Case Study
Built-In Batch Traceability
A global contract development and manufacturing organisation specialising in microfluidic and diagnostic consumables for the life sciences industry.
Client
Schott Minifab
Project Type
Reporting & Traceability DB
Delivered
2026
Location
Victoria
The problem
Overview
Operating in a highly regulated environment, Schott Minifab requires strict control over batch traceability, quality and compliance data across all production processes.
As part of the development of a new automated assembly cell, Schott needed to track lot and batch data across production, maintain traceability between upstream and downstream processes, and generate customer-compliant production reports for each manufacturing lot.
The machine was designed to be deployed in multiple sites with no reliance on existing on-site infrastructure. Because the machine needed to operate independently of that infrastructure, all traceability and reporting capabilities had to travel with it. This created a unique challenge: meeting full customer compliance requirements entirely within a self-contained, portable system.
The solution
What we built
Data Aggregation (Ignition)
- Installed local computer connected directly to machine PLC via network interface
- Reads real-time production data
- Central hub between control and database layers
Custom Database Layer (SQL)
- Stores lot, batch and production metrics
- Enables historical queries of production records
Traceability & Reporting (Ignition)
- Batch data identified via RFID-tagged trays
- Customised production data metrics: lot number, batch numbers, good/bad parts and material flow
- Automatic report generation at lot completion
- Multi-format reports customised as printable PDFs or digital
- Historic reports searchable by date and lot code
What was achieved
Results
End-to-End Traceability
Full visibility of how batches move through production into final assemblies, even when mixed across outputs, with lot numbers, batch numbers, good/bad counts and material flow captured for every product made.
Under 5 minutes
to trace any product’s full geneology
Zero Manual Reporting
Production reports generated automatically upon completion, replacing manual and incomplete tracking with a dataset ready for performance, compliance and audit distribution.
2 hours per run
of manual reporting eliminated
Low Cost, High Value
Delivered without a full MES deployment or changes to existing machine design. The architecture provides a foundation that can evolve into a full MES layer in the future, with no rework required on the control system.
Zero hours
rework of existing control system logic
Working with Cumulus was a really great experience during this project. Josh and the team were highly knowledgeable, responsive, and professional at every stage of the process while also being enthusiastic and fun to work with. Their support during both onsite commissioning and remote troubleshooting was excellent, helping ensure the project progressed smoothly and efficiently. They were proactive in resolving issues and demonstrated a strong understanding of the system and project requirements. We look forward to working with Cumulus again on future projects.
Jeffrey Daly – Automation Engineer, Schott Minifab | Kate Galvin – Project Engineer, Schott Minifab
The bigger picture
Conclusion
This project demonstrates how a targeted, lightweight architecture can solve complex traceability challenges in modern manufacturing environments.
By introducing a SCADA layer and structured data storage, we enabled Schott to capture critical production data, maintain compliance-ready records, and improve operational transparency, all without the cost and complexity of a full MES implementation.
The solution’s minimal infrastructure footprint and simple operator workflow means it can be maintained and extended by the existing team, positioning Schott for further digitalisation as their requirements evolve.
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