Vibe Coding and LEAN Manufacturing

🧠 Overview

This project began as a simple RFID test and evolved into a lightweight machine usage tracking system designed for LEAN manufacturing environments. The goal was to create a no-frills tool that captures real machine runtime data without adding complexity to the shop floor.

🎯 Objective

Develop a simple, reliable system to:

• Track machine start and stop events
• Record accurate runtime durations
• Provide clear, real-time feedback to operators
• Support LEAN principles by exposing inefficiencies

🛠 Tools & Technologies

• ESP32 microcontroller
• MFRC522 RFID reader
• ST7789 TFT display
• MQTT (for data transmission)
• NTP (for timestamp synchronization)
• Arduino IDE / C++
• Python (for data logging and CSV generation)

⚙️ Process

1. Initial Concept

The project started as a basic RFID reader test to detect user input and trigger events.

2. Workflow Expansion

Functionality was expanded to include:

• Machine start/stop logging via RFID scans
• Timestamp recording using NTP
• Prevention of conflicting inputs during active jobs

3. Real-Time Feedback

• Integrated a TFT display to show:
  • Active job status
  • Start time
  • Elapsed runtime counter
• Designed the interface for quick readability on the shop floor

4. Data Transmission

• Implemented MQTT to send scan and timing data
• Developed a Python-based receiver to log data into structured CSV files

5. Iteration & Refinement

• Adjusted logic to ensure accurate runtime tracking
• Improved display clarity and usability
• Debugged SPI conflicts between RFID reader and display

🚧 Challenges & Solutions

Challenge: Managing multiple SPI devices (RFID + display)
Solution: Configured shared SPI bus with proper chip select handling and timing adjustments

Challenge: Ensuring accurate and consistent timestamps
Solution: Integrated NTP synchronization to standardize time across sessions

Challenge: Preventing incorrect or duplicate scans during operation
Solution: Implemented logic to lock input to the active RFID tag until the job is completed

Challenge: Keeping the interface usable in a fast-paced environment
Solution: Focused on minimal, high-contrast display output with only essential information

📊 Results / Outcome

• Functional machine tracking system with start/stop logging
• Real-time runtime display visible to operators
• Automated data logging for later analysis
• Reduced ambiguity in machine usage tracking

🔄 Improvements / Next Steps

• Add multi-machine support
• Develop a web dashboard for data visualization
• Integrate downtime categorization (planned vs unplanned)
• Expand analytics for OEE (Overall Equipment Effectiveness)

📸 Visuals

💭 Takeaways

LEAN manufacturing is not about adding more systems—it is about removing friction and making the important data visible.

This project reinforced the value of building tools that are:

• Simple to use
• Focused on real problems
• Designed for the people actually doing the work

Even a small, well-targeted system can create meaningful visibility into process inefficiencies.