The company faced challenges related to inefficiencies in data collection and monitoring due to reliance on manual forms and paper-based records, leading to errors, delays, and difficulties in tracking production, quality, and assembly processes. The lack of real-time monitoring made it hard to detect issues promptly, impacting operational efficiency and delivery timelines. To overcome these challenges, the company developed a customized Digital Lean App and centralized digital dashboard, allowing for real-time production tracking, standardizing data collection, and minimizing reporting layers. This transition helped eliminate delays and manual entry errors, ensuring more accurate and timely decision-making.
The implementation of Digital Lean resulted in significant cost savings and operational improvements. By digitizing manual processes, the company saved RM57,420 annually, which includes productivity progress gains (RM40,800) and form/documentation reduction costs (RM16,620). The automation of data collection reduced reporting errors and streamlined quality control, leading to faster issue resolution and enhanced production efficiency. Additionally, the future state of the company includes automated tracking, enhanced reporting accuracy, and improved workforce productivity, ensuring smoother workflows and increased overall efficiency across production and assembly lines.
