How FalconPCS is fueling an Aviation & Defense company to boost their productivity while reducing labor costs?



About

“Rossell Techsys” is an Aerospace and Defense (A&D) Division of Boeing Limited is a CEMILAC approved organization for "Design, development and testing of hardware and software systems for airborne applications, Test Rigs and Fabrication of Aircraft Looms.

Business Situation

Rossell Techsys has a state of art aircraft component manufacturing unit in Whitefield, Bangalore. Rossell had been using its JD Edwards ERP system to manage its shop floor operations, relying on 100% manual data input and a paper-based routing processes. Also, Visibility on the shop floor activities was limited with several tools being used to capture and consolidate data to get the correct picture.

Theodore, Rossell identified that it’s time to restructure their complete processes and implement a production control system with objective of streamlining its shop floor process, thereby enhancing cost efficiencies, boosting productivity and maximizing production.


Key Challenges

Prior to implementing FalconPCS, Rossell has faced with key challenges including

  • Production Orders Accuracy
  • Routing Optimization
  • Poor Workstation and Operator Performance
  • Shop Floor Wastages
  • Inaccurate Data Collection
  • Obsolete Production Mechanisms
  • Unavailability of real time data
  • Labor idle times

The Solution

To effectively manage the execution of orders in multiple production lines and sales channels, along with its finished goods and spare parts inventories, Rossell required a sophisticated Production Control System with aerospace grade standards to manage such issues in a systematic manner, thereby reducing manual interventions and increasing workstations productivity.

Following a comprehensive review of five possible vendors, Rossell selected Inventrax due to its blend of rich functionality and ease of use solutions to meet their business requirements.


Solution Provided

Being a pioneer of supply chain operational technologies, Inventrax with its core SCM expertise and innovation, has implemented a robust Production Control System (FalconPCS) as a complete end to end traceability suite with its Shop Floor Tracker coupled with Warehouse Management System using adaptive multi-platform technology to delivery optimum production capability and to meet the rising business demand.

  • Centralized System handling multiple production lines and workstations
  • Adaptable workflow mechanism built for continuous process improvements
  • Tightly coupled integration with multiple execution systems
  • Dynamically managed production, storage, and distribution networks

Benefits

Some of the benefits the company has witnessed post the adoption of BizTalk Server and the migration of application to it are as follows:

Rational use of satellite bandwidth: Freeing up satellite bandwidth across all transponders of Express Queues, which is now being utilized for other type authorizations of conditional access system, thus drastically bringing down total cycle time of regular authorization and pairing commands.

Lesser Traffic to Conditional Access System: Post implementation, the traffic to the conditional access system has reduced by about 50 percent and now rests at a manageable level.


Solution Provided

Being a pioneer of supply chain operational technologies, Inventrax with its core SCM expertise and innovation, has implemented its Flagship solution-FalconWMS built with quality and traceability engines using adaptive multi-platform technology to streamline operations and create and maintain a more centralized fulfilment network for Nilkamal Industries

  • Strategic Implementation Timeline of 3 Weeks
  • Real Time Integration with dual SAP Landscapes(SAP R3 and SAP Retail)
  • Centralized System handling multiple production and distribution units
  • Adaptable workflow mechanism built for continuous process improvements
  • Tightly coupled integration with Conveyors, Sorters and other ADC systems

Benefits Delivered

By streamlining and future-proofing the operation, Inventrax has delivered mission critical time and cost saving with

  • Lean Inventory management
  • Improved order fulfillment, accuracy and speed
  • 100% inward quality control as per Aerospace standards
  • Efficient quarantine mechanism for rejected and scrapped material
  • Improved quality kitting at store level before issuing to production
  • Effective management and real-time visibility of shop floor activities
  • Increased yield along with product quality
  • Eliminate wastages throughout production, checks for – machine, material, worker, tool availability
  • Paperless shop floor and material dispatch management
  • Reduced labor Idle times and increased productivity