How APA Engineering Achieved Zero-Error Kitting with AI-Driven Process Monitoring

Using Jidoka’s AI-powered Nagare system, APA Engineering digitized kitting with real-time sequence and quantity verification—achieving zero-error packing, 35% higher productivity, full traceability and ROI in under one year.

How APA Engineering Achieved Zero-Error Kitting with AI-Driven Process Monitoring

Industry

Manufacturing & Engineering Services

Result 1

Zero-error guided kitting with real-time verification

Deployments

Nagare – Intelligent Process Monitoring System

Result 2

35% Increase in Productivity with < 1 Year ROI

Overview

APA Engineering Pvt. Ltd. is a leading provider of global sourcing and engineering services with a strong presence across India, USA, Germany, Singapore and Spain. With a diverse portfolio of export-oriented kits and high SKU variability, APA’s kitting operations demanded precision, speed and absolute process adherence.

Frequent packing errors, missed components and wrong kit dispatches resulted in costly recalls and operational disruptions. APA required an intelligent, real-time monitoring system that could eliminate errors, standardize processes and enhance productivity without adding manual inspection layers.

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Opportunity

High SKU variety led to frequent wrong parts packing and missed components.
Multiple instances of incorrect kits being shipped annually caused expensive export recalls.
Manual verification processes were reactive, not preventive.
Additional quality checks increased cycle time without guaranteeing zero defects.

APA needed a scalable, AI-driven solution to monitor kitting activities in real time, ensure correct sequence compliance, verify quantities and provide instant corrective feedback.

Jidoka's Approach

AI-Driven Video Process Monitoring

Real-time monitoring across defined process steps.
Parent SKU selection through system interface for kit validation.
Verification of right sequence and right quantities for each kit variant.
Detection of missing activities or excess components instantly.

Real-Time Error Prevention

Instant audio and visual alerts for deviations.
Immediate correction at source before the kit moves forward.
Detection of wrong sequence, missed steps or incorrect picking.
Prevention of defects without adding inspection manpower.

Productivity & Performance Intelligence

Cycle time monitoring per step and per kit.
Productivity tracking acrossstations.
Real-time dashboards visualizingprocess adherence and violations.
Complete video traceability forevery packed kit.

Big Wins

Intelligent Monitoring, Flawless Execution

Zero-Error Guided Kitting

Real-time AI verification eliminated missed components and wrong packing incidents.

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35% Increase in Productivity

Process standardization and ergonomic improvements significantly boosted throughput.

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< 1 Year ROI

Reduced recalls, improved efficiency and elimination of rework delivered rapid financial returns.

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Complete Process Traceability

Every step digitally recorded, enabling accountability and data-driven improvement.

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APA Engineering transformed its kitting operations with Jidoka’s AI-powered Nagare system, enabling real-time process verification and sequence compliance. The solution eliminated packing errors, improved productivity by 35% and delivered full traceability with rapid ROI.

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