Industrial Process Automation
The Organization is one of the world’s leading manufacturers of safety equipments. The organization is supplying its safety equipments made out of its huge facility situated at Lucknow (Uttar Pradesh) to some of big giants whose field staff is required to undertake risky tasks where they would need body safety. It is one of the most trusted brands for human safety.
The Organization is operating a huge manufacturing facility where almost 100s of workers are working on a single floor for production of the safety equipment. The raw material is being passed through various departments where an individual within a department is scheduled to undertake a set of activity upon the raw material to give it a particular shape. Every individual worker is maintaining the paper job card and gets it updated from the floor manager.
The Organization faced an immense issue in tracking the raw materials and could not account for proper utilization of the raw material. Further, due to manual maintenance of the job card, the system was highly prone to errors and extremely time consuming for the management staff to estimate the wages of the workers. It became more tedious where the Organization has to deal with huge quantity of contractual workers.
Thorough study of the entire process was undertaken at the customer’s site to understand each & every process very minutely. The solution has to be built in such a manner that it should not hamper the production speed of the business. End-to-end process automation was put in place right from issuance of the raw material till the product quality test & packaging. The solution was built utilizing barcoding technology for each and every item which was supposed to result in a single entity product and the workers were issued a Smart Card to maintain their auto job card.
Reduced manual interventions and smooth production resulted in increased productions within the same facility. With auto job card, a huge problem of the management staff that spent days and days on preparing wages for the workers is now done immediately and every worker can check his allocated wage as of the day at anytime. The solution thus increased greater satisfaction amongst the workers and has enabled the management & the floor in-charge to monitor the product quality and strategize the working procedures.