Mobile Data Collection: Unlocking Efficiency in the Manufacturing Sector – Case Studies

Key Takeaways

 

1. The manufacturing sector plays a crucial role in driving economic growth, innovation, and technological advancement in many countries around the world.
2. Manufacturing covers a wide range of industries, from automotive and electronics to pharmaceuticals and beverages, all focused on the mass production of goods.
3. The desire to stay competitive and streamline operations has pushed manufacturing companies to leverage data in assessing effectiveness and overall decision-making.
4. Mobile data collection tools like the Open Data Kit (ODK) have been extensively deployed in this sector alongside other data collection methods like drones and SMS-based surveys.
5. These technologies have enabled real-time data access and provided advanced analytics capabilities like never before.
6. This article explores how mobile data collection tools and other modern methods of data collection have improved the operations of different organizations in the manufacturing sector.

 

 

Also read: Mobile Data Collection in Tourism: Transformative Case Studies Shaping the Industry

 

 

Revolutionizing Manufacturing: The Role of Mobile Data Collection Tools and Emerging Technologies

 

Mobile data collection refers to the process of recording and managing data using mobile devices such as smartphones, tablets, or specialized handheld devices.

 

Mobile data collection is significantly faster than traditional paper-based methods, giving manufacturing engineers, quality control inspectors, and supply chain managers real-time data in managing operations.

 

Mobile tools are supplemented by equally powerful new technologies such as drones and RFID (Radio Frequency Identification) in routine data tasks such as tracking manufacturing inventory.

 

The reliability and convenience offered by mobile data collection have led many manufacturing firms to adopt the technology and train their staff, with some professionals opting for self-paced courses to master the approach.

 

How Does Mobile Data Collection Work?

Mobile data collection is an automated approach to collecting and recording data that generally works in the following steps:

 

1. Form Design: Creating Flexible and Dynamic Digital Forms

Survey authoring tools enable factory managers and other professionals to create custom data collection forms that can handle various data types such as text, GPS coordinates, barcodes, images, and voice recordings.

These tools help design, test, and deploy digital data collection forms.

 

Some mobile tools used in form design include:

 

1. XLSForms – Excel-based form design standard used by ODK, KoboToolbox, and CommCare.
2. ODK Build – Drag-and-drop form designer for ODK users.
3. Kobo Form Builder – Simplified visual form creator for KoboToolbox.
4. SurveyCTO Designer – Enterprise-grade form-building with conditional logic.
5. Google Forms – Basic web-based form creation tool.
6. Magpi Forms – Mobile-friendly form designer for surveys and data collection.

 

Survey authoring tools enable factory managers and other professionals to create custom data collection forms for various forms of data across the production line. Picture/Courtesy

 

 

2. Data Collection Using Mobile Devices

Many mobile data collection tools support multiple functionalities such as barcode scanning, GPS tracking, image capture, voice-to-text input, digital signatures, and many other functionalities.

Mobile data collection tools also offer offline functionality, allowing users to capture data without an internet connection and synchronize it later when connectivity is restored.

 

Some of the tools used to collect data using mobile devices include:

 

 

1. ODK Collect – Open-source mobile app for mobile data collection using ODK. ODK Collect can collect data offline.
2. KoboCollect – Mobile app for data collection using KoboToolbox.
3. SurveyCTO Collect – Secure, offline-first data collection platform.
4. Survey123 by Esri – GIS-enabled app for geospatial data collection.
5. CommCare – Mobile case management tool used in health and humanitarian projects.
6. TaroWorks – Salesforce-integrated data collection tool.
7. Magpi+ – Supports multimedia data input.

 

Dimagi CommCare – Supports longitudinal tracking and case management.

 

 

3. Offline Data Collection in Areas With Limited Internet

Mobile data collection tools allow uninterrupted work, even without internet access, by storing data offline and automatically syncing it when a connection is available.

Some of the mobile tools for offline data collection include:

 

1. ODK Collect – Stores responses offline and syncs later to a cloud server.
2. KoboCollect – Stores responses offline and syncs later to a cloud server.
3. Magpi+ – Designed for low-bandwidth regions.
4. TaroWorks – Works offline and syncs with Salesforce CRM.
5. CommCare – Enables offline case tracking for healthcare and NGOs.
6. Surveys on Tab – Offline-first solution for market and corporate surveys.

 

Mobile data collection is significantly faster than traditional paper-based methods, giving manufacturing engineers, quality control inspectors, and supply chain managers real-time data in managing operations. Picture/Courtesy

 

 

4. Data Synchronization: Uploading & Syncing to the Cloud

Mobile data collection tools automatically upload recorded data to a centralized cloud or physical servers for processing as soon as an internet connection is established.

