Welcome To Base Automation

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Successfully transforming the Industrial Manufacturing Business to achieve excellence for over 25 years!

276, 2nd Main Road, Nehru Nagar,

Kottivakkam, OMR, Chennai – 600096, India.

: 91 73388 97775

(Monday - Friday)

Overview

Client: A leading tire manufacturing company

Duration: 9 months

Process Areas: 35+

Number of Assets: 370+

Objectives

The primary objective was to implement a complete traceability system from raw materials inward to finished tires outward. This was not only to meet regulatory compliance but also to enhance quality control, reduce errors, and ensure accountability throughout the production process.

platform used

We selected Ignition as the platform of choice to connect with all the equipment, which included over 370+ assets from various OEMs. A Unified Namespace (UNS) was established to facilitate seamless communication and data exchange across the different systems and machinery.

Features of the Traceability System

1. Master Configurations:

a. Centralized control over machines, SKUs, and operators.

b. Each raw material’s journey was logged from the moment it entered the factory, ensuring comprehensive tracking from start to finish.

2. Barcode-Based Tracking:

a. Barcodes were used for operators and semi-finished goods at each production stage.

b. This created a robust record that linked each tire to specific presses and cavities, significantly enhancing tracking precision.

3. Real-Time Dashboards:

a. Live dashboards provided a real-time snapshot of the production floor.

b. Enabled quick decision-making and immediate identification of bottlenecks or issues.

4. Mold Life Tracking:

a. By recording data for each tire, the system monitored mold life.

b. Predicted maintenance and replacement needs, thus avoiding unexpected downtime and ensuring continuous production.

Implementation Steps

1. Initial Assessment and Planning:

a. Conducted a thorough assessment of existing processes and machinery.

b. Defined requirements and objectives for the traceability system.

c. Established a project timeline and allocated resources accordingly.

2. System Design and Configuration:

a. Developed the Unified Namespace (UNS) to standardize communication across different systems.

b. Configured Ignition platform to interface with all 370+ assets.

c. Designed and implemented master configurations for machines, SKUs, and operators.

3. Integration and Testing:

a. Integrated barcode scanners and other necessary hardware across the production line.

b. Conducted extensive testing to ensure data accuracy and system reliability.

c. Developed and tested real-time dashboards and mold life tracking functionalities.

4. Training and Deployment:

a. Provided comprehensive training for operators and managers on the new system.

b. Gradually rolled out the system across the production floor, ensuring minimal disruption.

c. Gathered feedback and made necessary adjustments to optimize performance.

Results

1. Quality Assurance:

a. With each tire’s history meticulously recorded, quality assurance became proactive.

b. Enabled early detection of potential issues, reducing the occurrence of defective products.

2. Operational Efficiency:

a. Reduced manual errors and increased the speed of production processes.

b. Streamlined operations through centralized control and real-time monitoring.

3. Data-Driven Decisions:

a. Access to real-time data empowered managers to make informed decisions.

b. Optimized production schedules and resource allocation based on accurate data insights.

4. Cost Savings:

a. Predictive maintenance of molds prevented unexpected failures and costly downtimes.

b. Enhanced efficiency and reduced waste contributed to significant cost savings over time.

Conclusion

The implementation of a comprehensive traceability system in the tire manufacturing plant was a strategic success. By leveraging Ignition and creating a Unified Namespace, we achieved seamless integration and real-time visibility across the production process. This not only ensured regulatory compliance but also significantly enhanced quality control, operational efficiency, and cost-effectiveness. The project stands as a testament to the transformative power of digital traceability in manufacturing.