# Alkhorayef Case

A leading industrial equipment manufacturer utilized data from i-5O’s manufacturing traceability system for productivity gains through real-time visibility into production operations.

# Overview

Founded in 1957, the Alkhorayef Group specializes in the production of water pumps, and agricultural, irrigation, and well drilling equipment. Apart from being a leader in the agricultural market, the company diversified its activities and continued its progress in various fields such as machinery systems, oil, contracting, printing, and paper. The Group enjoys a worldwide presence, operating in more than 40 countries, and representing renowned quality products and manufacturers. i-5O Computer Vision System is deployed in their manufacturing facility at Dammam, Saudi Arabia where Electric Submersible Pumps (ESP) are manufactured. The video data generated by i-5O has helped the team at Alkhorayef with productivity enhancement and labour optimization.

# Problem

Significant overtime labour costs due to lack of manufacturing traceability and visibility into operational efficiency

The production managers at Alkhorayef lacked visibility into their operations as the company did not have a traceability system for manufacturing in place. In the absence of adequate monitoring and tracking procedures, they were unable to understand the reasons behind downtime and idle time, accurately measure labor productivity, or identify areas of improvement. Labor productivity was manually measured by tracking the completion rate of orders by the end of each shift, and recording data in Excel sheets. Data collected was then compared across stations to determine the overall productivity. Not only was this process time-consuming, but the data collected was also inaccurate because the number of items produced wasn’t an accurate representation of labor productivity, as it failed to take into consideration other factors such as delays or wait time due to lack of resources and machine/equipment breakdowns. Furthermore, different products have different processing times and can span over several shifts, reducing the reliability of this measure.

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# Solution

i-5O’s manufacturing traceability system was installed across 4 winding station lines in Alkhorayef’s ESP production operations to determine changes in productivity across stations and shifts to identify areas of improvement.

i-5O’s productivity module was deployed to continuously monitor each worker on the production line to enhance traceability in their manufacturing operations. Through Value Stream Mapping, Alkhorayef’s management was able to gain a comprehensive view of their operations, enabling real-time identification of areas needing attention. Amplifying this situational awareness was i-5O’s Productivity Dashboard which provided granular insights into Overall Labour Effectiveness, Capacity, and Average Processing Time. Not only did this data allow for the identification of sources of downtime but was also used to uncover hidden production capacity, leading to an increase in overall efficiency and a reduction in overtime costs. For the first time in its history, Alkhorayef’s production management team had real-time visibility into all their winding operations and through continuous manufacturing traceability they could identify sources of variation between the different lines.

# Our Results

Unprecedented visibility into winding operations

99%+ accuracy in tracking productive time, downtime and processing times

First of its kind solution implemented in oil and gas manufacturing

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> “i-5O System was more than 99%+ accurate in identifying productive time and downtime”.  
> Alkhorayef  
> Senior Manufacturing Engineer