v 1.1.0 · April 2026
Enterprise Production Management Solution
Performance Monitoring
System
A specialized enterprise platform designed to enhance efficiency and provide real-time operational visibility within Jewellery Manufacturing Production environments.
1.1 — System Overview
The PMS Platform
The Performance Monitoring System is a specialized enterprise system designed to enhance efficiency and provide real-time operational visibility within Jewellery Manufacturing Production environments.
Improve Manufacturing Productivity
By measuring actual processing times against defined standards to drive efficiency
improvements.
Track Department Performance
Providing granular metrics on output and efficiency for every segment of the production
line.
Capture Accurate Processing Times
Utilizing a simple, terminal-based Scan-In / Scan-Out mechanism for precise
time-stamping.
Identify Bottlenecks
Pinpointing specific processes or departments causing delays, from initial order
creation to final dispatch.
1.1.1 — System Interfaces
🛡️
PMS-Admin (Panel)
Master Control
Master control of the system for staff, supervisors, and
managers. Used for configuration, reporting, and administration of the entire production system.
🏭
PMS-System (Shop Floor)
Production Interface
Production and QC level interface for workers. Accessed via
tablet or dedicated system directly on the shop floor at every department terminal.
1.2 — Onboarding
PMS Onboarding Kit
A structured deployment package ensuring every employee is fully equipped and the infrastructure is ready to support production-level operations.
Employee Device Kit
One dedicated tablet or system for each employee as a PMS onboarding kit — ensuring
every worker has direct terminal access.
Mandatory Infrastructure
Dedicated PMS server, network switch, router, tab holder, and QR code Tag Printer.
Required but separate from the employee kit count.
Support Team Ratio
A dedicated supporting member from the Master Maintenance Team is required for every
150–200 operational employees.
1.3 — Prerequisites
Project Prerequisites & Management Commitment
Successful deployment requires structured organizational commitment at multiple levels along with dedicated IT collaboration.
Review Schedule
Dedicated review schedule: Monthly with
Managers and Quarterly with Senior Management to track progress
and address operational challenges.
Benchmarking & Approvals
Benchmarking and other approval setups from Management to ensure targets are validated
and aligned with business goals before going live.
Rewards & Recognition
Yearly Rewards & Recognition programs and New Target Frameworks to incentivize
performance and sustain engagement on the shop floor.
Critical — IT Team Support
Collaboration and support from the existing IT team is mandatory to establish and maintain seamless communication between PMS
and existing software systems via APIs.
1.4 — Business Problem
Challenges in Traditional Jewellery Manufacturing
Traditional jewellery manufacturing processes often face significant challenges related to tracking, visibility, and quality control, leading to inefficiency and production delays.
Multiple Departments & Sub-Processes
Production involves a complex chain of specialized departments — Wax, Casting, Buffing,
Polishing, etc. — making end-to-end tracking extremely challenging.
Lack of Real-time Visibility
Managers often rely on delayed or estimated data, preventing proactive intervention
when issues arise on the floor.
Manual Job Tracking
Reliance on paper job cards or manual entry leads to inaccuracies, data latency, and
increased administrative overhead.
Production Delays
Unidentified bottlenecks and idle time contribute to missed deadlines and increased
operational costs across all production stages.
Quality Issues & Rework
Defects are often discovered late in the process, requiring costly and time-consuming
rework loops without root cause analysis.
🎯
PMS addresses all these pain points
with a single unified platform
1.5 — PMS Solution
PMS Solution Overview
PMS addresses the inherent complexities of jewellery production by digitalizing the shop floor and providing a single source of truth for all production activities.
Digital Job Card Management
Every order is tracked via a unique, scannable Job Card (barcode or QR code), creating
a complete digital audit trail.
Real-time Data Capture
Shop floor terminals capture precise timestamps for every operational step, ensuring
accurate processing time calculation.
Automated Performance Analysis
The system automatically compares actual performance against Standard Time to highlight
inefficiencies and overperformance.
Integrated Quality Control
Dedicated modules capture defect data at the point of inspection, driving quality
analytics and structured rework management.
Idle Time Monitoring
The system tracks and categorizes all non-productive time — breaks, no work, etc. —
providing actionable insights into capacity utilization.
Single Source of Truth
All production, quality, and workforce data is centralized, eliminating information
silos and ensuring data integrity.
2.1 — Production Workflow
End-to-End Production Workflow
The PMS tracks the entire manufacturing lifecycle, maintaining a clear audit trail and real-time status updates at every stage — from order creation through final dispatch.
