Optimizing MES: Shop Floor Insight for Dynamics 365 Business Central

Introduction

Today’s session covers manufacturing execution and how Insight Works can help in the Business Central environment. The focus is on Shop Floor Insight, with most of the time spent in a live demo. Questions are welcome throughout via the GoToWebinar panel, and the session runs approximately one hour.

About Insight Works

Insight Works has been around for just over ten years, with a large catalog of applications focused primarily on manufacturing and distribution, as well as retail solutions. The core value proposition is physical inventory: warehousing, manufacturing, and the sale of physical products.

Free Apps and Add-Ons

A significant number of Insight Works apps are free. Add-ons are available through the add-on catalog in Business Central. For manufacturing specifically, the following free apps are worth highlighting.

The Enhanced Planning Pack includes the Enhanced Planning Worksheet and Enhanced Forecasting Worksheet. This is a completely free app from Insight Works for Business Central. The Enhanced Planning Worksheet provides a better user interface for planning, saving time when reviewing messages. It also includes purchase planning logic that is meaningfully better than the standard Business Central functionality for warehouse operations and min-max purchasing.

The Graphical Scheduler is also free. Out of the box it displays production orders, but it can be configured to show workload, colors, and other production environment details. Drag and drop scheduling is supported, and the tool is fully configurable.

Doc Extender provides drag-and-drop document management, storing files in SharePoint in a human-navigable folder structure. In a manufacturing context, drawings can be dragged onto an item card or into a production order and made available directly on the shop floor.

Order Ship Express generates shipping labels for domestic parcel shipments from within Business Central, including real-time tracking numbers and cost. For LTL, international, or multi-carrier rate shopping, the Dynamic Ship product handles those scenarios.

WMS Express supports receiving, picking, shipping, inventory counts, and bin movements from handheld devices. In a manufacturing environment it can be used to receive components, pick or ship finished goods, and count the parts room. It installs quickly and enables barcoding inside Business Central. Notably, text on a label can be scanned as quickly as a barcode, so full product barcoding is not a prerequisite for automated data collection.

What Is MES?

MES, or manufacturing execution system, is a broad term. Anything that helps execute production activities qualifies. The range of capabilities is wide, from fully automated IoT approaches reading from PLCs to more manual methods. For the purposes of this session, MES is framed in three stages: planning, scheduling, and execution. These form a feedback loop: as execution happens, the schedule is updated, and the cycle continues.

Manufacturing Workflow in Business Central

The full workflow begins with the Enhanced Planning Pack for forecasting and production planning, then moves to scheduling. Two scheduling options are available. The Graphical Scheduler handles manual drag-and-drop scheduling and is a good fit for lower-volume environments. For higher-volume environments, APS (Advanced Planning and Scheduling) generates a schedule automatically by considering capacities, labor availability, material availability, floor space, and tooling. It can run on a schedule, such as every morning at 7 a.m., or on demand. The result is a schedule that can actually be executed on the shop floor.

Once the schedule is built, Shop Floor Insight handles the execution layer. It captures time against production orders (including setup and runtime), consumption and output, and quality entries. Non-productive tasks, such as toolbox meetings, can also be recorded. All of this data flows back into Business Central in real time and can be used to compare actuals against expected times, validate costing, and support OEE reporting.

After production is complete, Warehouse Insight or WMS Express handles fulfillment activities, and Dynamic Ship manages outbound shipping for parcel, LTL, and FTL scenarios.

Shop Floor Insight Capabilities

Barcoded data collection is the core of Shop Floor Insight. The goal is to make data entry as simple as possible for operators — ideally two scans and done. Mobile interfaces and touchscreen entry are also available for cases where scanning is not practical.

Additional capabilities include quality inspections, time and attendance with payroll integration, overtime and double-time calculation, and shift scheduling with alerts for missed or unscheduled shifts. Payroll integration is typically delivered as a text file, with API integration available where the payroll system supports it.

Deployment Options

The most common deployment is a fixed terminal, or kiosk, on the shop floor. These can be shared among several operators or dedicated to a single machine or workstation. Fixed terminals are often preferable to mobile devices in manufacturing environments because mobile devices tend to go missing. There is no limit on the number of terminals.

The kiosk interface runs in a web browser. Old Windows 10 laptops work, and Chromebooks are a popular choice given their low cost, lack of moving fans, and easy replacement. A USB barcode scanner is all that is needed to add scanning capability. Tablets and phones are also supported.

In addition to the web interface, there is a mobile interface that runs directly in Business Central, suitable for field service and project-based work. There is also a Warehouse Insight interface, which runs as a Windows or Android application and is ideal when built-in barcode scanners or tablets are already in use.

