What do you gain by tracking “worker presence” in the meat industry?

TAP Smart Factory System, Module: Integrated IoT Hybrid Platform

Problem Definition

Short-Term Challenges ·      Unplanned production stoppages due to worker absence at critical stations (cutting, packaging, disinfection) ·      Delays in machine startup or shutdown caused by schedule misalignment ·      Manual record-keeping hinders timely response and safety improvements

Long-Term Challenges ·      Reduced productivity and increased overtime costs ·      Difficulty in monitoring compliance with workplace safety procedures ·      Lack of reliable data for shift and capacity planning

Solution
A simple sensor-based system is introduced in the meat industry to detect workforce presence at key workstations—no cards or tags required. The system provides:
• Automatic tracking of worker numbers in cutting, packaging, and cleaning zones
• Local activation of sound and light signals when staffing is insufficient
• Wireless communication with the TAP Smart Factory platform for centralized analysis

How does the “Presence Tracking” solution work within the TAP Smart Factory system?

1. Detection Zone
   o Each critical station in the production process is equipped with a sensor unit that measures the presence
2. Data Processing
   o Aggregated real-time worker counts are transmitted to TAP Smart Factory
3. Alarm System
   o When staffing thresholds are exceeded or fall below minimums, the system sends automatic notifications to supervisors

 

Reporting System
Managers have access to the following types of reports:
• Daily and weekly station occupancy reports
• Compliance with shift plans and safety procedures
• Zones with the most frequent work interruptions
• Absence trends and downtime risk indicators
• Automatic generation of PDF and Excel reports
• Interactive web portal with detailed overview capabilities

 Benefits

For the Company ·      Reduced unplanned downtime and overtime costs ·      Improved capacity planning and shift scheduling ·      Rapid detection of safety and procedural risks ·      Transparent data for strategic decision-making

For Workers ·      Clear occupancy tracking without additional obligations ·      Enhanced safety through timely alerts ·      Improved coordination and reduced stress from uncertainty

Conclusion
Implementing sensor-based presence tracking in the meat industry via the TAP Smart Factory platform delivers improved safety, production continuity, and more efficient workforce utilization.

Note: This case study does not include technical implementation details or internal system architecture.