Client has been a significant player in the global automotive industry for over six decades. They are one of the prominent manufacturers of automotive components for the OEMs and Tier-I suppliers.

The US $610 Million Group, with a workforce of more than 16,000 employees, caters to the leading Passenger Vehicle, Commercial Vehicle, Motorcycle & Scooter, Off-road Vehicle & Tier 1 Manufacturers in India with presence in Indonesia, Vietnam, Europe, Japan and Uzbekistan.

1. Real Time & Historical data monitoring

2. Remotely access of all key data / KPIs

3. Eliminate all physical papers

4. Data transparency

5. Traceability (Man, Machines, Method & Material)

6. Minor losses identification

7. Escalation through mail & WhatsApp.

To maintain our competitive edge and ensure operational excellence, Client implemented FactoryMetrics, across all their 30 assembly lines in one of their plant in Noida.

FactoryMetrics is a smart machine monitoring Industry 4.0 system that acts as a watchdog for their manufacturing processes which utilises the Internet of Things (IoT) to provide real-time insights into the shop floor activities, offering a comprehensive 360-degree view of their operations.

FactoryMetrics serves as the central nervous system of our manufacturing process, focusing on the 4Ms: Man, Machines, Methods, and Materials. Here’s how it enhances each aspect:

Man:

• Verifies attendance and skill levels of operators and line leaders using thumb scanners.
• Ensures the right personnel are at the right place with the right skills before operations commence.

Machines:

• Monitors machine performance, breakdowns, alarms and alerts us to any issues or bottlenecks.
• Measures Overall Equipment Effectiveness (OEE), including availability, performance, and quality.

Methods:

• Integrates and controls the assembly line operations.
• Requires completion of specific checks before the line can be operated, ensuring adherence to our standard operating procedures.

Materials:

• Confirms the availability of raw materials and child parts through barcode scanners.
• Tracks material utilization and inventory levels in real-time.
• Operational Integration and Control

FactoryMetrics ensures that the assembly line cannot be started until all prerequisite checks are completed. These checks include:

• Attendance and skill verification of operators and line leaders.
• Availability of raw materials or child parts.
• Completion of the line verification checklist.

This rigorous process has led to significant improvements in our 4Ms, with all activities and accountabilities automatically recorded in the system.

FactoryMetrics ensures that if any production line is down due to any of the 4M reasons, then alert goes to the right personnel along with escalation metrics, and a ticket is automatically generated.

Upon receiving the alert, the right personnel immediately attend the down line, resolve the issue and provide a resolution remark to close the ticket.

Therefore, now with this practice in place, system automatically creates MTTR & MTBF reports and gives analytics with suggestions to improve the critical bottlenecks.

Now since the system is recording everything with time stamp like ticket open time, close time, problems, resolutions, it’s reasons. therefore, we are seeing that on shop floor every personal became more proactive, aware, well communicated and accountable for their duty.

Horizontal Installation of complete system was very easy, on-site team installed complete system on all our 30 lines without effecting our daily operations.

We were able to pay for the entire system within 4 months from the ROI.

So far here in Noida facility with FactoryMetrics, we have seen production increased from 70% to 83% on critical machine. We saw their utilization going from the mid 65% up to 79%. Their OEE went up from 68% to 78%.

Number of good parts that we producing monthly went from around x to consistently over x + 3k or lacs (whichever is realistic). That’s just been in 2023.

We have been using all the key modules provided from them such as:

• Overall Equipment Effectiveness (OEE)
• Downtime
• Attendance, Digital checklists
• Machine interlocking
• Automatic rejections
• Line & Man power utilization
• Planning & scheduling
• Preventive maintenance
• MTTR, MTBF, Rejection, Rework, Quality, Hourly, LVS, DRS reports and more

Post-implementation, FactoryMetrics team exceptional support continues to impress us.

Their proactive suggestions and ideas further enhance our ability to fine-tune this system for optimal performance in our daily operations.

We are glad that we have chosen them for our industry4.0 journey. Their subject matter expertise, on-site service and support has been invaluable.

Without their extensive industry experience and deep subject knowledge, realizing this solution would have been a significant challenge. Their contributions have significantly reduced our time to go live.

Within this financial year, we have plan to deploy this Industry 4.0 system across all other remaining assembly lines in this Noida plant. Following this, the implementation will extend to our Pantnagar and Pune plants. Subsequently, the system will be rolled out to other remaining plants.

In conclusion, the successful implementation of FactoryMetrics has revolutionized our manufacturing processes at our company. This Industry 4.0 solution has provided us with unparalleled insights and control over our operations, ensuring we maintain our competitive edge in the global automotive industry.

We look forward to continuing our journey of excellence with the ongoing support and partnership with Hiotron complete team.

Thank you.