Digital Transformation for a Global Tobacco Manufacturer

LeverX developed a comprehensive quality management system that fully digitized the client's fragmented workflows, ensuring end-to-end quality control and a significant reduction in product defects and production costs.

Client and Challenge

Our client is a leading global tobacco manufacturer, facing critical challenges in managing production and its supply chain.

Before implementing the solution, the company suffered from several problems that limited its operational efficiency and quality control capabilities:

• Fragmented and Paper-Based Processes: Production and supply chain workflows were fragmented and heavily reliant on paper documentation. This led to delays, a high risk of errors, and a lack of transparency.
• Absence of Centralized Quality Control: The company struggled to manage quality control at every stage of production - from raw material receipt to shipment.
• Difficulties with IoT Data Management: Despite the use of IoT sensors and scanners in production, the data they generated was not systematized or integrated into a single system. This made comprehensive analysis impossible.
• Lack of a Single Database: Data and documents were stored in disparate sources, creating issues with data consistency and accessibility.

Methodology and Approach

LeverX applied a flexible methodology that ensured adaptation to the client’s requirements. This allowed for the creation of a reliable and effective solution aimed at achieving the set goals.

We focused on a deep understanding of the client’s business needs to provide a planning tool for automatic campaign management, create a unified database, ensure end-to-end quality control, and evaluate employee performance in real-time.

As a first step, an MVP was developed—a simple SQL database. This allowed for testing various scenarios for centralized data management and document workflow digitization under optimal and cost-effective conditions. At this stage, we were able to identify the most effective scenarios for continuous quality control at each stage and form further conclusions that informed the implementation of the full-scale solution.

Throughout the project, we maintained close collaboration with the client and regularly updated processes, which ensured the successful creation of a full-fledged Quality Management platform. The solution was easily integrated into the client's existing ERP system.

Solution

LeverX developed a full-scale Quality Management System with a versatile set of functionalities that completely transformed the client's workflows.

Key components of the solution:

• Intelligent Production Planning Tool: An automated calendar was created to manage campaigns (lab trials, production runs, shipments), integrated with IoT scanners and printing tools.
• Real-time Data Management System: A unified database was implemented that integrated with the client's existing systems to automate and centralize data transfer, replacing paper documents with digital ones.
• IoT-Powered Integrations: The solution integrates with the client's IoT scanners and sensors used throughout the production process. This ensures real-time data collection and centralized storage.

• Smart Employee Tracking and Performance Management: A dedicated application provides real-time analytics on employee hours and production metrics, allowing the client to effectively assess workforce efficiency and make data-driven decisions for shift planning and resource allocation.

• Automated Quality and Performance Reporting: Continuous quality and quantity control was established by automating the generation of various reports. These reports, based on data from testing, mixing, and production campaigns, provide insights into quality deviations and overall production performance, enabling proactive decision-making.

• Smart Relabel Management: The solution includes a special module that automates the relabeling procedure for products with incorrect labels. Operators can initiate a relabeling order, and the system ensures the new label data is accurate and verified through an integrated IoT scanner, maintaining data consistency.

Technology Stack

The solution is built on a reliable stack that provides the necessary performance and integration capabilities:

• Frontend: React.js
• Backend: Node.js, Express.js, Nest.js 
• Data management: Microsoft SQL Server.
• Integrations: IoT sensors and scanners.

Results

The implementation of the quality management system led to significant, measurable business benefits for the client:

• Optimized Production Planning: Manual effort was reduced, and process transparency was ensured through faster campaign creation and data validation.
• Accelerated Document Workflows: The complete digitization of documentation saved time and reduced costs associated with manual work.
• Enhanced Quality Control: A significant reduction in product defects and production costs was achieved.
• Improved Employee Productivity: Overall employee productivity was increased with the help of a special application that prevented overtimes and professional burnout.