Product
Serial number, batch, carrier or identifier assigned in the process.
SystemTraceability / TraceSmart Platform
A SystemSmart product
TraceSmart – a platform for building digital product genealogy
The system organises line events and connects them with a specific product, batch or carrier. The plant receives one consistent answer about everything that happened from the first operation to production release.
Active productFRAME_001
Last measurement5,1 bar
✓Operation completed successfully
Scan or enter PartId…|
[20:59:37] PartId scanned: FRAME_001
[20:59:38] Test started at ST01_PRESSURE
[20:59:39] Result: OK · 5,1 bar
[20:59:40] Result saved and product released
ST01 · Online
TraceSmart does not replace the process. It creates a reliable record of it.
Each station may generate data differently. The platform gives it a common structure and builds relationships between products, components, operations and quality results.
Event
Completed operation, time, status and execution location.
Context
Component, recipe, tool, operator and relevant parameters.
Decision
Release, interlock, rework, alarm or customer report.
A different view for operators, quality and administrators
TraceSmart presents information according to each user’s task. Operators guide products through operations, quality teams analyse history, and administrators configure sources and process rules.
Production station
The operator sees the next correct step
The screen reduces the number of decisions required from operators. It shows the active product, required action, operation result and a message that enables safe process continuation.
- scanning or manual PartId entry,
- clear OK, NOK or BLOCKED status,
- confirmation that parameters and components were recorded,
- messages tailored to the station and product variant.
ACTIVE PRODUCTFRAME_001
LAST MEASUREMENT5,1 bar
CYCLE32,8 s
Operation completed successfully. The product can proceed to ST02.
Scan the next PartId…
14:22:07Pressure test resultOK
14:21:35Product activatedFRAME_001
TraceManager
Data sources defined in one place
The administrator configures stations, devices and process points while keeping the technical layer separate from the business description of the product.
- digital and analogue signals,
- device and channel mapping,
- filtering, units and measurement thresholds,
- versioning and approval history.
| PointName | Device | Type | Channel | Status |
|---|---|---|---|---|
| PressureValue | AI01 | Analog | 0 | ACTIVE |
| ResultOk | DI01 | Digital | 1 | ACTIVE |
| AlarmLamp | DO01 | Digital | 2 | OUTPUT |
| PartScanner | SCAN01 | String | TCP | ONLINE |
Process validation
A rule can be tested before activation
The logic defines when a result is valid, which components are required and what should happen when a deviation occurs.
- simulation of inputs and results,
- draft and production versions,
- change approval before activation,
- an audit trail of the author and modification time.
01-- validation of parameters and components
02local pressure = AI("PressureValue")
03local parts_ok = HasRequiredComponents()
04
05if pressure >= 4.5 and pressure <= 5.5 and parts_ok then
06 SaveResult("OK")
07 ReleaseToStation("ST02_TORQUE")
08else
09 SaveResult("NOK", "PROCESS_VALIDATION")
10end
02local pressure = AI("PressureValue")
03local parts_ok = HasRequiredComponents()
04
05if pressure >= 4.5 and pressure <= 5.5 and parts_ok then
06 SaveResult("OK")
07 ReleaseToStation("ST02_TORQUE")
08else
09 SaveResult("NOK", "PROCESS_VALIDATION")
10end
History and relationships
One PartId opens the complete genealogy
A product search shows completed operations, parameters, statuses, child components and the configuration version used during production.
- navigation from the product to the batch used,
- navigation from a component to all affected products,
- rework and revalidation history,
- data ready for complaint analysis.
PART IDFRAME_001
PRODUCT COMPLETE14:22:07ST04_FINAL · final inspectionOK
14:21:42ST03_ASSY · component assembly8 / 8
14:20:58ST02_TORQUE · tightening torque6,2 Nm
14:20:12ST01_PRESSURE · pressure test5,1 bar
4 stations · 0 missing operations · configuration v3.4
Quality and reporting
From one product result to a process-wide view
Filtering by station, time, variant and status helps reveal deviations that are not visible in a single cycle.
- OK, NOK, BLOCKED and ERROR results,
- measurement and nonconformity-cause trends,
- data export for further analysis,
- summaries for production and quality teams.
ALL RESULTS1 247
OK1 228
NOK19
Diagnostics
Stations, events and queues visible in real time
The runtime monitor helps quickly distinguish a communication problem from a rule error, device issue or missing production event.
- connection status and latest readings,
- FIFO queues between operations,
- system and business logs,
- data buffering during communication outages.
