Boosting Factory Efficiency: Real-Time Production Control Success Story

In their quest to propel operations into the future, our client faced the daunting challenge of enhancing visibility and efficiency across their factory floor. Determined to transform their production landscape, they partnered with Nigma, to build a cutting-edge solution that would deliver unparalleled insights and control.

The client was grappling with several critical issues:

  • Fragmented Data Collection: Production sheets were manually collected from operators, leading to incomplete and delayed information.
  • Production Delays: These delays were directly impacting the production schedule and causing costly bottlenecks.
  • Quality Control Issues: The absence of real-time data made it difficult to address quality issues promptly, affecting overall product standards.
  • Communication Breakdown: Incomplete information caused communication gaps between departments, hampering collaboration and coordination.

To address these challenges, the client aimed to implement a system for live data collection and automation, significantly enhancing operational efficiency, improving decision-making, and reducing paper usage.

Key Steps in the Collaboration

  1. Requirement Gathering: Nigma conducted comprehensive interviews and workshops with both the management team and factory operators. This deep dive ensured a clear understanding of the client's vision, specific feature requirements, and compliance with industry regulations.
  2. MVP Definition: Together, Nigma and the client defined the scope of the Minimum Viable Product (MVP), focusing on core features such as real-time workstation and factory floor oversight, product status tracking, a customized portal, and the ability to download specific product drawings.
  3. User-Centric Design: Nigma prioritized a user-centric design, ensuring that the new system was intuitive and straightforward for operators. Usability tests and user feedback were integral in refining the platform’s interface and functionality, making administrative tasks effortless and efficient.

Results and Impact

The collaboration with Nigma resulted in transformative benefits:

  • Dramatically Increased Efficiency: Real-time data collection streamlined operations, eliminating delays and reducing downtime.
  • Optimal Resource Utilization: Automated processes enabled better allocation of resources, enhancing productivity.
  • Data-Driven Decision Making: Access to real-time information empowered managers to make informed decisions quickly.
  • Paper Reduction: The digital platform significantly cut down paper usage, contributing to environmental sustainability.
  • Enhanced Accountability: Operators were more accountable with transparent, real-time tracking of their work.
  • Improved Quality Control: Immediate access to data allowed for swift identification and resolution of quality issues.
  • Better Compliance and Reporting: Automated data collection ensured accurate and timely compliance and reporting.

"Since implementing the new system, we've been able to increase our production capacity by 20% per week. The real-time data collection has eliminated delays and bottlenecks, enabling us to make swift, informed decisions. It's transformed the way we work, from the factory floor to management."
John - Production Manager


Implementing this innovative software system revolutionised factory floor management for our client. It led to heightened operational efficiency, cost savings, environmental sustainability, and a modernised factory poised for future growth.

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Post Date - 2023/11/09