Automating Production TAT Calculation for Maa Satti Using MIDAP FMS
About the Client
Maa Satti is a jewellery manufacturing business that manages its production workflow through a Flow Management System (FMS). The manufacturing process involves multiple operational stages, including Order Received and Diamond Setting, where production timelines depend on the quantity of materials and the number of skilled artisans (karigars) available.
To maintain production efficiency, the company needed accurate Turnaround Time (TAT) calculations for each stage of the workflow.
The Operational Challenge
During the Order Received stage, Maa Satti records key production inputs such as:
- Diamond Quantity
- Baggets Quantity
- Number of Karigars assigned for the task
However, the production team had to manually calculate the TAT based on these parameters. This created several operational issues:
- Higher chances of calculation errors
- Time-consuming manual computations
- Inconsistent production scheduling
- Difficulty in accurate resource planning
As order volumes increased, manual calculations became inefficient and slowed down workflow planning.
What Maa Satti Needed
Maa Satti required an automated workflow system that could:
- Dynamically calculate production Turnaround Time (TAT)
- Use real-time production inputs such as quantity and manpower
- Eliminate manual calculations
- Improve accuracy in production scheduling
The goal was to make the production workflow data-driven and automated.
MIDAP’s Solution: Automated TAT Calculation in FMS
To address this requirement, MIDAP (MI Digital Autopilot) implemented an automated calculation system within the Flow Management System (FMS) using Auto Calculate fields and Override TAT functionality.
This allowed production timelines to be calculated automatically based on operational inputs.
Step 1: Creation of Auto Calculation Fields
Two dedicated Auto Calculate fields were created to determine processing time for different materials:
- Diamond Quantity Processing Time
- Baggets Quantity Processing Time
These fields automatically calculate the production time based on the quantity and the number of karigars assigned.
Step 2: Diamond Processing TAT Formula
The system calculates the Diamond Setting TAT using the following formula:
TAT = Diamond Quantity ÷ (Karigar Count × 200)
Example:
- Diamond Quantity = 1200
- Karigar Count = 2
1200 ÷ (2 × 200) = 3 Days
This means the diamond setting process will require 3 days to complete.
Step 3: Baggets Processing TAT Formula
For Bagget’s processing, the system uses a separate formula:
TAT = Baggets Quantity ÷ (Karigar Count × 125)
Example:
- Baggets Quantity = 500
- Karigar Count = 3
500 ÷ (3 × 125) = 1.455 Days
This provides a precise estimate of the production timeline.
Step 4: Override TAT Integration
The calculated results from the Auto Calculate fields are then applied using the Override TAT feature.
This ensures that:
- The workflow timeline automatically adjusts
- Production scheduling reflects real input values
- The Diamond Setting stage receives the correct TAT dynamically
The system now calculates production timelines automatically without manual intervention.
Impact on Maa Satti’s Production Workflow
After implementing automated TAT calculation, Maa Satti experienced significant improvements:
- Elimination of manual calculation efforts
- Improved accuracy in production planning
- Faster workflow processing within the FMS
- Better resource planning based on available karigars
- More reliable production scheduling
Production teams can now plan tasks confidently based on system-generated timelines.
Transforming Workflow Planning with Automation
By leveraging Auto Calculate fields and the Override TAT functionality, MIDAP helped Maa Satti convert a manual production-planning process into an automated workflow.
The system now dynamically calculates production timelines based on real-time operational inputs, ensuring:
- Higher efficiency
- Accurate scheduling
- Scalable manufacturing workflows
This automation has significantly improved Maa Satti’s operational planning and production control.