Some of the mobile tools for data synchronization include:

 

1. ODK Central – Store and manage synchronized data.
2. ODK Aggregate – Store and manage synchronized data.
3. KoboToolbox Servers – Store and manage synchronized data.
4. Google Sheets API – Auto-syncs data to spreadsheets for easy access.
5. RedCap – Secure data management for research and healthcare projects.
6. ODK Cloud, Microsoft Azure, AWS S3, Digital Ocean, Google Cloud – Secure cloud-based data storage solutions.

 

Mobile devices enable seamless offline data collection, with automatic cloud synchronization ensuring data integrity and accessibility upon network reconnection. Picture/Courtesy

 

 

5. Data Management: Cleaning, Processing, and Storage

Once collected, the data is cleaned, processed, and organized to facilitate analysis and informed decision-making.

Some of the tools for data management include:

 

1. Microsoft Excel & Google Sheets – Used for basic data cleaning and filtering.
2. Power BI – Dashboard creation and business intelligence reporting.
3. Python & R – Advanced data processing and analytics.
4. Tableau – Data visualization and storytelling.
5. QGIS – GIS software for geospatial data mapping.
6. Google BigQuery – Cloud-based big data warehousing.

 

 

6. Reporting & Action: Analyzing Data for Decision-Making

With processed data in hand, organizations create reports, visualize key insights, and drive informed decisions.

Some of the tools for reporting & action include:

 

 

1. Microsoft Power BI – Interactive data visualization and reporting.
2. Google Data Studio – Cloud-based business intelligence platform.
3. Tableau – Advanced analytics and visualization.
4. SPSS & Stata – Statistical tools for complex data analysis.
5. QGIS – GIS mapping and spatial analytics.
6. Looker (Google Cloud) – Data-driven business intelligence platform.

 

Mobile devices help monitor production levels, and track materials, leading to better manufacturing resource allocation. Picture/Courtesy

 

 

 

Mobile data collection has improved manufacturing processes in the following ways:

 

1. Real-Time Data Access: Mobile data collection and drones provide instant, on-site data, allowing for quicker decision-making and response times.
2. Improved Accuracy: Automation and sensors reduce human error, ensuring more precise data collection and better quality control.
3. More Efficiency: Drones and mobile tools streamline inspections, inventory tracking, and maintenance, reducing downtime and increasing productivity.
4. Saving costs: Reducing the need for manual labor, travel, and paper-based processes cuts operational costs in manufacturing.
5. Better Resource Management: Mobile devices and drones help monitor production levels, and track materials, leading to better resource allocation.
6. Increased Safety: Drones can access hazardous or hard-to-reach areas, especially in warehouses, minimizing the need for workers to perform dangerous tasks.

Case Studies of Mobile Data Collection and Other Modern Methods in the Manufacturing Sector

 

1. Use of Drones in Warehouse Inventory Tracking – Amazon

Amazon is a global e-commerce giant that started as an online bookstore in 1994, founded by Jeff Bezos.

While Amazon produces its own branded consumer products, such as the Amazon Echo smart speakers and Amazon Kindle tablets, the company plays a more prominent role in logistics within the manufacturing sector.

The e-commerce giant acts as a massive distributor of manufactured goods, connecting consumers with products from manufacturers worldwide.

These extensive logistical operations resulted in the establishment of numerous warehouses, primarily in the United States, which serve as staging areas for goods being shipped to various global destinations.

 

Project Details

 

1. In 2013, Amazon introduced drone technology as a key component of its plan to enhance logistics and streamline the fulfillment of orders for its global customer base.
2. The drones, initially designed for inventory management, have now been integrated with Amazon’s warehouse automation system.
3. Drones have replaced traditional methods of manufacturing inventory tracking such as rope access, where technicians use specialized harnesses and climbing equipment for manual stock-taking.
4. The latest drones are equipped with advanced software like FlytWare, enabling them to instantly detect product barcodes and QR codes, significantly enhancing inventory tracking efficiency.

 

Challenges Before the Adoption of Drones in Warehouse Data Collection and Management by Amazon

 

1. Before drones, Amazon warehouses relied on manual barcode scanning and employee-led stock-taking, which was time-consuming and prone to human error.
2. Traditional warehouse systems struggled with accurately locating and retrieving items.
3. The repetitive and manual nature of data collection and inventory tracking tasks led to huge inefficiencies.

