Automation Solution for Engineering, Electrical & Electronics Industry

Typically the Engineering and Manufacturing Industries operate in (a) make to stock (b)assemble to order (c) job shop (d)make to order (e) engineer to order (f) Project based environment. This very nature of order management decides the optimisation strategies of planning, procurement, inventory management patterns. The Automation solution must address mechanism to handle such item management strategies.

Multiple bill of material for a single item has been a common requirement in this industry as the customer defines the design he requires. According to customer requirement, there is a need to alter the bill of material and the process plan. This hinders the processes planned and hence cause delays in delivery. In many cases the phantom items have to be incorporated in the bills of materials.

Most of the engineering companies manage subcontracting to meet the demand. Generation of challans and maintaining the stock status of material lying at the subcontract location is very important.

Electronics industry incurs high costs in inventory due to lack of visibility of the stock in work-in-progress stage. An insight on the inventory in WIP stage can help the companies plan their production more efficiently towards meeting the delivery schedules. The Production planning should address the planning of the production lines by considering the availability of lines and throughput times and order dispatch dates.

Around 50% of manufacturing overheads cost comprises of utilities such as Energy, Fuel, Water supply. If left unmonitored may lead to huge costs and losses.

Breakdown of machines may often lead to unplanned downtime in manufacturing operations leading to loss of production. Lack of predicting such machine breakdowns may result in last moment rush for spares inventory ordering & struggle in allocating maintenance engineers to resolve the problem. Monitoring machine parameters such as Temperature, Pressure, Humidity, Current on real time basis and understand the pattern of the machine failures remain a challenge for this industry.

Automotive & similar industry have to meet stringent quality parameters of Safety of the passengers. Any Quality defect of any automotive component can lead to costly recalls and repairs and endanger human lives. To ensure customer satisfaction, its necessary to ensure precise quality assurance and compliance parameters such as Leakages, Body damage, paint quality are strictly monitored.

Visual inspection in the manufacturing industry poses risks due to its reliance on human judgment, which can lead to errors, inconsistencies, and missed defects. Factors like fatigue, limited visibility, and subjective interpretation can compromise the accuracy of quality checks.