Real-Time Work-in-Progress Tracking in Cigar Manufacturing

In cigar manufacturing, precision and timing are everything. From rolling to packaging, each stage involves dozens of skilled hands and moving parts. Yet, without real-time visibility into what’s happening on the factory floor, managers risk losing control over productivity, materials, and deadlines.

This is where real-time Work-in-Progress (WIP) tracking transforms cigar production into a data-driven process — giving you instant insight into every cigar being made.

The Problem: Blind Spots in Production

Many factories still rely on manual logs, paper tickets, or delayed reports. This leads to:

Missed deadlines due to untracked bottlenecks

Increased waste and rework from unnoticed defects

Difficulty estimating true production capacity

Lack of accountability at the operator or team level

Without real-time information, managers are often reacting to problems after they happen.

The Solution: Real-Time WIP Tracking

A modern Manufacturing Execution System (MES) like CFM provides live visibility of production.
Each cigar in progress — from rolling to aging — is tracked in real time. Operators scan containers or batches at each stage, automatically updating progress in the system.

You can instantly see:

Which products are being rolled right now

Which department has delays

How much tobacco is in use or waiting

Which employee or pair is responsible for each step

Key Benefits

✅ Immediate Control: Detect problems early before they affect the final product.
✅ Reduced Waste: Monitor tobacco and materials in real time.
✅ Improved Planning: Know exactly how much work is pending in each area.
✅ Employee Accountability: Identify performance by station or operator.
✅ Accurate Costs: Track real costs and time spent per cigar or batch.

Example: Santiago Factory Workflow

In a Dominican cigar factory, rolling tables scan each container of cigars as they finish. The next department (pressing, banding, or packaging) receives them immediately — no paperwork, no delay.
Supervisors see progress live on their dashboard and can make quick decisions, like reassigning employees or adjusting production plans.

Conclusion

Real-time WIP tracking brings clarity, speed, and control to cigar production. It replaces guesswork with actionable data — helping factories deliver consistent quality and meet every order on time.

With CFM, you don’t just record what happened — you see it as it happens.