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Letting Data Speak!
Case Study
Optimizing Assembly Line Operations with Pick-to-Light System
About the Client
A diesel engine manufacturing company with multiple assembly lines
Challenge
The client faced challenges in increasing the throughput of their operations and wanted to analyze assembly cycles to identify delay patterns, bottlenecks, and their potential causes. They needed a solution that could handle high-paced environments where picking the right items in the correct quantities was critical.
Key Results
Increased assembly line efficiency by 25%
Reduced picking errors by 95%
Improved overall throughput by 30% across 36 assembly lines
Solution
JashDS developed a comprehensive pick-to-light system to automate and optimize the client's assembly line operations:
Created a central PC application capable of serving a minimum of 36 assembly lines in parallel
Implemented interfaces with lamp controller units and PLCs to manage lamp commands and receive engine model codes
Developed a real-time dashboard displaying ongoing assembly cycle details
Designed a system to import and export assembly station configurations via MS Excel files
Implemented cycle logging and database storage for further analysis
Integrated stock tracking functionality with alerts for low inventory levels
Incorporated diagnostics features for system troubleshooting
Ensured secure access through standard authentication mechanisms
The solution utilized an asynchronous multithreaded architecture to support high scalability and performance, ensuring no delays were introduced in the assembly process.
Technologies Used
C# with Visual Studio 2019
Microsoft SQL Server
TCP/IP protocol
AIOI pick-to-light system
Asynchronous multithreading
PLC integration
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