DEETEE Industries — Real-Time Production Intelligence Across Three Manufacturing Units

 

Industry: Precision Roll & Tooling Manufacturing
Units: Rolling Mill Rolls (RMR) · Tube Forming Rolls (TMR) · Tooling
Solution: Custom Manufacturing Execution System — Web Portal + Barcode-Enabled Tablet Application

 

The Challenge

DEETEE Industries operates a demanding precision manufacturing environment across three units — yet despite operational maturity, the shop floor was running entirely without data:

• No real-time machine visibility — supervisors had no way to know if a machine was running, idle, or in breakdown without physically walking the floor

• No order tracking — once a job was released to the floor, there was no digital trail of which stage it was at or how long each operation was taking

• No delivery ETAs — completion estimates were based on experience and gut feel, not actual production data

• No WIP visibility — work-in-progress across stages was unknown, making planning, prioritisation, and customer commitments unreliable

• No cycle time data — operations were never timed, leaving no benchmark to measure efficiency or identify process deviations

• Manual log books — operator production records were handwritten, error-prone, and never fully trusted

• No machine utilisation tracking — run time versus idle time was never measured, making capacity planning guesswork

• Slow breakdown reporting — machine stoppages and maintenance were communicated informally, with no digital history or escalation trail

• ERP blind spot — the ERP managed orders and inventory, but had zero visibility into what happened on the floor between order release and dispatch

The shop floor was operationally capable — but informationally invisible.

How We Solved It

Cycle Time Benchmarking

We mapped every product's manufacturing route and defined standard (ideal) cycle times for each operation on each machine — creating DEETEE Industries' first scientific production benchmark.

Machine-Operation Mapping

Every machine is mapped to its authorized operations. Operators on the tablet can only log operations their machine is built to perform — eliminating errors and enforcing process discipline at the source.

Live Plant Machine Heat Map

A real-time, color-coded heat map of the entire plant is accessible from the web portal — showing every machine as Running, Idle, Under Maintenance, or in Breakdown, at a glance, from any device.

Production Approval with Cycle Time Alerts

Every completed operation is automatically compared to the ideal cycle time. Operations falling outside ±10% tolerance are flagged — supervisors receive instant notifications, log root causes, and approve entries. This creates a continuous loop of performance accountability.

Sale Order Tracking with ETA

Every order is tracked stage by stage — quantities completed, quantities pending, current operation, and an estimated completion time calculated from remaining operations and benchmarked cycle times.

Quarterly Benchmark Auto-Refinement

Every quarter, the system analyses three months of actual data and suggests corrections to ideal cycle times — keeping benchmarks accurate and continuously improving over time.

Fully Barcode-Enabled Workflow

The entire shop-floor workflow runs on a barcode scanner. Scan to start. Scan to stop. Minimal tablet interaction means faster adoption and zero disruption to production pace.

Language Support for Operators

Tablet interfaces include regional language patches — removing literacy barriers and ensuring every operator can use the system confidently.

Role-Based Dashboards & Reports

Supervisors, HODs, plant heads, and top management each see a tailored dashboard with the metrics that matter to their role — WIP, machine utilization, cycle time adherence, order ETAs, and breakdown status — all automated, all real time.

Fully Self-Managed System

DEETEE Industries' own team manages everything — adding machines, operations, users, cycle time tables, and configurations — entirely independently, with no vendor dependency.

 

 

The Outcome

 

Before

After

No machine visibility

Live heat map, every shift

No cycle time data

Every operation benchmarked & tracked

Order ETAs unknown

Data-backed ETA per sale order

Manual log books

Log books eliminated entirely

Machine utilization unmeasured

Run time vs. idle time per machine

Informal breakdown reporting

Instant digital escalation & resolution tracking

 

"For the first time, we have a clear picture of what's happening on our shop floor — at every machine, for every order, at every stage."
— Plant Leadership, DEETEE Industries

Custom MES · Web Portal + Tablet Application · Barcode-Enabled · Self-Managed · Deployed across RMR, TMR & Tooling units