Challenge
Before the project, production quality was tracked in Excel. With 15 machines across 6 lines and a lean team of five operators, the lack of real‑time insights meant defective products could leave the factory, leading to penalties. The client needed immediate defect detection and end‑to‑end traceability for every part.
Solution
- PLC data collection via a custom bridge application built in Delphi.
- Centralized web administration in PHP that evaluates OK/NOK in real time.
- Mobile app on Zebra scanners (React + Capacitor): scan a barcode to view a product’s complete history immediately.
We started with a pilot on one line to validate the flow, then expanded to all lines after sign‑off.
Results
- Immediate defect detection on the line (faulty parts flagged in real time).
- Full traceability for every product — instant audit trail across machines and steps.
- Reduced penalties through early detection and containment of NOK parts.
- Faster response — operators and managers act within minutes instead of hours.
Technologies
- Delphi — PLC bridge
- PHP — web admin & analytics
- React + Capacitor — Zebra scanners
Rollout & Support
Pilot: 3 months of development and testing on a single line. Full rollout: additional 3 months to cover all lines and machines. Ongoing support: continuous statistics, data analysis, and iterative enhancements.