Manufacturing Intelligence

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Maximise Production Potential

Driving Overall Equipment Effectiveness (OEE), where peak efficiency is the constant objective. Gain insights for better decision-making, intelligent manufacturing, and superior efficiency with our manufacturing intelligence solutions.

Empowering

Key Features
Experience superior production monitoring with our manufacturing intelligence software.

Performance Monitoring

Equipment Availability Monitoring

Quality Assurance Monitoring

Machine Integration and Tool Tracking

Key Advantages

IoT-enabled High-performance Sensors

Cloud-based Analytics, Instant Updates and Breach Alerts

Remote Monitoring and Control

Quick Integration with ERP, MES, and Shop-floor Machines

Identify Defects in Real-Time

Equipment Utilisation and Efficiency Monitoring

Unlock full manufacturing capabilities

Improve Equipment Performance

Efficient Resource Allocation

Enhance Quality Control

Increase Operational Efficiency

Enhance Production Output

Ensure Regulatory Compliance

Industry Applications

Automotive

Enables advanced traceability and shop-floor integration, optimizing workflows while ensuring industry compliance.

Life Sciences

Manages BOMs, sensitive components, and automated machine data capture for zero-defect manufacturing.

Fast Moving Consumer Goods (FMCG)

Fast Moving Consumer Goods (FMCG)

Integrate with packaging lines and weighing scales, ensuring FIFO/FEFO compliance and agile production planning.

Fast Moving Consumer Goods (FMCG)

Consumer Durables & Electronics

Consumer Durables & Electronics

Integrate with reactors and distillation units for precise recipe control, material traceability, and adherence to compliance standards.

Consumer Durables & Electronics

Integrated Hardware Portfolio

IoT Sensor Stack

Wireless Access Point

Thermal printers

Print & Apply Label Applications

Featured Case Study

From Chaos to Clarity: RFID Tracking Simplifies Asset Movement for a Global IT Company

The client faced significant challenges with asset visibility and traceability, owing to manual processes and inaccurate data. These issues led to lengthy audits, asset loss, increased operational costs, and reduced work efficiency. Additionally, unauthorized movement of IT assets further compounded the issue.

Indian automotive giant achieves 100% traceability and zero-error vehicle inspection with BCI's machine vision solution

The client’s vehicle inspection process relied heavily on manual interventions across critical checkpoints - data entry, stamp validation, and image saving. This led to data inconsistencies, delayed reporting, and quality issues in stamp validations.

WIP automation for a global automotive components manufacturer to achieve real-time production tracking

Despite a robust ERP system, the client faced operational inefficiencies on the shop floor. Manual processes led to tracking gaps, errors in production reporting, and a lack of real-time visibility into material movement across workstations.

Digitizing Oil Transfer Processes for a Global Food Products Leader

The client faced significant challenges with their manual oil transfer processes, which were inefficient, error-prone, and lacked real-time visibility. These challenges affected their ability to ensure compliance, accurately monitor oil flow, and integrate seamlessly with systems like SAP and SCADA(PLC). They sought a digitized solution to streamline operations, enhance accuracy, and reduce user dependency.

Implementing RFID-Enabled Scalable and Streamlined Warehouse Operations for a Global Cables and Wires Manufacturer

The client’s warehouse operations were highly manual and inefficient, leading to significant time consumption and operational challenges. Processes such as barcode scanning, inventory counting, reconciliation, and dispatch lacked automation, resulting in errors, delays, and redundancies that hindered productivity and accuracy.

FMCG Leader Enhances Warehouse Efficiency and Accuracy with Warehouse Management System

The client faced challenges in improving visibility, accuracy, and speed in their warehouse operations for one of their largest portfolio brands. The warehouse handled shipments of approximately 7,000 items in various combinations, sent to 150 stores in the region. Their existing paper-based system for material picking and packing provided limited visibility and was prone to errors, creating delays in material dispatch. Additionally, the manual process for verifying, segregating, and sorting materials made it difficult to process orders for multiple stores in a single picking cycle. This resulted in lost sales opportunities due to inventory stockouts, as the delays and inaccuracies prevented timely replenishment at stores.

Enhancing Batch Traceability and Inventory Management in Electronics Manufacturing for a Leading Imaging Solutions Provider

The client struggled with batch traceability and warranty tracking due to a lack of unique identification for their products. With more than 40,000 SKUs coming from various vendors, tracking product origins and batches during the picking process was challenging. The manual data entry into their ERP (SAP) system hindered real-time inventory visibility, leading to inventory discrepancies, incorrect dispatches, and financial losses from warranty mismanagement.

Implementation of a Manufacturing Execution System (MES) for India’s Leading EMS player

The client faced several challenges that impacted their operational efficiency and growth. The absence of unique product serialization hindered traceability, crucial for quality assurance, especially with rising OEM and ODM requirements for real-time manufacturing visibility. Additionally, manual processes and data entries in quality control and material handling caused inconsistencies and delays. As the company aimed for scalability, addressing these issues became essential to enhance efficiency and meet growing market demands.

India’s Largest Glass Solutions Manufacturer Tracks 38,000 Pallets with 100% Accuracy

The client faced challenges in tracking over 32,000 pallets/Returnable Transport Items (RTIs) across 13 locations, including manufacturing plants, warehouses, and customer facilities. These high-value pallets, often designed to fit OEM-specific vehicle models, needed precise tracking to ensure production continuity and timely deliveries. The manual tracking method lacked real-time visibility, causing delays, misplacements, and inadequate accountability. This led to production downtime and unnecessary costs incurred from purchasing new pallets.

