What is Traceability in Manufacturing and How to Implement It?

Product traceability is an important process for manufacturers with products that have a shelf life. It’s also a tool that can help you optimize your production lines. In this article, we cover why it’s important, what are the benefits, and how you can implement it into your business.
Product traceability will help optimize your production lines and is a legal requirement for some businesses. But what is it, and how do you implement it?

Product traceability allows you to track your inventory movements from end-to-end, meaning you can track products to where they were shipped, or back through their operational steps.  

In this article, we’re going to look into traceability in manufacturing, why it’s important, the benefits, and how you can implement it.  

What is Traceability in Manufacturing? 

Traceability is the procedure of tracking (and documenting) all your raw materials, parts, and finished goods throughout your manufacturing process.    

The term itself is coined together from “Trace” and “Ability” and is used to describe the ability to track products by all manufacturing industries (though some have their own specialized terms).   

Having a traceability procedure for manufacturing in place will allow you to find historical information on a product, such as:  

— Suppliers;     

— Items;     

— Inspection notes;  

— Manufacturing details;  

— Time spent at each workstation; and 

— Distributors.  

There are two perspectives when it comes to product traceability:  

Chain traceability  

This is forward and backward product traceability. Meaning manufacturers can track products from raw material to the distributor.  

And the distributors or consumers can understand where the product came from.   

Internal Traceability    

This means product traceability with a limited scope, such as monitoring one specific manufacturing plant.   

For example, if you use outsource manufacturing, the information you receive about their components is internal traceability.   

Benefits of traceability in manufacturing include lowering costs and increasing profitability.

Why is Product Traceability in Manufacturing Important?  

It’s exciting times when your hard work pays off, and you see your business grow, and the number of products you manufacture expand.    

But it only takes one batch of faulty products to enter the market to: 

— Driveaway customers;  

— Damage your brand;   

— Hurt your bottom line; and   

— Undo all your hard work.   

If you don’t have a system in place to track products, it’s going to be impossible to effectively recall a defective or contaminated item.  

That’s why having systems in place to improve product traceability is essential. 

Not just for products that have a short shelf life, but for products that will become outdated due to technological advancements.   

You might think that you don’t need product traceability since you don’t sell perishable goods.  

However, product traceability systems will help you improve production efficiency and product quality control, as you’ll have real-time visibility to understand where along your production is causing problems, such as bottlenecks in production.   

Now you know what product traceability in manufacturing is and what can happen if you don’t implement it. But what are the Benefits of Traceability in Manufacturing?  

PRO TIP: Getting set up with product traceability systems is one thing. But product traceability won’t be able to help you if your inventory is in disarray. That’s why we put together the free and ultimate inventory management guide, so you can find the best process for your business. 

Katana’s inventory management guide for modern manufacturers.

Benefits of Traceability in Manufacturing  

When you start using product traceability, you can start taking advantage of:  

1. Root Cause Analysis      

Having your product information from end-to-end means you can perform an in-depth analysis of your manufacturing routes to see the root cause of any problem.    

This will enable you to see in which areas of your production are underperforming and help you make changes to improve your manufacturing lead time.    

For example, if some finished products have defects, you’ll have an overview of your entire production line so you can pinpoint where the defects are occurring, such as:   

— The products missed a particular process, like a quality check;   

— A new team member is making mistakes and needs to be trained; or   

— A faulty tool or machine needs repairing.    

2. Continuous Improvement     

Following on from the root cause analysis benefit of using product traceability, you can also implement continuous improvement into your production flow.   

A continuous improvement system is essentially a form of lean manufacturing.   

However, the biggest difference is that with continuous, you and your team members will take responsibility for identifying inefficiencies on the shop floor, developing plans, and implementing improvements.   

Product traceability systems will be a crucial tool for helping you gather real-time and accurate data on your manufacturing, so you can perform regular audits on your operations to make sure your production is always running smoothly.  

Continuous improvement in manufacturing is perfect for those looking to:   

— Remove waste; and   

— Adopt green manufacturing into their business.   

3. Value Stream Mapping               

Value stream mapping, also referred to as material and information flow mapping, is a lean management method for helping you understand your manufacturing process and how to redesign it to get the most value from manufacturing.  

The value stream map is a product traceability tool that helps you monitor your:  

— Operation steps;  

— The quantities of raw material needed; and  

— The time the product spends at each workstation.  

