Insights: Case Studies

Shopfloor Digitisation

Manual shopfloor inspections resulted in data entry errors, poor traceability and limited visibility into product quality.
Shopfloor Digitisation

Shopfloor Digitisation

Manual shopfloor inspections resulted in data entry errors, poor traceability and limited visibility into product quality.

Problems at hand:

At an excavator manufacturing company based in West Bengal, every machine underwent a Pre-Dispatch Inspection (PDI) after the paint process to verify coating quality. The inspection involved measuring Dry Film Thickness (DFT) using a DFT Meter and surface gloss using a Gloss Meter, along with visual checks and recording inspection observations. However, all inspection results were manually entered into paper forms and later transferred to Excel, making the process time-consuming and prone to errors. The absence of digital data capture resulted in poor traceability, limited historical analysis, delayed reporting and no real-time visibility into product quality.

The Intervention:

System Architecture

The solution was built around a Power Apps-based digital inspection platform running on a handheld device. During inspection, readings from the DFT Meter and Gloss Meter were transferred wirelessly via Bluetooth and captured directly into the Power App, eliminating manual data entry. Inspection data was stored centrally in a SharePoint database, enabling secure record management and traceability. Power Automate was used to generate and distribute automated reports, while Excel dashboards provided real-time visibility into inspection status, quality trends, and operational performance.

Benefits:

Real-time dashboards transformed inspection data into actionable insights. The system enabled live monitoring of inspection status, quality trends and operational performance while improving traceability, reducing manual effort and supporting faster data-driven decision-making.

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