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The Empowered Worker™: Whitepaper


An SME Leverages the Power of Industry 4.0 to Achieve High Value Digitalization at Low-Cost


THE PROBLEM:

A Small and Medium Enterprise (SME) job shop in India supplies parts to regional Tier 1 and Tier 2 suppliers of large automotive OEMs. Across its four plants, the job shop's tight margins were being strained by significant material loss, a high cost of quality, unplanned downtime, and siloed decision-making due to negligible real-time production intelligence.


THE SOLUTION:

5G bundled three of its Empowered Worker™ solutions at one of the SME's plants to facilitate digital transformation of its manufacturing processes:

a) Quality & Material Loss Tracking (BorgQ);
b) Production Performance Tracking (BorgV); and
c) Requirement Tracking.


5G's proprietary edge processing device, BorgConnect®, served as the IIoT gateway for integrating these to a plant operator's tablet (or website) for real-time visualization of quality, productivity and materials tracking performance on an intuitive dashboard.


THE RESULT:

The adoption of smart business processes allowed the job shop to achieve:

  1. Zero Material Loss;
  2. Elimination of Operator Errors & Improvement in Labour Training, Productivity, & Operator Empowerment;
  3. Intelligence-Driven Short Interval Control;
  4. Removal of Paper-Based Data Entry;
  5. Improvement in the Accuracy of Quality & Production Performance Data;
  6. Evidence-Based Decision-Making by Management.

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