OPTIMIZING
THE SUPPLY
CHAIN ON THE
PRODUCTION LINE
USING ARTIFICIAL
INTELLIGENCE
Case study
Project Challenges
Operating in a continuous production
environment, 24 hours a day, 7 days a
week, GIC Nosag Metal needed a sys-
tem to monitor the flow of raw materials
and containers with finished products in
real time. The previous manual process
was prone to delays, human errors, and
production stoppages, which affected
overall efficiency. The challenge was to
ensure continuous and uninterrupted
production by automating the monitoring
of the supply chain within their robotic
production lines.
“Operating a 24/7 production structure
presents unique challenges, especially
when relying on manual processes to
track raw materials and finished prod-
ucts. We often faced delays and produc-
tion stoppages, affecting delivery time-
lines. It became clear that we needed a
solution to automate and streamline the
entire process, ensuring a continuous,
uninterrupted flow.” Bogdan Ungureanu,
Plant Manager, GIC Nosag Metal
KFactory®’s Innovation
To address these challenges, KFactory®
implemented its module based on com-
puter vision technology. The system
continuously monitors the supply of raw
materials and tracks the loading levels
of containers for finished products. This
automated process includes real-time
alerts and notifications when materials
need replenishing or containers need
emptying, preventing delays and pro-
duction bottlenecks.
Key Features Offered to the
Client:
■
Real-time Monitoring: Cameras
were strategically placed in the
“Loading Area” (where kits are pre-
pared) and the “Robot Area” (where
materials are used). These camer-
as monitor the status of the carts
and alert when refilling or emptying
is required.
■
Automated Notifications: The sys-
tem generates automatic alerts
when carts are empty, indicating
what materials need replenish-
ment based on the operator’s cur-
rent tasks.
■
Color-coded Emergency Levels:
Notifications are color-coded to pri-
oritize tasks, helping teams focus
on the most important actions first.
■
Mobile
Integration:
Operators
responsible for transporting ma-
terials are equipped with tablets
to receive real-time notifications,
allowing timely deliveries and pre-
venting production interruptions.
■
Optimized Workflows: The system
tracks the time required for each
task, allowing efficient workflow
management using the FIFO (First
In, First Out) prioritization method.
■
Error Prevention: The system en-
sures accurate cart identification,
reducing the risk of errors in mate-
rial delivery.
GIC Nosag Metal is the largest company in the GIC
group, a traditional Romanian group in the automotive
market. Known for its high-quality products, GIC Nosag
Metal provides competitive and reliable solutions to
both local and international car manufacturers.
Optimizing the
Supply Chain on
the Production
Line Using Artificial
Intelligence
2 I KFactory®
Results and Benefits
The KFactory® system operates fully au-
tomated, eliminating the need for human
supervision, which brings several signif-
icant benefits:
■
Increased Efficiency: Full automa-
tion reduces human errors and
minimizes production downtime.
■
Reduced Operational Costs: By
eliminating the need for manual
monitoring, teams can be utilized
more effectively in other critical
areas.
■
Scalability: The system can easily
be adapted for various types of pro-
duction or industrial lines.
■
Real-time Optimization: Real-time
data collection allows for quick and
well-informed decisions to main-
tain maximum production capacity.
■
Reduced Unplanned Downtime:
Through automatic monitoring and
notifications, the system prevents
interruptions caused by material
shortages or lack of storage space.
KFactory® I 3
“The
implementation
of
the
KFactory® solution exceeded our
expectations. It brought a level of
automation and efficiency that sig-
nificantly improved our operations.
We are now able to monitor critical
processes in real time, reducing
overall downtime and improving
overall productivity. This solution
has streamlined our workflow, and
we are extremely satisfied with the
results.”, Bogdan Ungureanu, Plant
Manager, GIC Nosag Metal
Conclusion
Artificial intelligence is making its way
into business processes, with its appli-
cation bringing immediate and high-val-
ue benefits. The implementation of
KFactory® at GIC Nosag Metal trans-
formed the company’s supply chain
management, ensuring a more efficient
and error-free production process. The
solution has proven its ability to scale
and adapt, offering measurable value
by reducing downtime, optimizing work-
flows, and lowering operational costs.
UNITED KINGDOM
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