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In modern manufacturing, operational decisions depend heavily on the quality of shop floor data. However, many organizations still struggle with inaccurate, delayed, or incomplete data caused by manual entry, paper-based processes, and disconnected systems. These challenges impact production planning, quality, compliance, and responsiveness.
Connected Process Control (CPC) addresses these issues by enabling real-time, accurate, and standardized shop floor data collection. By connecting people, processes, and machines, CPC helps manufacturers significantly improve both accuracy and speed in data capture. At SCASYS, we work closely with manufacturing organizations to help implement such connected shop floor strategies using proven ERP and manufacturing execution technologies.
Traditional data collection methods often involve:
These approaches create multiple problems, including human error, inconsistent execution, delayed visibility, and limited traceability. Without timely and reliable data, manufacturers struggle to identify issues early, respond quickly, or make informed decisions.
Connected Process Control is a digital approach that embeds process guidance, data capture, and validation directly into shop floor operations. It ensures that tasks are performed in the correct sequence while collecting accurate data at the point of work.
CPC enables manufacturers to:
Modern ERP platforms such as Epicor, when extended with connected shop floor capabilities, play a critical role in enabling CPC by ensuring seamless integration between production execution and enterprise systems.
Digital Work Instructions - CPC replaces paper-based instructions with digital, task-level work instructions, ensuring consistent execution and reducing interpretation of errors. Operators always have access to the latest approved processes, improving compliance, and quality.
Built-In Quality and Error Proofing - Integrated checks such as scanning, validations, image capture, and pick-to-light prevent errors before they occur. Data is captured automatically, minimizing manual inputs and improving reliability across the production process.
Genealogy and Traceability - CPC records detailed process and component genealogy, linking materials, operations, and operators. This supports quality audits, compliance requirements, and faster root-cause analysis—especially critical in regulated and high-precision manufacturing environments.
Data Captured at the Point of Work - Instead of relying on delayed reporting, CPC captures data as tasks are performed. This eliminates reporting lag and provides up-to-date production information for supervisors and planners.
Device and Machine Connectivity - Integration with shop floor devices and machines enables automated data capture without disrupting workflows, significantly accelerating reporting and analysis. When integrated with ERP systems like Epicor, this data flows seamlessly from the shop floor to enterprise-level reporting.
Instant Visibility and Alerts - Supervisors and managers gain real-time visibility through dashboards, OEE metrics, and alerts, allowing faster response to quality issues, downtime, or production bottlenecks.
By improving both accuracy and speed, CPC delivers measurable benefits:
Organizations working with experienced implementation partners like SCASYS are better positioned to realize these benefits by aligning shop floor execution with ERP-driven business processes.
Connected Process Control enables the transition to paperless workstations, centralizing work instructions, quality documents, safety references, and training materials. This improves operational consistency and helps capture and retain tribal knowledge, reduce reliance on individual expertise, and supports workforce scalability.
Accurate and timely shop floor data is essential for effective manufacturing operations. Connected Process Control provides a practical, real-time approach to improving both the accuracy and speed of shop floor data collection.
By standardizing processes, enforcing quality controls, and connecting people and machines—supported by ERP platforms such as Epicor and guided by implementation expertise from SCASYS—manufacturers can improve performance, enhance decision-making, and operate with greater confidence in an increasingly competitive environment.
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