Trace your assets from start to end

By Staff Report April 1, 2025 6:13 pm IST

End-to-end traceability has made manufacturing processes more reliable. Sameer Gandhi, MD of OMRON Automation India, shares how they assist manufacturers with seamless traceability by integrating real-time data capture and compliance assurance into their production systems.

What challenges do manufacturers face in achieving seamless end-to-end traceability? How is OMRON placed to address them?

Manufacturers face challenges in achieving end-to-end traceability, such as data integration, technology compatibility, costs, regulatory compliance, and data security. Integrating consistent and accurate data from various sources is complex. Different technologies and standards hinder seamless interoperability. Also, implementing traceability systems is expensive and time-consuming, especially for SMEs. Compliance with varying regulations and protecting sensitive data from cyber threats are a few more significant concerns.

We are well-positioned to address these challenges with our comprehensive traceability solutions. Omron offers end-to-end traceability solutions that integrate seamlessly with existing manufacturing systems, including code reading, RFID technology, and laser marking for efficient product identification and tracking. Our solutions enable real-time data capture and analysis, providing manufacturers with immediate insights into their production processes and helping identify and promptly address issues. Our barcode verification and label inspection solutions confirm that all labels and barcodes meet industry standards and regulatory requirements to maintain compliance and avoid costly errors. Our traceability solutions are scalable and flexible, making them suitable for manufacturers of all sizes. They can be tailored to meet the specific needs of different industries, from automotive to life sciences. We also have expertise in implementing robust security measures to protect traceability data from cyber threats, ensuring data integrity and privacy and providing manufacturers with peace of mind.

With increasing supply chain disruptions (such as semiconductor shortages and geopolitical tensions), how can traceability technologies help manufacturers mitigate risks?

Traceability technologies, such as those offered by OMRON, mitigate supply chain risks like semiconductor shortages and geopolitical tensions by enhancing visibility, efficiency, and compliance. These technologies perform real-time tracking and comprehensive data collection, allowing manufacturers to identify and address potential bottlenecks early. Automating identification processes with RFID and barcode scanning reduces errors while integrating traceability data with predictive analytics helps with disruption forecasting and continuity maintenance.

Our traceability solutions ensure regulatory compliance and quality control by monitoring products and components at every stage. This compliance avoids legal issues and maintains market access. When supplier networks are managed effectively, and alternative sources are known, manufacturers can diversify their supply chains and reduce dependency on single suppliers. This mitigates risks associated with geopolitical tensions. However, manufacturers can take a significant amount of time to evaluate new suppliers and bring them on board. New suppliers can adopt traceability to assure customers of their processes’ robustness and quality and reduce onboarding time.

What are the cost implications of implementing advanced traceability systems, and how can businesses increase their ROI?

Investment in advanced traceability systems can give a competitive advantage by enhancing operational efficiency, product quality, and customer satisfaction.

Implementing advanced traceability systems involves initial setup costs like purchasing technology, upgrading infrastructure, and training staff, along with ongoing operational expenses for maintenance and data management. These systems can also incur indirect costs due to potential downtime and change management during implementation. However, optimising supply chain efficiency and predictive maintenance can lead to significant cost savings and improved ROI. A robust traceability system enhances product quality and regulatory compliance, reducing defects and legal issues.

Traceability systems help avoid product recalls by providing a detailed and accurate record of each product’s journey through the supply chain. This enables manufacturers to identify and isolate defective products while minimising the impact on consumers and financial losses. Efficient recall management prevents harm and protects the brand’s reputation by demonstrating a commitment to quality and safety.

Businesses can increase ROI using traceability data to make informed strategic decisions, improve customer satisfaction, and foster innovation. Providing transparency about product origins and quickly addressing issues builds consumer trust and loyalty. By transforming data into actionable insights, companies can optimise supply chain routes, select reliable suppliers, and forecast demand more accurately.

How does traceability impact regulatory compliance and quality assurance in highly regulated industries?

In highly regulated industries (like pharma), traceability systems safeguard regulatory compliance and quality assurance by providing detailed records, facilitating audit readiness, and enabling efficient recall management. It helps monitor product quality throughout production, optimise operations, and enhance supply chain visibility, building consumer trust. Traceability systems manage product recalls by swiftly identifying and isolating defective products, thus reducing potential harm and financial losses to companies. For instance, in healthcare and the food and beverage industries, traceability ensures patient safety and food safety by tracking products from production to end use, thus maintaining adherence to stringent regulations and preventing errors or contamination.