Communication Hub

Whether running on Business Central Cloud or on-premises, Shop Floor Insight requires a small application running on a local Windows machine. This communication hub is the only component that speaks to Business Central. Shop floor terminals communicate with the hub rather than directly with the internet, which improves security — terminals on the shop floor do not need internet access. All security is managed from one location, and operators do not need to log in individually at each terminal. The hub can also be hosted on Azure if a fully cloud deployment is required, though an on-premises installation is simpler and is the recommended approach.

Demo: Kiosk Interface

The kiosk interface runs in a web browser. When an operator arrives, they scan their ID badge to identify themselves and clock in. The system connects to Business Central in real time and displays the operator’s time card. On a first clock-in, the time card is empty. The operator then scans a barcode for the production order they are starting. That single scan pulls in the production order number, line number, operation, and other details. The work center can be updated by scanning a different work center barcode if needed.

When the operator moves to a different activity, they scan the next barcode. If it is a non-productive code, such as a cleaning task, the system automatically clocks them off the prior operation and begins recording the new activity. Units of measure for time (minutes, hours, days) can be configured per station, user, or work center.

This data provides labor traceability alongside the material traceability that manufacturers already track. If warranty or quality issues arise, it is possible to trace back exactly who performed a given operation and when.

Multiple Concurrent Production Orders

Three approaches are available for operators working on multiple production orders at once. First, orders can be clocked on and off independently and managed separately. Second, autosplitter batching allows an operator to scan a batch of production orders at the start of a task and clock off once at the end. The elapsed time is then split proportionally across all orders based on quantity or expected time. Third, orders can simply run concurrently, with the operator manually clocking each one off as needed — this is the behavior for users configured to allow concurrent activities.

Multiple operators can also be clocked on to the same production order simultaneously. Time can be tracked at the individual, group, or work center level depending on the level of detail required.

Dispatch List

For operators not using barcode scanning, the dispatch list provides a touch-friendly view of available work. Operators can search by production order number or description, or simply tap an order and select clock on. The dispatch list can be filtered to show only work scheduled for a specific workstation or work center, and the columns and assignments can be configured per employee or station. A dispatch list for projects is also available.

Each user’s interface can be configured independently. One operator might see work instructions and an image, while another sees a different column layout. Configuration is handled within Business Central and can be set by person, station, or group.

Consumption, Output, and Quality

From within an active operation, operators can access the bill of materials to record point-of-use consumption, including serial numbers and lot numbers. This is particularly useful for assembly operations where specific serialized items need to be tracked. Scrap quantities can also be recorded here.

Output can be recorded with serial numbers, lot numbers, and scrap codes. Quality inspections can be triggered at the time of output. Output to license plates is also supported for integration with Warehouse Insight.

Work instructions come from the operation comments or from the production order header. Document links can supplement work instructions. Using Doc Extender, a drawing dragged onto an item card becomes available to the operator directly from the shop floor view. Document access is permission-dependent.

Quality inspections are powered by the Quality Inspector module. They function as configurable entry forms tied to a specific operation, allowing operators to record any additional detail required — measurements, lot numbers, pass/fail results, and more. Failed inspections can trigger downstream actions through Business Central workflows or Power Automate.

It is worth noting that Business Central now includes a Quality Management module, which was licensed from Insight Works. The standard Quality Management module does not integrate with Shop Floor Insight. Only the Insight Works Quality Inspector module integrates with Shop Floor Insight at this time.

Rework Tracking

Rework can be tracked directly within Shop Floor Insight. Scanning a rework barcode flags any subsequent time on that operation as rework and prompts for a root cause code. These codes are fully configurable. Capturing rework time is important because rework carries a cost well beyond the time of the redo itself — it includes the time spent on the initial defective work, lost productivity, QC time, and material handling. Shop Floor Insight makes it straightforward to capture this data consistently.

Project Time

Project time can be captured using the same interface as production order time. The process is identical from the operator’s perspective; the entry is simply flagged as a job or project rather than a production order. Fixed asset, service order, and non-productive time are also supported.

Demo: Mobile and Warehouse Insight Interfaces

The mobile interface runs in the Business Central mobile app on a phone or handheld scanner. It displays the time card, supports swipe-to-clock-on and clock-off, and provides access to work instructions, bill of materials, output recording, and project time. It is well suited to field service scenarios where operators are mobile.

The Warehouse Insight interface runs as a Windows or Android application and includes the full Shop Floor Insight feature set. It is highly configurable directly from within Business Central using the Warehouse Insight application designer — menus, colors, fact boxes, and layouts can all be adjusted without code. This interface also supports barcode scanning. Maintenance activities can be included in the dispatch list through the Maintenance Manager solution, which integrates directly with Shop Floor Insight.

Time Cards in Business Central

All shop floor activity flows into Business Central in real time. Time cards are visible to engineers, production planners, and supervisors without requiring anyone to go to the shop floor. Drilling into a production order’s routing shows accumulated time per operation, who performed the work, and when. Rework entries are flagged and attributed to the recorded root cause.

