Application
Software
| Development of
Shop Floor Management system |
 |
Customer
A leading PC manufacturing plant in India
Business Challenge
The customer was getting end-user complaints to an extent of 2%
because of over /under shipping against the customer orders. There
use to be revenue losses as support personnel were unable to judge
the warranty claims due to lack of item tracking procedures.
The current production process was totally human /resource dependent
– such as identification of right set of drivers for a given
configuration, validation of the installed drivers / components
etc. The company wanted to automate most of their critical operations
of the manufacturing process
Solution
Caravel did the complete business process re-engineering by visiting
multiple plants and devised a new shop floor management process
[adhering to standard engineering practices] to bring down the end-user
[customer] complaints to literally 0%.
Caravel had devised new techniques of automating most of the critical
tasks so as to bring in fool-proof mechanisms in Item tracking,
Component based signature collection, Configuration validation,
Automated OS loading with right set of drivers, packing and dispatch.
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| Development
of Customer Support System |
|
Customer
A leading PC manufacturing plant in India
Business Challenge
The customer would like to have the data that was collected in their
shop floor management system to be on-line in order to validate
the customer complaints, especially when the part /item replacement
is taking place during the on-site repair process by their service
personnel.
Solution
The qualitative data that was captured during the PC manufacturing
process is made available on-line through this system.
The customer support personnel, can check / validate the component
serial numbers directly from the site[ end-user location] before
taking action against the warranty claims / repair calls / replacements.
Job order based data replication procedures were established to
replicated the data from the factory based SMS server to on-line
customer support system.
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| Development
of Item tracking System for manufacturing industry |
|
Customer
A leading PC manufacturing plant in Singapore
Business Challenge
The customer is a large OEM for multiple PC brands.
As the PCs are getting shipped to various countries of the world,
the local service centers were finding difficulty in warranty replacements,
as the data pertaining to part number / manufacturer batch numbers
of component OEM is not enough to substantiate warranty claims.
Solution
The system was designed in such a way that it acts as an extension
to the ERP system [its manufacturing module] to collect qualitative
information, as quantities and customer order processing is getting
managed within the ERP itself.
The qualitative data collection starts from Stores where the raw
materials received gets scanned to collect the bar-coded serial
numbers.
At the time of issuing the material to shop floor for manufacturing
against the launched jobs, the system facilitates to collect the
serial numbers of all the items that are used in each every machine
in the given job order.
The system guides the assembly operator with an engineering approach
by display the assembly drawings / instructions that are specific
to current assembly process.
The systems takes care of packing and dispatch functions in a controlled
manner, so as to have details on other external components such
as keyboard, mouse, speakers etc that are part of each CPU box and
by which transport /courier the items of the job got shipped.
Using the serial number data that was captured in the kitting phase,
the service personnel located at [country specific] service centers
can check the warranty details directly from the component OEM web
sites.
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| Development
of Automated OS loading System for PC OEM manufacturer |
|
Customer
A leading PC manufacturing plant in Singapore
Business Challenge
The customer is a large OEM for multiple PC brands. Most of the
PCs gets shipped with an OS. While preparing a reference system
with the required OS, there is a tedious and time consuming task
of identifying and installing the appropriate drivers for various
components of the PC, by referring to the respective versions, tracing
the right driver CDs etc.
Solution
This system creates job specific Windows OS images based on Microsoft’s
OPK technologies and linux OS images using the variant specific
automation procedures, by choosing the right set of drivers from
the driver repository.
The Engg personnel keep the driver repository up-to-date, as and
when they receive the latest drivers from various component OEMs,
time to time.
It also verifies the assembled system configuration against the
customer order, on getting the compliance report, job specific OS
images gets installed over Ethernet, after preparing the machine
using WinPE.
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| Development
of Web Based Ordering System |
|
Customer
A leading PC manufacturing plant in Singapore
Business Challenge
The customer is a large OEM for multiple PC brands. The system integrators
/ resellers across the world wanted to build a custom PC based on
the requirements laid down by their end-users. They wanted to make
sure whether the chosen custom configuration is ‘feasible’
to manufacture, because of compatibility /performance related issues.
Solution
The system is intended to avoid the gap /constraints in manufacturing
the custom configured machines [PCs] by the registered Independent
Hardware Vendors [IHVs] and resellers and the marketing personnel.
This system allows the registered users to ‘build’
the machine over web by validating the compatibility of components
against the motherboard, memory, and all other sub-systems in terms
speed, connectivity, compatibility etc. with the help of the product
configuration engine.
The system also provides a tentative base figure of the cost for
volume sales based on the pricing / discount information uploaded
at the given point of time.
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| Development
of On-line verification system |
|
Customer
A leading PC manufacturing plant in Singapore
Business Challenge
With the availability of high-speed internet connectivity, the customer
wanted to save the time of their resellers / IHVs by avoiding the
air-travel to Singapore, just to validate /inspect the production
process of their large orders, on shop-floor.
Solution
This system is intended to provide on-line access to the machines
of the designated job order that belongs to the registered customer
over web.
Besides look at the Job order status as report, the customer can
get hands-on control of a selected PC [ target machine] to personally
examine the configuration, installed custom software etc.
To conduct special test, provision is made to upload the test suite
to designated folder on the server such that the uploaded stuff
is made available to the customer as a shared folder over factory
LAN. The customer can run the specific test out the uploaded the
test suite, the resultant log files can be downloaded back for further
analysis and reporting.
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| Development
of defect tracking system |
|
Customer
An ATM [Automatic teller machine] manufacturer
Business Challenge
The customer is an ATM manufacturer with their HO in Europe.
The customer had engaged multiple OEMs to manufacturer various parts
/ sub-systems for the ATM. The OEMs are expected to deliver 100%
error free items, and checked for their quality directly during
assembly process. If any part is found faulty while assembling over
the conveyer, the entire high-speed production gets slowdown as
the respective operator need to document the defect details against
the respective OEM
The customer wanted to automate the defect logging procedures to
save the precious time.
Solution
A defect tracking system was designed and implemented to cater the
defect logging needs of their multiple assembly lines.
Each assembly line may manufacture different kind of sub-system
that belongs to various types of ATM models.
This system displays the engineering documents pertaining to part
/item that is being assembled on the conveyer based on the stage
of assembly and the type of sub-system that is being manufactured.
If any part is found faulty, the operator scans the part of items
/ its bin from which the part was fetched. The system displays the
respective defect codes to quickly select and close the defect logging
procedure in a shortest possible time. |
