Powering shop floor efficiency with data analytics

Powering shop floor efficiency with data analytics

Manufacturing

Powering efficiency on the shop floor

An Iris innovation helped a diesel engine manufacturer eliminate production bottlenecks.

Client

A leading diesel engine manufacturer

Goal

Reduce bottlenecks on the production line that arise from last-minute changes to orders and ensure compliance with build instructions

Tools and technologies

Windows, SQL Server, C#, .NET, ESB, HTML5, Angular, GitHub, JIRA, Visual Studio, and WebStrom

BUSINESS CHALLENGE

A diesel engine manufacturer based in Detroit faced frequent production delays. The cause of the inefficiency was its build book system. The manufacturer used a printed build book to communicate the specifications of the engine being built to the production floor. But, often after the book was sent to the shop floor, the manufacturer had to make changes to specifications. In such cases, those working on the production line would not be able to use the printed build book. Waiting for a reprinted book would halt production. As a result, the changes were usually communicated outside the manual and assumed to be followed. If the new specifications weren’t followed, they would be discovered only in quality assurance, leading to a loss of time and dollars.

SOLUTION

The client wanted a solution to resolve bottlenecks created by the printed build book and ensure compliance with build instructions. Ideally, the build book is dynamically pushed onto a handheld device assigned to the shop floor. The system would allow managers to update the specifications in the build book on the fly and alert the production team to the changes.

The device would also communicate the status of production to managers. For example, they would know which work center is working on an engine so that relevant pages of the build book could be updated and displayed to those work centers. 

Iris custom-built an application that allowed real-time updates of the build book. It was designed to push the build book to work center operators on V10 devices (RFID transponders) with screen sizes ranging from 3 inches to 10 inches. The solution included a consolidated dashboard that provided the management near real-time visibility of work centers and the status of the engine production.

OUTCOMES

During Phase 1 of the project, we deployed 250 V10 devices. After a pilot run of four weeks, the client stopped printing build books; the handheld devices with our application were a superior alternative. The solution helped eliminate printing costs and allowed the manufacturer to accommodate last-minute changes in specifications without disrupting production.

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An agile sprint for financial data

An agile sprint for financial data

An agile sprint for financial data

How Iris helped a mega sportswear brand’s global operations and financial reports go flexible, agile, and analytical.

Client

Among the world’s largest manufacturers of sportswear, the client sells its products in more than 120 countries and employs more than 13,000 people.

Goal

To significantly reduce turnaround time and ease associated with report creation.

Tools and technologies

Microsoft SQL Server’s Analysis Services (SSAS), Microsoft SQL Server Integration Services (SSIS), Microsoft SQL Server Reporting Services (SSRS), Boomi AtomSphere, and Power BI.

BUSINESS CHALLENGE

The client’s finance department was using standard SAP reports which limited the flexibility to slice and dice data or add fields to reports. Modifying or creating new reports was either difficult or expensive. Top management, including the CFO and financial controllers, were finding it difficult to create a high-level, integrated view of the company’s finances. The existing process required data transposition between various systems, including the SAP and Oracle systems. Much of this data was extracted and consolidated manually, which was time-consuming, and took around a week.

SOLUTION

Iris executed a distributed Agile framework for the client’s global delivery model. Our solution pulled data out of the client’s SAP ERP system using Dell Boomi adapters, and leveraged SSIS (SQL server integration services) to transform it into enriched data. This data was mapped and made actionable through interactive PowerBI Tableau dashboards. With the help of a custom-made finance data model, a data warehouse was created. The easily shareable data cubes not only replaced all legacy reports, but also reduced the number of SAP user licenses.

OUTCOMES

With the availability of Power BI dashboards and the capability to slice-and-dice financial data, client managers now have a better view of operations and accounting flows. The data consolidation allows users to create need-based reports without additional licenses. The automation of the entire process from data extraction and transformation to publishing of analytical cubes has enabled the client teams to significantly reduce time required to produce reports – from days to a few minutes. They have been able to achieve a 95% reduction in time and effort.

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