Implementation of Industrial Traceability Systems: A Case Study of a Luxury Metal Pieces Manufacturing Company

Abstract

Technological advances have shown an accentuated growth trend, which is directly proportional to the quality of life in today’s society. As a result, the business market is becoming increasingly competitive and customers are becoming more demanding, forcing companies to look for new tools and adopt new work methodologies to improve their flexibility, effectiveness and efficiency, ensuring a better response to market needs. In this context, the tools for tracking objects, totally or partially automatic, are considered essential technologies to all kinds of analysis and the treatment of business data, providing several benefits to companies, including waste reduction, identification of bottlenecks, cost reduction, improvement of product quality and the entire flow of business information. A case study of an industrial company specializing in machining, polishing and galvanoplasty of metallic alloys, small size pieces to be incorporated in luxury fashion accessories, is presented. Derived from the difficulties underlying the implementation of a traceability system supported by identification technologies and obtaining data in an automatic way, the focus of the study is based on the identification of a base model, with sequential steps, which allows any industrial company to adapt these types of technological tools and systems. Based on the pillars of knowledge acquired through a bibliographic review on the subject, as well as on the recognition of the whole production flow, this work makes use of an implementation model already developed, studied and tested, supported by a project viability analysis measuring the benefits obtained with the results found after the respective implementation. Production performance increased with the implementation of a traceability system, as the time worked throughout the flow decreased. Production performance prior to implementation was around 98.6%. Applying a Kaizen (continuous improvement) strategy and based on the times collected in the pilot test, this indicator rose by 0.5%, obtaining a production performance of 99.1%, corresponding to an annual increase of 99 pieces. The integration of a robust and simple traceability system supported by automatic identification and data capture (AIDC) technologies in this industrial environment allowed for automated data collection and processing. In addition to the financial and productive benefits, this Industry 4.0 implementation encompasses a huge medium- to long-term impact in functional and monitoring terms, providing enormous aid to the management of production flows.