Manufacturing Automation
Manufacturing Automation Solutions - Material Movement, RFID and Asset Tracking
Manufacturing automation solutions remove the manual, error-prone work that quietly drains margin: counting, keying, searching for stock, and reconciling what moved where. Ajinkya Technologies automates material movement, asset tracking, dispatch and maintenance with RFID, barcode and IIoT so your plant runs faster, cleaner and with far fewer errors.
These are not pilots. Our automation runs at industrial scale - tracking 720,000 material movements per day and dispatching at 16,800 paint barrels per hour via RFID - for some of the most demanding plants in the world.
RFID and barcode material movement at scale
We automate the entire material journey - gate-in, receiving, binning, consumption, movement and dispatch - with RFID and barcode capture that replaces clipboards and manual entry. The result is real-time inventory accuracy and dispatch that is fast and virtually error-free.
In one steel-plant deployment this approach tracks 720,000 material movements per day and underpins a dispatch line running at 16,800 paint barrels per hour, with manual labour on receiving, binning, consumption tracking and returns cut by up to 60%.
- RFID and barcode gate-in / gate-out and dispatch automation
- Automated receiving, binning, consumption tracking and returns
- Real-time inventory accuracy and reconciliation
- Up to 60% reduction in manual material-handling labour
Asset tracking and traceability
Know where every asset, tool and material is, in real time. We deploy RFID, BLE and GPS asset tracking across plants and yards, and QR-based traceability for finished and in-process goods - including across blast furnaces, coke ovens and rolling mills - so genealogy and chain-of-custody are always one query away.
Traceability is not just compliance; it is speed. When a quality question lands, your team answers it in seconds instead of reconstructing it from paper across a week.
Preventive and predictive maintenance
Automation extends to keeping machines healthy. Our maintenance systems schedule preventive work, capture machine faults, and - paired with our IIoT and AI stack - move you toward condition-based and predictive maintenance that converts unplanned downtime into planned interventions.
Every maintenance action ties back to the asset, the work order and the spare, so reliability improves and MTBF trends become something you manage rather than discover.
- Preventive maintenance scheduling and digital work orders
- Machine fault capture tied to assets and spares
- Path to condition-based and predictive maintenance via IIoT
- MTBF and reliability analytics
Faster, more accurate operations you can prove
Automation only matters if it moves the numbers. Our systems benchmark 40% faster transactions, query response and dashboard loads than leading global systems, while removing the manual steps that cause dispatch and inventory errors.
We integrate automation tightly with your MES and ERP so automated events become trusted, costed records in the back office - closing the loop between the physical movement of material and the financial view of it.
Industrial automation: control panel, SCADA, PLC and Siemens integration
Industrial automation is more than moving material. It is the coordinated behaviour of the control panel on the machine, the PLC inside it, and the SCADA that supervises the line. We integrate with the automation stack you already run, including Siemens PLC and HMI equipment, so upgrading data flow does not require replacing the control layer.
The result is a plant where PLC and SCADA signals feed the MES and IIoT layer, the control panel keeps doing its job, and industrial automation and information systems finally speak the same language.
- Industrial automation integration with existing control panel, PLC and SCADA
- Support for Siemens PLC, HMI and drive families alongside other vendors
- PLC and SCADA data mapped into the MES and Unified Namespace
- Non-invasive retrofits so production keeps running during upgrades
Deployed across US, India and Middle East manufacturing hubs
The industrial automation stack is universal, the buyer context is not. Control panel, PLC and SCADA engagements look different in each region.
United States
Industrial automation for US automotive, aerospace and semiconductor plants, integrating with Siemens, Allen-Bradley and Rockwell PLC and SCADA installed bases.
India
Control panel, PLC and SCADA integration for Indian steel, cement, auto ancillary and pharma plants, including brownfield sites where the automation layer predates the IT stack.
Middle East
Industrial automation for GCC oil and gas, petrochemicals and metals, with PLC and SCADA integrations tuned for high-availability, 24x7 process operations.
Frequently asked questions
What is SCADA?
SCADA (Supervisory Control and Data Acquisition) is the software and hardware layer that supervises a production line or plant. It pulls signals from PLCs and other controllers, shows plant status on operator HMIs, logs process data to historians and lets supervisors issue set-point changes. In modern industrial automation, SCADA is the bridge between the machine layer and the MES or IIoT layer above it.
What is a PLC?
A PLC (Programmable Logic Controller) is an industrial computer that runs the deterministic logic controlling a machine or line, reading sensor inputs and driving actuator outputs on fixed cycles. Vendors include Siemens, Allen-Bradley, Mitsubishi and many others, each with its own control panel conventions. A PLC sits between the physical process and the SCADA, and it is the primary source of the real-time signals that MES and IIoT platforms consume.
What can RFID automation realistically do for our plant?
RFID and barcode automation replace manual counting and keying across gate-in, receiving, binning, consumption and dispatch. In production we track 720,000 material movements per day and run dispatch at 16,800 paint barrels per hour, with up to 60% less manual material-handling labour and near-elimination of dispatch errors.
How do you track assets and materials in real time?
We deploy RFID, BLE and GPS for asset and material tracking across plants and yards, plus QR-based traceability for finished and in-process goods - including across blast furnaces, coke ovens and rolling mills - so location, genealogy and chain-of-custody are always available instantly.
Can automation include preventive and predictive maintenance?
Yes. We schedule preventive maintenance with digital work orders and machine-fault capture, and - paired with our IIoT and AI stack - move you toward condition-based and predictive maintenance that turns unplanned downtime into planned work, with MTBF and reliability analytics.
Will the automation integrate with our MES and ERP?
Yes. Automated events flow into your MES and ERP (SAP, Oracle, Microsoft Dynamics or custom) so physical material movements become trusted, costed records in the back office - with benchmarks showing about 40% faster transactions than leading global systems.
Explore related solutions
Talk to our manufacturing engineering team
Tell us about your plant, your machines and your ERP. We will scope a pragmatic, measurable digital-transformation roadmap with clear ROI - typically a focused proof-of-value in weeks, not years.
Book a consultation