Top ignition system manufacturer in India achieves 100% traceability compliance in PCB manufacturing

The client required complete component-level traceability in PCB manufacturing to comply with their OEM partners' regulations. They faced challenges such as error tracking during production, implementing 'poka-yoke' for defect prevention, integrating machine data, and automating manufacturing rules.

Streamlining Warehouse Operations: NTF India's Digital Transformation Journey with BCI's WMS

The client struggled with slow and disorganized processes, as they were tracking items stored in multiple locations and relying on paper-based manual data recording methods. Accurate material delivery to the manufacturing floor was critical, which necessitated end-to-end traceability of their warehouse operations.

An Indian Transport Company Boosts Yard Efficiency and Visibility to Cut Costs and Improve Customer Satisfaction

The client needed to improve their system for tracking radio taxis at New Delhi's airport parking. The current manual process caused errors and delays, leading to traffic congestion and long wait times for taxis. The unorganized system also made it difficult to track parking fees.

From Chaos to Clarity: RFID Tracking Simplifies Asset Movement for a Global IT Company

The client faced significant challenges with asset visibility and traceability, owing to manual processes and inaccurate data. These issues led to lengthy audits, asset loss, increased operational costs, and reduced work efficiency. Additionally, unauthorized movement of IT assets further compounded the issue.

Digitizing Oil Transfer Processes for a Global Food Products Leader

The client faced significant challenges with their manual oil transfer processes, which were inefficient, error-prone, and lacked real-time visibility. These challenges affected their ability to ensure compliance, accurately monitor oil flow, and integrate seamlessly with systems like SAP and SCADA(PLC). They sought a digitized solution to streamline operations, enhance accuracy, and reduce user dependency.

Implementing RFID-Enabled Scalable and Streamlined Warehouse Operations for a Global Cables and Wires Manufacturer

The client’s warehouse operations were highly manual and inefficient, leading to significant time consumption and operational challenges. Processes such as barcode scanning, inventory counting, reconciliation, and dispatch lacked automation, resulting in errors, delays, and redundancies that hindered productivity and accuracy.

FMCG Leader Enhances Warehouse Efficiency and Accuracy with Warehouse Management System

The client faced challenges in improving visibility, accuracy, and speed in their warehouse operations for one of their largest portfolio brands. The warehouse handled shipments of approximately 7,000 items in various combinations, sent to 150 stores in the region. Their existing paper-based system for material picking and packing provided limited visibility and was prone to errors, creating delays in material dispatch. Additionally, the manual process for verifying, segregating, and sorting materials made it difficult to process orders for multiple stores in a single picking cycle. This resulted in lost sales opportunities due to inventory stockouts, as the delays and inaccuracies prevented timely replenishment at stores.

Enhancing Batch Traceability and Inventory Management in Electronics Manufacturing for a Leading Imaging Solutions Provider

The client struggled with batch traceability and warranty tracking due to a lack of unique identification for their products. With more than 40,000 SKUs coming from various vendors, tracking product origins and batches during the picking process was challenging. The manual data entry into their ERP (SAP) system hindered real-time inventory visibility, leading to inventory discrepancies, incorrect dispatches, and financial losses from warranty mismanagement.

Implementation of a Manufacturing Execution System (MES) for India’s Leading EMS player

The client faced several challenges that impacted their operational efficiency and growth. The absence of unique product serialization hindered traceability, crucial for quality assurance, especially with rising OEM and ODM requirements for real-time manufacturing visibility. Additionally, manual processes and data entries in quality control and material handling caused inconsistencies and delays. As the company aimed for scalability, addressing these issues became essential to enhance efficiency and meet growing market demands.

India’s Largest Glass Solutions Manufacturer Tracks 38,000 Pallets with 100% Accuracy

The client faced challenges in tracking over 32,000 pallets/Returnable Transport Items (RTIs) across 13 locations, including manufacturing plants, warehouses, and customer facilities. These high-value pallets, often designed to fit OEM-specific vehicle models, needed precise tracking to ensure production continuity and timely deliveries. The manual tracking method lacked real-time visibility, causing delays, misplacements, and inadequate accountability. This led to production downtime and unnecessary costs incurred from purchasing new pallets.

Top ignition system manufacturer in India achieves 100% traceability compliance in PCB manufacturing

The client required complete component-level traceability in PCB manufacturing to comply with their OEM partners' regulations. They faced challenges such as error tracking during production, implementing 'poka-yoke' for defect prevention, integrating machine data, and automating manufacturing rules.

Streamlining Warehouse Operations: NTF India's Digital Transformation Journey with BCI's WMS

The client struggled with slow and disorganized processes, as they were tracking items stored in multiple locations and relying on paper-based manual data recording methods. Accurate material delivery to the manufacturing floor was critical, which necessitated end-to-end traceability of their warehouse operations.

An Indian Transport Company Boosts Yard Efficiency and Visibility to Cut Costs and Improve Customer Satisfaction

The client needed to improve their system for tracking radio taxis at New Delhi's airport parking. The current manual process caused errors and delays, leading to traffic congestion and long wait times for taxis. The unorganized system also made it difficult to track parking fees.

From Chaos to Clarity: RFID Tracking Simplifies Asset Movement for a Global IT Company

The client faced significant challenges with asset visibility and traceability, owing to manual processes and inaccurate data. These issues led to lengthy audits, asset loss, increased operational costs, and reduced work efficiency. Additionally, unauthorized movement of IT assets further compounded the issue.

Our Latest Blogs

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Automation in Textile Industry

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Supply Chain Management in the FMCG industry

21 May 2025

Benefits of Inventory Management

21 May 2025

Humidity Sensor in IoT

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