 

 

Drones can navigate tight spaces within the warehouse, accessing higher shelves without the need for ladders or additional human intervention. Picture/Courtesy

 

 

Key Benefits After the Adoption of Drones for Data Collection

 

 

1. Drones now conduct regular inventory audits by flying around warehouses and quickly scanning products on the shelves.
2. Drones enable Amazon to update inventory records in real-time, increasing the accuracy of stock levels.
3. Amazon has been able to reduce costs related to inventory data collection, tracking, and management.
4. Drones can navigate tight spaces within the warehouse, accessing higher shelves without the need for ladders or additional human intervention.
5. Drones help reduce the time between product retrieval and shipment, ensuring quicker deliveries to customers.
6. Drones can handle routine inventory checks and inspections in high-risk areas of the warehouse, contributing to more safety of workers.

 

Source

Drones for Racking & Warehouse Inspection – COPTRZ

 

 

2. Use of ODK in Examining the Effects of Reverse Logistics on Pharmaceutical Manufacturing Companies – Ghana

Ghana’s pharmaceutical manufacturing industry has seen significant growth in recent years, positioning the country as a key player in West Africa’s healthcare sector.

 

The industry is thriving in strategic locations such as the nation’s capital Accra and Kumasi in the Ashanti region, which is Ghana’s second-largest city.

 

Ghana’s pharmaceutical companies face challenges in complying with various regulations, including product take-back (particularly expired drugs), an activity also known as reverse logistics.

 

Reverse logistics refers to the process of managing the return of goods from consumers back to the manufacturer or distributor, often for recycling, refurbishment, or disposal.

 

Project Details

 

 

1. The Open Data Kit (ODK) was implemented in a 2024 study conducted on Pharmaceutical manufacturers operating in the Ashanti region of Ghana.
2. The study sought to examine how efficient reverse logistics processes impacted operational costs, customer satisfaction, and overall company performance in Ghana’s pharmaceutical sector.
3. The decision to adopt ODK was made to streamline data collection, ensure greater accuracy, and improve the speed of the research process.

 

Challenges Before the Adoption of ODK

 

1. Before adopting ODK, the research team relied on paper-based surveys, which were slow and prone to human error.
2. In remote or rural areas, where some pharmaceutical companies have satellite facilities, data was difficult to collect and consolidate.
3. With paper-based methods, data analysis was delayed as it required manual entry into spreadsheets and databases.

 

Pharmaceutical factories produce medicines, ensuring strict quality control and regulatory compliance. Picture/Courtesy

 

 

Key Benefits After the Adoption of ODK

 

 

1. ODK enabled the research team to collect data in real-time using mobile devices, eliminating the need for paper forms.
2. The use of mobile forms helped reduce data entry errors. ODK’s validation features ensured that responses met certain criteria before submission, enhancing data quality.
3. ODK allowed the researchers to access data in real-time, even from remote locations with limited connectivity.
4. The research project reduced both time and resource costs by reducing manual data collection efforts.
5. Researchers could make quicker, data-driven decisions about reverse logistics practices and their effects on organizational performance.
6. The study provided valuable data on the state of reverse logistics in Ghana’s pharmaceutical sector, helping policymakers improve logistics infrastructure and regulations.

 

Source

The effects of reverse logistics on organizational performance of pharmaceutical manufacturing companies: A case study in the Ashanti region of Ghana – World Journal of Advanced Research and Reviews

 

3. Diageo’s Use of Mobile SMS Surveys for Agile Decision-Making – Nigeria

 

Diageo is a leading manufacturer and distributor of alcoholic beverages in Africa, known for producing iconic brands like Johnnie Walker, Smirnoff, Baileys, and Guinness.

 

The British multinational is headquartered in London, England, and also produces local African beverage brands, such as Star and Harp.

 

To preserve its status as Africa’s finest beverage manufacturer, Diageo regularly researches to assess the needs, perceptions, and experiences of its customer base.

 

Project Details

 

1. Diageo Nigeria began using mobile SMS surveys in 2020, working closely with GeoPoll to conduct rapid customer research.
2. The decision was driven by the need for agile, real-time data collection to respond quickly to changes in the market.
3. This project was also necessitated by the highly uncertain operating environment following the historic global strike by the COVID-19 pandemic in early 2020.

 

 

Challenges Before Adopting SMS-Based Data Collection Methods

 

1. Traditional methods like face-to-face surveys and paper forms took longer and could not provide immediate insights, which were crucial in the competitive industry.
2. Diageo needed a more responsive research method to quickly assess customer perceptions and market conditions, especially when urgent business decisions arose.
3. It was also difficult to approach respondents physically for face-to-face surveys due to the prevalence of the lethal COVID-19 disease.

 

Diageo’s Hungarian headquarters in Budapest. The British multinational operates in many other regions including Africa. Picture/Courtesy

 

 

Key Benefits of the SMS-Based Data Collection on the Diageo Customer Research Project

 

1. Mobile SMS surveys allowed Diageo to collect data from over 1,000 customers in under 48 hours, enabling faster decision-making
2. The SMS survey method provided immediate data analysis, helping Diageo respond quickly to market dynamics.
3. SMS surveys didn’t require smartphones or internet access, ensuring a more diverse sample across different demographics.
4. The SMS data collection method was more affordable than traditional data collection methods, saving Diageo time and money.

