Barcode Based Assets Tracking Solution for Manufacturing Unit

Background
One of the big manufacturing company in India was dealing with the issues related to under utilization of fixed assets like machinery, equipment & tools. In the absence of machinery crackdown and maintenance data, the management unable to develop and execute plans for assets replacement. Thus, the company implements new technology to maintain real-time records of assets for better planning and full utilization of resources.

Challenges
  1. The plant needs to maintain records of machinery, tools, equipment, and raw material. But these were located at different facilities and it was difficult to keep update the inspect record of all the assets manually.
  2. The manual process was time-consuming and unreliable. The records were written on paper which could subject to errors.
  3. Company has many manufacturing facilities in different locations. Maintain the records of all the facilities’ assets in real-time was not possible which could lead to a potential risk of sudden breakdown of machinery.
  4. As assets data was not available in real-time, so immediate action could not be taken to replace the machinery.
 
Solution
An automatic barcode-based tracking solution was proposed by Chainway for assets tracking. Chainway’s C4000 mobile computers were deployed by the client in the manufacturing facilities. This was the best-fitted device as per the budget and specific requirement of the client’s application. Chainway fist suggested the management to identify the assets needed to be tracked such as machinery, equipment and tools and then assigned unique barcodes label for each asset. These barcodes carried all the essential information such as name, location, purchase date, repair date, service details, etc. C4000 mobile computers were integrated with client software. Later, these mobile computers were assigned to maintenance staff in different locations. The operator could scan the assets at the time of repair or services and update the data with the help of a mobile computer. The updated data was transferred and saved in the main server in a real-time.

Effects
  1. With the new solution, inspection work becomes easier and fast.
  2. Management ensures the proper maintenance and full utilization of assets.
  3. The company achieves a good return on investment as it has avoided sudden breakdown happens due to machine failure.
  4. As all the data are stored automatically. So, instant report generation is possible now.
  5. Timely replacement of assets is possible because management can access the maintenance data for replacement planning.
  6. Accountability of an individual can be defined for maintenance and missing of assets.
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