Project Guardian

The project aims to enhance business efficiency, establish robust controls, improve data accuracy, and increase profitability through the implementation of QR Code and Barcode systems for real-time monitoring and an RFID system for asset tracking. The solution operates in the complex environment of automobile wire harness manufacturing, where tracking over 3,000 assets, monitoring production operations across 300,000+ SKUs, and managing approximately 18,000 raw materials require precise coordination.

Through this implementation, the following goals were achieved:

a) Full Automation of Data Capture: Eliminating manual entry across production, asset tracking, and inventory management.

b) Real-Time Visibility: Providing instant access to operational data for agile decision-making.

c) Enhanced Accuracy: Minimizing errors by leveraging automated data capture methods.

d) Proactive Decision-Making: Enabling timely, data-driven decisions to anticipate and address potential challenges.

e) Cost Reduction: Streamlining workflows and reducing resource waste.

Automobile wiring harnesses are complex products that require detailed monitoring due to the use of a vast array of small SKUs in high quantities. This solution will elevate business efficiency by ensuring timely customer deliveries, preventing inventory shortages, facilitating effective production planning, optimizing human resource allocation, and supporting prompt, strategic decision-making.

• Real-Time Inventory and Asset Tracking: The implementation provided real-time visibility into inventory and asset, improving overall stock and asset management and responsiveness.
• Timely Fulfillment of Customer Orders: With optimized inventory tracking, customer orders are consistently fulfilled on time, enhancing satisfaction and reliability.
• Increased profitability was achieved through the following outcomes:

1. Reduced Inventory Shortages: By minimizing stock outs and eliminating the need for costly, unplanned air shipments, inventory costs were significantly lowered.
2. Efficient Resource Allocation: The project enabled timely allocation of human and machine resources, boosting productivity and maximizing resource use.
3. Reduced Labor Overtime: Streamlined processes and optimized schedules resulted in decreased labor overtime, cutting operational expenses.
4. Enhanced Customer Attraction: Timely deliveries improved client satisfaction and attracted prospective customers, expanding business opportunities.
5. Enhanced Asset Monitoring: Improved asset tracking reduced theft and misuse, effectively lowering total asset-related expenses

Software, Equipment, and Auxiliary Systems Used

· Honeywell handheld scanner for QR and Barcode reading.

· Honeywell printer for QR and Barcode printing

· HP Aruba wifi Networking to cover all production and store areas.

· Zebra Handheld RFID scanner

· Zebra RFID fixed gate reader with its application.

· SAP FIORI application to read Barcode and QR code data with real-time updates.

· Android application to read RFID tags.

This project faced several challenges due to its scale and integration requirements across departments. Ensuring the timely delivery of equipment was critical, as delays could impact the entire production schedule. Additionally, seamless coordination among the production, inventory, and IT teams was essential but challenging due to the diverse functions and goals of each department. Another significant obstacle was maintaining accurate Master Data updates; business users were required to continuously update master data, yet this posed a challenge due to varying levels of familiarity and consistency.

The adoption of new processes by business teams was also a hurdle, requiring extensive change management to align practices with the automated system. Achieving agreement on the business blueprint and process flow took considerable time and effort, as teams needed to reach a shared vision for each step of the operation. Additionally, there was a strong emphasis on increasing the use of automation to full capacity, aiming to bring all processes to 100% automation—a task that demanded thorough training and system adjustments.

Diagnosing and resolving issues during real-time data capture presented technical difficulties, often requiring immediate troubleshooting to prevent data inconsistencies. Furthermore, aligning stakeholders on a realistic project timeline was complex, as each team had distinct milestones and dependencies, making agreement on timing challenging. These difficulties underscored the project’s complexity, requiring precise planning, agile coordination, and high adaptability across all departments.

IT Department with the help of supply chain, production and finance took the initiative to increase business profitability and data accuracy with the usage of technology.

The project was executed in 2 phases.

1. Implementation of RFID on fixed assets.

2. Barcode and QR code implementation for production and inventory.

Project feasibility with its ROI was presented to board for investment approval. After board approval we moved for acquisition of required hardware and development of software. Phase 1 was live after 6 months of board approval. Phase 2 took around 8 months after completion of phase 1 and now its live.