Firmware Solution for Efficient Inventory Management in Production
Summary:
A production company had two types of controllers, type Y and Z, with identical hardware but different firmware functionalities. With my custom firmware solution, the company can now keep only one type of hardware in stock and reprogram it on the fly to the desired variant, leading to lower inventory costs and higher efficiency.
Background and Challenge:
The production company uses two different controllers, type Y and Z, in their production processes. Although these controllers are identical in hardware, they have different software functionalities and product codes that determine their operation. The company wanted to reduce inventory costs by keeping only one type of controller in stock and reprogramming it to the required variant when needed. The question was whether this could be achieved without complex IT solutions, as most production workers are not comfortable using computers.
Approach:
After thoroughly analyzing the hardware of the controllers, I designed an interface that allows the firmware and settings of type Y to be read and then installed into type Z, and vice versa. This required reverse-engineering the existing firmware and developing a simple yet robust solution that could be used by production staff with no technical background.
To keep the solution user-friendly and fully independent from any computer or software, I developed a standalone device—a “firmware flash box.” This compact unit connects directly to the controller, and with just a push of a button, the desired firmware is automatically flashed. An LED indicator blinks during flashing and turns off when the process is complete. This standalone approach means no PC or additional software is required, allowing anyone in production, regardless of their technical knowledge, to change the firmware when needed.
Solution and Results:
With this solution, the production company can now keep only one type of controller in stock instead of two, resulting in significant cost savings in inventory management. Additionally, production speed has increased since no time is lost searching for the correct type of controller. The simple use of the standalone firmware flash box ensures that all employees can perform the process without any training or computer skills.
Benefits of this Solution:
- Lower Inventory Costs: Keeping one type of hardware in stock instead of two reduces costs and simplifies inventory management.
- Faster Production Processes: Employees no longer need to wait for the correct type of controller; they can easily adjust the firmware with the push of a button.
- Standalone Device, No PC Needed: The flash box is a self-contained solution, requiring no connection to a computer or external software, designed for maximum simplicity.
- Accessible for Non-Technical Staff: No need for computer training or technical knowledge, reducing the risk of errors and increasing productivity.
Price Indication:
While this is not a formal quote, the price indication for a similar solution is approximately €5,000 excl. VAT. This amount depends on the specific requirements and complexity of the project. I sell solutions, not hours. We agree on a fixed price for the solution, and you only pay once everything is delivered according to the agreed specifications and is working to your satisfaction. Feel free to contact me for a detailed discussion of your specific project and an exact quote.
