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Shop Floor Automation
40%
60%
70%
80%
About
Our client is the world’s leading manufacturer of construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives. The company principally operates through its three primary segments – Construction Industries, Resource Industries and Energy & Transportation – and also provides financing and related services through its Financial Products segment.
Business Challenges
The shop floor comprises supervisors and operators. Supervisors have to schedule job cards for the operators. They should also measure their performances at the end of the day. This was performed manually by the client. The process was time-consuming, lacked accuracy which impacted their overall productivity and efficiency.
Solution
The solution simplified the laborious manual process of assigning job cards to the operators on a day-to-day basis. The plant supervisors were able to assign tasks with a touch of a button and the operators were able to update their job details, factors impacting efficiency by the end of the day without breaking a sweat. The shop floor digitization solution reduced the time and cost involved in the process and made the process completely paperless.
Our Approach
Our Steps
Outcome
Frequently Asked Questions
How did Caterpillar digitize its shop floor job card assignment process?
Hakuna Matata replaced Caterpillar's manual job card system with a digital platform where plant supervisors assign tasks with a single tap and operators update their job details and efficiency factors at end of shift — eliminating paperwork entirely and reducing the time and cost of the process.
What productivity gains did Caterpillar achieve with shop floor automation?
The shop floor automation solution delivered a 60% increase in overall productivity, 40% improvement in labour efficiency, 70% reduction in data entry time, and an 80% reduction in shift handover time — giving supervisors and managers real-time visibility through interactive dashboards.
What technology stack powers Caterpillar's shop floor automation solution?
The solution was built using Angular and .NET Core for the web-based supervisor dashboard, and React Native for the mobile app used by shop floor operators — enabling cross-platform access across both web and mobile devices on the factory floor.
How does the shop floor mobile app help operators and supervisors coordinate shift handovers?
Operators update task status and log efficiency factors directly via the mobile app, while supervisors can dynamically reassign tasks for the next shift or day with a single action. This real-time coordination cut shift handover time by 80% and eliminated the accuracy issues caused by manual tracking.
Selected Work
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