Eyewear Manufacturer Replaces Manual Production Tracking with Connected Factory Floor ERP
Production ran on manual logs and physical stock counts. Raw material, dye batches, and work orders lived outside the system, leaving little visibility into what was finished, what was still in process, and what was ready to ship. Every stock check meant physically walking the floor, since there was no live record of what stage a job had reached. Dye and batch details were tracked separately from the orders they belonged to, which made it difficult to trace a finished pair of lenses back to the raw material and recipe used to produce it. Handoffs between order confirmation and the factory floor added further delay, with production teams often working from information that was already out of date by the time it reached them.
The Challenge: Manual Production Tracking & Limited Factory Visibility
The client, an eyewear manufacturer producing prescription lenses and frames for retail and optical partners, needed its factory floor to keep pace with growing order volumes. Production ran on manual tracking: raw material, dye, and batch records lived outside the order system, and stock levels relied on physical counts. There was little live visibility into what was finished versus what was still in process, and handoffs between order intake and the factory floor slowed down every production start.
"We couldn't tell what was actually finished until someone walked the floor and counted it by hand."
— Operations Manager
- Raw material, dye, and batch records lived outside the order and production system
- Stock levels relied on physical counts, with no live view of finished versus in-process inventory
- Limited visibility into production status until units reached packaging
- Handoff gaps between order intake and the factory floor slowed production starts
Operational Impact Before Implementation:
Production Tracking
Manual & Paper-Based
Raw Material & Batch Data
Disconnected from Orders
Inventory Visibility
Physical Counts Only
The Solution: Factory Floor ERP + Batch Traceability + Live Inventory Visibility
Synkrone8 implemented a connected factory floor ERP that brings order intake, raw material tracking, dye and batch management, and packaging into a single production workflow.
Factory Floor ERP & Production Automation
Confirmed orders move straight onto the factory floor as live production jobs, with no re-keying into a separate system. Jobs progress through each stage, raw material, dyeing, batching, and packaging, as one connected workflow.
Raw Material & Supplier Traceability
The system tracks raw material and supplier consumption against every product, so the factory always knows what each SKU consumes and where it came from.
Dye & Tint Batch Management
Dye and tint are managed per product and batch, giving colored lenses and frames full recipe and lot traceability from raw input to finished unit.
Live Inventory, WIP & Dispatch Visibility
Live inventory and work-in-process visibility replace physical stock counts, with packaging and dispatch tracked as a connected final stage before delivery.
End-to-End Order-to-Delivery Traceability
Because every production stage runs against the same record, any unit on the floor can be traced back to its originating order, and every completed order can be traced through its full production and dispatch history.
The Results: End-to-End Production Visibility
After Synkrone8
Faster Batch Turnaround
45%
Fewer Stock Discrepancies
58%
Full Rollout
45 Days
Business Impact:
- Live Production Visibility: Finished units, work-in-process, and material levels are visible in real time, replacing manual stock counts on the floor.
- Material & Batch Traceability: Raw material, dye, and packaging are tracked per product and batch, giving every order a clear production lineage.
- Faster Production Handoff: Confirmed orders move straight into production with no re-keying between systems, cutting the delay between order intake and production start.
Beyond the Numbers:
- Reduced fragmentation between order intake and factory operations.
- Clearer accountability for material consumption and batch quality.
- A production record built to scale as order volumes grow.
Enable Connected Eyewear Production
Discover how factory floor ERP, batch traceability, and live inventory visibility can help you eliminate manual tracking, reduce stock discrepancies, and scale production with confidence.
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