Industry 4.0 Solution

Digital Checksheet Application for Controlled Shop-Floor Checks

Replace paper checksheets in any plant. Operators record on Android tablets, supervisors and managers see completion, exceptions and trends in real time — connected to the ERP you already run.

Android Operator AppNo-Code TemplatesOffline-FirstAbnormality & CAPAAnalyticsAny ERP
About Digital Checksheet

From Paper Clipboards to Controlled Checks

A configurable checksheet platform that makes routine operator entry fast, but makes exceptions, revisions, approvals and history fully traceable — for any plant, any product and any process.

Current Challenges

  • No live visibility — completion means walking the line
  • Skipped checks stay invisible for days
  • Out-of-limit readings are written down and the shift continues
  • Abnormalities have no owner, due date or closure evidence
  • Audit evidence means searching physical files
  • Operators may inspect to a superseded standard
→

Business Benefits

  • Live completion and overdue status by plant, line, shift and machine
  • Missed checks flagged and escalated automatically
  • Readings validated instantly against approved limits
  • Owner-wise abnormality and corrective-action tracking
  • Audit evidence retrieved in seconds with full provenance
  • Every record locked to the revision it was entered against

Speed for normal checks. Control for abnormal checks. Most entries take one tap or one numeric reading. NG and out-of-limit events require evidence, disposition and accountable closure.

See the Solution

Every check on every machine. Every exception owned until it’s closed.

See the operator tablet, the live line view, the abnormality workflow, the template builder and the manager dashboard in one walkthrough.

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The walkthrough is shown live. Share two or three of your current paper checksheets, and we will show them configured on the platform.
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The Solution

Three surfaces over one platform

An Android application for operators, a web portal for supervision and management, and an administration console — all served by the same secure API.

Android Operator Tablet

For operators on the line
  • Only checks assigned to this operator, machine and shift
  • One item at a time with standard, method and unit visible
  • Large labelled OK / NG / N-A buttons — never colour alone
  • Numeric readings validated instantly against limits
  • Camera, QR / barcode scan and evidence capture
  • Works through Wi-Fi loss; electronic confirmation

Supervisor & Manager Web

For supervisors and plant management
  • Live completion and overdue status by plant, line, shift, machine
  • Review, approval and controlled correction with audit
  • Abnormality queue with owner, due date, escalation and ageing
  • Drill from line status to exact item, value and evidence
  • Parameter trending against approved limits
  • Shift handover, target vs actual and KPI dashboards
  • Key observations, trends and integration error view

Administration Console

For administrators, quality and IT
  • Users, roles and plant / line / shift scope
  • Plant, shop, line, machine, operation, model, work-centre, shift calendar, units, responsibilities, QR codes and production targets — new lines and machines added without code
  • No-code checksheet templates with revision approval
  • Device registry, mail, notifications and reminders
  • Licence management and interface monitoring
  • Draft vs published settings — unpublished changes never affect production
  • Append-only audit log; referenced records cannot be hard-deleted
Operator Workflow

Designed around speed and control

If routine entry costs the operator more effort than the clipboard, the platform gets abandoned. Every screen is built for the shop floor.

1

Sign In

Individual ID and PIN with role and plant / line scope.

2

Open Due Task

Line, machine, shift and revision filled in automatically.

3

Complete Checks

One item at a time — OK / NG / N-A or a numeric reading.

4

Handle Exception

Mandatory reason, disposition and photo evidence on NG.

5

Review & Submit

Electronic confirmation and controlled sync to the server.

Large, glove-friendly targetsNo colour-only meaning — every result button is labelled.
Minimum typingAuto-filled context, numeric keypad and controlled choices.
Immediate validationUnit and limits shown before a numeric value is saved.
Progress visibilityCompleted / remaining count and due / overdue status.
Safe autosaveDraft saved after each entry with local / synced status.
No silent correctionSubmitted values stay; amendments show old and new values.
Application Features

Everything the shop floor needs for controlled production checks

01

Assigned Task List

Due, in-progress, completed and overdue checks filtered by plant, line, machine, shift and responsibility.

02

Instant Validation

Numeric readings checked against min, max, target and tolerance the moment they are entered.

03

Photo & Evidence

Photo capture, file attachment, paired before-and-after evidence and conditional remark rules.

04

QR / Barcode Scan

Scan machine QR codes to open the right checksheet; capture lot, part and material references.

05

Smart Scheduling

Tasks generated from the shift and holiday calendar with due, late-entry and missed-check rules.

06

Abnormality & CAPA

Auto-raised on NG or out-of-limit, with disposition, owner, escalation, verification and closure.

