A plastic extrusion (plastic film - roll form) manufacturer I am working for, receives orders from his clients in the following manner:

100 000 lbs of film A103, thickness 0.00125

Upon creating a work order with a unique production control number (or work order no), the above order becomes the following for the operators on the plant floor:

Order Qty: 100 000 lbs
No of Rolls to producs: 1000
Weight per Roll: 100 lbs
Film: A103 Blend Code: C402 B2
Gauge: 1.25 MIL
Extruder/Machine/Line: 103
Extruder Running Speed: 300 ft/ minute
...and so on

*** Note, the company I am consulting has 11 extruder/production lines , and only 4 computer workstations, and 3 weigh stations ***

I need some advice for the following scenario during production and weighing:

I need to register all rolls produced for any given production run.

In order to accomplish this I force the operators to print a label (production number and roll number ID) from one of the 4 workstations on the plant, which they must stick on the finished roll, as it is released from the extruder.

With this discipline, the program also adds a date & time stamp to every new roll line in the table.

In the above example if the job is started at 10:00 and it takes 5 minutes to produce each roll, the program registers the follwong information for each roll, coming off the extruder, upon printing the label:

Roll Number ID Time
-------------- --------
roll 1 @ 10:05 am,
roll 2 @ 10:10 am,
...
roll 100 @ 6:20 pm

If any roll is rejected due to non-comformity the operator MUST go the the workstation again after a quality inspection, select the particular production control number, find the Roll ID entry (from a grid list) and change the status to "Rejected", and selecting a valid reason.

Next all rolls, "Rejected" and "Accepted", move on to a Weigh station. Each roll is individually placed on the electronic scale and the operator using hand held barcode scanner, scans the label (already on the roll). The application automatically finds the roll in the table and updates the weight from the reading it gets from the scale device. Unique roll is identified by Production Control Number + Roll Number ID

The owners of the company do NOT like the fact that the operators must, attend the workstation so frequently to:
(1) to produce a label as the rolls are produced,
(2) to go back to change the status of the roll" to "Rejected", especially since the like I mentioned, there are 11 production runs at the same time, only 4 workstations and 4 label printers.
(3) They might have to go again, to enter QC data for the rolls that are inspected.

In the above example the operator must go 100 times to the workstation.
If the rolls are coming off 2 at a time, they must visit the station 50 times.

They do like the fact that every roll produced, rejected or accepted is accounted for.

Is there another way to achieve the above results (account for all rolls) without all the trouble to the operators?

Registering a date & time stamp for each roll is NOT mandatory and might not be required, since I already register the running speed of the machine, and the start and end time of the production for any job as a whole. Using a formula I can estimate very closely the production time of each roll!

What is very important is that I have an exact count of all the rolls produced, so the production controllers are aware of them, and the weigh station operator has to get the weights for each and every roll?