Emerging contact-less technologies, wireless mobility and distributed application services are enabling real-time operational visibility and intelligence.

It’s time to empower your operation with network-enabled manufacturing.

Start on the pathway with OMNITROL’s Real-time WIP Visibility.

Give your Lean Manufacturing the Intelligent Edge.

OMNITROL Work-in-Process (WIP) Visibility SolutionReal-time operational visibility that gives you an intelligent edge

Increase your Bottom-line with Real-time WIP VisibilityLow-cost wireless sensors are creating new ways to track and act on your inventory and assets in real-time. Sophisticated automated manufacturers are using wireless sensors to derive incremental efficiencies that drive financial performance and competitive advantage.

Real-time visibility is a key enabler for dramatic performance gains. Lean manufacturing methodologies like JIT and Kanban are intended to increase yield and reduce costs by increasing productivity and improving process efficiency and quality. The thread that connects all of these business objectives is visibility. Not just what is available on today’s ERP and planning screens but the visibility into real-time physical operations that these sensors bring to life.

Act in Real-time not on historyToday’s complex processing systems for enterprise planning and execution can effectively coordinate business and manufacturing operations but the information available is often not an accurate representation of real-time physical operations. Responding to real-time production issues requires millisecond visibility, not a historical hourly or daily record.

Manufacturers face many challenges that affect their bottom line: costly stock outs and high “safety” stock levels, and production bottlenecks that increase cycle-time, delivery errors and lost orders. In addition, their customers are demanding transparency on status of work-in-progress and pedigree data for parts, components, or raw materials that make up the end product.

Velocity through real-time operational visibility – Search and Alert!OMNITROL’s WIP Visibility solution is specifically designed to solve production and operational problems in real-time, supporting both repetitive and discrete (work-order) manufacturing methods. It provides exceptional flexibility and ease-of-use for single and multi-site wide WIP-tracking and includes rich reporting and alerting capabilities.

Benefits of OMNITROL Real-time WIP Visibility to your operations:

Operational Benefits of OMNITROL Pedigree and Audit:

What is the most effective way to arm your staff and operations to improve your bottom line?

Add Real-time WIP Visibility to your inventory management, order management and production systems.Real-time visibility on materials, process, or machine interactions can be leveraged to fix real-time production problems by quickly identifying the source, enabling product recalls, or validating the end product for customers.

Other organizations have achieved dramatic business benefits for their manufacturing operations when deploying a real-time WIP Visibility solution :

• Up to 27% yield increase*• Up to 34% improvement in manufacturing cycle*• 28% reduction in change-over time*• Reduction of safety stock of 4 days• Up to 6% improvement in on-time delivery*• 16% reduction in Out-of-Stock• Deliver lot & serial number traceability to finished parts• Increase customer satisfaction by providing real-time order status and delivery dates

• Offers a consolidated view of several assembly lines through a secured Web or Java-based portal providing alerts, tracking information, and historical data.

• Provides Remote visibility using handhelds.• Real-time Exception Notification triggered by events such as exceeding timing threshold, dwell time, or invalid employee with automatic rule-based alerts through email, text and voice messages or html push.

• Automated work-order creation – no paperwork, no barcode scans • Automatic import of work order pick-list• Maintains pedigree data for process management and defect analysis for field failures

* Source: Aberdeen Research

OMNITROL Smart ShelfThe OMNITROL Smart Shelf provides virtual locked access to items that are removed or added to the Smart-Shelf. Access to the Smart Shelf is triggered when a single authorized user activates the Smart Shelf. Employees and all components including raw material storage containers, partially built product removed or added to a Smart Shelf are tracked. Similarly, anything added or removed without appropriate authentication will be alerted.• Automatic creation of work orders and

reporting • Employee tracking productivity assessment

• Work order status and real-time alerts • Manage work orders at outsourced operations

OMNITROL Smart Assembly CellThis unique and powerful real-time visibility assembly cell enables rapid creation of workflow automation that is repeatable by simply chaining together multiple cells. The integration of these smart assembly cells into the production process automates assembly line visibility and traceability with minimal impact to the existing production and stocking process.