Since product traceability in manufacturing monitors how your products move through your shop floor, it lends itself well to designing your value stream mapping.  

Doing this will help you get a granular picture of your operations and more of an idea on what could be improved.  

4. Quality and Engagement 

Including product traceability in your manufacturing means that you and your team members can take accountability and be more engaged along the shop floor by having the processes in place to continuously monitor progress.  

Product traceability systems allow you to identify if you need extra quality check-ups along your manufacturing process to avoid the chance of a defective product being shipped to a customer or distributor.  

5. It’s Your Obligation  

Finally, a lot of manufacturing industries are highly regulated, and having product traceability is a legal requirement (especially in places such as food production).   

That’s why if you work in one of these highly regulated areas, finding batch inventory management systems that can track your end-to-end product development and handle batch numbers is important to avoid any of the issues mentioned earlier in the article.   

However, even if you’re not a manufacturer with products under intense scrutiny, using product traceability systems allows you to:   

— Improve inventory management;   

— Maximize your return on investments; and   

— Make better business decisions with improved analytics.    

These were the benefits of using product traceability within your manufacturing. But how do you go about improving product traceability?   

Knowing how to improve traceability is going to help you improve your manufacturing processes.

How to Improve Traceability?         

If you want to start improving product traceability in manufacturing, you can do so by following these four points:  

1. Tracking and Record-Keeping          

If you ever need to do a product recall, your priority is going to be identifying all the affected products, so you can better inform the public when you put out the notice.    

Without proper records in place means that locating the products is going to be difficult and will ultimately increase the cost of the product recall, not to mention the damage it’ll do to your brand.     

Product traceability systems allow you to keep records of:   

— Batch numbers and production dates;   

— Product order numbers;   

— Expiration dates; and   

— Production timestamps.   

2. Supply Chain Visibility       

Product traceability in manufacturing not only needs insights into your own production but improving product traceability also needs a better understanding of your supply chain.   

Without these insights, you could put yourself in a position to have to initiate more recalls than you’d have to.   

This can be due to a 3rd party business incorrectly handling your finished goods after they left your warehouse or a supplier sending you faulty materials or components.   

You need to be able to trace your batches both forward to retailers as well as backward to your suppliers, by having a system in place that can quickly identify products history by their batch numbers.   

3. Proactive Monitoring       

The longer you leave defective products in circulation, the more difficult it becomes to trace them as they make their way through your supply chain.    

One of the goals of improving your product traceability is the ability to spot problems soon, so you can nip any potential issues in the bud and avoid it turning into an even bigger problem.   

Being proactive becomes far easier if you’re using product traceability systems that provide you with real-time information of production progress, so you can immediately see problems as soon as they appear.   

4. Mock Recalls    

Finally, how do you improve at anything in life?    

With practice, practice, and then some more practice.    

Performing periodic mock recalls will allow you to determine how long it takes your business to recoup the defective products.   

When planning a mock recall, you should:   

— Be realistic and use a scenario that could likely happen in your business;   

— Record everything that happens during the mock;   

— Review the results and your product traceability systems; and   

— Assess your business's effectiveness in handling the mock recall.   

Doing this will help you realize where you’re underperforming in product traceability and fix them now, instead of struggling with a product recall later.   

Now you know the benefits of traceability in manufacturing, and how to improve traceability,  you need a system that can help you bring it all together.   

Product traceability systems allow you to easily locate your products along your distribution chain.

Using Katana for Product Traceability

Katana traceability software is a tool for SME manufacturing businesses looking to upgrade their product traceability within their business.

Using our product traceability systems allows you to easily:  

— Add batch/lot numbers; 

— Track expiry dates of products;  

— Track the best before date of products; 

— Trace any defective or contaminated products back to their batch; and  

— Make your product recall process as smooth as possible.  

Want to find out how Katana can improve your workflows? Then check out our complete overview of how Katana works:  

Better yet, why don’t you see for yourself? We offer a 14-day free trial, so you can get the first-hand experience and learn how Katana will help improve your product traceability.   

And that’s it for today, we hope that you found this article on product traceability useful, and if you have any questions, please don’t hesitate to get in touch.  

And until next time, happy manufacturing.  

Katana Smart Manufacturing Software.