iProTraX (formerly ProTracker)

🚀 Introduction

iProTraX is an AI-powered production tracking system that bridges the gap between rigid ERP systems and the dynamic shop floor.

🇺🇸 English | 🇨🇳 简体中文

🎯 The Problem

In modern high-mix manufacturing, relying solely on heavy ERP systems like SAP or ME POD creates critical operational gaps:

1. System Rigidity: SAP is powerful but inflexible. It cannot adapt quickly to the fluid reality of the shop floor (machine breakdowns, urgent re-prioritization).
2. Data Lag: ME POD data often has a synchronization delay when importing to SAP. This means the "System Truth" (SAP) is often hours behind the "Ground Truth" (Shop Floor).
3. Invisible Steps: Operational steps often get skipped or not recorded in SAP due to complexity, causing orders to appear "stuck" in the wrong status.
4. The "Black Box" Effect: Planners and Supervisors cannot see real-time progress. They rely on:
   • Manual spreadsheets (siloed data).
   • Social media/chat apps for updates (unprofessional, hard to track).
   • Human memory (prone to error).

Result: You cannot precisely schedule manpower or machines because you don't know the actual state of the floor.

iProTraX is not a replacement for SAP. It is the Agile Collaboration Layer that sits between your heavy ERP and your agile teams.

It provides a lightweight, real-time visual interface that:

• Visualizes the Invisible: Tracks the micro-steps and real-time status that SAP misses.
• Empowers "Super Edit": Allows Supervisors to correct data instantly (e.g., bypassing a "stuck" step) without waiting for IT tickets.
• Kiosk Mode: Replaces "asking via WhatsApp" with large, auto-updating shop floor monitors.
• AI-Driven Insights: A built-in AI assistant that analyzes risk and generates reports, replacing manual data crunching.

flowchart TB
 subgraph RigidERP["Rigid ERP"]
        SAP["SAP / ME POD"]
  end
 subgraph DynamicShop["Dynamic Shop Floor"]
        Worker["Mobile Worker (Frontline)"]
        Kiosk["Kiosk Display (Dashboard)"]
  end
 subgraph AgileCore["Agile Collaboration Layer"]
        App["iProTraX Core"]
        Scheduler["Smart Scheduler
        (Autopilot / Auto-Flow)"]
        DB[("Real-time DB")]
        AI["AI Copilot (DeepSeek/GPT)"]
  end
 subgraph DecisionMakers["Decision Makers"]
        Supervisor["Supervisor"]
        Admin["Admin"]
  end
    SAP -- "1. Auto-Import Orders" --> App
    Worker -- "2. Track Time & Output" --> App
    App -- "3. Live Progress & Efficiency" --> Kiosk
    App <--> DB
    App <--> AI
    AI -- "4. Bottleneck Analysis" --> Supervisor
    App -- "5. Efficiency Reports" --> Supervisor
    App -.->|Webhooks| ExternalApps["External Apps (DingTalk/Slack/Telegram)"]
    Supervisor -- "6. Autopilot Planning" --> Scheduler
    Scheduler -- "7. Optimized Schedule" --> App
    Supervisor -- "8. Shift Planning" --> Worker
    Worker -- "9. Smart Comments" --> Supervisor
    App -- "10. Audit Logs" --> Admin
    Supervisor -. "11. Reconciliation" .-> SAP
    ExternalApps -- "12. Query/Update" --> App
    
     SAP:::sap
     Worker:::shop
     Kiosk:::shop
     App:::core
     Scheduler:::ai
     DB:::core
     AI:::ai
     Supervisor:::manage
     Admin:::manage
     ExternalApps:::core
     
    classDef sap fill:#1e3a8a,stroke:#333,stroke-width:2px,color:white
    classDef core fill:#4f46e5,stroke:#333,stroke-width:2px,color:white
    classDef shop fill:#f59e0b,stroke:#333,stroke-width:2px,color:black
    classDef manage fill:#059669,stroke:#333,stroke-width:2px,color:white
    classDef ai fill:#db2777,stroke:#333,stroke-width:2px,color:white