[14:22:03.105] ST04 · part FRAME_001 activated
[14:22:04.778] read FinalCheck = 1
[14:22:05.024] component validation: PASS
[14:22:06.331] product status saved: COMPLETE
[14:22:06.519] FIFO OUT · position removed
[14:22:07.013] payload queued for MES export
[14:22:07.221] acknowledgement received: 200 OK
[14:22:08.006] waiting for next PartId…
[14:22:04.778] read FinalCheck = 1
[14:22:05.024] component validation: PASS
[14:22:06.331] product status saved: COMPLETE
[14:22:06.519] FIFO OUT · position removed
[14:22:07.013] payload queued for MES export
[14:22:07.221] acknowledgement received: 200 OK
[14:22:08.006] waiting for next PartId…
When does TraceSmart deliver the greatest value?
When data exists but does not form one history
Information is often scattered across PLCs, testers, scanners, station databases and report files. TraceSmart organises it around the product identifier without imposing one automation method on the entire line.
- complaints cannot be linked quickly with production events,
- stations cannot confirm whether the previous operation was completed,
- test results are stored locally and are difficult to compare,
- rework and process re-entry are handled inconsistently,
- audits require manual merging of data from many sources.
A model fitted to the processnot a process forced into a fixed template.
Five layers that turn signals into genealogy
Each layer is designed around the production flow and the responsibilities of systems already operating in the plant.
01
Data acquisition from the existing environment
Barcode scanners, RFID, PLCs, testers, vision systems, label printers and measurement devices can provide different event types. Integration begins by defining the responsibility of each source.
PLCRFIDData MatrixOCRtesters02
Control of what should happen next
Rules can verify the operation sequence, product variant, component completeness and inspection result. The system returns an unambiguous status to the station or operator application.
sequencevalidationinterlocks03
Relationships, not just an event table
The model connects a product with subassemblies, materials, parent identifiers and completed operations. It reconstructs history in both directions: from product to component and from batch to finished products.
productbatchcomponentoperation04
Information tailored to the recipient
Production needs the current status, quality needs test history, and managers need cross-process reports. Data can be displayed in an application or delivered to higher-level systems.
reportsAPIMESERP05
Integration health control
Communication diagnostics, error logging and data-quality monitoring help keep the solution running and quickly distinguish device issues from application issues.
logsalarmsmonitoringserviceA platform between the shop floor and plant systems
TraceSmart can organise data between automation and business applications. Responsibility boundaries and interfaces are agreed before implementation.
Devices and automation
PLCs, RFID readers, scanners, vision systems, testers and label printers.
Higher-level systems
Identifiers, orders, statuses and results exchanged with MES, ERP, WMS or SCADA.
Applications and reports
Information for operator applications, quality analysis and reporting tools.
A system scope selected for the problem—not the number of available features
The platform can start at one station and expand with further lines, identification methods and reporting needs.
One platform, modules selected for the process
Data passes through a shared core, while devices, logic, applications and integrations can expand without rebuilding the solution from scratch.
01
Data sources and OT
Production-line data
PLCRFIDScannersOCRTestersVision systems
02
TraceSmart Core
Shared process and product model
RuntimeProcess rulesGenealogsaData buffer
03
Applications and integrations
Information for people and systems
HMI panelTraceManagerQuality reportsMESERPSCADA / API
Signal and eventValidation and recordingReport or data exchange
TraceSmart Runtime
Live events, stations, products and device connections.
TraceManager
Environment, data-point, user and approved-version configuration.
Station application
Product identification, operation guidance and clear messages for operators.
Product genealogy
Product relationships with batches, components, operations and process results.
Quality and reporting
Search, filters, result trends and information export for analysis.
Flow and interlocks
Control of sequence, statuses, rework and missing process stages.
IT/OT integration
Data exchange with PLCs, MES, ERP, SCADA, databases and APIs.
Identification
Scanners, RFID, barcodes, Data Matrix, labels and vision systems.
Process rules
Validation conditions, versioning, testing and controlled activation of changes.
Runtime monitoring
Communication status, queues, events, alarms and runtime diagnostics.
Roles and audit
Permissions, activity history, logins and the user decision trail.
Data continuity
Local storage, buffering and controlled resumption of data exchange.
Complaint analysis no longer starts with searching folders
Searching for a PartId opens an organised list of operations, components and results. The team can immediately narrow the analysis to a specific time, device or batch.
ID
FRAME_001
The product was processed at four stations. All required operations are complete, and the saved configuration makes it possible to reconstruct the conditions used during production.
14:22:07Final inspectionOK
14:21:42Component assembly8 / 8
14:20:58Tightening torque6,2 Nm
14:20:12Pressure test5,1 bar
14:19:54Material batch verificationLOT_78421
v3.4Process configurationAPPROVED
Where do TraceSmart functions work together?
The greatest value appears when identification, flow rules and quality records form one mechanism rather than several independent tools.
Serial product assembly
The system confirms the product variant, required components and operation sequence. It links station results and used batches with the serial number.
