Digital Automation for Manufacturing
Company Overview
The client is a large-scale manufacturing company in the industrial equipment sector. With highly complex assembly lines and a wide variety of SKUs, they needed to improve efficiency, minimize downtime, and ensure consistent quality. Manual setup of machines and repetitive operator tasks slowed production and introduced human error.
Problem
The production process faced several bottlenecks:
Time-consuming equipment setup
operators needed hours to configure machinery for new product runs.
Error-prone manual processes
repetitive tasks increased the risk of setup mistakes and inconsistent quality.
Lack of digital traceability
limited ability to track production steps and detect root causes of defects.
These challenges reduced throughput, increased defect rates, and created delays in fulfilling customer orders.
Solution
We designed and delivered an AI-driven automation platform that streamlined setup processes and digitized manufacturing workflows. The solution combined voice-enabled AI assistants, process automation, and real-time analytics to improve efficiency and ensure traceability across production lines.
Key Technologies Used
Whisper (speech-to-text)
for hands-free, voice-driven equipment setup.
Python scripts & automation frameworks
to orchestrate workflows and reduce manual steps.
IoT data integration
for machine telemetry and production monitoring.
Digital Traceability Systems
ensuring every step was logged for compliance and QA.
BI Dashboards
real-time visibility into performance and quality metrics.
Team Composition
- 2 AI Engineers — built voice recognition and automation logic.
- 2 Data Engineers — integrated machine telemetry and production data.
- 1 Project Manager — ensured coordination with factory operators and on-time delivery.
Responsibilities & Execution
Operators used an AI assistant powered by Whisper to configure equipment hands-free, reducing setup time and errors.
Replaced manual steps with scripted processes that triggered automatically when conditions were met.
Implemented end-to-end logging of production activities, ensuring full visibility and compliance.
Built BI views of throughput, defect rates, and downtime, enabling supervisors to act instantly on issues.
Delivered an intuitive system that minimized training time and improved operator productivity.
Results
- 15–20% increase in throughput, enabling faster production cycles.
- 25–35% reduction in defects, driven by automated setup validation and error prevention.
- Significant time savings in equipment setup, cutting hours down to minutes.
- Higher operator efficiency — workers could focus on oversight rather than repetitive tasks.
- Full traceability across manufacturing processes, improving compliance and audit readiness.