07

Change Events

4M change, tool / die change and after-power-interruption checks raised as unscheduled tasks.

08

Live Line View

Supervisor dashboards with overdue and abnormality queues, review, approval and shift handover.

09

Management Analytics

Completion, on-time, NG, CAPA ageing and production KPIs with rule-based key observations.

10

Revision Control

Maker-checker-approver workflow. Published revisions are frozen; every record keeps its revision.

11

Search & Reports

Filter by date, plant, line, machine, sheet, shift, user, status, lot, material or order. Excel, CSV, controlled PDF and audited email.

12

Traceability

Raw material, lot, part and production order linked to every inspection run.

Configurable Template Engine

Digitise any checksheet — without code

One common engine converts monthly, weekly and shift-wise paper layouts into controlled digital templates. New lines, machines and checksheets are added through configuration, not development.

Controlled template definition

HeaderPlant, shop, line, machine, operation, model, date, shift, document number, revision and effective date.
ItemsSerial, inspection item, standard, method, frequency, responsibility and optional A / B / C shift sub-rows.
ValidationResult type, required rule, min / max / target / tolerance, decimal places, unit and reference list.
EvidenceRemarks, photo, paired before / after evidence, barcode / QR, electronic confirmation and severity rule.
ControlMade by, checked by, approved by, reason for revision, publish / retire and full revision history.

Nine result types

OK / NG / N-ANumericTextDate / TimeSingle ChoiceMultiple ChoicePhotoSignatureBarcode / QR

Frequency model

Every ShiftShift Start-upDailyWeeklyMonthlyAfter Power InterruptionAfter ChangeEvent-Based

Scheduled checks follow the shift and holiday calendar. Event-based checks are raised the moment an operator or supervisor declares the event — and recorded distinctly from a scheduled check that was missed.

Version and approval lifecycle

DraftAuthor configures fields and rules
CheckerContent and source verified
ApproverEffective date and scope approved
PublishedFrozen; available for new tasks
RetiredNot reused; history retained

Ready-to-configure checksheet library

01
Machine Start-up & ConditionMachining, presses, moulding, assembly cells
02
In-process Quality InspectionDimensions, appearance, gauges
03
First-off / Last-off InspectionSet-up approval
04
Process Parameter SheetWelding, moulding, painting, heat treatment
05
Poka-Yoke VerificationError-proofing devices
06
Autonomous Maintenance / TPMCleaning, lubrication, inspection
07
Preventive MaintenancePlanned maintenance tasks
08
Tool & Die ChangeTools, dies, moulds, fixtures
09
4M ChangeMan, machine, material, method
10
Gauge & Instrument CalibrationDue dates and verification
11
Safety & 5S AuditWorkplace, PPE, housekeeping
12
Layered Process AuditLine / process / layered
13
Material Handling & FixturesConveyors, fixtures, trolleys
14
Production Log & Daily ReportLot / order / shift / day
15
Traceability RecordMaterial batch, lot and serial
+
Your Own ChecksheetsConfigured from your controlled masters

No guessed standards. Production templates are configured only from the plant’s approved controlled masters. Any row that is unverified cannot be published without explicit confirmation and an approver audit event.

Sample Checksheets

See how paper checksheets look once digitised

The same familiar layout your teams already know — now with validated readings, enforced evidence, automatic abnormalities and a controlled revision on every sheet.

Illustration only. All items, standards and values shown are sample data. Production templates are configured from each plant’s own approved controlled masters.

Exception Management

NG, abnormality and corrective-action workflow

An NG selection or a reading outside the approved limit automatically raises an abnormality. It cannot be closed without the required evidence and an effectiveness check.

1 · ContainObservation, immediate action, evidence and production disposition.
2 · AssignSeverity, owner, due date, priority, escalation and ageing.
3 · CorrectCorrective action, evidence and completion time.
4 · VerifyEffectiveness check by a verifier — close, reject or reopen with reason.

Production disposition

Stopped
Held
Continued under deviation
Resumed

Full context captured: run, machine, item, shift, operator, actual value, template revision, category, repeat indicator — with optional linkage to 4M change, tool change, breakdown, audit finding and ERP quality notification.

Analytics & Intelligent Observations

Turn checksheet data into management action

Explainable before predictive. Every observation states the rule that fired, the period and the records behind it.

