Raw Material Registration & Verification DX

Introduction

In the dynamic landscape of the steel industry, efficiency, accuracy, and streamlined processes are paramount for success. One critical aspect is the management of raw materials, where traditional methods often lead to inefficiencies, errors, and operational bottlenecks. Recognizing these challenges, our team embarked on a transformative journey to modernize the Raw Material receiving and verification process at a prominent Steel Service Center.

Challenges Faced

Traditionally, the Raw Material receiving, and verification process relied heavily on manual interventions, presenting several challenges:

1. Manual Preparation: Daily preparation of raw material arrival lists and printing of a large quantity of pre-printed plant labels posed a significant operational burden.
2. Error-Prone Verification: Human errors in picking up the correct plant label and verifying crucial but non-human-readable details against mill labels were prevalent.
3. Non-Conformance Material Incidents: Despite efforts, incidents of non-conformance material (IZAI) persisted, necessitating additional resources for verification.

These challenges not only hampered operational efficiency but also strained manpower resources, leading to suboptimal outcomes.

The Solution

To address these challenges comprehensively, we implemented a robust solution centred around technological innovation:

1. Mobile-Based App and Printer Integration: Introducing a mobile-based application along with a mobile printer revolutionized the process. It enabled on-the-fly printing of plant labels, eliminating the need for manual preparation.
2. OCR Technology Integration: Leveraging Optical Character Recognition (OCR) technology, the verification process was standardized and automated. This integration with the ERP system ensured accuracy and efficiency in verifying critical details.
3. User-Friendly Interface: The solution boasted an intuitive and user-friendly interface, empowering operators to complete tasks swiftly and accurately with minimal training required.
4. Streamlined QC Process: The implementation streamlined the Quality Control (QC) process of inbound raw materials, ensuring adherence to standards and specifications.
5. Real-Time Analytics and Dashboard: A real-time data analytics dashboard provided actionable insights for the operations team, facilitating continuous improvement and informed decision-making.

Results Achieved

The implementation of this digital solution yielded transformative results, empowering the site team and enhancing operational efficiency:

1. Expedited Operations: The operation process saw a remarkable acceleration, with efficiency gains of up to 90%, enabling faster throughput and reduced lead times.
2. Manpower Optimization: Manpower requirements per Raw Material receiving station were halved, allowing for resource reallocation to more value-added tasks.
3. Automation and Standardization: A staggering 95% of the manual processes were automated and standardized, minimizing errors and enhancing consistency.
4. Elimination of Non-Conformance Incidents: By integrating robust verification mechanisms, incidents of non-conformance material (IZAI) during the raw material receiving process were virtually eliminated.
5. Enhanced Traceability and Transparency: The data collection capabilities of the solution facilitated comprehensive traceability and transparency throughout the process, enhancing accountability and quality control measures.

Conclusion

In conclusion, the successful implementation of our digital solution has not only addressed the inherent challenges of the Raw Material receiving and verification process in the steel industry but has also set a new standard for efficiency, accuracy, and operational excellence. By embracing technological innovation and leveraging data-driven insights, organizations can navigate the complexities of modern industry landscapes with confidence, resilience, and sustainable growth.