What is the Thing about Internet of Things

The Thing in the ‘Internet of Things’ could be an asset, a person or a key process parameter, that a Production Manager would want to measure and improve……..

Production Line Enabling

As a Production Manager you may have one or more of these Problems

  • Improving Process Efficiency by reducing TAKT (Process Turnaround Time)
  • Pallet Tracking in-house and at vendor locations
  • Asset Tracking in-house and at vendor locations
  • Vehicle Tracking 
  • Forklift Tracking and Optimization
  • Casual Labor Tracking 

What do I do as a Production Manager?

  • Identify Key Pain Areas and Process Improvisation Opportunities
  • Workout Tangible outcomes e.g. TAKT to reduce by 20%, Yield per day to increase by 10% in one month and so on
  • Select a small business case/process area
  • Work out all the challenges, Inputs and outputs to the system
  • Seek and Solution Provider and work out candidates for digitalization
  • Identify Automation Opportunities using IoT
  • Defined Dashboards and key metrics for predictable gains and Hyper Decisions
  • Roll-out POC plan and execute
  • Observe outcomes and then scale to bigger process applications

Solution to Business Problems

Improving Process Efficiency by reducing TAKT (Process Turnaround Time)

IoT Production Dashboard

Pain Area

  • Too much time gets  wasted using manual processes for material request from stores
  • Time wasted in holding production line for want of material from vendor
  • Production Delays due to a technical issue on assembly lines and delayed resolution

Solution Approach

A heterogeneous ISAE (Intelligent Systems Around Everything) Framework based on IoT that connects Pallets, Production Jobs, ANDON Calls, People and Material to give:

  • Real time production status of a production line on a huge TV screen (As seen above) 
  • The TV screen depicts the following and can be used for hyper decision making based on real-time data
  • In Progress work stations with lapsed and planned process time (purple color blocks)
  • Material or Assistence calls (color red), These are called warehouse kanban or ANDON calls
  • Normal operations (color green)
  • Inferences in numbers for Week, Month and Quarter as seen on the screen for predictive analysis and planning

Business Benefits

  • Upto 30% Improved TAKT resulting in ROI and savings
  • 10% to 30%Capacity enhancement resulting better yield
  • Customer Delight due timely and quality deliverable

Pallet Tracking in-house and at vendor locations

how pallet tracking works
pallet tracking solution

Pain Area

  • Pallets at various locations and vendors not available in time or have been inefficiently used
  • This causes production delays or damage to products due to wrong pallets
  • Revenue losses due to lost pallets, unaccounted for pallets and subsequently new pallet manufacturing when already pallets are at vendor location

Solution Approach

  • Enabling smart pallets with use of BLE Tags and BLE Gateways. 
  • Putting the information on Web using Real-Time Location System and ISAE framework
  • Putting the Gateways in Trucks to track Pallets in Transit and estimated time to arrive
  • Realtime dashboard on Laptops and TV screens for hyper decision making

Business Benefits

  • Save 100% of revenue lost in misuse of pallets by Vendors
  • Accurate location of pallets helps plan delivery and saves TAKT by 20% or more
  • Cost of pallet manufacturing can be reduced by upto 30%
  • ROI can be realised within 2 months of implementation

Detailed Solution available on Warehouse Pallet Tracking

Asset Tracking in-house and at vendor locations

Asset tracking

Pain Area

  • Assets at at various locations in-house and at vendor shops
  • These include Dies, Jigs and Fixtures 
  • Finding the location of assets during health audit is a major pain area and impacts audit timelines and data relevance
  • Finding the location and tracking of assets on demand becomes a bottleneck in a manual process system

Solution Approach

  • Onboard all assets on the system using BLE Tags and Gateways devices
  • Put the information on Web using Real-Time Location System and ISAE framework
  • On demand audits and health checks using custom apps
  • Real-time dashboard on Asset Age, Health and Location details
  • Analytics for decision making
  • Digitalization of asset movement and tracking

