Supply chain operations are distributed across several stages, and the production phase is crucial. But how do you handle the complex set of activities involved across the chain of actions—from raw material arrival at the plant to the finished goods leaving the factory premises? The simple answer is automation.
In-plant functions play an important role in ensuring the flow of materials, equipment, and finished goods throughout the facility. Latest technology innovations have changed the narrative – automation has stepped in as a key agent of transformation.
What is In-Plant Logistics?
Plant logistics refers to logistics activities involving the systematic management of materials and goods within the plant facility. Coordinating such crucial internal movements maintains production schedules, minimizes delays, and balances all compliance requirements.
However, traditional methods involving manual management processes such as pen-and-paper or spreadsheets have become outdated, with high instances of errors and delays and ultimately compromise customer satisfaction.
Consequences of Uncoordinated In-Plant Logistics
Manual handling of plant logistics poses significant challenges that hamper the overall supply chain.
Longer Turn-Around-Times (TAT)
Manual operations and paperwork cause delays, stretching turnaround times and impacting overall production.
Financial Impact of Weighing Errors
Manual weight recording leads to billing inefficiencies with vendors. Moreover, incorrect weighing records cause financial losses.
Resource Underutilization
Due to congestion in the yard, equipment and labor utilization might not be optimum, leaving a significant scope for improvement.
Safety Risks
Manual operations are repetitive and often lead to ignorance, causing workplace injuries and cargo damage.
Disruptive Information
Due to the involvement of paperwork and manual operations, information silos are created, affecting communication among departments.
Introducing AI capabilities into yard operations is the only way to streamline activities and enhance overall efficiency. Fleetx, aided with innovation, has been able to address the challenges by harnessing the power of AI.
Emerging Trends Simplifying the Process
With the growing focus on technology, digital solutions are gaining steady popularity. Some of the latest shifts are:
AI & Machine Learning - Application of machine learning and automation for faster decision-making, simplifying workflows, and improved risk detection.
Integrated Virtual Ecosystems - A unified digital landscape combining plant, yard, and the supply chain network offering holistic control over operations.
Cybersecurity Developments - Security frameworks have undergone significant enhancements to secure interconnected systems from several cyber threats.
Automated In-Plant Components: Essentials of a Thriving Supply Chain
IIoT (Industrial Internet of Things) Integration
Interconnected smart sensors and devices for collecting real-time data and facilitating insightful analysis. A technology integration that has been highly efficient in predicting equipment failures, streamlining timely maintenance, and minimizing downtime.
Robotic Process Automation (RPA)
Robotic processes are designed to assist humans in improving operational efficiency and safety. The AI and ML-based systems adjust operations dynamically to enhance performance and reduce waste.
Distributed Control Systems (DCS)
Advanced control mechanisms where each process is localized and also integrated into a centralized system for a comprehensive business view.
Edge Computing
Comprises real-time data processing systems that reduce latency by leveraging the cloud infrastructure for analytics and faster decision-making.
Smart HMI
Systems built to improve operator interactions with automated systems through intuitive dashboards, AR/VR support, and multi-device connectivity.
Smart Plant Logistics Management Solution from Fleetx
To find concrete solutions to challenges such as visibility issues and higher costs, Fleetx has utilized its technology expertise and developed a robust yard management system as part of the TMS offering. The system features are:
Gate Management
To efficiently execute the process of truck management at gate-in and gate-out. Our in-plant app helps security personnel identify the vehicle number using OCR technology to avoid thefts at the gate and the security person can record the gate-in/out timings.
Weighbridge Functionalities
Users can record the tare and gross weight readings automatically or integrate with any weighbridge to record these readings. Automated practices ensure accurate load management and meet compliance requirements.
Task Management
Yard personnel receive updates on their systems or smartphones regarding their assigned tasks, thereby improving resource utilization and saving time. The approval mechanism in the platform enables better alignment.
Insightful Reporting
The platform captures key KPIs digitally including gate metrics, LR generation, and yard check efficiency.
How do the Users Benefit?
The various advantages of using an automated YMS include:
- Higher Visibility
Integrating yard management software in the plant operations provides real-time visibility into the yard operations, enabling adequate resource utilization and addressing the demand-supply fluctuations better.
- Automated Vehicle Entry and Exit
Capturing the gate-in, and gate-out data helps keep a tab on the vehicle’s movement within the facility. Digital workflows enable driver compliance management and streamlined vehicle registrations, eliminating laborious paperwork.
- Real-Time Data Availability
System integrations that include weighbridge automation, RFID, and GPS technology provide ready information on the weight and location of vehicles and shipments within the facility.
- Cost-Effectiveness
With digitized operations, plant expenses can be reduced significantly by removing labour and detention charges
- External Integration Capabilities
The Fleetx YMS can be seamlessly integrated with existing systems or new ones to enhance the plant’s operational capacities and improve inter-departmental communication.
- Higher Scope of Monitoring
The AI-driven visibility into in-plant processes offers real-time control over several elements of operations, from the vehicle entry to its exit. The security standards rise as well.
- Improved Efficiency
By bypassing the need for paperwork related to invoicing, waybills, goods received notices (GRNs), and more, plant managers save operational time, remove manual errors, enhance compliance standards, and ultimately fuel customer satisfaction.
- Ongoing Focus on Process Improvement
Setting strategic KPIs ensures accurate measurement of performance metrics, aiding the managers in quick detection and modification of the problem areas, improving yard processes continually.
Manage Your In-Plant Operations with Fleetx Intelligence
With the world gradually shifting to AI and IoT-based solutions, organizations are setting new standards for measuring success. The adoption of technological advancements is leading to significant cost savings, higher productivity, and organized workflows, making this the ideal time to implement the much-needed operational reforms.
At Fleetx, the latest technological updates are consistently leveraged to deliver state-of-the-art solutions to clients while optimizing their plant logistics and enabling higher efficiency.