Every stage maintains a real-time digital audit trail. Rework is fully tracked — a job card sent back for
rework cannot bypass QC until the Re-Production Scan is registered, ensuring mandatory
validation.
2.2 — Job Card Tracking
Job Card Tracking
The Job Card is the central entity for production tracking. PMS utilizes two primary deployment modes with a comprehensive employee workflow at every terminal.
PLAN A
Default — QR Scan-Based
1
QR Login
Employee logs in via QR code scan at terminal
2
Scan-In
QR scan to start work; start timestamp captured
3
Scan-Out
QR scan to complete work; end timestamp & processing time calculated
4
Auto Idle Control
Automatic break trigger screen when no activity is detected
PLAN B
Fire Fighting — Manual Fallback
1
ID/Pass Code Login
Manual credential entry when QR scanning is unavailable
2
Manual Bag/Job Entry
Manual entry of bag or job card number
3
Pause Button
Manual break registration via dedicated pause control
4
QC Checklist
Quality defect selection via manual checklist in Plan B mode
2.2.1 — Advanced Process Controls
Late Logging Control
Automated oversight using the Shift Master to flag and manage late scan-in entries.
Bag Working Options
Support for both Single and Multiple Bag working modes for flexible production
configurations.
Process Overrides
Functionality for Override Parallel working as a controlled process exception.
Asset Terminal Control
Centralized Asset Terminal Controls from the Admin backend. Each terminal is assigned a
Unique ID.
User Interface Alerts
Confirmation Windows for alerts and Fade-out Pop-up Message Boxes displaying bag number
and required details.
Terminal Robustness
Designed for robust QR code scanning including in low-light conditions on the shop
floor.
Process change is allowed within the currently logged-in department. Logging into a terminal in a
different department requires master data changes, enforcing process discipline.
2.3 — Departments
Department Processing
The system is configured to map to the specific sequence of operations required for jewellery production, capturing performance metrics at every stage.
🕯️
Wax
Initial wax mold
→
⚗️
Casting
Wax → Metal
→
🔧
Buffing
Surface prep
→
✨
Polishing
Final luster
→
🔍
QC
Inspection
→
📦
Dispatch
Order complete
2.3.1 — Performance Metrics Captured
Throughput
Total units completed per shift or day, aggregated at department and individual level.
Efficiency
Comparison of actual processing time to the defined Standard Time for each sub-process.
Utilization
Percentage of available employee time spent on productive, value-adding work
activities.
2.4 — Production Question & Kaizen
Production Question & Kaizen
The Production Question module extends the PMS quality philosophy directly onto the production floor — enabling structured Kaizen (continuous improvement) by capturing real-time operational observations, process deviations, and improvement suggestions at every Working Path.
Production Question Types
Define configurable question types per department or Working Path — checklist-style,
numeric input, dropdown selection, or free-text observation — tailored to each production stage's unique
Kaizen requirements.
Formula-Based Calculations
Attach custom formulas to production questions — e.g., weight variance %, material
yield, or cycle efficiency — enabling automated KPI calculation directly from worker-entered data at the
terminal.
WP-Level Customization
Each Working Path can have its own unique set of production questions and formulas,
ensuring relevant data is captured for each specific process — Wax questions differ from Polishing
questions.
Kaizen Data Capture
Workers answer production questions during Scan-Out, capturing process observations,
material conditions, and improvement suggestions — creating a rich Kaizen data repository.
Trend Analysis & CAPA
Aggregated production question responses power trend dashboards — spotting recurring
issues, tracking improvement actions, and feeding into Corrective and Preventive Action (CAPA)
workflows.
Admin-Controlled Configuration
Questions, formulas, and WP assignments are fully managed from the PMS Admin Panel —
add, modify, or deactivate questions without disrupting ongoing production operations.
2.4.1 — How It Works — Production Question Flow
1
Admin Configures Questions
Admin creates production question sets with types, formulas, and assigns them to
specific Working Paths via the Admin Panel.
2
Worker Triggers at Scan-Out
When a worker performs Scan-Out on a job card, the system presents the relevant
production questions configured for that terminal's Working Path.
3
Data Entry & Auto-Calculation
The worker fills in responses; any attached formulas (e.g., yield %, variance)
are auto-calculated and stored with the job card record.
4
Kaizen Analytics & Reporting
Responses feed into Kaizen dashboards — enabling management to identify recurring
issues, track improvement trends, and initiate CAPA actions.