Business Benefits

  • Save 100% of revenue lost in misuse of assets by vendors
  • Accurate location of assets helps ensures securing stakeholders interest
  • 70% cost reduction in audits due to automation 
  • ROI can be realised within 6 months of implementation

Vehicle Tracking

Vehicle Tracking

Pain Areas

  • Tracking of Vehicles in Yard and big areas is a manual process and takes hours to search
  • Tracking and Scheduling of Supplier vehicles is a great challenge
  • Vehicles in indoor locations and time at each location is unaccounted for and manually reported introducing efficiency and delay in dispatch 

 

Solution Approach

  • Asset tags go on sun visors of vehicles
  • BLE Relays are placed at locations that need to be tracked at micro level
  • BLE gateways cover wider range and transmit signals received from Relays to IoT servers using WiFi
  • Onboarding and Mapping against Vehicle Identification Number is done using mobile app
  • Once on system Vehicles is seen on a virtual floor and can be tracked in real-time
  • Real-time dashboard on dwell time and location inference available for management decisions in real-time synthesis

Business Benefits

  • Reduction in GATE TAKT for supplier vehicles 20% or more
  • Production of automobile and its delivery 100% Predictable for automobile industries resulting in customer delight
  • Hyper Decision making using real-time dashboards
  • Ready for Future Capacity Planning based on historical data

Forklift Tracking and Optimizing

Fork Lift Tracking

Pain Area

  • Not knowing how many forklifts are really needed in production increases the holding cost of forklifts
  • Path optimizations where dozens of forklifts are used is very important to generate savings

Solution Approach

  • BLE based asset tags with accelerometer goes on the forklifts 
  • BLE relays are placed in the pathway at reasonable distance for range
  • BLE Gateways are placed at intermediate locations – 
  • A web app with floor map for real-time location tracking is made available to users
  • The web has default dashboard with basic analysis on forklift movement and inferences
  • An application server has the data and application code
  • IoT server is hosted on QuicSolv’s cloud or local datacenter for Forklift location data from gateways and sending back information to application server

Business Benefits

Based on industry standard practices and past experience of experts in the area of cost optimization we could think of the following value to business.

  • Reducing number of forklifts – based on Industry analysis we have seen at least 10% to 15% fleet can be reduced after data analysis of actual usage
  • Substantial Savings – Based on real-life applications we have achieved as high as 15% Savings within two months of implementation.

Casual Labor Tracking (Dynamic Production Planning)

track trace

Pain Areas

  • Contractors or in-time labor is a boon but it is very difficult to mange their productivity 
  • Tracking them on the job is very difficult as they are not on the main HR channel
  • Billing/invoicing and security are big challenges when it comes to casual labor

Solution Approach

  • BLE based ID cards assigned to Casual Labors
  • Gateways go in Pick-up Bus and Real-time Locations on shop floors
  • Before one is logging into gate the real-time picture of strength of team is known well in advance
  • This help replanning and dynamic changes to scheduled deliverable

Business Benefits

  • 20% time saved in re-planning
  • 30% cost saved in production losses
  • 100% ROI in 6 months

Click here to know more on Dynamic Planning and Control

General IoT Architecture for Production Line

  • BLE Tags are used on Pallets, Vehicles and Assets send singles of their location
  • BLE ID cards are used to allocate human resources to operations and for visitors
  • Zone Mapping is done using BLE Relays which also receive Signals from Tags and ID cards and transmit to Gateway Devices
  • Gateways  are devices which which receives signals from Relays over BLE and Transmits to IoT server over WiFi
  • IoT processes that data and gives it to Application server where the business logic is applied and send to web portal for display
  • The display is done using Mobile Devices, laptops, Tablets and TV screens

Business Value of Implementing IoT Based Processes

  • Real-time Tracking  of Process parameters and Critical Operations
  • Asset, People and Vehicle Tracking
  • Reduced TAKT for all operations thereby greater capacity and higher revenue growth
  • Hyper Decision making looking and live dashboards
  • Data Analytics 
  • Better Control over Production Processes
  • Asset Mapping and location tracking at finger tips – smooth audits
  • Predictable delivery of products
  • Customer delight

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