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Guide: 7 steps to digital production
1. identify paper-based processes
The first step on the way to digital production is a thorough analysis of existing paper-based processes. Many processes are still analog, e.g:
- Work instructions in paper form
- Quality checks with handwritten logs
- Manual inventories
- Maintenance logs on routing slips
These processes are error-prone, slow and often difficult to understand. Digitizing these processes offers enormous potential for increasing efficiency and data quality.
Do you know where your biggest efficiency losses occur? We analyze your processes together - individually and practically.
2. analyze existing systems and data sources
Which ERP, MES or QM systems are already in use? What data is already available digitally - and where is there a need for improvement?
Important questions in this step:
- Can existing systems be integrated?
- Are there media breaks in the workflows?
- What is the quality of the existing data?
The better your database, the greater the benefits of digital processes.
3. recognize weak points and discover potential
Where do delays, errors or additional work arise today? Where can efficiency be gained through automation or real-time data?
Examples of typical weak points:
- Lost or illegible routing slips
- Incorrect or late entries during quality inspections
- Inaccurate inventory management
- Manual maintenance documentation that is difficult to access
This is where digital technologies such as RFID can be used particularly effectively:
- RFID tags on workpieces, machines or materials enable automatic identification and data capture.
- RFID readers transmit data in real time - without any manual intervention.
- Error reduction: Automated processes minimize human error.
- Live tracking: Workpieces, materials and machine statuses can be tracked at any time.
4. evaluate digital solutions - e.g. RFID
Use technologies such as RFID to automatically record production data, inventories or maintenance activities - without any paper.
- In production: Workpieces with RFID tags are automatically tracked throughout the production process.
- In quality control: recorded data is compared directly with the target values - including automated OK/NOK decisions
- In inventory management: stock movements and material consumption are documented in real time.
- In maintenance: RFID-supported sensors detect anomalies at an early stage, e.g. vibration or overheating - ideal for predictive maintenance.
5. plan integration into existing systems - with GRAIDWARE®
The best tools are useless if they don't fit into the big picture. Pay attention to interfaces to your ERP or MES system. This is how integration works:
- Data acquisition: RFID tags & sensors provide raw data (e.g. status, location, condition)
- Data transmission: Our GRAIDWARE® middleware receives the data directly from the readers - e.g. via API or OPC UA.
- Processing: GRAIDWARE® automatically transfers the data to your ERP or MES system, which links the data with the relevant modules (e.g. warehouse, production, quality).
- Automation: Processes such as stock updates, production releases or maintenance planning are triggered automatically.
6. involve employees at an early stage
No digitalization without acceptance. Digital projects often fail not because of the technology, but because the workforce is not involved. These measures are crucial:
- Early communication: Explain the purpose & benefits of the changes
- Pilot projects: Small tests create trust & practical experience.
- Training courses: Easy-to-use systems and practical training lead to success.
- Obtain feedback: Employees know weak points best.
7. define key figures and measure success
Define clear KPIs to evaluate and optimize the success of your digital production. The following key figures help with the evaluation:
Key figure | Meaning |
Error rate | Fewer transmission and input errors thanks to automatic recording |
Rework effort | Decreases due to more precise data and clear documentation |
Process time savings | Faster processes thanks to direct data availability |
Productivity | Higher output through more efficient processes |
Reaction speed | Real-time data enables immediate intervention |
Downtimes | Early maintenance minimizes downtime |
Inventory accuracy | Automated recording increases transparency |
Paper consumption | Savings through complete digital documentation |
Employee satisfaction | Less routine work, more focus on value creation |
Conclusion: Digitizing production - step by step to paperless manufacturing
The digitalization of production is not a one-off project, but a strategic transformation process. However, with a clear roadmap - such as this checklist - the path becomes clear and feasible.
Whether you want to improve individual processes or digitally transform your entire production: Now is the right time to take the next step. We support you from the first workshop through pilot projects to full system integration - including the right hardware and software.
We will be happy to present solutions for your industry and your processes. Talk to the specialists for SMEs.
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