operator and makes it easy to identify bottlenecks on the production line.

Real-Time Production Monitoring

With real-time data flow, the production floor remains constantly visible and up to date:

• Live status of all ongoing production orders,
• Which product is being processed at which station,
• Which operator is currently working,
• How long the current operation has been running,
• Pending work orders and capacity status,
• Automatic downtime detection via API integration.

Production managers can monitor the entire shop floor from their screens without needing to walk the line physically.

By-Product & Subcontracting (Toll) Production Management

IQ Production is designed to support complex production models:

• Operations that generate by-products,
• Alternative and variant productions,
• Subcontracting (toll manufacturing) processes,
• Subcontract in/out control,
• Dedicated traceability for subcontractor-related operations.

This provides significant flexibility for organizations with complex production structures.

Production Reservations for Capacity & Rule Management

With the production reservation system, production runs are executed in a fully controlled manner:

• When each order will be produced,
• Capacity limits,
• Machine/station utilization rates,
• Rules such as first-in–first-out or customer priority,
• Specific constraints based on production lines.

This structure brings order to chaotic production environments and enables a predictable, well-structured production flow.

Full Lot Traceability in Production

All lot and serial information used in production is tracked automatically:

• Material lot transitions,
• Prevention of incorrect lot usage,
• Lot-based backward and forward traceability,
• Automatic lot change rules,
• Lot and expiry date controls.

This is especially critical for sensitive industries such as food, medical devices, pharmaceuticals, chemicals and automotive.

Scrap & Performance Analysis by Station

Scrap ratios at each station are analyzed in detail:

• How much scrap is generated at each station,
• Scrap reasons,
• Scrap statistics by operator,
• Scrap trend analyses,
• Automatic CAPA (DÖF) triggers via QMS integration.

This significantly reduces production losses.

Full Traceability by Customer and Supplier

The entire production journey of each product can be tracked end-to-end:

• When products for a specific customer were produced,
• Which suppliers’ raw materials were used,
• Full serial/lot-level traceability,
• Supplier quality performance,
• Customer-specific reporting.

This provides a major competitive advantage from both an operational and quality perspective.

Key Advantages of the IQ Production Module

• Real-time visibility across the entire production process,
• Smart production powered by automation and machine data,
• Performance measurement by operator and station,
• Full traceability in by-product and subcontracting processes,
• Analytics that reduce scrap and increase efficiency,
• End-to-end lot traceability,
• Detailed reports per customer and supplier,
• Controlled and predictable process management through production reservations.

In summary, the IQ Production Module is a production management platform that centralizes all the needs of modern shop floors in a single place. It is designed to increase production performance, reduce losses and build a sustainable competitive advantage for manufacturing organizations.