#Safety Equipment Manufacturing
Manufacturing
B2B
India
KARAM is a leading global occupational safety brand with a vast portfolio of over 3500 certified products, conforming to multiple national and international standards. With o perations spanning over 100 countries and a workforce of 4200+ professionals, KARAM is dedicated to providing world-class personal protective equipment (PPE), fall protection solutions, and fixed-line systems. The company is committed to innovation, efficiency, and sustainability.
Lack of Production Visibility:
No real-time tracking of work progress in the production line, leading to inefficiencies and order status ambiguity.
Unorganized Workflow Management:
The production process, spanning multiple stages (Cutting Rope, Stitching, Assembly, Stitching Again, Fusion, QC, and Packaging), lacked structured monitoring
Absence of BOQ & SOP:
No standardized Bill of Quantities (BOQ) or Standard Operating Procedures (SOP), leading to material wastage, excess consumption, and production delays.
Manual Employee Tracking:
Employee work tracking was done in Excel, requiring extensive time for monthly consolidation and making wage calculations inefficient
Ineffective Material Utilization:
Excessive or insufficient material cutting resulted in increased costs and decreased operational efficiency.
50% Increase in Production Efficiency: Real-time tracking streamlined operations and reduced delays.
30% Reduction in Material Wastage: Implementation of BOQ and SOP minimized excessive consumption and cutting errors.
80% Reduction in Manual Work Tracking Effort: Automated tracking eliminated the need for Excel-based manual consolidation.
Improved Workforce Utilization: Employees' productivity was effectively monitored, ensuring fair wage calculations and better resource allocation.
Enhanced Order Management & Customer Satisfaction: Accurate production tracking improved order fulfillment and timely deliveries.
Informed Business Strategy – The availability of accurate forecasting data enabled management to make proactive and strategic business decisions.
Smart Card System: Employees were provided with smart cards that served as both digital job cards and ID cards.
Automated Tracking via Data Acquisition System: A custom hardware solution was developed to track order progress at each stage. Employees scan a barcode at each stage of production, updating real-time order status and work logs.
Real-Time Work Monitoring: The system tracks production in real time, allowing management to monitor work status across all production stages and optimize resource allocation
SOP & BOQ Implementation: By defining precise material requirements and step-by-step workflows, material wastage was reduced, and production delays were eliminated.
Automated Employee Productivity & Wage Calculation: The barcode system automatically tracks work hours and completed tasks, replacing manual Excel tracking, saving time, and ensuring accurate wage calculations based on output.
Employee Performance Tracking: Integrated analytics that provided insights into employee productivity based on projected vs. actual sales, helping in performance management and workforce optimization
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