Case Study

Production Monitoring System

Ver. 0 Dated: 13/02/2017 The above logo used belongs to its respective owner
Overview:
Endurance Technologies is one of India's leading automotive component manufacturing
companies. Anurang Engineering Company Private Limited which merged into our company in
2006, commenced manufacturing of aluminium castings in Aurangabad, Maharashtra, India in FY
1986. Over time, it has grown organically in India and diversified its capabilities by introducing
suspension products, transmission products and brake systems. Starting with two aluminium casting
machines in FY 1986, Endurance Technologies has grown to operate 18 plants in India and 7
plants in Europe. Today Endurance Technologies is the largest aluminium die casting manufacturer*
in India and one of the leading automotive component manufacturers in aluminium die casting
(including alloy wheels), suspension, transmission and brake systems.

Challenges:

To maintain the company production target and constantly motivate its employees, Endurance
Technologies wanted to translate the performance target into real-time visual indication at the end
of each production line. Actual visual indication of production and performance target will help
motivate the employees and on achieving the target will boost their morale and confidence level.

Solution:

Compucare with its expertise was able to rise up to the challenge of Endurance Technologies by
providing Production Monitoring System. The Production Monitoring System consists of
Production Sensor, Web Interface Unit, Smart Electronic Display. The Web Interface Units is
centrally located to manage connectivity with the Production Sensors for one or more production
lines. The supplied Smart Electronic Displays are of different shapes and sizes. At the assembly line
the installed small sized Smart Electronic Display is single sided with bright red LED display, the
display boards are clearly visible upto a distance of 8 meters, there is also a medium sized double
Smart Electronic Display installed commonly for two assembly lines. A large double Smart
Electronic Display is installed in the middle for cumulative display to data of different assembly
lines. All the Smart Electronic Display are designed to suit their factory condition.

The installed Smart Electronic Displays installed at the assembly lines visually represent the
following data such as Date, Time Target and Actual of Shift A, Shift B, Shift C. The large display
shows the parameter such as Scheduled Production Quantity for the month, Cumulative Production
Quantity for the month, Present Average Quantity per day, Asking Average Quantity per day, Target
and Actual for the day from Assembly Line 1 - 5.
How Production Monitoring System is achieved?

The Web Interface Unit is installed

The Production Sensor is installed at the end of every production line

The Production Sensor communicate with the Web Interface Unit wirelessly

The Smart Electronic Display is installed at the end of every production line

As and when an object comes in close range of the production sensor at the end of
production line, the Production Sensor is triggered and sends signal wirelessly to the Web
Interface Unit

The Web Interface Unit receives the signal and communicates with the software server via
TCP/IP line

The data is populated in the Production Monitoring Software server from the Web Interface
Unit

The Smart Electronic Display software is also installed in the software server

The data from the Production Monitoring Software is fetched and populated in the Smart
Electronic Display software

The populated data is then transmitted via TCP/IP to the Smart Electronic Displays placed
at every production line

The data for Smart Electronic Display is refreshed at regular intervals

Technical Layout:

Production Monitoring System

Web Interface Unit

TCP/IP TCP/IP
PMS & LED Software Server
Router/Switch

Production Production Production Production Production

Sensor Sensor Sensor Sensor Sensor
Conveyor Conveyor Conveyor Conveyor Conveyor

Line 1 Line 2 Line 5 Line 6 Line 7

TCP/IP

TCP/IP TCP/IP TCP/IP TCP/IP

Another
Unit

Assembly Line Assembly Large Double Assembly

Display 1 Main Line Display 5 Display Line Double
Unit Display
Actual Images:
Conclusion:

The installation of the Production Monitoring System has provided the real time dynamic visual
indication of production and performance target. This has also increased the motivation of the
employees and also has instilled confidence in their ability to achieve the timely company target.