6 Powerful Benefits of iMonitor Smart Manufacturing Software

Find out more about how iMonitor can benefit your manufacturing processes.

As a manufacturer, you may already have an ERP or inventory management solution in place. But these solutions commonly do not cover process and quality management during production. You may still have difficulty accessing production and compliance data in a timely or comprehensive manner, due to paper files or spreadsheets.

With iMonitor's smart manufacturing software, you can digitize your production floor and track quality control from start to finish. This includes checking goods as they come in, preventing issues during production. Plus, granularly tracing products, ingredients, equipment and operators throughout the whole factory.

This results in increased profits, reduced waste, and decreased business risk.

Your benefits of using the iMonitor Manufacturing System

iMonitor’s smart manufacturing solution enables you to gain a significant competitive advantage by transforming your quality control and production management.


Eliminate waste and reduce costly batch re-works or write-offs

Manual errors in production can lead to costly re-works or write-offs of affected production batches. Common causes for production waste are:

  • mixing/compounding errors, e.g. adding the wrong ingredient or quantity of ingredients to processing equipment during production;
  • processing errors, e.g. heating a product at the wrong temperature;
  • packaging errors, e.g. using the wrong types or sizes of packaging for the final product.

iMonitor can help you increase productivity and profitability by reducing the amount of resources you need to produce your final products.

Prevent expensive mixing, processing and packaging errors

iMonitor can minimize the risk of production errors by automatically calculating the Bill of Materials for a given batch. Operators will receive a list of ingredients in the exact amounts needed to run the batch.

  • The manufacturing software drives all processes.
  • It automatically sends alerts when thresholds are reached, so the right person gets the message at the right time.
  • Receive alerts as issues occur on the production floor. This allows you to take immediate corrective action and prevent processing errors from ruining a batch.
  • Operators can reduce packaging errors significantly by scanning in packaging barcodes to verify that the correct packaging is used.

The FAO (Food and Agriculture Organization of the United Nations) estimates that 14% of annual food loss worth over USD 400 billion occurs between the harvest and retail supply chain stages. This includes storage on the farm, transport, processing, and wholesale.

 iMonitor projects that manufacturers using smart manufacturing solutions and IoT technology can reduce food loss by 90%.


Accelerate product releases

Paper-based processes are inefficient, contain redundant data and can delay product release times. A production team uses an average of 14 paper-based processes, while a quality assurance team uses 24 paper-based processes.

Speed up data flow to improve manufacturing process times

iMonitor can help you digitize paper-based processes, assign intelligent workflows, and capture process, safety, and quality data digitally. This can help streamline workflows between different departments and roles, and allows everyone to access data analytics much quicker.

Centralized supplier database

  • A centralized supplier database can help simplify your workflow by providing easy access to all your key contacts in one place.
  • Your operators can use a tablet app to capture quality data, just like they do with paper forms. The app includes pre-built fields, such as Bill of Materials or tables.
  • Improve manufacturing process times by reducing double entries of common data points. 
  • By collating production and laboratory records into one simple workflow you can improve production efficiency. This results in accelerated product release times, reduced warehousing costs, and even prolonged product shelf life.

iMonitor estimates that manufacturers can reduce their projected product release time by 80% simply by creating intelligent workflows.


Be audit-ready 24/7

Storing data securely in the cloud can help reduce compliance costs and improve product quality. With iMonitor smart manufacturing software, your business will always be audit-ready.

iMonitor helps you create reports that are easy to share and meet audit requirements. It also helps you maintain industry standards across processes, control points and corrective actions.

iMonitor is compliant with FDA, European (ESMA), New Zealand and Australian food safety acts (FSANZ). Constant updates to the most recent regulations facilitate ongoing compliance.

iMonitor smart manufacturing software also offers process update verification and full sign-off approval capabilities to enhance compliance.


Enhance traceability

Manufacturers are now tracking and tracing every single ingredient used in their products.

iMonitor easily tracks data related to specific batch runs, enabling digitized traceability of products, their sensitive ingredients, and traceable details. For example, delivery date, delivery temperatures, process CCP, equipment used, operator, etc.

You can use the iMonitor software to keep track of supplier compliance certification and link it to an incoming lot. This will help you ensure that your suppliers are meeting your standards.

Facilitate traceability exercises

iMonitor's search feature allows you to quickly find and track specific SKUs, processes, steps, batches, ingredients, machinery, operators, and data.

iMonitor believes that manufacturers can reduce their time spent tracing products from hours or even days, to just a few minutes. This would reduce the risks of product recalls.


Respond in
real time

Paper forms and spreadsheets do not provide you with the data analytics you need to improve your processes.

With iMonitor, you get real-time actionable data insights to analyze trends and prioritize processes. Rather than entering data into separate spreadsheets to generate trends, you have direct access to all data in one place.

The smart manufacturing software solution creates a single source of truth to ensure that:

  • Your operators know what they are supposed to do at any given time;
  • You know what batches are produced where and when;
  • You can see all the production data in one place, like how many batches were made or how many problems happened.

iMonitor helps you keep track of quality, compliance, and production processes, so you can spot issues quickly and reduce costs.

Get real-time production insights

  • Access all production and compliance data via real-time dashboards. 
  • Integrate with SCADA, PLC systems or IIoT-enabled devices to know in real-time what’s happening on your shop floor. 
  • Enable a smooth data low from your factory’s edge to your control rooms by creating a smart digital factory.

Run AI-powered analytics to enable data-driven decisions

Get a competitive advantage by using the power of artificial intelligence to make data-driven decisions.

  • Get in-depth production and compliance insights with the help of AI-powered analytics. 
  • Run trend analysis to detect anomalies and variations.
  • Use intelligent forecasting to predict various business metrics.

Track process times and equipment to uncover opportunities for improvement

The iMonitor software lets you track the times each production and compliance process step takes, so you can control all processes. To improve efficiency, uncover best practices that can be rolled out across the wider team or remove bottlenecks.


Empower your staff

If staff are uninformed or poorly trained, they mishandle errors or cause errors themselves. With iMonitor you can now empower your operators on the production floor to make faster decisions and improve efficiency.

Digital operator guidance and training

The iMonitor tablet app presents all information to the operator to make decisions during production runs. They can easily calculate production metrics on the production floor, e.g. the fat-to-protein ratio of a food product.

Operators will be able to access SOPs, recipes, and training materials digitally, so they can make quick and informed decisions.

Free up staff for more important tasks

Digitized checks and streamlined processes take less time than hunting for and filling out paper forms with repetitive data. With iMonitor, your team will have more time to concentrate on more important tasks to improve efficiency.  

Ready to see iMonitor in action?
Start your free trial now or contact us for a demo.
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Helpful resources

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