HEADQUARTERS
Delhi, HR
EMPLOYEE STRENGTH
2,500+
INDUSTRY
Automotive parts
Neolite ZKW is an Indian automotive lighting manufacturer that designs and produces headlamps, tail lamps, LED lighting, and other vehicle lighting systems for OEMs across passenger, commercial, and two-wheeler vehicles worldwide.
Despite strong SOPs and supervision, hidden inefficiencies on the shop floor continued to impact output consistency. The challenge was not a lack of process maturity — it was the inability to see what was actually happening at every workstation in real time.
Atanu Prasad Ray
Head of Projects, Neolitezkw
OLD WAYS
Human supervision didn't scale
Track real-time operator productivity
Optifye AI Cameras gave Neolite ZKW live visibility into what was actually happening at every workstation — including cycle execution, waiting time, interruptions, and operator movement.
Detect hidden micro-losses
The system uncovered small delays between cycles, inconsistent work pacing, and temporary station blockages that were previously invisible but collectively reduced overall throughput.
Identify shifting bottlenecks instantly
Instead of relying on periodic studies, teams could now identify which stations were slowing the line in real time and take corrective action immediately.
Standardize best-performing behaviors
By comparing execution patterns across operators and shifts, Neolite ZKW replicated the practices of top-performing stations across the entire line.
Atanu Prasad Ray
Head of Projects, Neolitezkw
THE SOLUTION
Monitoring with no manual intervention
Track real-time operator productivity
Optifye AI Cameras gave Neolite ZKW live visibility into what was actually happening at every workstation — including cycle execution, waiting time, interruptions, and operator movement.
Detect hidden micro-losses
The system uncovered small delays between cycles, inconsistent work pacing, and temporary station blockages that were previously invisible but collectively reduced overall throughput.
Identify shifting bottlenecks instantly
Instead of relying on periodic studies, teams could now identify which stations were slowing the line in real time and take corrective action immediately.
Standardize best-performing behaviors
By comparing execution patterns across operators and shifts, Neolite ZKW replicated the practices of top-performing stations across the entire line.
RESULTS
Results in the first 3 weeks
26% increase in line efficiency
11% reduction in operator idle time
With Optifye, Neolite ZKW transformed its manual assembly lines into real-time visible operations — enabling continuous optimization through AI-powered production intelligence.
