AI-Powered Work Allotment & Shop Floor Tracking
An intelligent manufacturing execution system developed for an automotive and industrial manufacturer operating in partnership with a Spain-based organization, featuring automated task dispatch and SAP synchronization.
Client Profile & Industrial Context
The client is a premier high-precision component manufacturing company established as an international joint venture in partnership with an industrial leader based in Spain. With strict European and Indian quality certifications, their shop-floor operations run 24/7 across multiple rotational shifts, handling complex multi-stage machining and assembly jobs.
The Production Challenge
Prior to implementing the AI Work Allotment solution:
- Manual Shift Handover: Production supervisors spent 45–60 minutes per shift manually assigning work orders to hundreds of operators based on memory and paper rosters.
- Skill & Machine Mismatch: Inexperienced operators were occasionally assigned to high-precision CNC machines, leading to part rejections and tool breakage.
- Lack of Real-Time SAP Sync: Completed operations were batched and entered into SAP at the end of the day, resulting in delayed inventory valuation and inaccurate job progress data.
- Unbalanced Workloads: Overloading certain workstations while leaving parallel machines idle due to a lack of live capacity visualization.
The Solution: AI Work Allotment Engine
KY Technologies designed and deployed an AI-Powered Work Allotment Application built with React, Python, PostgreSQL, and Power BI that seamlessly integrates with the client's SAP ERP:
AI-Recommended Allocation
Intelligent algorithm calculates optimal operator assignment matching employee skill matrices, past quality ratings, shift stamina, and machine workload.
Live SAP Synchronization
Automated bi-directional integration: pulls work orders instantly from SAP and pushes back completed cycle counts and scrap quantities in real time.
Shop-Floor Kiosk Interfaces
Touchscreen operator terminals allow workers to check in, review digital drawings, log cycle times, and flag machine maintenance calls.
Productivity & Efficiency Dashboards
Live Power BI analytics displaying Overall Equipment Effectiveness (OEE), labor utilization, downtime analysis, and planned vs. actual throughput.
Business Impact
- Shift allocation time reduced from 50 minutes to under 3 minutes.
- Shop-floor machine utilization increased by over 18%.
- Scrap and machining errors reduced by 24% through enforced skill-matrix matching.
- 100% real-time inventory visibility inside SAP ERP.
Project Facts
Client: Manufacturing Enterprise (Spain Partner)
Industry: Automotive & Precision Engineering
Frontend: React, Tailwind CSS, TypeScript
Backend: Python, FastAPI
Database: PostgreSQL
ERP Sync: SAP RFC / BAPI Connectors
BI Analytics: Microsoft Power BI
- Plant Workflow & Time-Study Assessment
- AI Allocation Algorithm Modeling
- SAP Integration Middleware Development
- Kiosk Interface Deployment
- Operational Support & Maintenance
Smart Manufacturing
Ready to automate shop-floor job distribution and connect your factory with SAP?
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