WIPPlan & Execute
Order & WIP Management
Sequenced to Plan. Verified by Exception. Execution Without Surprises. Order-first, exception-driven execution that sequences, tracks and governs every order from release to completion, with full auditability.
The challenge
Manufacturers juggle high-mix products, strict regulatory demands and just-in-time schedules. When order execution runs on paper travellers, spreadsheets or disconnected systems, the result is delays, mis-sequencing and compliance risk, with supervisors firefighting instead of managing flow and operators facing unclear priorities. The cost is missed schedules, excess changeovers and reduced customer confidence.
Overview
The LOGICAL SYSTEMS Order & Work-in-Process (WIP) application turns order execution into a governed, real-time process. Built on Inductive Automation's Ignition platform and grounded in ISA-88/95 principles, it sequences, tracks and controls every order from release to completion. Operators control execution directly from the cockpit, while supervisors monitor deviations, SLAs and cycle-time performance as they happen. Suborders, holds and rework are managed with full auditability across continuous, discrete and batch work centres.
Unlike traditional MES modules that blur inventory and execution, WIP stays order-first and exception-driven. Dashboards surface only what needs attention, sequencing intelligence minimises changeover losses, and every confirmation, hold or reject is logged for audit. Native integration with planning, materials, warehouse and genealogy systems keeps production aligned with the wider supply chain, whether WIP runs on a single line or is deployed enterprise-wide.
Typical results
Typical results reported in the WIP datasheet. Results depend on each site's starting point and scope.
Capabilities
What WIP does
Order Modeling & Execution
- Equipment-aware order modelling for discrete routings and batch phases (ISA-88/95 aligned)
- Suborders and partial completions with full parent–child traceability
- Start, pause, resume, stop, confirm, reject, hold and rework actions in the cockpit
- Audit trail enriched with signatures, reason codes and photo/attachment evidence
Sequencing & Campaigns
- Family-based sequencing rules to minimise changeover and allergen loss
- Campaign planning for high-mix and seasonal production runs
- Split, merge or reprioritise orders without losing traceability
- Sequencer dashboard with active rules, changeover matrices and family groups
Material Tracking
- Continuous visibility of quantities in progress, confirmed, rejected and reworked
- Automatic reconciliation of subassemblies across parent–child orders
- Balances tracked against planned values with early deviation warnings
- Material readiness and consumption tracking
Exceptions & Compliance
- Deviation-first dashboards surfacing holds, overruns and rework loops
- Exceptions auto-generate TMS tasks for supervisor review and closure
- SLA compliance and cycle-time references benchmarked against plan
- Immutable execution records supporting audits
Performance & Analytics
- Real-time KPIs for schedule attainment, cycle-time integrity and SLA adherence
- Changeover losses, rework rates and scrap cost attributed per order
- Exception-driven monitoring that reduces supervisor review time
- Management dashboards spanning orders, lines and multi-site roll-ups
Scalability & Integration
- Deployed on Ignition with modular expansion across lines, plants and enterprises
- Native connectivity with APS, MM, WD, WMS, TXG, OEE, CMMS and UNS
- Hybrid support for continuous, discrete and batch work centres
- Secure, role-based access with audit-ready event publishing across the enterprise
Benefits
Why manufacturers choose WIP
Better schedule attainment
A 10-15% improvement in schedule attainment by surfacing and resolving deviations early.
Lower changeover losses
5-10% lower changeover losses through family-based sequencing and campaign logic.
Less supervisor review time
A 20-30% reduction in supervisor review workload thanks to exception-driven monitoring.
Stronger compliance posture
Auditable execution records and governed holds strengthen your compliance posture.
More reliable flow
Flow reliability increases by aligning material readiness, equipment status and sequencing.
Higher customer confidence
On-time, in-sequence and audit-verified order completion raises customer confidence.
Before WIP, order execution at our sites used to be a daily firefight. Now every batch runs in sequence, deviations are flagged instantly, and our teams focus on making product and not chasing down problems.
Ask WIP in plain language
LS Assistant, the AI assistant in every Logical Systems application, answers questions from your live WIP records and shows the sources behind every answer. It keeps learning as your records, work instructions and resolved issues grow, and your data is never used to train AI models.
Answers with sources
Every answer cites the records and work instructions it used.
Your role, your site
It sees only what each user is allowed to see.
Asks before it acts
Every change it proposes needs a person's confirmation and is audited.
18 languages, voice on mobile
Questions, answers and content in your teams' languages.
Integration
Connects to the systems you run
Systems & protocols
- MQTT
- OPC UA
- OPC DA
- REST API (JSON payloads)
- Kafka (via connector)
- Snowflake (via pipeline, data bridge)
Standards
- ISA-88
- ISA-95
Datasheet
Order & WIP Management datasheetWorks with
Related solutions
See WIP in action
Book a demo with our engineers, using scenarios from your own plant.