Real-Time Operations Tracking

The BellHawk Online Real-Time Operations Tracking System (RT-OPS) is a comprehensive real-time operations tracking and management system. It is especially suitable for mid-sized and growing industrial organisations.

Production · Warehousing · Installation

RT-OPS captures all aspects of transforming raw materials into finished products and shipping them to site: orders, operations, materials.

Applications by industry

Food processors
Life Sciences
Pharmaceuticals
Manufacturers
Convertors
Industrial Distributors
Engineering
Construction
Test · Repair

Real-Time Tracking

Materials
Receipt · Put-away · Issue · Returns · Scrap
Production
Operations · WIP · Finished goods
Products
Storage · Packing · Shipping · Installation

Capabilities

1. Real-time visibility

Provides managers, supervisors, and other staff members with a real-time view of work orders and materials, including the status of work-in-process and customer orders.

2. Production costs

Collects actual cost data in terms of labour and materials consumed to make products and compares this with projected costs.

3. Error avoidance

Prevents mistakes, such as using the wrong material, by comparing the material scanned-in with stored bills of materials.

4. Track & Trace

Tracks materials by lot-numbers, serial-numbers and expiration dates. Records the history of materials used for each product. Provides one step back and forward traceability.

5. Production performance

Captures performance data, such as how long each operation took, how many parts were scrapped and why, and how long materials were waiting for use.

6. Inventory and assets at multiple locations

Tracks numbered containers of raw materials, intermediates, work-in-process and finished goods at multiple locations. This includes serially numbered parts, products, tools, vehicles and assets.

7. Regulatory Compliance

RT-OPS is compliant with EU GMP Annex 11 and FDA Part 11 standards for electronic record keeping when used with the Quality Control and Materials Traceability modules.

Results

Immediate

• Productivity
  Real-time data capture from barcodes saves a lot of time.
• Alerts avoid errors
  Warnings help operators avoid mistakes, such as loading the wrong material.
• Visibility
  Managers get a real-time view of the status of operations on their smartphones and tablets.

On going

• Demand driven materials planning*
  Increases availability, reduces over generous 'safety' stock, and cuts waste from out of date inventory and overstocks.
• Real-time scheduling of orders and materials*
  Boosts workflow and on time delivery performance.
• Traceability*
  Comply with regulations, resolve issues with customers, minimise recall risks.
• Supply chain performance*
  Improvements due to tracking materials and operations at multiple facilities (plants, warehouses) and remote locations (construction projects, maintenance sites, service vehicles)
  
  * – requires optional module(s)

PDF

BellHawk Online modules

Base systems

1. Materials Tracking System (LP-MTS)
   Track materials without the need to create or track orders.
2. Simple Production Tracking System (SPTS)
   Track work order status and job times by operation.
3. Real-Time Operations (RT-OPS)
   Track all aspects of production and materials.

LP-MTS and SPTS are entry level systems. RT-OPS adds many transactions for tracking operations and usage of materials.

The WMS bundle adds warehouse management to LP-MTS and RT-OPS

Manufacturing options

1. Equipment Tracking Option (ETO)
2. Work Centre Scheduling (WCS)

Warehouse options

1. Warehouse management system (WMS) for LP-MTS or RT-OPS
2. Purchase Order Receiving (PO, in WMS)
3. Ship Order (SO, in WMS)
4. Picking (PICK, in WMS)
5. Shipping Dock Option (SDO, in WMS)
6. Directed Zonal Picking (KIT) for assembly kits and ship orders
7. Inventory Auditing Module (IAM)

Materials Traceability options

1. Materials Traceability (TRACE) for RT-OPS
2. Quality Control (QC) for RT-OPS

Operations Management options

1. Project Tracking (PROJ) for RT-OPS
2. Available Inventory Prediction (AIP) for RT-OPS
3. Dynamic Demand Driven MRP (DRP) for RT-OPS

IIOT Interface Appliances

1. Data Exchange Interface Box (DEX)
   Provides for exchange of data between the plant and BellHawk Online.
2. Barcode Label Printing (BLPA)
   Adds to all systems except SPTS. Needs a BarTender or NiceLabel Automation licence for the barcode label printers.
3. Weighing Scale Interface (WS)
   Provides an interface for scales: floor, bench, lab.
4. RFID Interface (RFID)
   Provides an interface for RFID data collection devices.