Process parameter control
Measurements from a tester or PLC are evaluated against the active recipe. An out-of-range value creates a NOK result and can block further flow.
Rework handling
Rework follows an agreed path. The history retains the reason, completed actions, repeated test and approving person.
Packing and labelling
Before printing a label, the platform verifies process completeness and then links the product with its packaging, pallet or shipping unit.
Component batch analysis
After identifying a defective batch, all products in which it was used can be found, reducing the scope of further inspection or quality action.
Existing-line modernisation
TraceSmart can begin recording at selected stations using available signals and interfaces, then expand to further production areas.
Implementation starts with questions, not software installation
First we define the decision that should be supported by data. Only then do we design identifiers, communication and the record structure.
Process audit
Product flow, identification points, data sources and current challenges.
Information model
Identifiers, relationships, validation rules, retention and system responsibilities.
Pilot
A controlled launch and verification in the real production cycle.
Expansion and support
Further lines, reports, training, documentation and the agreed service model.
TraceSmart by SystemSmart
A product developed by a team that understands industrial automation
We combine software expertise, industrial integration and knowledge of production-station work. This allows us to design not only the system interface but also a reliable method of acquiring each event.
Processthe production flow is the starting point
Datarecorded with clear context
Integrationwith the plant OT and IT layers
Expansiona scope that can be implemented in stages
The same product history, different user questions
The platform does not show everyone the same dashboard. Each role receives the tools required to perform its own task.
| Area | Operator | Quality | Administrator / IT |
|---|---|---|---|
| Main question | What should I do with this product? | Why was the result nonconforming? | Are the sources and rules operating correctly? |
| Primary view | Active operation and station message | Genealogy, results and trends | Configuration, versions and runtime |
| Action | Scanning, confirmation and error handling | Filtering, analysis and export | Mapping, diagnostics and publishing changes |
| Process protection | Flow interlock when a condition is not met | Complete quality-decision trail | Roles, permissions and versioning |
| Result | Clear and repeatable station operation | Faster narrowing of the problem cause | Controlled solution maintenance |
Data, configuration and support under control
A traceability system is part of the production process and therefore requires predictable change management, diagnostics and a problem-response plan.
Versions and permissions
Configuration and rule changes can be prepared, tested and approved before production use.
Buffering and data backups
Recording continuity, retention and backups are designed according to the plant infrastructure and risk profile.
Service matched to criticality
Agreed support packages, remote diagnostics and 24/7 coverage with contractually defined response times are available.
TraceSmart implementation cost
Traceability system pricing – where does an implementation start?
A starter TraceSmart implementation for one station begins at PLN 20,000. It provides a clear baseline for a pilot that can later expand with the production line and plant requirements.
The final traceability system price depends on the number of signals, identification method, required devices, reporting and integration with MES, ERP or SCADA. Following a technical analysis, we prepare a defined scope, schedule and individual quotation.
Questions before a TraceSmart presentation
Is TraceSmart an off-the-shelf system or a project-based solution?
The platform provides a common functional foundation, while the data model, integrations and process logic are configured for the specific plant.
Can the platform be launched on one production line only?
Yes. A limited pilot helps validate the information model, usability and data quality before expansion.
What information does TraceSmart store for a product?
The scope can include PartId, batch and order number, station, time, operator, operation result, measurements, components used, error cause, configuration version and rework history.
Does TraceSmart support process interlocks and rework?
Yes. Rules can block the next operation when a product does not meet requirements, and the agreed rework flow can be recorded as part of the product history.
Does the platform integrate with an existing MES or ERP?
It can exchange data with higher-level systems once interfaces and application responsibilities are agreed. We do not assume that MES or ERP should automatically be replaced.
Can TraceSmart operate without MES?
Yes. The platform can provide its own database, station interface, process configuration, history search, reporting and exports. The final scope depends on the plant architecture.
Does implementation require PLC-program changes?
The data-acquisition method is selected after an audit. In many cases, available signals or secure interfaces can be used without modifying machine-control logic.
How can a product or carrier be identified?
Depending on the process, barcodes, QR, Data Matrix, RFID, batch numbers, labels or an identifier assigned by a higher-level system can be used.
Where is production data stored?
Most often in the plant’s local infrastructure. Selected information can be sent to central databases, the customer’s cloud or reporting systems according to the agreed architecture.
How should we prepare for the first consultation?
Identify the product or line, business problem, available identifiers and current data sources. We can prepare the detailed process map together.
What determines implementation cost?
It depends on the number of stations and signals, identification method, required devices, reports, higher-level-system integrations and the scope of on-site work.
Is 24/7 service support available?
Scope and response times can be agreed in a service contract according to installation criticality and plant requirements.