Optimising the Supply Chain on the Production Line Using Artificial Intelligence
GIC Nosag Metal is the largest company in the GIC group, a traditional Romanian group in the automotive market. Known for its high-quality products, GIC Nosag Metal provides competitive and reliable solutions to both local and international car manufacturers. In order to stay competivie, GIC Nosag choose optimising the supply chain on the production line using artificial intelligence based solution from KFactory.
Project Challenges
Operating in a continuous production environment, 24 hours a day, 7 days a week, GIC Nosag Metal needed a system to monitor the flow of raw materials and containers with finished products in real time. The previous manual process was prone to delays, human errors, and production stoppages, which affected overall efficiency. The challenge was to ensure continuous and uninterrupted production by automating the monitoring of the supply chain within their robotic production lines.
Operating a 24/7 production structure presents unique challenges, especially when relying on manual processes to track raw materials and finished products. We often faced delays and production stoppages, affecting delivery timelines. It became clear that we needed a solution to automate and streamline the entire process, ensuring a continuous, uninterrupted flow.
die KFactory-Plattform®‘s Innovation
To address these challenges, die KFactory-Plattform® implemented its module based on computer vision technology. The system continuously monitors the supply of raw materials and tracks the loading levels of containers for finished products. This automated process generates real-time alerts and notifications when materials need replenishing or containers require emptying. Consequently, it prevents delays and avoids production bottlenecks, ensuring smooth workflow.
Key Features Offered to the Client
■ Real-time Monitoring: Cameras monitor carts in real time, strategically placed in the “Loading Area” and “Robot Area.” They provide alerts when refilling or emptying is needed, ensuring smooth operation.
■ Automated Notifications: The system generates automatic alerts when carts are empty, indicating what materials need replenishment based on the operator’s current tasks.
■ Color-coded Emergency Levels: Color-coded notifications prioritise tasks, directing teams to focus on the most important actions first.
■ Mobile Integration: Operators responsible for transporting materials are equipped with tablets to receive real-time notifications, allowing timely deliveries and preventing production interruptions.
■ Optimised Workflows: The system tracks the time required for each task, allowing efficient workflow management using the FIFO (First In, First Out) prioritisation method.
■ Error Prevention: The system ensures accurate cart identification, reducing the risk of errors in material delivery.
Results and Benefits
The die KFactory-Plattform® system operates fully automated, eliminating the need for human supervision, which brings several significant benefits:
■ Increased Efficiency: Full automation reduces human errors and minimises production downtime.
■ Reduced Operational Costs: Eliminating manual monitoring reduces operational costs, allowing teams to focus on critical tasks more effectively.
■ Scalability: The system can easily be adapted for various types of production or industrial lines.
■ Real-time Optimisation: Real-time data collection allows for quick and well-informed decisions to maintain maximum production capacity.
■ Reduced Unplanned Downtime: Through automatic monitoring and notifications, the system prevents interruptions caused by material shortages or lack of storage space.
The implementation of the KFactory® solution exceeded our expectations. It brought a level of automation and efficiency that significantly improved our operations. We are now able to monitor critical processes in real time, reducing overall downtime and improving overall productivity. This solution has streamlined our workflow, and we are extremely satisfied with the results.
Schlussfolgerung
Artificial intelligence is making its way into business processes, with its application bringing immediate and high-value benefits. The optimisation of the supply chain on the production line using artificial intelligence at GIC Nosag Metal, powered by KFactory®, transformed the company’s supply chain management. This approach ensured a more efficient, streamlined, and error-free production process.. The solution has proven its ability to scale and adapt, offering measurable value by reducing downtime, optimising workflows, and lowering operational costs.
