Production Management ERP
Industry
Textile
Platform
Web and Mobile App
Country
India
Partnership Period
Feb 2020 to Present
Team Size
5 Experts
Overview
A comprehensive software and hardware solution designed to manage industrial production processes such as Pickling, Drawing, Annealing, Profiling, Hardening & Tempering, Pattending. The system integrates with Oracle Fusion via REST APIs and includes mobile applications for real-time inventory management.
Key Stakeholders involved
Employee
The employees are the primary users of the system. They are responsible for receiving the raw materials from the vendor, inspecting them, and storing them in the inventory. They also generate a unique serial number for each coil and attach it to the coils. Using the mobile application, they find the FIFO coil, scan the picked coil label in the device fitted in the machine, and take the output coil by putting it on a weighing scale connected to the device.
Supervisor
Supervisors oversee the work of the employees. They ensure that the processes are carried out correctly and efficiently. They may also be responsible for quality control, checking that the coils meet the necessary standards. In addition, they might have the authority to handle exceptions or issues that arise during the process.
Admin
Admins have the highest level of access to the system. They can view stocks and reports in the admin console, allowing them to monitor the overall operation and make informed decisions. They might also be responsible for system settings, user management, and ensuring the integration with Oracle Fusion is functioning correctly.
Preconditions
- Raw materials are received from the vendor.
- A receipt is created, and an inspection is performed against the receipt.
Main Flow
- Receipt of Raw Materials: The process begins when employees receive raw materials from the vendor. These materials are inspected against the receipt created during the procurement process. This step ensures that the materials received match the order placed and meet the quality standards set by the company.
- Inventory Storage: Once the raw materials are accepted, they are stored in the inventory. This is known as the putaway process. The inventory system is updated to reflect the addition of new materials. This step is crucial for maintaining an accurate record of the materials available for production.
- Coil Serial Number Generation: For each coil, a unique serial number is generated and attached. This allows for precise tracking of each coil throughout the production process. The serial number serves as an identifier that can be used to retrieve information about the coil at any stage of production.
- Coil Selection and Scanning: Employees use the mobile application to find the First-In-First-Out (FIFO) coil. This ensures that the oldest coil in the inventory is used first, preventing materials from becoming obsolete or spoiling. The picked coil label is scanned using the device fitted in the machine, linking the coil to the specific production process.
- Weighing of Output Coil: After the production process, the output coil is placed on a weighing scale that is connected to the device. The device auto-captures the weight, eliminating the need for manual entry and reducing the chance of errors.
- Inventory Update: The output coil is then added to the inventory. The inventory system is updated to reflect the addition of the output coil. This step is crucial for maintaining an accurate record of the products available for distribution.
- Sync with Oracle Fusion: The details of the produced coil are synced with the Oracle Fusion portal by creating and completing a work order. This allows for seamless integration with other business processes such as sales and distribution.
Alternative Flows
- Rejection of Raw Materials: During the initial inspection process, if the raw materials do not meet the company’s quality standards or do not match the order placed, they are not accepted. This could be due to various reasons such as damage during transportation, incorrect quantity, or substandard quality.
- Return to Vendor: The rejected materials are then returned to the vendor. This process involves updating the inventory system to reflect the return of materials and communicating with the vendor about the issue. The vendor may then replace the materials or provide a refund, depending on the terms of the agreement.
- Resumption of Main Flow: Once the new materials are received and pass the inspection, they are stored in the inventory, and the main flow of the process resumes.
Technology used
- React and React Native for frontend
- Python for backend
- Embedded C for the IoT device
Post Conditions
- Inventory Update: After the production process, the inventory is updated to reflect the addition of the output coil. This ensures that the inventory records are accurate and up-to-date, which is crucial for effective inventory management.
- Admin Console Access: The admin console provides a comprehensive view of stocks and reports. This includes information about the quantity and status of raw materials and output coils in the inventory, production statistics, and other relevant data. This information can be used for monitoring operations, identifying trends, and making informed decisions.
- Oracle Fusion Sync: The details of the produced coil, including its unique serial number, weight, and production details, are synced with the Oracle Fusion portal. This is done by creating a work order in the portal and marking it as complete. This ensures that the Oracle Fusion portal has the latest information about the produced coils, which can be used for sales, distribution, and other business processes.