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---

🚀 Quick Start

1. Install Dependencies

npm install

2. Configure Environment Variables

Add your OpenAI API Key to the .env file:

OPENAI_API_KEY=sk-your-api-key-here
LICENSE_KEY=your-license-key-here  # Optional: Leave empty for Free Tier (1 Line, 10 Users)

3. Start Development Server

npm run dev

Visit http://localhost:3001

4. Default Credentials

After the initial deployment, use the following credentials to access the SuperAdmin account:

• Employee ID (UserID): SUPER001
• Default Password: superadmin123

Important

For security, it is highly recommended to change this password immediately after your first login via the User Management settings.

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✨ Key Capabilities

1. 🖥️ Shop Floor Kiosk (The "Control Tower")

• Purpose: Replaces social media updates. A passive, always-on monitor for the floor.
• Features:
  • Auto-Scroll & Refresh: No mouse needed. Cycles through active orders.
  • Visual Priority: Color-coded status (WIP, HOLD, QN) for instant awareness.
  • Privacy & Security: Locked down mode with password-protected admin access.

2. ✏️ Super Edit Mode (Agile Correction)

• Purpose: Fix "SAP Lag" and "Missing Steps" instantly.
• Features:
  • Direct Manipulation: Supervisors can "force" a step to complete or correction data directly in the UI.
  • Optimistic UI: No waiting for server round-trips; changes feel instant.
  • Audit Trail: Every change is logged, ensuring accountability while allowing flexibility.

3. 🤖 AI Copilot (The "Digital Planner")

• Purpose: Augment human decision making.
• Features:
  • Risk Analysis: "Which orders are stuck in WIP for >24h?"
  • Context Aware: Knows your specific product lines and terminology. Supports DeepSeek (China).
  • Smart Comments: Tracks discussions per-step, allowing precise problem-solving directly in the flow.
  • Zero-Wait Auto-Flow: Automatically schedules the next step immediately upon completion, minimizing idle time (Pull System).

4. ⏱️ Productivity Engine (Efficiency Loop)

• Purpose: Quantify worker output and efficiency, eliminating guesswork.
• Features:
  • Active Session Cards: Integrated view for workers with live timer, progress bar, and standard time (Std) reference.
  • Compact Stop: One-click quick stop with strict quantity validation/limits.
  • Standard Time Mgmt: Admin configurable standard times (HH:MM) and target quantities per step.
  • Efficiency Analytics: Supervisor-exclusive dashboard showing daily output heatmaps and efficiency rankings.

5. ⚡ Real-time Engine (Redis)

• Purpose: Zero-latency collaboration.
• Features:
  • Instant Sync: Updates appear on all screens (Kiosk, Dashboard) effectively instantly (<50ms).
  • No Polling: Replaced old "refresh every minute" mechanism with efficient Server-Sent Events.

6. 🔔 Real-time Notifications (Webhook)

• Purpose: Keep stakeholders informed without checking the dashboard.
• Features:
  • Multi-Channel: Built-in support for DingTalk, WeCom, Feishu, Slack, Telegram, Discord, Bark and more.
  • Smart Triggers: Alert Supervisors on Hold/QN, notify Planners on Done, and send Daily Morning Reports.
  • Dynamic Config: Customize payloads, headers, and endpoints for any system integration.

7. 🔌 External REST API v1

• Purpose: Securely integrate with other factory systems (MES, WMS, BI).
• Features:
  • Management UI: Create and revoke API keys with granular permissions (e.g., orders:read, reports:read).
  • Bearer Auth: Standardized token-based authentication for secure machine-to-machine access.
  • Comprehensive Docs: Built-in testing guide for rapid integration.

