Trace every unit from barcode to final audit package.
FlexIPS links each serial number to its inspection images, video replay, process values, operator actions, station decisions, and MES handshakes so quality teams can prove exactly what happened on every build.
100%
inspection, media, recipe, operator
< 1s
serial, station, variant, verdict
1 click
images, video, logs, measurements
Flow
Auto-synced
MES push
Success
Ready for audit
Full evidence package
Root cause
Station + image history
Every decision is recorded with the evidence behind it.
FlexIPS goes beyond counters and daily reports. Each unit gets a searchable digital record containing the serial, variant, station, operator, images, video, measurements, logic log, and final verdict.
Centralized retention
Station data streams to one traceability hub instead of living in PLC logs, camera folders, spreadsheets, and disconnected USB exports.
Audit-ready evidence
Export a complete evidence package with original images, overlays, video replay, step logs, station details, and integration status.
A complete manufacturing record, not a loose pass/fail log.
FlexIPS builds the unit history from identity, machine vision, process data, operator actions, and integration events. The result is useful for customer evidence, warranty analysis, launch containment, and recurring defect investigation.
Part identity
Barcode, Data Matrix, DPM, RFID, lot, variant, and customer serials are normalized into one unit record.
Inspection evidence
Original images, overlays, measurements, tool outputs, confidence values, and pass/fail results stay tied to the unit.
Operator actions
Manual confirmations, controlled overrides, rework decisions, user IDs, and timestamps are preserved for review.
Station context
Recipe version, PLC handshake, camera setup, fixture, tool ID, cycle time, and line location are stored with the verdict.
Process data
Torque, angle, sensor, temperature, test values, and limits can be captured next to machine vision decisions.
Genealogy links
Parent and child assemblies, sub-components, batches, and previous station results build a complete product history.
From serial scan to searchable genealogy.
Traceability should run in the background without slowing production. FlexIPS captures the station cycle, verifies data completeness, and synchronizes the record while the line keeps moving.
Step 1
Identify
Read or receive the serial, lot, and variant before the station starts the cycle.
Step 2
Capture
Store images, video snippets, machine vision results, and process values as the work happens.
Step 3
Validate
Gate release on PASS criteria, recipe match, operator permissions, and required data completeness.
Step 4
Synchronize
Push the record to FlexDashboard, MES, SQL, ERP, or customer systems with retry handling.
Step 5
Investigate
Search a serial, compare stations, export evidence, and isolate root cause in minutes.
Search any serial, then export the story behind it.
Every record from every station lands in FlexDashboard. Search a serial to pull up captured images, video replays, step-by-step logic logs, operator, recipe, and final verdict. Filter by station, operator, variant, or pass/fail, then export the evidence package for audits, returns, or customer evidence.
FlexDashboard
Traceability, audit, and quality investigation hub
Live station data - synchronized
Serial Search
Trace records
52,408
current selection
Images stored
218,940
serial-linked, original res
Video replays
41,702
handling and inspection clips
Avg search time
< 1s
any serial, any station
SN: A14-9X2-00451
PASSCaptured media
Step and logic log
Complete unit timeline
Open any serial to see images, video replay, the step-by-step logic log, operator decision, station timestamps, and MES trace records in one investigation view.
Fits the factory data model you already have.
FlexIPS can act as the station traceability layer, a complete local trace database, or a data bridge into MES and ERP. The architecture is mapped to your retention, access, and export rules instead of forcing a generic cloud workflow.
Configurable retention
Keep high-resolution images, thumbnails, video, and raw values by product family, customer, or program.
Local-first or cloud-ready
Run on local factory storage, a central SQL server, or a controlled cloud architecture depending on IT policy.
Controlled access
Role-based access helps separate operators, quality engineers, supervisors, and administrators.
Audit trail
Changes, overrides, exports, failed pushes, and rework decisions can be logged against users and timestamps.
Find whether the issue came from the part, process, station, or data push.
When a customer claim or line issue appears, traceability should shorten the investigation. FlexIPS lets teams compare failed images, last-good cycles, operator decisions, recipe changes, and station timing without manually collecting files from multiple computers.
- Compare PASS and FAIL images for the same station and variant
- Trace rework and controlled overrides with user and reason
- Find repeated failures by station, recipe, camera, tool, or shift
- Export evidence packages for customers, audits, and supplier claims
Claim investigation
SN: A14-9X2-00451
Barcode read matched variant X1
Connector close-up image below confidence limit
Supervisor accepted after repair image
Evidence exported
12 files, 3.8 MB
Likely root cause
Connector seating
Traceability becomes strongest when every station contributes evidence.
FlexIPS traceability connects naturally with the inspection and guidance modules used across assembly, test, and end-of-line workflows.
Barcode & QR Reading
Decode the serial, lot, and variant that start the trace record.
Assembly Verification
Store step-gated work instructions, torque values, image checks, and operator decisions.
Wiring Harness Inspection
Trace connector, wire routing, fixture, and variant evidence for harness boards.
PCBA End-of-Line
Link full-board images, critical module checks, handling video, and station verdicts.
Common questions from quality, production, and IT teams.
How FlexIPS captures unit history, visual evidence, integrations, retention, and audit exports for real production lines.
What is industrial traceability in manufacturing?
Industrial traceability is the ability to search a finished part or serial number and see the complete production history behind it: stations visited, inspection results, captured images, process values, operators, recipes, timestamps, rework decisions, and data sent to MES or ERP systems.
Can FlexIPS trace images and video, not just pass/fail results?
Yes. FlexIPS can store original camera images, overlay images, short video replays, barcode payloads, measurements, logic logs, and the final verdict against the serial number. This gives quality teams visual evidence instead of only counters or text logs.
How does FlexIPS connect traceability records to MES, ERP, or SQL systems?
FlexIPS can exchange data through common factory interfaces such as OPC UA, SQL, REST APIs, file export, and PLC handshakes. The integration is mapped to the customer data model so serials, lots, variants, results, and media references land in the correct systems.
Can operators override or repair a failed traceability record?
Controlled overrides and rework flows can be logged with user, reason, timestamp, image evidence, and final disposition. The goal is not to hide exceptions, but to make every exception reviewable later.
Is FlexDashboard used only for audits?
No. FlexDashboard is also used for production monitoring and root-cause analysis. Teams can filter by station, product, failure mode, operator, recipe, or time range to find recurring issues before they become customer complaints.
Can traceability run locally inside the factory network?
Yes. FlexIPS can be deployed in local-first architectures where production records and media stay inside the plant network. Cloud or hybrid deployment is also possible when the customer IT policy allows it.
Have a question we didn't answer? Request a demo and we'll map it to your line.
Get started
See unit-level traceability in action
Share a sample serial flow, station map, or MES data model. We will configure a tailored demo around your inspection evidence, retention rules, and export requirements.