Guidewheel Revolutionizes T&C's Manufacturing Operations for Enhanced Efficiency

Tile and Carpet (T&C), a prominent distributor and manufacturer of interior and building products in Kenya, has established itself as a leader in the industry with a rich history dating back to the late 1940s. From importing basic tiles and other materials from Europe, T&C has evolved into a global player, boasting a diverse product line under brand names such as Tactile Roofing, TopTank, Top-Pipe, TopFrame, and TopRoof.

In the pursuit of operational excellence, T&C integrated Guidewheel into its manufacturing facility in Athi River, Kenya, marking a significant shift from manual tracking to a more efficient, data-driven approach. Mr. Sobran S. Kadam, Head of Maintenance at T&C, recounts the challenges they faced before adopting Guidewheel, emphasizing the reliance on pen-and-paper methods and lack of real-time visibility that led to inaccuracies, particularly during night shifts.

“Most of the tracking was done using pen and paper. We had a lot of inaccuracies in the data collected and could not rely on it completely for decision-making. We lacked real-time visibility into our operations especially for night shifts. Operators kept notes on major occurrences like machine stoppages, but it was not possible to verify exactly when the machines stopped or when production started.”

Guidewheel proved to be a game-changer for T&C, providing real-time monitoring and notifications for critical machine data. Mr. Sobran, responsible for ensuring uninterrupted production, has found Guidewheel to be an effective tool in reducing equipment downtime. Notifications via SMS enable swift response to machine stoppages, contributing to a seamless production process.

“Guidewheel has become a big part of our operations since we installed. Everyone on my team is set up on the platform and receives notifications whenever a machine goes offline or when there is extended idling on a machine that was scheduled to run. We can now confidently account for when a machine stops in the middle of production. By receiving notifications via SMS, I am able to dispatch someone from maintenance to immediately attend to the issue. This has greatly helped us reduce equipment downtime.”

Operating 24 hours with distinct day and night shifts, T&C utilizes Guidewheel to bridge the information gap between shifts. Mr. Sobran uses Guidewheel to get an accurate view of machine runtime, issues recorded during the night shift, and energy consumption across the plant. This allows him to start each day well-informed, minimizing the time spent discussing the night's occurrences with operators who have already completed their shifts. It also equips the oncoming shift to understand what they’re walking into and make adjustments to meet their targets.

Guidewheel's impact extends beyond machine monitoring. T&C leverages the platform to analyze energy consumption patterns, fostering a culture of efficiency among operators who actively contribute to reducing idling energy. The automated tracking system has resulted in a notable reduction in energy wastage, keeping peak demand within the targeted range of 800kVA - 1000kVA.

“I also use Guidewheel to monitor energy consumption across the plant. By looking at the production quantity vs the energy consumption, we are able to determine whether or not we are running efficiently. Guidewheel allows my team to analyze our consumption patterns and minimize energy waste. Since everyone is aware that we now have an automated tracking system in place, we have noticed significant reduction in idling energy. Operators are keen to switch off machines when there is no production. We have also managed to keep our peak demand between 800kVA - 1000kVA by bringing machines on one at a time. Guidewheel does a good job of notifying us whenever we deviate from this standard.” 

By giving T&C real-time visibility into machine performance, downtime and energy consumption in Guidewheel, the system has become an indispensable tool for Mr. Sobran and his team. The platform's features, including real-time tracking, alerts, and detailed reports, empower T&C to enhance overall operational efficiency, ensuring that every aspect of the manufacturing process aligns with the company's commitment to quality and excellence.

T&C's adoption of Guidewheel signifies a transformative leap in manufacturing operations. By embracing advanced tracking and monitoring capabilities, T&C has not only addressed historical challenges but has also fostered a culture of efficiency and accountability. Guidewheel's real-time insights have proven instrumental in minimizing downtime, optimizing energy consumption, and maintaining the company's commitment to quality production. As T&C continues to thrive in the global market, Guidewheel stands as a reliable ally in the pursuit of operational excellence.