Impact of IoT on Employee Dynamics and Manufacturing Processes

This project focuses on the implementation of Internet of Things (IoT) technologies to improve productionprocesses and quality management at Roots Cast Private Limited, Coimbatore. The company specializes inHigh Pressure Die Casting (HPDC), where several operational inefficiencies and quality issues wereidentified, including high rejection rates, lack of automation, and poor real-time monitoring capabilities. Theproject explores how integrating IoT solutions—such as Siemens PLCs, HMIs, pressure transducers,biometric authentication, and real-time dashboards—has revolutionized these processes. The adoption ofIoT technologies has enabled the company to achieve significant operational gains, including reducing theproduction rejection rate from 6% to 2%, improving shots per hour from 69,033 to 86,348, and enhancingOverall Equipment Effectiveness (OEE) from 33,476 to 40,933.8. A key focus of the project is thecomparative analysis of data before and after IoT implementation, which highlights the improvements inproduction efficiency, defect reduction, and equipment uptime. The implementation has also contributed tobetter employee engagement and a shift toward a more data-driven, predictive maintenance approach.Moreover, the integration of Poka Yoke systems has further minimized human error and reinforced qualitycontrol. This project also emphasizes how IoT has supported the company’s transition to Industry 4.0,fostering a smarter and more sustainable manufacturing environment. The findings suggest that IoT not onlyimproves operational performance but also facilitates smarter decision-making, predictive analytics, andenhanced process control, paving the way for the next phase of digital transformation in the manufacturingsector.