Across UK and Irish manufacturing, most plants still run critical production, quality, and logistics processes on a mix of paper, spreadsheets, and manual reports. In a year where competitors are investing in smart factories and real-time analytics, that approach is no longer sustainable.
This blueprint shows how an operations leader can move from paper and Excel to real-time manufacturing dashboards in roughly 90 days, without replacing existing ERP or core systems.
Why paper and Excel are quietly killing performance
Paper and spreadsheets feel flexible, but they create invisible losses every day. Common symptoms include:
- No single version of the truth – each manager has their own sheet and numbers
- Lagging reports – last week’s performance is reviewed this week, when it is too late to act
- Manual data entry – operators and supervisors copying figures between systems, introducing errors
Real-time manufacturing dashboards are a key 2025 trend because they eliminate this lag and provide a live view of throughput, OEE, quality, and on-time delivery in one place. The good news is that you do not have to rebuild everything to get there – you can layer a platform like WrxFlo on top of what you have.
Days 0–30: Discover, map, and connect your data
The first month is about understanding where data lives and how it flows – not about buying new machines. In this phase, a typical WrxFlo project will:
- Map critical value streams (for example, order to ship, or cast to pack) and the key KPIs for each
- Identify current data sources – ERP, MES, machines, barcode scanners, manual logs, spreadsheets
- Establish secure connections to these sources via APIs, databases, or lightweight edge connectors
By the end of this phase, leaders have a clear picture of how data currently moves, where it gets stuck, and which signals matter most for decision-making.
Days 31–60: Build real-time dashboards for one pilot area
The second month focuses on one high-impact pilot area – a specific line, plant, or logistics process where better visibility will quickly pay back. Using WrxFlo’s unified data layer, the team will:
- Clean and align data from multiple systems so part numbers, orders, and timestamps match
- Design role-based dashboards for operators, supervisors, and leadership
- Configure alerts for deviations – for example, unplanned downtime, missed takt time, or late loads
Modern real-time dashboards consolidate dozens of machine and process signals into a single, always-on view that operators can act on immediately. This is where teams often see early wins such as reduced changeover times, fewer stockouts, and faster response to breakdowns.
Days 61–90: Scale, standardise, and embed into daily routines
The final phase is about making dashboards part of “how we run the plant”, not just a side project. With the pilot proven, WrxFlo dashboards can be rolled out to additional lines, shifts, or sites while standardising KPIs and views across the business.
Key actions in this period:
- Extend connectors and dashboards to more assets and processes, using the same data model
- Embed daily stand-ups and weekly performance reviews around live dashboards instead of static reports
- Train supervisors and team leaders to use alerts, drill-downs, and historical trends for continuous improvement
By day 90, many manufacturers move from fragmented, after-the-fact reporting to a culture where performance is monitored and improved in real time. Leaders can see plant status from anywhere, compare sites, and link operational performance directly to financial outcomes.
Why operations leaders cannot wait beyond 2025
Industry reports show that most manufacturers are investing in ERP modernisation, AI, and real-time analytics to drive productivity, resilience, and sustainability. Those who remain stuck in paper and Excel will struggle to compete on cost, lead time, and customer service as the bar rises.
For operations leaders, the question is not whether to move to real-time dashboards, but how quickly you can do it with minimal risk. A 90-day blueprint using a platform like WrxFlo – layered on top of SAP, Oracle, and your existing shop-floor systems – is a practical, low-risk way to step into smart manufacturing and give your teams the live visibility they need to deliver.