Core management KPIs

Completion %Completed due checks / due checks
On-time %Completed by due cut-off
Missed ChecksNot submitted in permitted window
First-pass ApprovalApproved without return
NG / Repeat RateExceptions and repeat patterns
CAPA AgeingOpen actions by ageing bucket
JPH & Target vs ActualProduction against plan
PPM / OE / BreakdownQuality and equipment effectiveness

Key observations — rule based

  • Repeated NGSame item fails on the same machine across periods.
  • Near-limit trendReadings approach a boundary before becoming NG.
  • Late confirmationCritical checks repeatedly completed after cut-off.
  • Overdue actionCorrective action open beyond its due date.
  • Cross-line varianceCompletion or NG differs materially by line.

Dashboard governance: every KPI displays its definition, unit, target source, actual source and refresh timestamp. Observations can be acknowledged, assigned or dismissed.

Offline-First

A full shift with no network. Zero lost entries.

Entry writes to the tablet before anything touches the network, so the operator never waits on plant Wi-Fi. Completed checks queue on the device and upload in order the moment connectivity returns.

Built on a proven open-source synchronisation engine. Self-hosted on your infrastructure, it keeps your data inside your plant. On-device data retention is configurable.

1 shiftoffline endurance
1 tapfor a routine OK
0 lossacross retries
Assignment packageTasks, revisions and masters for the current and next shift held on the device.
Encrypted local cacheEvery entry saved instantly and securely on the tablet — no network round trip.
Durable upload queueSurvives app restarts and device reboots; uploads in order on reconnection.
Duplicate-safe submissionEach submission carries a stable unique ID — a retry never creates a second record.
Authoritative timeServer time governs submission and approval; device time retained for comparison.
Sync visibilityLast sync, pending records and errors shown for every tablet on the web portal.
Integration

Works with the ERP and systems you already use

ERP-agnostic and API-first. The platform connects to your existing ERP, MES and traceability systems through configurable mapping — it does not replace them.

SAPS/4HANA & ECC
OracleE-Business & Fusion
MicrosoftDynamics 365
Infor / EpicorManufacturing ERP
Tally / OdooSME ERP
MESProduction systems
TraceabilityLot & part systems
SQL DatabasesDB views
EmailSMTP / Microsoft 365
Excel / CSVFile exchange

Inbound to platform

  • Plant hierarchy — plant, work centre, line, machine, operation and status
  • Production context — material, model, production order, quantity and dates
  • Targets / plan — line, model, period, JPH and approved metric targets
  • Traceability — raw-material lot, batch / serial, material and external reference
Integration Queue MappingIdempotencyRetryError detailReconciliation

Outbound to ERP

  • Check completion — status, timestamp, machine, revision, sign-off
  • Process readings — item, actual value, result, unit, external keys
  • Deviation reference — NG, severity, action status, quality notification
  • Analytics feed — optional data warehouse or BI extract
REST / ODataIDocBAPI / RFCMiddlewareFile / DB View

Configuration, not code: field and code mapping is configurable per environment, so a change in ERP field names does not need a software release. Credentials are held as protected service accounts. The exact interface method, write-back objects, frequency and network route are confirmed for your ERP version during discovery. If the ERP interface is not ready at go-live, the platform runs fully on its own and the interface is switched on later.

Access Control

Role-based privileges and segregation

Every page and API action is restricted by role plus plant / line scope. Deactivation preserves historical identity, and shared production accounts are not allowed.

OperatorOwn assigned tasks, drafts, immediate actions and permitted history.
SupervisorLine / shift monitoring, review, controlled correction and CAPA ownership.
ManagerPlant-level dashboards, observations, approvals and management reports.
AdministratorUsers, roles, masters, templates, devices, licensing and interfaces.
AuditorApproved read-only search, export, template history and audit trail.
CapabilityOperatorSupervisorManagerAdministratorAuditor
Enter checksAssigned onlyException onlyNoNoNo
Review / approveNoAssigned linesAssigned plantsConfigureView
Assign / close actionsImmediate actionYesYesNoView
Dashboards / historyOwn scopeLine / shiftPlant / managementAllRead only
Export / emailLimitedYesYesConfigureExport only
Users / roles / devicesNoNoView statusYesView
Templates / mastersNoOptional checkerOptional approverDraft / manageView history
ERP / API / licenceNoView statusView statusManage with ITView logs
Licensing & Deployment

Flexible terms. Deploy where you choose.

Time-bound licensing

3 months6 months1 year
  • Scoped by plant, with optional user and device limits
  • Server-side signed entitlement — not dependent on device clock
  • Renewal reminders at 30, 15, 7 and 1 day
  • Agreed offline grace when the server cannot be reached

Renewal & expiry

Renew and extend without reinstalling or changing historical data. On expiry, new entries are blocked while read-only access and export stay available for an agreed grace period.

