Consultancy that Delivers

Every operational challenge is an opportunity – if you can see it clearly

In today’s environment, economic pressure and political uncertainty are having a real impact on productivity across the UK, and Europe. When margins are tight and confidence is fragile, clarity becomes critical. Are you recognising your operational challenges within the process – and, more importantly, the wish to improve efficiency?

Industry 4.0 isn’t about complex or disruptive technology. It’s about understanding what is really happening in your business, in real time. Then using the insight to make better decisions. Having the information available to answer customers’ questions, improving customer service.

Creating true and real time visibility of your process

With over 30 years of international experience, we support organisations in designing smarter process flows and implementing practical data capture methods that teams can use. The focus is straightforward: improved real-time visibility, leading to an increased control and understanding where the pain points in the process are and can be improved.

First step: Start with a Scoping

It is important to begin with a structured approach, understanding the process and mapping out the existing data collection point, as well as the requirements for that data.

The scoping phase is a well-designed and proven structure:

Gaining a deep understanding of the current process flows, what data is being collected, and how it is captured. This includes on-site observation and discussions with operators to understand how the process really works in a day-to-day practice.
Reviewing and validating these observations with you and your team to ensure a shared and accurate view of the current state.
Designing a structure for automatic identification and data capture, reducing manual recording and providing real-time visibility of the process.
Developing a clear business case, including potential ROI, and reviewing this together with your team.
Purpose: Presenting the findings in a concise report to support your internal discussions and decision-making.

Advice, considerations and key lines to consider

A process fitting a ERP / MRP / WMS system is not a simple to install off-the-shelf, ‘plug and play’ product.

Salespeople will tell you ‘Their’ system will be able to run your business. It probably can, but it’s likely to require after sales (often) expensive customisation – taking far longer than planned.

Integration will probably require changes – not considered currently – re-engineering the process thinking and operational procedures

Solution Approach

The solution is typically a hybrid of barcode and RFID, designed to be practical, scalable, and aligned with existing operations. Data capture points record key process events— primarily, but not limited to, product ID, date and time, and location. Sometimes including the operator ID.

Key process events are captured at defined points, creating reliable visibility of product movement and process performance. The basics for your KPIs.

These events are stored in a SQL database, providing a reliable and structured data foundation. A RESTful API enables existing management or ERP systems to access selected data fields for further processing, ensuring integration rather than disruption. In addition, the SQL database supports the development of tailored management information dashboards, using targeted queries to provide additional insight, visibility, and performance tracking as required. This is based on WebApps which makes information visible on standard desk tops, tablets and other mobile devices with an internet access.