---

🛠️ Technology Stack

flowchart TB
    subgraph Client ["Frontend (Next.js 16)"]
        UI[React 19 UI]
        TW[Tailwind CSS v4]
        Icon[Lucide Icons]
        Chart[Recharts]
    end

    subgraph Server ["Backend Services"]
        API[Next.js API Routes]
        Scheduler["Smart Scheduler
        (Weighted / Auto-Flow)"]
        Watcher[Chokidar File Watcher]
        Prisma[Prisma ORM]
    end

    subgraph Data ["Data Persistence"]
        Postgres[(PostgreSQL Database)]
        Redis[(Redis Pub/Sub)]
        Excel["Excel Files (.xlsx)"]
        ApiKeyStore["ApiKey Store (Encrypted)"]
    end

    subgraph AI ["Intelligence"]
        OpenAI["OpenAI / DeepSeek / Ollama"]
    end

    %% Connections
    UI --> API
    API --> Prisma
    API --> Scheduler
    Scheduler --> Prisma
    Prisma --> Postgres
    API --> Redis
    Prisma --> ApiKeyStore
    Watcher -->|Auto-Import| Excel
    Watcher -->|Write| Prisma
    API -->|Context| OpenAI
    OpenAI -->|Analysis| API

    %% Styling
    classDef fe fill:#e0f2fe,stroke:#0284c7,color:#0c4a6e;
    classDef be fill:#dcfce7,stroke:#16a34a,color:#14532d;
    classDef db fill:#f3e8ff,stroke:#9333ea,color:#581c87;
    classDef ai fill:#fee2e2,stroke:#dc2626,color:#7f1d1d;

    class UI,TW,Icon,Chart fe;
    class API,Watcher,Prisma,Scheduler be;
    class SQLite,Excel,Postgres,Redis,ApiKeyStore db;
    class OpenAI ai;

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🔒 Security & Management

• Role-Based Access: Strict separation between Admin, Supervisor, User, and Kiosk roles.
• Log Management: Full CSV export capabilities for post-mortem analysis.

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Visual Experience

1. The Gateway (Login)

Stunning dark-themed login portal with the new v8.0.0 branding featuring internationalization support.

2. The Command Center (Dashboard)

Comprehensive production data grid with detailed management controls.

3. The Control Tower (Kiosk Mode)

Optimized for large screens, this view aligns data perfectly for shop floor visibility.

4. The AI Assistant (Production Copilot)

Real-time risk analysis and data insights powered by LLMs.

5. The Frontline (Mobile Worker View)

Simplified, touch-friendly interface for operators on the floor.

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DEMO

• Live App: https://protracker.puppy101.dpdns.org/
• Showcase & Docs: https://iprotrax.work Contact author for access: contact@iprotrax.work

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📝 Changelog highlights

• v8.2.0: Smart Scheduler 2.0 - "Zero-Wait" Auto-Flow feature, Simplified priority logic (Red Bonus/+1000) and optimized default weights (50/50). Dashboard - Enhanced sorting (Red > Yellow > Date). Operation UI - Improved target quantity display in header. Batch Edit stability fixes.
• v8.1.0: Security Upgrade - Implementing ES256 hardware-backed signing (YubiKey) for licenses. Free Tier - Now supports permanent free use for small teams (1 Line, 10 Users). Productivity Engine - "Active Sessions" card, Real-time Efficiency, Quick Stop.
• v8.0.0: Enterprise Edition - Full internationalization (English/Chinese), enhanced security (session encryption), comprehensive testing framework (Vitest/Playwright), performance optimizations, and improved Docker deployment automation.
• v7.0.0: Smart Comments (Order-level Collaboration), Configurable AI Visibility, Enhanced AI Privacy (Strict ID mode), Supervisor Excel Import, and Multi-tier Employee Cooperation.
• v6.5.0: Docker Production Support (Node 22, Fixed Watcher, CVE Remediation).
• v6.4.0: Added Order Deletion & Kiosk Alignment fixes.
• v6.3.0: Introduced Super Edit Mode.
• v6.1.0: Launched Professional Kiosk Mode.

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🛡️ License & Community

📈 Git Trend