We developed a custom mobile PLM application to complement our cloud-based Product Lifecycle Management solution for a Kolkata-based automotive parts manufacturer. The app empowered shop floor workers, managers, and executives with real-time production data, quality alerts, and machine health indicators on their smartphones. Key features included barcode scanning for inventory, AR-assisted equipment maintenance, and push notifications for urgent issues. This mobile extension reduced paper-based reporting by 90%, decreased machine downtime by 35%, and improved cross-shift communication. Production supervisors could now approve workflows, monitor KPIs, and address bottlenecks from anywhere in the facility.
Client Industry
Automotive Components Manufacturing
Client Location
Kolkata, India
Project Duration
5 months (Mobile App Development & Integration)
Team Size
8 (Mobile Developers, UX Designers, Backend Integration Specialists)
Technology Used
- Frontend: React Native (Cross-platform iOS/Android)
- Backend: Node.js (Integration with existing PLM system)
- AR: ARKit/ARCore (For equipment maintenance guides)
- Security: Biometric login, Role-based access control
- Offline Capability: Local SQLite database with cloud sync
- Hardware Integration: Bluetooth barcode scanners, IoT beacons
Client Background
The client operated three manufacturing plants with 500+ shop floor employees still relying on paper logbooks and desktop terminals. While our PLM system had digitized their processes, critical time was lost as workers walked to fixed terminals to report issues or check schedules. Management needed real-time visibility into production bottlenecks, while frontline workers required mobile-first tools that fit their workflow. The aging workforce initially resisted technology adoption, necessitating an intuitive, vernacular-supported interface. Security concerns about sensitive production data on mobile devices also needed addressing.
Project Scope
- Shop Floor Operations App
Enabled workers to log production counts, report defects, and request maintenance via mobile with photo/video attachments. - Manager Dashboard App
Provided real-time OEE metrics, production alerts, and approval workflows with digital signatures. - AR Equipment Maintenance Guide
Overlaid repair instructions and schematics when technicians pointed cameras at machinery. - Bilingual Interface
Supported English and Bengali with voice command options for low-literacy users. - Offline Mode
Critical functions remained available during network outages with automatic sync when reconnected.
Our Approach
- Worker-Centric Design
Conducted shadowing sessions to understand shop floor workflows before prototyping. - Phased Rollout
Piloted with 20 power users before plant-wide deployment. - Gamified Training
Used AR simulations to teach app features in a practical context. - Performance Optimization
Ensured smooth operation on mid-range Android devices common among workers.
Features Introduced
- Machine Health Alerts
Push notifications warned supervisors about predicted equipment failures. - Visual Work Instructions
Animated guides showed complex assembly steps. - Digital Andon System
Instant alerts when production line issues occurred. - Voice Logging
Workers could verbally report issues in native language. - Shift Handover Notes
Secure digital transfer of pending issues between teams.
Addressing Challenges
- Technology Resistance → Simplified UI with large buttons and visual cues increased adoption
- Data Security → Implemented biometric login and auto-logoff after inactivity
- Network Gaps → Offline mode maintained functionality in signal-dead zones
- Multi-Generational Workforce → Contextual help videos available at every screen
Business Impact
- 90% Reduction in paper logbooks and manual reports
- 35% Faster issue resolution via mobile alerts
- 28% Improvement in first-time equipment repair success
- 40% Fewer production delays from real-time monitoring
- 85% Employee Adoption within 2 months
