About the customer
Our client is one of the world’s leading manufacturers of electrical appliances and consumer goods, with annual revenues exceeding USD 1.5 billion. The company specializes in manufacturing and distributing home appliances, lighting solutions, electrical wiring accessories, and various electrical products. In India, the company operates state-of-the-art manufacturing facilities producing over 300,000 ceiling fans monthly, serving both domestic and international markets.
Business scenario
Prior to partnering with Maventic, the client faced significant operational challenges impacting efficiency, accuracy, and customer satisfaction. The packaging process for ceiling fans, with motors and blades produced on separate lines, struggled with synchronization issues.
Challenges
Operating without an automated synchronization system, the client struggled with manual processes that led to inefficiencies, errors, and quality issues.
- High Rejection Rate of 3.5% – Manual matching of motors and blades resulted in a 3.5% rejection rate, translating to 10,500 rejected units monthly and substantial costs from wasted materials, rework, and delayed shipments.
- Tedious Labor-Intensive Processes – Manual screening of 1,250 motor and blade daily combinations was labor-intensive and error-prone, creating bottlenecks during peak seasons and limiting scalability.
- Lack of Real-Time Synchronization – Separate production lines of motors and blades lacked automated tracking systems, leading to frequent mismatches, increased search times, and production delays.
- Manual Process Dependencies – Paper-based tracking and lack of SAP integration created bottlenecks, hindering component traceability and resulting in out-of-sync inventory data.
Solution
Maventic implemented mDEW (Mobile Digital Enterprise Warehouse), leveraging barcode technology, mobile readers, and seamless SAP integration to automate the fan manufacturing and packaging process.
- Barcode Integration for Sub-Assemblies – Child barcodes were created for both motors and blades, linked by a final item code, allowing them to move through
separate production lines with a common identifier. - Mobile Barcode Verification at Packaging – Packers utilized HHT Motorola mobile devices equipped with barcode readers to verify the synchronization of motor and blade
components during the packaging process. - Integration with SAP Warehouse Management – Achieved seamless integration with SAP’s Warehouse Management functionality for end-to-end digital workflow. The system provided intelligent picking guidance, directing workers along optimized routes to exact bin locations.
