Swastik Case Study – Copper Winding Industry Automation

Hubli, Karnataka

Project Overview

Swastik, a copper winding manufacturing unit based in Hubli, faced major financial and operational inefficiencies due to manual errors in weighing and inventory handling. We designed a custom software + hardware-integrated solution to digitize weighing, barcode generation, and inventory tracking — saving lakhs of rupees monthly and automating work order creation.

Challenges

Client Challenges

Manual Weighing Errors

Ground staff often entered incorrect weight values for copper reels. For example, mistakenly entering 83kg instead of 33kg led to an instant 50kg copper loss — a significant cost in a business where 1kg = ₹1,000.

Inventory & Reordering Confusion

  • Overstocking of materials already in inventory.

  • Missed reordering led to delayed customer deliveries.

  • No visibility into available vs. required stock.

Our Solutions

Barcode-Based Weighing Integration

  • When a copper bobbin is weighed, the system automatically generates a barcode.

  • This barcode is affixed to the bobbin.

  • During winding, the bobbin is placed on a digital weighing scale.

  • The scale auto-feeds weight into the system — no manual input allowed.

Smart Inventory and Work Order Management

  • While creating a quotation, the system auto-detects stock availability based on:

    • Thickness

    • Width

    • Material type

  • If a product is in stock, it’s auto-listed; if not, a work order is instantly created for production.

  • The entire flow — from quotation to production — happens in a single form.

Impact & Benefits

  • Eliminated manual weighing errors, reducing copper losses

  • Improved inventory accuracy, avoiding overstock or stockouts

  • Faster work order processing, leading to better on-time delivery

  • Monthly savings in raw material misuse and operational time

Technologies Used

To deliver a robust and scalable solution integrated with industrial hardware, we used:

  • Weighing Scale Integration: RS232 interface or Bluetooth-based input

  • Barcode Generator: Dynamic barcode linked to system ID

  • Backend Logic: PHP (Laravel Framework) for business logic and automation

  • Frontend UI: HTML5, Bootstrap for operator-friendly interface

  • Database: MySQL to store weight logs, stock, work orders

  • Hardware-Sync Modules: Custom middleware to connect weighing hardware with the software

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