The challenge: manual processes and lack of transparency
In many manufacturing environments, production control is still dominated by manual workflows and paper-based forms. Regardless of the products being manufactured or the specific production processes, companies face several fundamental challenges:
- Paper-based orders create information gaps and sources of error. The break between software-based planning and manual execution leads to high coordination effort and inconsistent information.
- Intralogistics side processes frequently interrupt value creation. Operators leave their workstations to search for materials or trigger transport orders, reducing productivity and increasing walking paths.
- Manual processes do not provide sufficient transparency regarding the status of ongoing orders, as no real-time information is available. As a result, bottlenecks cannot be identified at an early stage and processes cannot be controlled in real time.
In the automotive or supplier industry, these problems have a particularly strong impact, as downstream processes depend on precise and up-to-date information. In this situation, manufacturing companies require a digital job traveler that enables automation and can be implemented quickly.
From paper-based processes to the digital job traveler
A digital job traveler contains all information required to manufacture a product. Typically, a digital job traveler includes the bill of materials, work plans, machine and tool assignments, quality requirements, inspection specifications, as well as time and material specifications.
It is created and managed entirely digitally and transmitted to the relevant systems and individuals. Instead of paper documents, the entire process is handled via IT systems for production control that consolidate data from design, planning, and manufacturing.
The challenges at a glance
- Paper-based orders lead to information gaps and delays
- Because the order’s current location is unknown, search effort is required
- Logistics-related side processes disrupt the value creation flow
- Media discontinuities between IT systems and the shopfloor lead to inefficiencies in production execution
The solution: Digital job traveler with OX-Label and the ORGATEX Cloud
ORGATEX, a Germany-based company headquartered in Langenfeld (Rhineland) and a specialist in lean production systems, has developed a solution for a digital job traveler using OX-Label and the ORGATEX Cloud, providing greater transparency in production.
E-ink technology for the digital job traveler
OX-Label is a digital label that can be attached to containers, packaging, or components. It replaces the printed job traveler and integrates seamlessly into existing production and logistics systems.
A low-power E-ink display shows the current order data. The display can be individually customized and can also be adapted during the process flow to meet the requirements of individual production stages. The displayed content is synchronised with the ERP system and updates automatically when the order status changes. Employees can see directly at their workstation which work steps are upcoming and can acknowledge them at the press of a button.
The label features a configurable button for various actions, such as acknowledgements or fault notifications. In general, the button can be assigned any function depending on the specific application. Inputs made on the digital job travelerare transmitted immediately to the ORGATEX Cloud and from there to the connected systems. Communication takes place via the local Thread wireless network or, optionally, via industrial cellular communications (NB-IoT/LTE-M).
Stable and secure communication
Thread is a wireless, encrypted mesh network protocol that is particularly suited for local communication between small, energy-efficient IoT devices within a building. The devices operate as equal participants and forward information from one to the next, increasing the stability and reliability of the network.
Thread-compatible devices such as OX-Label can be operated both within a local network and without local infrastructure via cellular communications. Installation effort is low, and updates are deployed automatically over the air without IT intervention or production downtime. An included gateway is used to connect to the cloud via cellular communications.
Device management and data analysis in the cloud
The ORGATEX Cloud manages all devices, provides interfaces to ERP, MES, and logistics systems, and enables processes related to the digital job traveler to be configured without programming knowledge. Users can create their own dashboards, analyse data, and adapt workflows. The cloud is hosted in a GDPR-compliant manner on AWS servers in Frankfurt and ensures encrypted data transmission as well as regular updates.
As a result, control over digital processes shifts from IT to the specialist departments. Smaller companies with limited IT resources can also use the digital job traveler. Another advantage is the openness of the system. The solution integrates easily into existing infrastructures. Data is exchanged bidirectionally with ERP and MES systems such as SAP, Business Central, or ProAlpha via standardised APIs.
Easily configurable platform for greater autonomy
Implementation and maintenance effort for the digital job traveler is low, as no proprietary interfaces need to be developed. Customers can adapt and extend the solution independently. This principle of self-enablement characterises ORGATEX’s philosophy: instead of costly project-based services, the company offers standardised products that can be configured directly by specialist departments.
The ease of use allows processes to be mapped individually and adjusted when required. This significantly reduces the effort needed for subsequent changes. Maintenance requirements also remain low, as the system operates in an energy-efficient manner and is powered by standard commercial batteries.
The result: connected production with measurable benefits
The digital job traveler with OX-Label links physical processes with digital data. Employees have access to all status information at any time and no longer need to rely on paper documents. This reduces error rates and helps prevent downtime.
This creates the foundation for connected, agile manufacturing. ORGATEX Cloud combines device management and data analytics, making the entire production process transparent, measurable, and controllable. As a result, companies increase productivity, improve day-to-day operational responsiveness, and maintain their competitiveness in a demanding market environment.
The system’s flexibility also has a positive impact. Adjustments to the digital job traveler can be made without external support. Changes to job logic, layout, or prioritization can be configured directly in the cloud. This gives companies a new level of independence in designing and optimizing their processes.
Summary of results
- End-to-end data connectivity between production and IT systems
- Reduced error rates through real-time information
- Greater flexibility thanks to a configurable cloud platform
- Low implementation effort combined with a high degree of user autonomy