Wrong labels. Skipped steps. Missing documents. Unresolved quality problems. These aren't operator failures — they're system failures. FloorOps replaces guesswork with guided, enforced, auditable processes on every shift.
Manufacturers lose between 5–15% of revenue to quality failures, rework, and compliance incidents every year. The root cause is almost never the people — it's the lack of a system that makes the right process the only option.
Without a scan-verify step, operators rely on memory and habit. One distracted moment and a whole batch ships with the wrong label — often not caught until the customer finds it.
Paper-based or spreadsheet audits mean findings get logged but never driven to closure. The same non-conformance appears in next year's audit. Customers notice before you do.
When work instructions, PFMEA, and control plans live in shared drives with no version control, operators can't be sure they're following the current process. You can't prove it either.
Customer complaints get acknowledged. A 4C gets filled in. But without a structured, tracked 8D process, the containment action becomes the permanent fix and the problem comes back.
These are not isolated problems. They feed each other. A mislabelled part triggers a customer concern. The concern needs an 8D. The 8D identifies a missing work instruction. The instruction isn't controlled. The process repeats.
FloorOps breaks the cycle by giving you connected tools that make the right process unavoidable at every step.
See How Each Tool HelpsSubscribe to the tools you need today. Add more as you grow. Every tool is designed specifically for manufacturing — not adapted from generic project management software.
Stop labelling errors before they leave the building
Part to Label turns your paper-based or verbal processes into enforced, step-by-step digital workflows. Every operator is guided through barcode scanning, quality checks, and photo capture — in the right order, every time. Wrong scan? The system stops them. Skipped step? It won't advance. Every action is logged with timestamp and clock number.
Turn audit findings into closed actions, not forgotten paperwork
Audit Manager digitises your entire audit programme — 5S, layered process audits (LPA), product audits, system audits, and supplier audits. Build reusable audit templates, schedule audits in advance, capture findings on a tablet, and drive every corrective action to verified closure with email escalation and evidence upload.
Every operator, every shift, working from the same current document
Document Hub gives you a controlled library for all your manufacturing documents — work instructions, control plans, PFMEA, SOPs, drawings, and standards. Documents are versioned, approved through a configurable review workflow, and published to operators on the shop floor. New revision? Old version is instantly superseded. Operators can't accidentally use a document that isn't current.
From customer complaint to verified root cause in days, not months
Quality Concerns is a structured problem-solving platform built around the methodologies your customers demand — 4C, 8D, A3, and PDCA. When a concern is raised (internally or by a customer), the team is guided through containment, root cause analysis, corrective action, and verification. Every step is tracked, timed, and evidenced. No more concerns that drift for weeks without resolution.
These aren't vanity metrics. Every number below came from a live customer deployment — tracked before and after going live with FloorOps tools.
A plastic injection moulding company producing instrument panel components for a major UK automotive OEM was averaging 3 mislabelling incidents per month. Each incident triggered a full vehicle stop-ship notice, costing an average of £4,800 in rework, re-delivery, and customer charges. Their process relied on operators manually checking part numbers against a paper traveller and applying the correct label from a tray of pre-printed labels.
The team built a 5-step workflow in under 2 hours: scan the mould number, scan the part number, perform a quality check on each unit, confirm the label matches, and photograph the finished tray. If the scanned part number didn't match the label being applied, the system halted the operator and raised an immediate supervisor alert. Operators could not advance to the next step until the mismatch was resolved.
"The operators adapted in one shift. The management dashboard meant I could see every inspection in real time from my phone. We haven't had a single mislabelling since go-live."— Operations Manager, West Midlands
An electronics assembly business producing PCBAs for automotive tier 1 customers had received the same corrective action request from their customer audit two years in a row: "demonstrate evidence of an effective layered process audit programme with closed corrective actions." Their existing process involved paper audit sheets that were filed in a folder. Actions were tracked in a shared spreadsheet that nobody was responsible for updating.
The team created three LPA templates (line-level, area manager, senior management) and scheduled 12 audits per month. Findings were raised on-the-floor on a tablet, automatically assigned to the relevant process owner with a deadline, and escalated to senior management if 48 hours passed without an update. For the first time, the quality manager could show an auditor a live dashboard of all open and closed findings with photographic evidence of completion.
"The auditor asked to see our finding closure evidence. I opened my laptop and showed them the dashboard. He said it was the best LPA system he'd seen in a tier 2 supplier."— Quality Manager, Midlands Electronics
A food packaging manufacturer producing printed flexible films ran a BRC audit and received a major non-conformance: operators on two production lines were working from printed work instructions that had been superseded 4 months earlier. The updated versions were on the quality manager's shared drive but had never been physically distributed to the lines. The business faced potential customer delisting if the issue wasn't resolved before the next audit in 90 days.
All controlled documents were uploaded to Document Hub within a week. Each operator was required to acknowledge the current version via their workstation before starting their shift. When a new revision was approved, the old version was instantly removed from operator view and replaced. The system provided a full log of who had read which version on what date — exactly the evidence the auditor needed.
"The auditor asked for evidence that operators were working from current documents. I printed the acknowledgement log. Major NC closed on the spot."— Quality Director, Yorkshire
An automotive injection moulding business supplying door handles to a tier 1 assembler had a recurring cosmetic defect — sink marks on a visible A-surface — that had been the subject of four separate customer concern notices over 18 months. Each time, the team had issued a 4C with a containment action (100% visual inspection). The root cause analysis section was always vague: "process parameters not maintained." The defect always returned within weeks.
When the fifth concern was raised, the quality engineer used the guided 8D workflow for the first time. The platform walked the team through a structured D4 root cause analysis — building a fishbone diagram and running a 5 Why from each bone. The true root cause emerged: the mould temperature controller had a faulty thermocouple that caused ±12°C variation, and the process control plan didn't require the operator to record mould temperature. The corrective actions — replace the thermocouple, update the control plan, add temperature monitoring to the operator checklist — were tracked with evidence to verified closure.
"We'd 'solved' that problem four times before. The 8D process forced us to actually find the cause instead of just containing it. The thermocouple cost £85 to replace. The previous year of rework cost us £28,000."— Quality Engineer, West Midlands
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