Watco Tanks faced significant challenges managing a highly dynamic production environment. With dozens of workers and hundreds of custom projects, the management team struggled to forecast the cascading impacts of unplanned events, including rush orders, material constraints, and employee time off. Their existing reliance on Excel and off-the-shelf software could not account for the unique variables of tank manufacturing, such as specific worker skill sets and multi-step assembly processes. This lack of a dynamic system meant the production schedule was often outdated the moment it was printed, leading to suboptimal resource use.
Business Need: Watco Tanks faced significant challenges managing a highly dynamic production environment. With dozens of workers and hundreds of custom projects, the management team struggled to forecast the cascading impacts of unplanned events, including rush orders, material constraints, and employee time off. Their existing reliance on Excel and off-the-shelf software could not account for the unique variables of tank manufacturing, such as specific worker skill sets and multi-step assembly processes. This lack of a dynamic system meant the production schedule was often outdated the moment it was printed, leading to suboptimal resource use.
Solution: Kinetech designed and deployed a custom cloud-based scheduling application to serve as the operational brain of the factory. The solution utilizes an intelligent algorithm that factors in delivery dates, material availability, and individual worker certifications to produce an optimal daily schedule. Dynamic Orchestration: Management can submit new order requests and instantly visualize the downstream impact across the entire production line, enabling better management of high-priority orders. Mobile Shop Floor Integration: Operators use a mobile application that provides a visual representation of the schedule at their workstations. This ensures tasks are executed in sync with management priorities and allows operators to set appropriate expectations in real time. Parameter-Driven Control: The system allows for granular control over production steps and estimated task times, enabling more accurate projections and a better customer experience.
Results: The implementation provided Watco with a strategic advantage through total schedule visibility. By moving from a static to an intelligent scheduling model, the company achieved a triple-digit ROI and established a foundation for a true Digital Factory. The feedback loop between the shop floor and the schedulers enables continuous optimization, as actual production results are compared with forecasts to fine-tune efficiency. Watco now manages its growth with confidence, knowing it can maximize its capacity and labor resources while maintaining strict delivery deadlines for its global energy clients. Full Case Study: https://www.kinetechcloud.com/case-studies/watco-tanks