Introduction
Navyug Cycles, a contract manufacturer for Decathlon, required a cutting-edge track and trace system to gain visibility into their production processes. The goal was to capture crucial data on cycle times, defect rates, reasons for defects, slow production causes, and enable advanced analytics to attribute defects to specific stations and workers. This implementation aimed to significantly improve production efficiency, reduce defects, and promote data-driven decision-making.
Key Challenges
Integration with Existing Infrastructure: Design and deploy a state-of-the-art data gathering and tracking system compatible with existing manufacturing setups.
Unit Traceability: Ensure the ability to trace each unit across the entire manufacturing line.
Station and Worker Attribution: Accurately associate and measure the performance of each unit at various process stations.
Defect Management: Implement guided quality checks to attribute defects or rework to specific stations or workers.
Sustainability Goals: Measure energy consumption and calculate the carbon footprint for every production cycle.
Solution
SynergyLabs proposed and implemented a holistic solution combining hardware and software to meet Navyug Cycles’ requirements. Below are the details:
Laser QR Code Marking: Production begins by marking each metal BB shell with a durable laser QR code. This ensures resilience in the harsh factory environment, enduring welding gases and polishing agents.
Custom Station Additions: Each station is equipped with a scanner that reads the QR code on the unit. The process at the station can only commence after a successful scan, enabling precise cycle time measurement.
Integrated Welding Machines: Panasonic tick welding machines were integrated into the system to record gas consumption, cycle start, and end times.
Worker Identification: Fingerprint scanners were deployed at stations to record the worker’s identity, ensuring accountability for production steps.
Enhanced Quality Checks: Quality check stations were equipped with rugged touch-screen tablets. These devices featured pre-configured quality checklists overlaid on images of the cycle frame. Inspectors could tap on joins, mark them as “OK,” “Rework,” or “Rejected,” and route units to the appropriate bins or rework stations.
Our Role
SynergyLabs played a pivotal role in the successful implementation of the system:
Initial Design: Conducted factory visits and collaborated with Navyug Cycles’ senior management to design the track and trace system.
System Development: Developed and implemented both software and hardware components, partnering with Variety Innovation for hardware solutions.
Deployment and Training: Executed deployment and proof of concept (POC), followed by handover. Comprehensive training was provided to shop-floor staff to ensure effective usage of the system.
Outcomes
Comprehensive Process Visibility: Captured complete details of the production process, including precise cycle times and unit traceability from start to finish.
Enhanced Efficiency: Improved station-level efficiency and overall production performance through data-driven insights.
Defect Reduction: Significant decrease in defect rates due to clear attribution of defects to specific stations and workers.
Analytical Insights: Enabled proactive maintenance by identifying stations with consistently high defect or rework rates. For example, management could now schedule maintenance of welding equipment based on analytical findings.
Improved Production Planning: Accurate forecasting and production planning were made possible through real-time data and analytics.
Real-Time Monitoring: Provided stakeholders with real-time visibility into production processes, fostering collaboration and quick decision-making.
Sustainability Metrics: Enabled the measurement of energy consumption and carbon footprint, aligning production processes with sustainability goals.
Conclusion : Track and Trace System
The track and trace system designed by SynergyLabs has revolutionized Navyug Cycles’ production processes. By integrating advanced hardware and software solutions, the company now benefits from improved efficiency, reduced defect rates, and actionable insights. This successful implementation underscores SynergyLabs’ commitment to delivering cutting-edge solutions that empower businesses to achieve operational excellence and sustainable growth.
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