Shop Floor Automation

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About Client

Our client, an ISO 9001:2015 certified, is a leading integrated, value-added solutions provider for infrastructure, industrial packaging and specialty chemicals for water treatment. The company is a one-stop destination for its customers’ infrastructure needs in the value-added, science-led sustainable manufacturing supply chain. Their Specialty Chemicals division manufactures and supplies water treatment chemicals to various industries.

The Challenge

The client’s shop floor operations data had to be measured in real-time, including the machine and labour data. The manufacturing plant managers were accessing the machine and operator data manually. Measuring the overall production efficiency and preventing downtime was challenging. Lack real-time data led to increased overhead, production cost and low productivity rate. This was hindering their growth and beating the brimming competition. Simply put, the client was looking for a “connected factory” to improve their overall efficiency.

Key Results

Dinamalar is the third largest Tamil daily newspaper by circulation (Over 900,000), printed from across 10 cities. With over 100 photographers spread across the country, they had a robust capability to supplement news with images. To sustain their competitive edge in a cut throat market, they created an exclusive, secure portal for photographers to upload their images. But, in the age of the mobile and ‘breaking news’ it was not enough.

Our Approach

Our team of experts visited the plant. Understanding the challenge, we started working on a solution that would help the plant managers to track, monitor and measure the machine performance. The challenge for our experts was to develop a solution (coupled with IoT, Mobile App, Web App) that should not only provide managers with real-time data but also enabled them to measure labour efficiency and improve production quality & performance.
Arriving at a one-stop solution to track end to end the material’s journey through the Yard and the site.
Developing a technology solution that’s easy to use in a construction site scenario
Evolving business requirements and short timelines

Our Solution

We proposed an industry 4.0 solution for digitizing the shop floor operations. The IoT device was implemented in selected machines to capture the real-time data. The data was used to improve the maintenance cycles of the machines, which furthered efficiency. The operators had a mobile app to access the machine data on-the-go and this was pushed to the Private Cloud of the client. The solution also enabled the managers to look into the labour efficiency and day-to-day machine performance using a web dashboard instantly. This helped the Manufacturing leader save, time and money.


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The Impact

30% Reduction in overhead, labour and production cost
Improved production rate
Improved production quality
Seamless preventive maintenance

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