• Provides visibility into dwell time at assembly cells

• Identify production bottlenecks instantly, as they occur

• Automatically creates a complete pedigree audit of lots, parts and staff (optional pedigree module)

OMNITROL Smart BenchThe OMNITROL Smart Bench is an RFID enabled work desk where production item location and status can be tracked in real-time. Once the assembly process is completed, the OMNITROL Smart Bench maintains the components added, timing and location of the item as it is being tested, packaged, or inspected. Users can also scan Smart Benches to locate an item that may be in any of the test, packing, or inspection phases of the assembly line.

• Tracks multiple employees on one work order with exception alerting and handling

• Ideally-suited for test bench, or quality cells

• Rapidly identify quality issues

Get a Smarter Assembly Process with OMNITROL WIP Visibility Solution

The OMNITROL WIP Visibility Solution can be deployed in any manufacturing scenario that involves discrete elementsbeing combined to create an end product, part, or material. By simply overlaying multiple manufacturing SmartShelves,SmartBenches and SmartCells to the existing manufacturing process, the OMNITROL adds real-time visibility and qualitycontrol data to the production line.• Drive work order status to your outsourced partners for remote visibility• All-in-one Appliance Solution delivers Lower Total Cost of Ownership and shorter time to ROI• Scalable distributed peer-to-peer edge deployment• Deploy WIP Visibility on today’s IT infrastructure• Extendable to support Tomorrow's requirements

Building blocks for Real-time WIP Visibility

OMNITROL WIP Visibility Dashboards, Reports and AlertsDashboards are accessible by production and order processing staff and management. Customizable reports include:• Automated Daily Operating Reports and

direct integration with excel • Status/location of in process work

orders • Number of work-orders waiting at each

stage of the workflow• Average duration of each type of work

task• Average wait time per work order per

workstation• Hourly production rate by work order

typeException alerts include:• Delayed work order • Work-orders overflow alert • Work task bottleneck alert

OMNITROL Smart Shelf

OMNITROL Smart Assembly Cell

OMNITROL Work Order Report

Omnitrol Networks, Inc.2025 Landings DriveMountain View, CA 94043Tel: +1 (650) 625-1400Fax: +1 (650) 625-1414www.omnitrol.com

© 2004 - 2007 Omnitrol Networks, Inc. All rights reserved. All other registered trademarks and service marks are property of their respective owners. Specifications are subject to change without notice. The only warranties for OMNITROL products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty.

Ordering InformationModel Part Number DescriptionOMNITROL 1020 MQ2-256 2x RXM-Modules, 256MB RAM

Smart Shelf SS-4-1 Smart Shelf supports Alien, Intermec and Motorola RFID Readers. Smart Shelf includes Quad Antenna Array

Smart Bench SB-2-1 Smart Shelf supports Alien, Intermec and Motorola RFID Readers. Smart Shelf includes Quad Antenna Array

(SmartShelf includes mounting brackets, proximity detector, stack light. Attaches to rear of existing industrial shelving.)

Mobile Readers MR-1 Options include Motorola and Intermec RFID Handhelds

Printer:Fixed Printer- Zebra FP-Zebra Zebra R110Xi RFID Printer

Optional Database Server:IBM Dual-Core Pentium DS-IBM 1U, Dual-core Pentium, 1GB RAM, Raid 1 with 2x160GB HD

Solution Package ContentsOMNITROL Appliance with installation guide and resource CD, SmartShelf or SmartBench with RFID reader, antennas, and accessories, RFID Printer, and Mobile Reader.

OMNITROL Solutions are pre-integrated and have no hidden costs, no 3rd party licenses, no middleware, no extra hardware. To order, or to request Extended Warranty and Service Agreement pricing, call (650) 625-1400, ext. 226.

Industrial Deployment Solution for WIP VisibilityThe OMNITROL WIP Solution enables a collective workflow involving your internal manufacturing operations, suppliers and customers via powerful, flexible, and reliable edge services. The challenge of driving visibility from distributed facilities to distributed work cells and inventories demands real-time processing performance. The OMNITROL appliance was purpose-built for the performance demands, deployment and scalability challenges facing manufacturers today.

In Store Subsystem

AssemblyIn Store

ReceivingInspection Subsystem

Work OrderArchive Subsystem

ShippingInspection Subsystem

RIT

Work Order

Shipment

Audit

OMNITROL WIP Visibility System

WIP ControlSubsystem

Work OrderTracking

Audit

Assembly Cell Subsystem