- Data Availability for Analysis: The data generated during the production process is available for analysis. This includes machine usage data, production times, coil weights, and other relevant data. This data can be used for predictive analysis, future forecasting, and other analytical purposes.
Business Impact
- Improved Efficiency: By automating various aspects of the production process, from inventory management to coil tracking, your system can significantly improve operational efficiency. This can lead to faster production times, reduced errors, and increased output.
- Real-Time Tracking: The system allows for real-time tracking of production processes. This can help in identifying bottlenecks, optimising workflows, and improving overall productivity.
- Predictive Analysis: The system’s integration with Oracle Fusion and its ability to generate and store detailed data allows for predictive analysis. This can be used to forecast future machine availability, estimate manufacturing times, and make informed decisions about production schedules and resource allocation.
- Cost Savings: Improved efficiency and productivity can lead to substantial cost savings. By reducing waste, optimising resource use, and speeding up production times, your system can help to lower operational costs.
- Quality Control: By tracking each coil through the production process, the system can help to ensure consistent quality. This can enhance the company’s reputation, lead to higher customer satisfaction, and potentially increase sales.
- Data-Driven Decision Making: The system provides valuable data that can be used to make informed decisions. This can lead to better strategic planning, more effective resource allocation, and improved business outcomes.
- Scalability: The system is designed to handle the demands of growing operations. As the business expands, the system can scale to manage increased production volume without a significant increase in operational complexity.
Related Use Cases
- Vendor Management: The system can be used to manage interactions with vendors. This includes receiving raw materials, inspecting them against the receipt, and returning materials that do not meet the company’s standards. The system can track vendor performance over time, which can be useful for negotiating contracts and making procurement decisions.
- Quality Control: The system can play a crucial role in quality control. By tracking each coil through the production process, the system can help ensure consistent quality. If a coil does not meet the necessary standards, the system can trace it back to its raw materials and production processes. This can help identify the source of the problem and prevent similar issues in the future.
- Inventory Management: The system can be used to manage the company’s inventory of raw materials and output coils. This includes storing materials in the inventory, finding the FIFO coil, and adding output coils to the inventory. The system can provide real-time inventory data, which can be used to optimize inventory levels and reduce carrying costs.
- Production Planning: The system’s ability to generate and store detailed data about the production process can be used for production planning. This includes forecasting future machine availability, estimating manufacturing times, and scheduling production processes. The system can also provide data for capacity planning and resource allocation.
- Integration with ERP Systems: The system’s integration with Oracle Fusion demonstrates its potential to be integrated with other ERP systems. This can allow the system to be used in conjunction with other business processes such as sales, distribution, and finance.
Assumptions
- All machines and materials follow the same process.
- The weighing scale is accurately calibrated.
Future Considerations
- Integration with Other ERP Systems: While the system currently integrates with Oracle Fusion, future considerations could include integration with other ERP systems. This would allow the system to be used in a wider range of business environments and could enhance its functionality by allowing it to interact with other business processes.
- Expansion to Other Industrial Processes: The system could be expanded to manage other industrial processes beyond the ones it currently handles. This could make the system more versatile and increase its value to businesses operating in different sectors of the industry.
- Advanced Analytics and Machine Learning: With the wealth of data generated by the system, future considerations could include the implementation of advanced analytics and machine learning algorithms. These could provide deeper insights into the production process, identify patterns and trends, and enable more accurate forecasting.
- Enhanced Mobile Application Features: The mobile application could be enhanced with additional features such as real-time notifications, advanced search and filter options, and personalised user interfaces. This would improve the user experience and could lead to increased efficiency and productivity.
- Improved Hardware Capabilities: Future considerations could include the development of improved hardware for the system. This could involve more accurate weighing scales, faster and more reliable devices for scanning coil labels, and more robust devices for use in industrial environments.
- Sustainability Features: As businesses increasingly focus on sustainability, the system could incorporate features to support this. This could include tracking and reducing energy use, minimising waste, and supporting recycling initiatives.
Conclusion
The system provides a robust solution for managing industrial production processes, improving efficiency, and enabling data-driven decision-making.
