How to Improve Cross-Team Collaboration on the Shop Floor

Manufacturers rely on seamless coordination between departments to deliver high-quality products on time and schedule. Therefore, teams on the shop floor must have access to the same data and be able to communicate in real-time. Improving cross-team collaboration isn’t just about teamwork; it’s about making sure everyone has the same, accurate information when they need it.

Unfortunately, many production environments still operate with data trapped in siloed systems. This includes legacy IBM i (AS400) platforms that were never designed to integrate with modern equipment or cloud-based tools. When these systems can’t communicate, neither can the teams.

Let’s explore how manufacturers like you can enhance communication and foster stronger cross-functional collaboration across operations with the aid of data integration.

The Power of Linking Legacy Systems to Modern Equipment

A major roadblock to collaboration on the shop floor is the lack of integration between legacy IBM i systems and newer tools like ERP platforms, MES solutions, sensors, and production equipment. These systems often store valuable historical and operational data, but that information is difficult to retrieve or use in real-time without integration.

By linking legacy IBM i systems to modern systems and machines using RESTful APIs or JSON-based integrations, manufacturers can unlock:

1. Centralized Dashboards

Everyone, from operators to supervisors, can access the same live data through unified dashboards. This reduces miscommunication and supports better cross-team collaboration by giving everyone a shared view of current production status, inventory, scheduling, and quality metrics.

2. Faster Decision-Making

When updates from machines, inventory, and ERP systems flow freely across departments, teams can respond quickly to issues like equipment failures or material shortages. No more waiting on manual updates or chasing down paper reports.

3. Real-Time Alerts

Smart notifications allow the right teams to act instantly when thresholds are exceeded, production goes off-track, or maintenance is needed. Maintenance, quality, and production teams can coordinate quickly to resolve issues before they grow.

4. Reduced Manual Work

Automated data sharing eliminates time-consuming data entry between systems and reduces the risk of human error. This lets teams focus on production instead of paperwork.

5. Improved Traceability

Data from across systems, including legacy records, can be accessed and audited when needed. That’s crucial for compliance, quality control, and customer service.

Real-World Examples: Why Communication Matters on the Shop Floor

Here are three common scenarios where improving communication with integrated data makes a real difference:

1. Preventing Costly Downtime

• With access: A maintenance supervisor sees real-time alerts from both modern sensors and legacy equipment logs, enabling proactive maintenance before a breakdown occurs.
• Without access: Maintenance teams operate on guesswork or delayed reports. A minor issue gets missed and halts an entire production line, costing thousands in lost output.

2. Accurate Order Fulfillment

• With access: Sales, inventory, and production teams see synchronized data, ensuring the right materials are available to fulfill custom orders on time.
• Without access: Legacy systems contain accurate inventory counts. However, without integration, inventory numbers may be off or production scheduling information may be outdated, leading to production delays and missed shipping deadlines.

3. Faster Quality Control Response

• With access: Quality assurance teams can instantly pull historical production data and specs from the IBM i system to trace the root cause of a defect.
• Without access: It takes hours or days to track down records manually, delaying corrective action and risking customer dissatisfaction.

Kato Integrations: Helping Manufacturers Improve Communication

At Kato Integrations, we understand the challenges manufacturers face when legacy systems don’t speak the same language as modern tools. That’s why we specialize in creating scalable, secure API connections for IBM i (AS400) platforms.

By using RESTful APIs and JSON-based integration with RPG API Express, we help manufacturers:

• Improve communication between departments
• Enable real-time collaboration across the shop floor
• Keep using the systems you trust, without costly replacements
• Build centralized dashboards that give every team the data they need
• Move faster and smarter, with fewer delays and errors

Whether you need to connect IBM i to your MES, ERP, or equipment controllers, our team works closely with your developers, IT, and engineering staff to ensure seamless integration that supports your business goals.

Ready to improve cross-team collaboration and unlock the full potential of your shop floor?

Let’s talk about how Kato Integrations can bridge the gap between your legacy systems and today’s digital manufacturing tools.