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®