2.4.2 — Production Question vs QC Question — Comparison
| Aspect | QC Question | Production Question (Kaizen) |
|---|---|---|
| Purpose | Defect detection & quality gate enforcement | Continuous improvement & process observation |
| Triggered At | QC Department Scan-Out | Production Department Scan-Out |
| Customizable Per WP | Yes — per QC Working Path | Yes — per Production Working Path |
| Formulas | Defect % calculation | Custom formulas (yield %, variance, efficiency) |
| Outcome | Pass → Dispatch or Fail → Rework | Kaizen data → Trend analysis → CAPA |
| Question Types | Defect checklist selection | Checklist, numeric, dropdown, free-text |
Production Questions function as a Kaizen engine on the shop floor — while QC focuses on
pass/fail quality gates, Production Questions continuously collect process intelligence to drive
incremental improvements, reduce waste (Muda), and optimize cycle times across every Working
Path.
2.5 — Quality Control
Quality Control Module
The QC stage is a critical data capture point that determines the subsequent path — Dispatch or Rework — of every Job Card.
Key quality objectives include tracking Defect% and performing Defect
CAPA (Corrective and Preventive Action) to analyze responsible departments and drive continuous
improvement.
2.6 — Rework Management
Rework Management
When a defect is identified in QC, the job card enters a structured Rework loop — fully tracked by PMS to prevent unmonitored production cycles.
2.6.1 — Rework Parameters Captured
| Parameter | Description |
|---|---|
| Defect | The specific flaw identified during QC inspection |
| Reason | Why the defect occurred — machine fault, operator error, etc. |
| Subprocess | The specific corrective action required for this defect |
| RB Type | Common / Metal / Diamond — categorization of rework nature |
| Working Path | The designated production path for the corrective work |
2.6.2 — Route Control Logic
Route Control Enforced
A job card sent back for rework (Re-Production Scan) cannot be QC scanned
again until the Re-Production Scan is registered, ensuring mandatory validation of all
corrective work.
Disable Route Control Option
If "Disable Route Control" is enabled for a department, the job card can be moved
freely across any stage without sequence restrictions — allowing flexible workflow handling.
After corrective work is completed, the job card must re-enter the QC stage for final
approval before it can proceed to dispatch. This closed-loop ensures quality gates are never bypassed.
3.1 — Break Monitoring
Break Monitoring System
The Break Monitoring System tracks non-productive periods to differentiate between value-adding and non-value-adding time, ensuring complete workforce utilization visibility.
Break Trigger Logic
The system monitors terminals and triggers a mandatory action when an employee is
logged in but has not performed a Scan-In/Scan-Out for a defined idle duration.
Break Master Entry
When triggered, the employee must select a reason from the Break Master before resuming
work or logging out — ensuring all idle time is categorized.
Supervisor Notifications
A Blinking Break Screen notification alerts supervisors for easy visibility of idle
confirmations, enabling proactive intervention.
⛔ NVA — Non-Value Added Time
Time that does not contribute directly to production:
Waiting in Queue
Loading /
Unloading
Movement
Calling someone /
something
Transportation
🔶 ENVA — Essential Non-Value Added
Necessary but non-productive operational tasks:
Tally
Cleaning
Tool / Process making /
5S
Lunch / Rest
Room
Marking Jobs
3.2 — Master Data
Master Data Architecture
The PMS relies on robust and accurately defined Master Data to ensure system integrity and relevant reporting across all modules.
Organization, Location, Unit
Defines the company structure, factory sites, and resource groups forming the
foundational hierarchy.
Employee, Shift Time
Detailed records of personnel, working hours, and shift schedules including late
logging control.
Department, Process, Sub Process
Hierarchical structure defining the operational flow of manufacturing from coarse to
fine granularity.
Working Path
Predefined, optimized sequential routes for job cards through the production facility.
Standard Time
The defined optimal time for an employee to complete a specific sub-process — the
performance benchmark.
Defect Master, Rework Code
Standardized lists for quality issues and corresponding corrective actions used in QC
scanning.
Break Master, RB Type
Categorized reasons for idle time and rework classification (Common / Metal / Diamond).
Project, Teams
Metadata used for grouping and classifying job cards and performance for reporting
purposes.
Role and Permissions
Configuration for user security, defining access levels for workers, staff,
supervisors, and administrators.
Terminals
Shop floor hardware inventory configuration linking each terminal (T1, T2, T3…) to its
Working Path.
3.3 — Working Path
Working Path (WP) Concept
The Working Path is a crucial configuration component that defines the legitimate, sequential route a Job Card must take through the factory floor — enforcing process discipline and controlling data capture accuracy.
WP Composition Formula
Location
LocationA
+
Unit
Unit1
+
Department
Casting
+
Process
Buffing
+
Sub-Process
Sub-001
=
Working Path
WP001
Only employees logged into a terminal tied to the correct Working Path can interact with a
job card designated for that stage. This prevents process skips or errors, maintaining a strict sequence of
operations.