For salaried or office staff, time can be entered directly in Business Central using the time card interface.

Reporting and Analysis

The built-in analysis view in Business Central can be used to create ad hoc reports against shop floor data — equipment utilization by work center, rework time by root cause, average hours per employee by week, and so on. The Enhanced Planning Pack includes a production analysis and routing analysis for examining variance and process variability.

Standard dashboards are also available, including base Business Central manufacturing dashboards that work well with Shop Floor Insight data. Insight Works also provides dashboards for productivity analysis (productive versus non-productive time), activity code reporting, and time and attendance breakdowns including overtime versus regular time. Power BI dashboards can be built on the underlying data as well.

Time Card Approvals

Time card approvals are optional in practice, though time cards do need to be approved before posting. Approval can be automated if desired. The typical workflow has a supervisor reviewing the time cards for their direct reports at the end of a shift. The approval view shows all time cards and flags any that have validation errors in red. Configurable validations can check for things like missing setup time, missing runtime, or output quantities that exceed expected values. A supervisor can correct errors directly in this view, revalidate, and then approve all cards in bulk. For a team of ten, this typically takes three to four minutes.

Project-based approvals are also available. A project manager can review time entered against their project regardless of whether those employees report to them, and can determine billability or reassign time to a different project task.

Graphical Scheduler

The Graphical Scheduler is free and provides a visual view of the production schedule. Colors, workload overlays, and views are fully configurable. Color coding can reflect status — late, in progress, complete — providing real-time feedback from the shop floor. Drag and drop rescheduling updates all related operations automatically.

For environments that require automated scheduling, the APS (Advanced Planning and Scheduling) solution generates schedules automatically and eliminates the need for manual drag and drop. Videos covering both the Graphical Scheduler and APS are available on the Insight Works YouTube channel.

Pricing and Implementation

Shop Floor Insight is licensed per employee, ranging from just under three dollars to just over seven dollars per month depending on the number of licensed employees. Licensing only covers employees who will be recording time by name. Work centers or machine centers can be used as the “employee” if individual traceability is not required, and two employees can share a single login if needed — though this sacrifices individual labor traceability.

For terminal licenses, each terminal requires either a team member license (which does not allow posting consumption or output) or a device license (which does). Device licenses are concurrent, meaning ten terminals that are never all active simultaneously would only require licenses equal to the peak concurrent usage.

Implementation is available at a fixed price, covering setup, user acceptance testing, and go-live support. Partners can also handle implementation. Hardware costs depend on the approach: existing laptops can be repurposed, or new Chromebooks can be added for a few hundred dollars per terminal.

An ROI calculator is available on the website and as an Excel file on request. In most scenarios, the payback period for Shop Floor Insight compared to manual time tracking is measured in months.

Questions and Answers

Q: Where are things like work instructions and other data stored?

A: Everything is stored inside Business Central. There is no separate database. Work instructions come from the operation comments or the production order header comments.

Q: Can Shop Floor Insight be used for professional services or project-based work?

A: Yes. Time can be entered against projects, service orders, production orders, fixed assets, and non-productive time. Engineers and similar staff often enter time against production orders or projects directly within Business Central using the time card interface.

Q: Where do the barcodes come from?

A: Barcodes are generated from Business Central using the reports included with Shop Floor Insight. The employee badge and traveler barcodes use the Insight Works barcode generator tool. For item labels, the barcode generator is a reasonable starting point, though there are many ways to print barcodes from Business Central.

Q: Can the interface be customized?

A: Yes. The web interface is built in HTML and JavaScript, and the source code for the communication service is accessible, so tenant-level customizations are possible. Custom buttons can also be added directly from within Business Central by creating workflows that define the button behavior — those buttons will automatically appear in the interface.

Q: Can operators clock in as a work center instead of an individual?

A: Yes. Time can be recorded at the individual, group, or work center and machine center level. A supervisor can clock in on behalf of a group of people. If individual labor traceability is not a requirement, clocking in as a work center is a valid approach.

Q: Can operators be clocked on to multiple jobs at the same time?

A: Yes. Concurrent clock-on is supported. Operators can manage orders independently, use autosplitter batching to split time proportionally at clock-off, or simply run multiple orders concurrently and clock each off manually.

Q: How does the communication between terminals and Business Central work?

A: All terminals communicate with a local communication hub, which is the only component that talks to Business Central. Terminals do not need internet access. For technical questions beyond this, the Insight Works support team can assist.

Q: Is there support for Chinese language?

A: There is a translation tool for the Shop Floor Insight web client and for Warehouse Insight, and some translations exist. Chinese is not believed to be available as a translation today.

Q: Can the dispatch list be filtered to show only relevant work?

A: Yes. Filters are set within Business Central and can be configured per workstation. For example, when an operator scans in at the assembly table, they can be shown only work scheduled for assembly within the next day or whatever timeframe is appropriate.