Overview
Why we are moving to scanner-based production tracking
If it is not scanned, it does not exist.
A box that has been packed but not scanned has no identity in the system. It cannot be moved to the warehouse, counted in stock, or dispatched. Every scan also sets a location — location is not a separate step, it is built into every scan itself.
This document explains the proposed scanner-based system that replaces manual hourly counting on the production floor. It is a living reference — updated as the process is refined.
What We Are Solving
At present, every hour of a shift an operator physically counts containers and types the total into the system. This process is the single largest source of stock inaccuracy. The new system eliminates it entirely.
There is nothing to type anymore. The count is the scan. An operator who packs a box and scans it has already counted it — no entry screen, no keyboard, no estimates.
Goals
Eliminate Manual Counts
Remove hourly count entries and the transcription errors they introduce.
Count Every Box at Packing
Count automatically at the moment a box is packed — not an hour later.
Track Every Box Location
Know where every box is from machine-side through warehouse to dispatch.
Catch Variances Same Day
Surface discrepancies at run close — not at month-end stock take.
Real-Time Visibility
Supervisors see live production counts and last-scan times for every machine.
Full Audit Trail
Every scan records who, what, where, and when. Nothing is untraceable.
No typing. No estimating. No memory required. Every scan is physical evidence that a box exists and is at a specific place.