A case on how production approvals, reporting, and maintenance planning were automated end-to-end with Microsoft Power Platform tools.
The Client
The client is a global manufacturer of automotive components and energy-related products, with a presence spanning 200+ subsidiaries worldwide. Backed by decades of industry experience, the company provides nearly every essential part that makes up a vehicle, serving both OEM and aftermarket needs. Known for its strong manufacturing practices, advanced technology development, and extensive global operations, the organization focuses on delivering high-quality, reliable products across markets.
Challenges Faced by the Client
In the automotive manufacturing sector, precision, speed, and coordination between departments are essential for daily plant operations. However, with our client, the production teams were heavily dependent on manual processes, slowing down critical functions like reporting, approvals, and coordination as follows:
- Manual, Paper-Based Data Handling: Daily production reports, breakdown entries, rejections, and attendance were recorded using paper forms and spreadsheets, making the process time-consuming and prone to human error.
- High Dependency on Excel for Historical Records: Legacy data was spread across multiple Excel files, which made tracking historical patterns or performance comparisons complex.
- Lengthy Approval Cycles: Any change or update in operations (like a 4M change point – Man, Machine, Materials, Methods) had to be communicated manually and approved through physical paperwork or email, leading to delays in corrective action.
- No Real-Time Visibility: Data was only available after manual compilation and entry, which made it difficult for leadership to get a live view of production performance.
Solutions
To address the client’s manual-heavy operations, we implemented a structured, tablet-based system using Power Platform tools. Here is how it was delivered:
- Canvas App Rolled Out Across Departments: A tablet-friendly Canvas App was developed for multiple production lines and sub-lines. Each department has its own interface with dropdown-based inputs tailored to its specific workflow needs.
- Master Data Structured Using Dataverse: We created 30+ master tables in Dataverse to standardize information across machines, employees, rejection reasons, issue types, and more. These serve as the backbone for form input and reporting.
- Digital Forms Built for Key Operations: Daily activities were digitized through well-defined forms, namely:
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- Daily Breakdown
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- Daily Production
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- Rejection Logs
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- 4M Change Point Tracking
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- Skill Matrix Tracking
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- Attendance
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- Real-Time Gallery View for Review and Updates: A gallery screen was added for users to view, filter, and update their submissions, making it easier to track ongoing issues or form statuses without re-entering data.
- Approval Workflows Automated via Power Automate: For 4M Change Points and other critical updates, approval workflows were automated. Once submitted, alerts were sent to relevant stakeholders via email for validation. Depending on the response, forms either moved forward or returned to the originator for revision.
- Excel to Dataverse Migration Using Dataflows: Historical and operational data from Excel was migrated to Dataverse using Dataflows, ensuring a clean transition without losing records.
- Cumulative Production Linked to Maintenance Planning: The app automatically calculates Cumulative Production quantities, linking them to Preventive Maintenance forms, helping the Press Shop plan ahead and reduce unexpected downtime.
- Power BI Integration for Live Dashboards: All form data and production metrics were reflected in Power BI dashboards with live refresh, giving supervisors and management a real-time view of production performance.
Solutions Benefits
By shifting from manual processes to a centralized digital platform, the client saw noticeable speed, accuracy, and coordination improvements. Below are the key benefits realized:
- Paperwork Fully Eliminated: All daily reporting, approvals, and tracking were moved into the app, removing the need for paper-based forms and manual entries.
- Faster Decision-Making Through Automated Workflows: With automated email alerts and approval flows, critical updates like 4M changes were processed and resolved much faster, reducing delays in action.
- Real-Time Visibility into Production Data: Power BI dashboards offered live production data, allowing managers and department heads to monitor performance and make quick decisions on the shop floor.
- Higher Accuracy and Accountability: With dropdowns, filters, and structured forms, human error in data entry dropped significantly.
- Stronger Coordination Across Departments: The app was linked with key functions like Die and Machine Maintenance, Production Planning and Control (PPC), Quality Control (QC), and Process Engineering. Now, all the teams operate with the same data and act in sync when issues arise.
Conclusion
The shift from manual processes to a unified digital app made daily operations faster and easier for the client. With automated workflows and real-time dashboards, teams now act on accurate data without delays. Approvals, reporting, and attendance are handled in one place, with no more paperwork or follow-ups. UB Technology Innovations, Inc. continues to support production companies in building reliable, future-ready systems that simplify work where it matters most.
About Us
UB Technology Innovations, Inc. (UBTI) is a leading global technology solution provider with over 3 decades of experience across all industries, specializing in Capital Markets, Logistics, and Healthcare. We are the preferred Microsoft Solutions Partner backed by a world-class team of Microsoft Certified experts with rich experience in Azure Cloud Platform and Data Analytics.
Winner of the prestigious Azure
Synapse Hackathon 2021 award
One of the Top 10 winners of the
Microsoft’s Azure AI & ML Workathon