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Quality products manufactured on time. That’s engineering.

Manufacturing companies are focused on delivering competitive products on time. This customer, a global manufacturer of compressed air and gas solutions, was looking to integrate and transform its manufacturing operations. Tata Technologies leveraged its proprietary accelerator and solutions to connect plant-wide manufacturing operations and improve productivity.
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Challenge

For most of its manufacturing processes, the customer traditionally relied on manual production planning that was not aligned to LEAN manufacturing principles. This led to inefficient inventory management and lack of warehouse integration, which resulted in poor plant floor visibility. The customer contemplated implementing a suitable enterprise solution to align its manufacturing processes and remove friction between its traditionally siloed business functions. With its reputation as a leading global provider of digital solutions for enterprise modernization, the customer chose Tata Technologies to turn its vision into reality.

Solution

To address the lack of tight integration of MES system with the customer’s ERP and third-party logistics software, shop floor control system, and finished good yard, Tata Technologies leveraged its IP – FactoryMagix, a proprietary MES solution.

From product tracking and genealogy to maintenance management and document control, our MES solution – ‘FactoryMagix’ is designed to enable connected plant-wide manufacturing operations. As part of the FactoryMagix solution provided to the customer, the functionalities included – order management, kitting, pick list generation, JIT/JIS, e-KANBAN, ANDON system, genealogy, traceability, torque and test data logging, and digital work instructions. Through our proprietary MES platform, we delivered a modular solution built to accelerate digital transformation while improving operations efficiency and driving compliance. As part of the engagement, we also leveraged Ignition MES to meet the customer requirements during the later stages.

For better visibility and real-time decision making, we also integrated multiple PLCs, barcode printers, and scanners at two assembly plants for the customer’s make-to-order and make-to-stock products. Moreover, reporting of real-time information, reflecting actual results via dashboarding & e-mail alerts, ensured communication of process and production information to the right people at the right time. This helped improve decision-making related to maintenance, productivity, and quality purposes.

What started off as a partner-client engagement, has now grown from strength to strength, recognizing our trusted ability to deliver successful digital enterprise solutions above and beyond. The customer realized 95% reduction in WIP inventory (72 hours to 4 hours), 30% improvement in production planning, 10% improved productivity, and 100% visibility into shop floor operations with the implementation of the platform.

Highlights

30%
improvement in production planning
10%
improvement in productivity

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