 

Source

Case Study: Diageo Nigeria Uses Mobile Surveys for Agile Decision-Making – GeoPoll

 

 

4. DAW SE’s Use of LP EasyClient Tool for Mobile Data Collection – Europe

DAW SE refers to Deutsche Aktiengesellschaft (German Stock Corporation), which is a public limited company based in Germany.

The company operates in the coatings and paints industry, specializing in the production of architectural and industrial coatings.

It serves a wide range of customers, including those in construction, infrastructure, and various industrial sectors.

DAW SE uses the LP EasyClient, a mobile data collection tool specifically designed for liquid packaging system manufacturers.

Project Details

 

1. DAW SE adopted the LP EasyClient tool in 2020 to optimize warehouse operations at 15 locations in Sweden, Austria, and at its headquarters in Ober-Ramstadt Germany.
2. The company integrated the LP EasyClient mobile data collection with its warehouse management software.
3. The adoption of the LP EasyClient tool revolutionized DAW’s warehouse management, enabling them to scale operations and respond to customer demands more efficiently.

 

Challenges Before the Adoption of LP EasyClient Mobile Data Collection Tool

 

1. The manual entry of data led to issues with consistency and real-time processing.
2. Warehouse processes were prone to human errors due to paper-based systems.

 

 

DAW SE uses the LP EasyClient, a mobile data collection tool specifically designed for liquid packaging system manufacturers. Picture/Courtesy

 

 

Key Benefits After the Adoption of LP EasyClient by DAW SE

 

 

1. LP EasyClient allowed mobile and stationary RF (Radio Frequency) transactions, improving the speed and accuracy of warehouse operations.
2. The tool enabled paperless processing, removing the risk of manual errors and making processes more efficient.
3. With an intuitive interface, warehouse employees found the tool easy to use, even with minimal training.
4. Customers continue to experience faster order fulfillment and improved service quality due to more efficient warehouse operations.

Source

Mobile data collection in the warehouse with LP EasyClient – LogiPlus

 

 

Also read: Mobile Data Collection Digitizes the Mining Sector: Real-World Case Studies

 

 

5. Röchling Industrial SE & Co. KG’s Use of L-mobile App for Mobile Data Collection

Röchling Industrial SE & Co. KG is a global company that specializes in the development and production of high-performance plastics and polymer-based products for industrial applications.

The company is headquartered in Mannheim, Germany, and serves a variety of industries including automotive, medical technology, food processing, and chemicals.

 

Project Details

 

1. Röchling Industrial SE & Co. KG adopted the L-mobile app for mobile data collection in 2020.
2. The app was integrated to enhance data recording directly at the point of origin in production facilities, improving transparency and accuracy in operations.
3. Röchling Industrial needed what it termed as a real-time transparent overview of its entire production process.

 

Challenges Before the Adoption of Mobile Data Collection

 

1. The company relied on manual entry for production data, which resulted in inaccuracies and delays.
2. Data collection was slow, and there was a delay in updating real-time production information, causing inefficiencies.
3. Managers had difficulty obtaining up-to-date insights for decision-making since there was no direct data collected from production.

 

Drones and mobile data collection tools streamline inspections, inventory tracking, and maintenance, reducing downtime and increasing productivity. Picture/Courtesy

 

 

Key Benefits After the Adoption of Mobile Data Collection

 

 

1. The L-mobile app enabled prompt, seamless, and accurate collection of production data, such as working times, machine downtimes, and quantities produced.
2. Röchling gained greater oversight of their production processes, improving operational decision-making.
3. The digitalized approach allowed for more agile decisions regarding resource allocation, machine maintenance, and production schedules.
4. Production Teams benefited from streamlined processes, reducing time spent on manual tasks and improving accuracy.

Source

Production Data Collection | The Production Data Collection System for Greater Transparency in Your Manufacturing – L Mobile

 

Conclusion

In summary, case studies from companies like Diageo Nigeria, DAW SE, and Amazon highlight the transformative impact of mobile data collection tools and modern technologies such as drones in the manufacturing sector.

 

Whether through mobile apps like L-mobile for production data or drones for inventory tacking, these technologies empower manufacturers to respond quickly to market changes and maintain a competitive edge in a rapidly evolving industry.

 

As demonstrated in the case studies, the integration of mobile and automated data collection methods is no longer just for convenience but a crucial addition in today’s manufacturing environment.

 

Post Tags:#Manufacturing#Mobile data collection