TML
Every material loss has an owner, a cause and a value in EUR
TML follows every board from goods-in to delivery. The operator scans, the form fills itself, and the defect, the rework or the sort is recorded at the cell β with who, when, which line and which shift. Every loss is priced by the same formula, in EUR.
TML is a quality and traceability system for electronics manufacturers, built by Share IT Smart (Arad, Romania). It follows every board from goods-in to delivery β recording defects, rework and sorting at the work cell, and pricing every material loss in EUR.
TML is not an ERP, an MES or a LIMS. It does not schedule production and it does not hold inventory. And it is not BatchTrace β that is electronic batch records for pharmaceutical and regulated manufacturers, where TML is defect, rework and scrap traceability with the loss costed, for electronics.
Nobody can say what yesterday's scrap cost.
Four gaps repeat in the electronics plants we visit β and all of them start in the same place: the loss is neither attributable nor costed.
The loss lives in a spreadsheet
Material loss is tracked in spreadsheets, or not at all. Nobody can put a number on the cost of a single scrap or rework event.
Defects with no owner
Defects are recorded but not attributable: there is no reliable link to the cell, shift, line, process or operator that produced them. Pareto analysis becomes guesswork.
Scrap declared by whoever is nearest
Scrap is declared by whoever is closest to the board, with no separation at all between declaring, confirming and validating a write-off.
No budget, no alarm
There is no monthly loss budget to measure against. Overruns are discovered after the close, not during the month.
How TML solves it
Capture the loss where it happens, price it the same way every time, and keep the record so it survives an audit.
The operator scans, the form fills itself
Badge-barcode login, a browser-connected serial scanner remembered across sessions, and barcode decoding configured per product type. On boards with a QR code on both faces, the system explicitly prompts the operator to flip the board and scan the second face.
The same formula for every loss
Loss value = (standard price / EUR rate / reference quantity) Γ defective quantity, against a currency table maintained in administration. The result: the numbers from SMT and the numbers from final assembly are directly comparable.
Nothing is overwritten, nothing disappears
All-or-nothing saves, updates that version instead of overwriting (the old row goes inactive, the new one is linked by reference number), soft deletes, and a per-record history showing who changed what and when.
TML does not try to be your ERP or your MES. It is the layer where material loss becomes attributable and costed: every defect has an owner, a cell, a shift, a line, a code and a value in EUR β and updates never overwrite, deletes never remove.
Six interfaces, one per kind of work cell
The cell type determines the interface an operator sees, so each station shows only its own job. Cell type, area and cell are chosen once, and the three lists filter each other and can be filled in any order.
- ICQU β Incoming Quality: defects found on arriving material, with supplier and 4M cause
- QAAS and QAMO β QA Assembly and QA Module; QAMO works piece by piece rather than by lot
- RESO β Rework Sort: splits a lot into OK and NOK after repair, validated against the original quantity
- REWK β Rework: records the components replaced and scans the new component's barcode
- PROD β Production: returns a recovered product to the production flow
Scrap has to be authorised, not just entered
Three ordered stages with three different owners: Scrap (QA operator) β Confirm Scrap (supervisor) β Validate Scrap (quality manager), then Processed in SAP. Nothing can be confirmed before it is declared, and neither flag can be cleared once set.
- Enforced order: no Scrap, no Confirm Scrap; no Confirm Scrap, no Validate Scrap
- Three distinct roles β the operator who declares is not the one who validates
- Flags cannot be cleared: a wrong call is corrected in the open, not quietly
- Returning a product to production explicitly reverses all three flags and moves the whole NOK quantity to OK β visibly, because the loss then leaves the reporting
Where the money went, by month
Daily scrap value in EUR against a projected line and a budget line built from the monthly budget and the working-day calendar. Beside it, a Pareto of defect descriptions with its cumulative percentage curve.
- A budget line from the monthly budget and the working-day calendar, with budget-per-day recalculated automatically
- Pareto with a Top-N selector (default 30) showing "30 / 214", so the month's total is never misread
- Breakdowns by project and by process, with a full scrollable legend
- The active view compares this month to last: OK / scrap / WIP, entries by stage, and the worst part numbers
One measured result and one model, kept apart
The first figure comes from a real deployment. The second is a worked example β and we build it with your plant's numbers.
At Yazaki, TML cut material loss by 60%. The result has held for four years and the system is in daily use.
What the arithmetic looks like for a β¬5M plant
- Plant material throughput
- β¬5.0M / year
- Measurable loss at about 3%
- β¬150K / year
- Recovered with TML at β60%
- up to β¬90K / year
- Typical payback
- within the first year
Example only. The figures in the table above are an illustrative model, not a measured result. We build this table with your real plant numbers in a short scoping session.
Your questions about TML
What you need to know about recording and pricing material loss
TML works with the products you already have
TML records and prices the loss. Three other Share IT Smart products handle what comes before it and what comes after.
BatchTrace
The same idea, a different sector. BatchTrace keeps electronic batch records for pharmaceutical and regulated manufacturers, built around batch release; TML keeps defect, rework and scrap traceability with the loss priced in EUR, for electronics.
Learn MoreJidoka Kanban
Defects interrupt the flow of line supply. Jidoka Kanban gets material to the line at the right moment, and TML shows where that material was lost β on which line, in which shift and at what cost.
Learn MoreFactory Assistant
A Pareto shows where the problem is; it does not fix it. Factory Assistant carries TML's findings into the quality meeting and turns them into owned actions with a deadline, tracked to closure.
Learn MoreFind out what material loss is actually costing you
Not a generic demo. A 20-minute conversation about your areas, your cells and your numbers β and we tell you honestly whether TML fits.