Developing over 25 systems that streamlined operations and data management across the plant
Challenge: Owens Corning, a global leader in the production of fiberglass and building materials, sought to modernize and digitize its operations at the Taloja Plant in India. With a vision of efficiency and precision, they required a comprehensive system overhaul to streamline processes and harness data for informed decision-making.
Solution: Our team embarked on a journey of digital transformation, delivering more than 25 tailored systems and applications to meet Owens Corning's unique needs.
Key Features
1. Shopfloor Systems with Weighing Scale Integration:
>> Developed systems with seamless integration of weighing scales to ensure precise measurements in production processes.
>> Utilized barcode and QR scanners to enhance inventory and production control.
2. Label Printing Systems:
>> Designed label printing systems to enable efficient and accurate labeling of products, improving traceability and compliance.
3. Quality MIS:
>> Created a comprehensive Management Information System (MIS) to monitor and optimize quality control processes.
4. EHS Systems (Environmental, Health, and Safety):
>> Implemented systems to enhance safety protocols and streamline environmental compliance.
5. Employee Trainings:
>> Developed a platform for managing and tracking employee training programs, ensuring compliance and skill development.
6. Employee Performance Card Creation:
>> Facilitated the creation and management of employee performance cards to track and enhance workforce productivity.
7. Audit Systems:
>> Introduced audit systems to automate and streamline auditing processes, improving transparency and accountability.
8. Gatepass System:
>> Streamlined entry and exit processes with a gatepass system, enhancing security and access control.
9. Downtime & Maintenance Portal:
>> Designed a portal for monitoring equipment downtime and scheduling maintenance, reducing production disruptions.
10. Power BI Dashboards:
>> Implemented Power BI dashboards for real-time data visualization and analysis, enabling data-driven decision-making.
11. Big Data Analysis:
>> Big data analysis tools were implemented for in-depth insights into plant operations and performance.
Technology Stack
>> Front-End: ASP.Net Web Forms, Angular JS
>> Back-End: C#.Net Web APIs
>> Database: SQL Server
Results
The digital transformation initiatives had a profound impact on Owens Corning's Taloja plant:
>> Operational Efficiency: The integration of shopfloor systems, labeling, and quality control led to significant improvements in operational efficiency.
>> Safety Enhancements: The implementation of EHS systems contributed to a safer work environment, reducing risks and incidents.
>> Employee Empowerment: Employee training and performance tracking systems improved workforce management.
>> Data-Driven Decisions: The availability of Power BI dashboards and big data analysis tools allowed for data-driven decision-making.
>> Cost Savings: The streamlining of processes and improved quality control resulted in cost savings.
Conclusion
The comprehensive digital transformation at Owens Corning's Taloja plant redefined their operations, enhancing efficiency, quality, and safety.
With a suite of tailored systems, the plant is well-equipped to adapt to industry demands, optimize processes, and make informed decisions through data analysis.
This digital evolution positions Owens Corning for continued success in the competitive manufacturing landscape.
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