3.4 — Standard Time
Standard Time & Bottleneck Detection
PMS uses Standard Time master data to perform continuous performance comparison and identify critical areas of inefficiency across all production stages.
Bottleneck Detection
Flags processes, specific products (Bottleneck Product Identification), or individuals
(Bottleneck Person Identification) where Actual Time consistently exceeds Standard Time.
Overperformance
Identifies employees or teams that consistently complete work faster than Standard Time
— valuable data for benchmarking and reward programs.
Productivity Insights
Granular reports on variance allow management to understand efficiency losses and make
data-driven improvements at every level.
3.5 — Dashboards & Reporting
Dashboards & Reporting
The PMS platform provides comprehensive, role-based dashboards and static reports to visualize real-time operational status and historical performance trends.
Department Productivity
Real-time visualization of job status, Work in Progress (WIP), and overall throughput
by department.
Employee Performance
Metrics tracking individual efficiency, attendance, idle time, and historical quality
output per employee.
Defect Trends
Charts showing frequency and impact of defects, categorized by type, time, and
responsible department.
Bottleneck Analysis
Heatmaps and trend reports highlighting processes that frequently exceed Standard Time
targets.
Production Throughput
Overview of order completion rates and status, comparing planned schedule vs. actual
dispatch time.
Real-Time & Historical
Both live operational status and long-term trend data available through role-based
access dashboards.
3.6 — Access Control
Role Based Access Control (RBAC)
PMS implements a structured four-tier role hierarchy with clearly delineated permissions ensuring secure, appropriate access at every level of the organization.
🏭 Worker
Terminal Login
Scan-In / Scan-Out
Personal Metrics View
Break Registration
Current Status View
Running Time View
📋 Staff
Master Record Entry
Basic Reporting Access
Shift Management
All Worker Permissions
Data Entry Functions
Intermediate Access
👔 Supervisor
All Dept. Dashboards
Team Performance View
Rework Assignment
Shift Execution Oversight
Break Screen Monitor
All Staff Permissions
🔑 Administrator
Master Data Creation
User Role Assignment
System Settings
Terminal Configuration
Full System Access
All Supervisor Permissions
3.7 — Terminals
Shop Floor Terminals
Terminals are the physical interface connecting the digital PMS to the physical manufacturing process — placed strategically at every department across the facility.
Hardware Type
Ruggedized tablets or dedicated shop floor computer systems, strategically located
throughout the production facility. Labeled
T1, T2, T3, etc.Primary Use
Exclusively used for the Job Card Scanning workflow — Login, Scan-In, Scan-Out — and
each terminal is tied to a specific Working Path.
Data Capture Reliability
By placing terminals at the point of action, PMS ensures high accuracy and minimizes
time lag between action and data capture — including in low-light conditions.
3.8 — Business Benefits
Business Benefits & Objectives
Implementing the Performance Monitoring System provides tangible and quantifiable advantages for jewellery manufacturers across all operational dimensions.
Increased Productivity
By identifying and resolving bottlenecks and minimizing idle time
Enhanced Quality
Structured defect capture and rework loops reduce costly errors
Improved Monitoring
Fair, objective performance tracking on time-stamped data
Full Visibility
Real-time dashboards replace manual reporting entirely
Greater Efficiency
Faster turnaround times and lower operational costs
3.8.1 — Measurement Objectives
Time Management
- → Total Hrs. (Payroll vs Operations)
- → Production Hrs.
- → Rework Hrs.
- → Idle Hrs. (No Work Hrs.)
Productivity
- → Output Grams per Hour
- → Output Carats per Hour
- → Points per Hour
NVA Tracking
- → Waiting in Queue
- → Loading / Unloading
- → Movement & Transportation
- → Call someone / something
Quality
- → First Time Right Quantity
- → Defective Qty
- → Defect%
- → Defect CAPA
ENVA Tracking
- → Tally & Cleaning
- → Tool / Process making / 5S
- → Lunch / Rest Room
- → Marking Jobs
Delivery &
Inventory
- → Lead time monitoring
- → Lead time reduction → Inventory turnover ↑
- → Loss reduction due to FTA improvement
Efficiency
- → Achieved % against Standard Avg. Time
- → Individual Performance Measurement
- → Benchmarking
Bottleneck
Identification
Process Level
Bottleneck Process Identification — pinpoints which
production stages slow throughput.
Product Level
Bottleneck Product Identification — identifies
specific SKUs or designs that cause delays.
Person Level
Bottleneck Person Identification — highlights
individuals requiring training or support.