Factory Control System
Project Overview
I spearheaded the development of a Factory Control System (FCS) for CAFCA Limited, the largest cable manufacturer in Zimbabwe and a monopoly in the sector. The system was designed to digitize and control end-to-end production workflow, material tracking, and performance monitoring across the factory floor.
The core of the system is a process ticketing mechanism that governs how production units (bobbins) move through manufacturing stages. Production tickets are generated in the planning department and act as mandatory “travel documents” — a bobbin cannot move to the next machine or stage without a valid ticket. This enabled full traceability of each cable from initial drawing through to rewinding and final stages.
By integrating planning, machine-level execution, and administrative reporting, the system created a single source of truth for production flow, copper usage, downtime, and operational KPIs.
Key Features
End-to-End Production Traceability
Implemented inlet and outlet process tickets at every machine stage, ensuring each cable is digitally tracked from start to finish, with weight or length captured at each operation.
Real-Time Shopfloor Integration
Planning-generated tickets automatically appear at machine-level interfaces, allowing operators to select the correct ticket with pre-filled production data, reducing manual errors and delays.
Material & Copper Tracking Analytics
Delivered administrative reports including copper summary by factory stage, copper movement tracking across machines, and visibility into material location and weight at any point in time.
Operational KPIs & Performance Monitoring
Automated KPI generation using fault cards, machine breakdown job cards, and digital timesheets, providing team leaders with real-time insights into efficiency, downtime, and productivity.