  • Every licence event is audited
  • Licence status visible on tablets and portal

Deployment flexibility

The same Docker-based build runs on-premise, in your private cloud or as a vendor-hosted cloud service — matched to your IT and security standards.

  • Separate DEV, UAT and PROD environments
  • Backup, restore, retention and archival
  • Scales from one line to multiple plants
Data Privacy & Security

Designed for audit-grade production records

01

Identity & Access

Individual users, RBAC, plant / line scope, session timeout, lockout, device registration and server-side API authorisation. Optional web SSO.

02

Transport & Storage

TLS / HTTPS throughout, encryption at rest, protected attachments with checksums, no public URLs and managed secrets.

03

Auditability

Append-only audit trail recording actor, action, before and after values, time, device / IP and result for every controlled change. Retiring a template or deactivating a user never deletes history.

04

Offline Integrity

Encrypted local cache, unique IDs, idempotent sync, server timestamps and visible pending / error state.

05

Resilience

Backup and restore, retention, archival, health checks, retry queues and monitoring of API latency, sync failures, database health, job status and licence validation.

06

Application Security

Input validation, rate limits, file controls, safe logs and testing against common web, mobile and API risks.

Measured acceptance targets

< 2 sOperator home / task list load on plant network
ImmediateNext-item display and local save, even offline
< 3 sTypical dashboard and history query
0 lossAccepted entries across retry and disconnection
Implementation

From discovery to pilot to rollout

A proven path that starts with your controlled masters and ends with a measured pilot on one line before plant-wide rollout.

STEP 1

Validate

Confirm controlled sheets, lines, machines, roles, shifts, KPIs, ERP interface, hosting and licence policy.

STEP 2

Configure Prototype

Configure your priority templates on the platform and agree screen and workflow changes.

STEP 3

Technical Design

Finalise data model, API, security, offline, reporting and integration specifications.

STEP 4

Build & UAT

Integrate and test on the actual tablet — role, offline, NG, report and licence scenarios.

STEP 5

Pilot & Rollout

Pilot one line, stabilise and train, then expand to remaining lines and templates.

Go-live gate: approved masters, user / role list, devices, integration mapping, backup / restore test, licence key and support contacts are signed off. Open critical issues block release.

Optional extensions

Multilingual & voice entryRegional-language operator labels and voice input.
PLC / SCADA auto-captureMachine parameters captured directly — the platform is API-ready.
Predictive analyticsML-based root-cause and maintenance suggestions.
Advanced corporate SSO / MDM / SIEMCorporate identity, device management and security monitoring.
Historical digitisationMigration of past paper or Excel checksheet records.
Scheduled distributionAutomated report emails and advanced shift handover.
Common Questions

FAQ

Does it work with our ERP?

Yes. The platform is ERP-agnostic and is designed to connect to SAP, Oracle, Microsoft Dynamics, Infor, Epicor, Tally, Odoo and others through REST / OData, IDoc, BAPI / RFC, middleware or file / database views. It can read masters, orders, targets and traceability references, and write completion, readings and deviation references back. The exact method is confirmed for your ERP version during discovery.

Can we digitise our own checksheets?

Yes. The no-code template engine supports nine result types, numeric limits, eight frequency modes, A / B / C shift sub-rows and conditional evidence rules. New checksheets are configured from your approved masters without software changes.

Does the tablet work when the plant Wi-Fi drops?

Yes. Every entry is saved on the device first and synchronised automatically on reconnection. The tablet is designed to run a full shift with no network, and duplicate-safe submission means a flaky connection can never corrupt the inspection history.

Will operators find it slower than paper?

No — that is the first design rule. Operators see only their assigned checks, one item at a time, with large labelled OK / NG / N-A buttons. A routine check takes one tap or one numeric reading.

What happens when a reading is out of limit?

The reading is flagged instantly, the required remark and photo evidence are enforced, and an abnormality is raised with disposition, severity, owner and due date. It escalates and ages until corrective action is verified and closed.

How do you prevent inspection to an outdated standard?

Template revisions pass maker-checker-approver before they take effect, and a published revision can never be edited. Every inspection record permanently stores the revision it was entered against.

Can it be hosted on our own servers?

Yes. The same build runs on-premise, in a private cloud or as a vendor-hosted service, with time-bound licensing for 3, 6 or 12 months.

Want to see the Digital Checksheet with your own production checks?

We can show how your current paper checksheets, abnormalities and approvals can be brought into one controlled, real-time platform connected to your ERP.

Request a Demo