Case Study

Production Monitoring System

Ver. 0 Dated: 23/12/2016 The above logo used belongs to its respective owner
Overview:
The Bata brand was established on August 24, 1894 in Zln, then in Austria-Hungary (now in Czech
Republic). The company first established itself in India in 1931 by renting a building to start an
experimental shoe production plant in Konnagar, West Bengal with 75 Czechoslovak experts. Jan
Antonin Bata then built up an industrial manufacturing city called Batanagar in 1934, as well as
other factories in Digha and Patna, and elsewhere in India, employing more than 7,000 people.
Later Batanagar became one of the bigger suburban towns near Kolkata.

Challenges:

To maintain the company production target and constantly motivate its employees, Bata wanted to
translate the performance target into real-time visual indication at the end of each production line.
Actual visual indication of production and performance target will help motivate the employees and
on achieving the target will boost their morale and confidence level.

Solution:

Compucare with its expertise was able to rise up to the challenge of Bata by providing Production
Monitoring System. The Production Monitoring System consists of Production Sensor, Trigger
Switch, Smart Electronic Display one each in every production line. The Web Interface Units is
centrally located to manage connectivity with PMS devices for one or more production lines within
a building. The supplied Smart Electronic Displays are single sided with bright red LED display, the
display boards are clearly visible upto a distance of 10 meters and is designed to suit their factory
condition.

There are four updatable data parameters such as Dept. No. for that particular production line,
Target for the day, Actual achieved and the production percentage.
How Production Monitoring System is achieved?

The Web Interface Unit is installed

The Production Sensor are coupled with their mechanical switch at the end of every
production line

The Production Sensor communicate with the Web Interface Unit wirelessly

The Smart Electronic Display is installed at the end of every production line

As and when the mechanical switch is triggered at the end of production line the Production
Sensor is also triggered and sends signal wirelessly to the Web Interface Unit

The Web Interface Unit receives the signal and communicates with the software server via
TCP/IP line

The data is populated in the Production Monitoring Software server from the Web Interface
Unit

The Smart Electronic Display software is also installed in the software server

The data from the Production Monitoring Software is fetched and populated in the Smart
Electronic Display software

The populated data is then transmitted via TCP/IP to the Smart Electronic Displays placed
at every production line

The data for Smart Electronic Display is refreshed at regular intervals

The software is accessible from remote devices such as Smart Phone, Tablet, Laptop using
internet connectivity
Technical Layout:

Production Monitoring System

Web Interface Unit

TCP/IP TCP/IP
PMS & LED Software Server
Router/Switch

Production Production Production Production

Sensor Sensor Sensor TCP/IP Sensor
Conveyor Conveyor Conveyor Conveyor

Trigger Trigger Trigger Trigger

Switch Switch Switch Switch
TCP/IP
TCP/IP TCP/IP TCP/IP TCP/IP

Production Production Production Production Line

Line Display 1 Line Display 2 Line Dispay 3 Display N
Actual Image:

Wi-Fi Sensor

Smart Electronic
Display

Trigger Switch

Conclusion:

The installation of the Production Monitoring System has provided the real time dynamic visual
indication of production and performance target. This has also increased the motivation of the
employees and also has instilled confidence in their ability to achieve the timely company target.