CASE STUDY

Streamlining Production Management
with the Kysis System

Custom Software Development
Automotive

Project Highlights

Scope

  • Developed the Kysis system to manage, track, and report on cover manufacturing production across various machines.
  • Integrated with SAP for hierarchy, production operations, and part numbering management.
  • Enabled data-driven decisions through extensive part tracking and resource optimisation.

Challenges Overcome

Addressed inefficiencies in production tracking and reporting.

Integrated data tracking across multiple machines into a centralised system.

Streamlined operations by automating part identification with QR codes.

Business Impact

The Kysis System delivered significant improvements in production management and efficiency.

Production Tracking Efficiency

Data Accuracy in Reporting

Resource Optimisation

Operational Downtime Reduction

These advancements streamlined production processes, improved data-driven decision-making, and optimised resources across the factory.

The Client

A global leader in the automotive industry, the client is recognised for their innovative manufacturing practices and cutting-edge engineering.

  • 130+ years of automotive expertise and manufacturing excellence.
  • Produces over 2 million vehicles annually for global markets.
  • Employs a workforce of more than 150,000 people worldwide.
Mechanic holding a digital tablet with car diagnostic software in front of a vehicle engine.

The Problem

The client’s bus factory required an efficient solution to:

  • Manage and report on cover manufacturing production across multiple machines.
  • Track operations with detailed data while ensuring seamless integration with existing SAP systems.
  • Optimise resource usage and simplify part identification.

The Solution

BGTS designed and implemented the Kysis System to meet these requirements:

Comprehensive Production Management

Enabled tracking, follow-up, and reporting throughout production stages.

SAP Integration

Linked with SAP to streamline hierarchy, operations management, and part numbering.

Advanced Data Tracking

Captured over 200 data points per part, enabling precise monitoring and reporting.

QR Code Optimisation

Converted part numbers into QR codes, enhancing operational efficiency and resource utilisation.

Team & Technology

Tech Stack Utilised

Frontend

  • MVC
  • HTML
  • JavaScript

Backend

  • Entity Framework
  • Microsoft SQL Server
  • SAP Integration

Team Composition

2 backend developers

1 frontend developer

1 project manager

The Outcome

The Kysis System revolutionised production management at the client’s bus factory.

Enhanced Production Oversight

Centralised tracking and reporting improved visibility across multiple machines.

Seamless SAP Integration

Streamlined operations by aligning with existing systems for part numbering and hierarchy management.

Improved Resource Utilisation

QR code implementation optimised operational efficiency and reduced manual effort.

Data-Driven Decisions

Detailed tracking of over 200 data points per part enabled precise insights, leading to smarter resource allocation.

This advanced system significantly improved production efficiency, resource usage, and operational oversight, aligning with the client’s commitment to manufacturing excellence.