How Wonder Cement streamlined its in-plant logistics with IoT – ET CIO

As India begins to compete globally within the manufacturing area, adopting worldwide finest practices is a should. But extra importantly, doing extra with much less in lesser time is one thing that may make industries actually aggressive.

For Rajasthan-based cement producer Wonder Cement, chopping down on provide chain delays and handbook course of was one thing that had been appearing as a deterrent for his or her development.

With an annual capability of manufacturing near 11 million tonne cement, Wonder Cement is already amongst India’s largest cement producers. But strengthening that place required large adjustments.

While Wonder Cement’s vegetation have been constantly grinding and producing massive volumes of cement, it was usually challenged with the in-plant logistics and provide chain processes involving the actions of supplies and vans from yards to vegetation, loading/unloading of products & uncooked supplies, and order allocations to transporters, environment friendly manufacturing and its well timed supply and extra.

The processes have been principally handbook due to which a variety of time used to get wasted for a truck to get by means of loading and safety checks. From checking, verification, motion, loading to cost, every part was handbook.

Cutting the ready time with automation

How Wonder Cement streamlined its in-plant logistics with IoT“To overcome this challenge, we deployed an Integrated Logistics Management System encompassing its fleet vehicles, weighbridges and production systems. This included IoT-based RFID tags & sensors, positioning sensors, cameras, LED displays and software (integrated with ERP),” Arun Attri, VP-IT, Wonder Cement, advised ETCIO.

The complete resolution was built-in with Wonder Cement’s current core ERP system in order that the administration will get a single view and full management over the information stream.

Trucks have been then outfitted with RFID tags and the second they entered the manufacturing unit gate, the journey would start. In case the automobile is bringing in uncooked supplies, which should be unloaded, the mapping of that truck is completed in opposition to the cost order.

Queues for the vans are made by the system on a first-come first-in foundation. With the assistance of LED shows, the truck drivers are guided the place they’ve to achieve to the designated location for unloading.

To lower down handbook intervention even additional, Wonder Cement Weighbridges utterly automated the weighbridges and weighing of vans is now performed with none human intervention.

“Earlier, each weighbridge was handled by one person and there were three shifts every day. With a total of 17 weighbridges across the plants, 51 employees were needed to manage them. Now, they are totally unmanned,” Attri stated.

The safety of us chargeable for dealing with logistics have been outfitted with digital tablets, which fetch the details about the truck in entrance of them. With this, they get to know who’s the seller, what materials is being carried, its weight, designated unloading space, and many others.

After the unloading course of is accomplished (with none exceptions within the journey), the system creates a receipt and it goes to the transporter.

“With this initiative, the turnaround time of in-plant logistics has reduced by 50 percent. The visibility has increased dramatically leading to smooth and clutter-free movement. Because of the reduced TAT, the transporters are also reaping benefits through additional trips in the same amount of time,” stated Attri.

The firm can now examine historic information of a transporter and in addition settle conflicts with distributors/transporters as each information level is being captured transparently.

For outbound logistics (carrying cement), nearly all of truck fleet related to Wonder Cement is supplied with GPS. Once the truck leaves the premises, the purchasers (seller & distributors) get notified about the identical. The cargo can be tracked utilizing the app.

Attri’s staff has additionally created a digital portal for transporter engagement known as Transportal.

On the portal, the corporate posts (a number of occasions a day) calls for for vans to move sure masses throughout numerous places. This is completed by bidding on the portal the place transporters bid for the routes and masses that they want to carry.

Another problem was the late arrival of receipt, which the truck delivering the consignment acquired from the seller. This mechanism, primarily based on bodily receipts, delayed the cost course of for transporters. To make the funds course of faster for the transporters, Wonder Cement additionally carried out Electronic Proof of Delivery.

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