A leading manufacturer of AC/DC power supply units faced challenges in tracking production order confirmations at a serial number level within SAP. Their existing process relied on manual confirmations, leading to errors, inefficiencies, and inaccurate time tracking for machine and labor costs.
To overcome these challenges, they implemented a SwiftConfirmation: Seamless Production & Instant Assurance that streamlined operations, improved cost accuracy, and enhanced traceability
The organisation had the following challenges:
- No Serial Number-Wise Confirmation – SAP’s standard process only allowed order-level confirmations, making it difficult to track individual unit progress.
- Manual Data Entry Delays – Operators had to enter confirmation details manually, leading to delays and errors.
- Inaccurate Machine & Labor Costing – Lack of real-time start/end time tracking resulted in costing variances.
- Disjointed Quality Inspections – In-process quality checks were recorded separately, increasing the risk of missed defects and rework.
- Complex User Navigation – Operators had to switch between multiple SAP screens, slowing down workflow.
Our Solution provides:
- Barcode/RFID Scanning for Serialized Confirmation – Operators scan each unit at the start and end of an operation, automatically confirming the serial number in SAP.
- Real-Time Machine & Labor Time Capture – System logs start/end times to improve cost tracking and efficiency analysis.
- Integrated Quality Inspection at Scan-Out – Defects and test results are entered at the time of confirmation, eliminating redundant steps.
- Single-Screen Interface – A user-friendly dashboard consolidates order confirmation, serial tracking, and quality checks in one place.
- SAP BAPI/API Integration – Ensures seamless data flow into SAP PP (Production Planning) and SAP QM (Quality Management).
The next phase of our app will use AI to analyse production times across multiple orders, helping manufacturers optimise labor, machine utilisation, and capacity planning.
How It Works
- AI tracks actual production times for serial numbers confirmed across different orders.
- It identifies inefficiencies and calculates the optimal labor and machine time needed per unit.
- The system suggests optimized routing values for future production.
- Users review and approve changes in one screen, ensuring quick decision-making.
- Once approved, the app automatically updates SAP routings, aligning planning with real production performance.
Key Benefits
- Better Capacity Planning – Ensures accurate labor and machine allocation, preventing bottlenecks.
- Optimized Resource Utilization – Reduces idle time and improves overall efficiency.
- More Accurate Costing – Eliminates over/underestimation of machine and labor costs.
- Reduced Manual Adjustments – Automates updates, streamlining SAP processes.
- Continuous AI Learning – Improves efficiency with ongoing data-driven insights.
The Use of Artificial Intelligence
The next phase of our app will use AI to analyse production times across multiple orders, helping manufacturers optimize labor, machine utilisation, and capacity planning.
How It Works
- AI tracks actual production times for serial numbers confirmed across different orders.
- It identifies inefficiencies and calculates the optimal labor and machine time needed per unit.
- The system suggests optimized routing values for future production.
- Users review and approve changes in one screen, ensuring quick decision-making.
- Once approved, the app automatically updates SAP routings, aligning planning with real production performance.
Key Benefits
- Better Capacity Planning – Ensures accurate labor and machine allocation, preventing bottlenecks.
- Optimized Resource Utilization – Reduces idle time and improves overall efficiency.
- More Accurate Costing – Eliminates over/underestimation of machine and labor costs.
- Reduced Manual Adjustments – Automates updates, streamlining SAP processes.
- Continuous AI Learning – Improves efficiency with ongoing data-driven insights.
By aligning production planning with real-time data, this enhancement will drive higher efficiency, cost savings, and smarter decision-making—helping manufacturers scale operations seamlessly.
