Production process monitor, Stores management and Job tracker (Case Study).
In flexible packing and printing industry most of the profit margins depend upon the wastage control. Client agrees to bare certain amount of wastage, keeping production wastage within the agreed limit was big challenge.
Since purchase department is located in Bangalore, they had hard time in maintaining and ordering new stock. They required real time status and data from production plant.
Keeping track on stock level was major challenge.
Huge combination of parameters make a job-spec, for repetitive jobs it was unwanted time-consuming task to create job cards for production. There was serious need for creating job-spec library with respect to clients.
Once the job card is created and issued, it starts appearing on the dashboard of operators of only those processes, which belonging to the sequence though which the job card progresses. Notifying them with new job-cards every day.
Operator use tablet stationed at various places in production floor. Every operator has his own login credential. For given process operator inputs roll from stores or from previous process and logs output roll weight at each process, output rolls number are automatically generated by the system and are passed on to next process for inputting. Operator also logs machine down time and change over time with highly intuitive interface. System calculates over all wastage in each process of sequence from out put and input weight logged by operators. At the end of the sequence dispatch department logs all the rolls or pouches ready for delivery.
Now it required, no time for management to attend client calls and update them about production status on the go. Job card module provides progress bar indicating percentage of completion of job
Now management can see real time production quantity of each process in the sequence.
Real time wastage report gives extra control over the process and help them in maintaining profit margins.
In detail report for each process would capture roll weight, wastage, reason for wastage and operator name.
Successful implementation of above is leading towards further steps of automation using IoT. The data will be captured through QR codes and load cell integrated with the platform. Polymer roll as input to an process comes with QR code encoded with weight, roll-no. and other information from previous process or stores. Out put roll of an process goes out with QR code encoded with roll detail and weight captured by load-cell integrated with cloud platform.