Problem Categories
Problem Statements
PS_ID | Problem Title | Detail | |
---|---|---|---|
SH01 | Digitization of DISA Production Records |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/5/ Digitization of DISA Production Records - SH01 Currently, many of the production records in the company are entered manually, leading to issues such as data inconsistency, delays in reporting, and lack of real-time tracking. There is a pressing need to digitize this process through a secure and user-friendly portal to improve efficiency, traceability, and data integrity. This will also enable better analysis of production trends and quicker decision-making. A web-based portal where DISA machine operators or supervisors can digitally enter production data. The portal should allow: 1) Should work on standard shop-floor tablets or desktops 1) Web technologies (HTML5, CSS, JavaScript, React/Angular) |
SH02 | Automation of Breakdown Intimation Process |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/6/ Automation of Breakdown Intimation Process - SH02 Currently, breakdown reporting on the shop floor is handled manually through logbooks or verbal communication, resulting in delayed responses, lack of visibility, and incomplete historical data. Additionally, maintenance work often begins without proper issuance or tracking of safety work permits, posing operational risks. There is a need to digitize the entire breakdown intimation process—including mandatory safety permit generation and automated alerts to the safety team—to enhance operational safety, documentation, and response time. A digital system (mobile/web portal) that enables: 1) Easy-to-use interface for operators 1) Mobile app: Flutter / React Native |
SH05 | Smart Monitoring System for Returnable Packing Box Lifecycle |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/7/ Smart Monitoring System for Returnable Packing Box Lifecycle - SH05 In logistics and dispatch operations, returnable packing boxes are reused multiple times to transport castings and components. However, there is currently no system in place to track the individual lifecycle of each box. Manual tracking results in box loss, overuse, and quality deterioration without timely replacement. A smart system is required to uniquely identify each box and monitor its usage history to ensure optimal utilization and timely disposal or maintenance. " 1) Durable ID tagging (QR code/RFID) on each box " |
SH03 | Real-Time Stock Alert System for Rough Casting Warehouse |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/8/ Real-Time Stock Alert System for Rough Casting Warehouse - SH03 To meet daily production targets, the rough casting warehouse must maintain an adequate stock of required castings. Currently, stock shortage information is communicated manually via phone calls, which leads to delays, miscommunication, and potential production halts. A digital system is needed to display real-time stock availability and trigger automated alerts when inventory falls below threshold levels, ensuring timely replenishment and seamless production flow. A system that provides: 1) Real-time display of stock levels on a digital dashboard or board in the warehouse and production areas 1) Dashboard: Web-based (React / Angular) with integration to large display units |
SH04 | Automation of Cutting Tool Issue and Receipt Management |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/9/ Automation of Cutting Tool Issue and Receipt Management - SH04 In the machining section, over 100 types of cutting tools are used for various operations. Currently, the issuance and return of these tools are managed manually, which often leads to errors, delays, and a lack of traceability. An automated system is needed to track the issue and receipt of cutting tools accurately, reduce human error, and improve inventory visibility, tool life tracking, and accountability. A digital tool management system that enables: 1) Must support over 100 tool types with categorization 1) Suitable tech for tool tracking |
SH06 | Digital Monitoring System for Raw and Mixed Coolant Consumption |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/10/ Digital Monitoring System for Raw and Mixed Coolant Consumption - SH06 In machining operations, both raw coolant oil and mixed coolant (coolant + water) are used extensively. Currently, there is no digital system in place to track their separate daily consumption, leading to challenges in monitoring usage patterns, detecting overconsumption, and planning refills. A smart digital control system is needed to independently monitor the consumption of raw coolant oil and mixed coolant in litres/day to ensure efficient usage, cost control, and timely replenishment. A digital system that: 1) Flow sensors or digital meters to be integrated at both raw coolant and mixing points 1) IoT-enabled flow sensors |
SH07 | Digital Quality Control & Assurance Document System for Machining Sections |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/11/ Digital Quality Control & Assurance Document System for Machining Sections - SH07 In machining sections, Quality Control (QC) and Quality Assurance (QA) activities generate large volumes of paper-based documents such as inspection reports, control plans, gauge calibration records, rejection notes, and corrective action reports. Managing these manually leads to issues with traceability, real-time accessibility, and compliance with IATF 16949 standards. A digital system is required to transform these records into a fully paperless, searchable, and auditable format—supporting faster decision-making and compliance readiness. A digital quality documentation system that enables: 1) Interface for inspectors and QA engineers on shop floor terminals 1) Frontend: Portal using (Angular / React) |
SH08 | Centralized Backup and Access System for Machine Shop Programs and PLC Logic |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/12/ Centralized Backup and Access System for Machine Shop Programs and PLC Logic - SH08 The machine shop operates over 6 different makes of CNC and special-purpose machines, each with its own set of part programs, PLC logic, passwords, parameter settings, and control configurations. These are currently stored in local PCs, USB drives, or operator notebooks—posing a risk of data loss, unauthorized changes, and version confusion. A centralized, secure, and traceable software system is required to back up, manage, and retrieve machine-specific programs and logic settings for maintenance and process continuity. A secure software/application that enables: 1) Must support file types used by popular CNC/PLC platforms 1) Backend: Node.js / Django / Firebase |
SH09 | Predictive Life Monitoring and Notification System for Machine Critical Spares |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/13/ Predictive Life Monitoring and Notification System for Machine Critical Spares - SH09 "In CNC machines and other precision equipment, critical spares such as ball screws, LM guideways, and tool magazines have defined service lives. However, there is currently no system to monitor their usage or predict wear-out in real-time. This results in unexpected breakdowns, poor maintenance planning, and production losses. A digital solution is needed to track usage life, generate timely alerts, and support preventive replacement of these critical components. A smart system that: 1) Should support multiple spare types with configurable life thresholds 1) IoT-enabled sensors (optional) for auto data capture |
SH10 | Smart Notification System for Preventive and Predictive Maintenance in Manufacturing |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/14/ Smart Notification System for Preventive and Predictive Maintenance in Manufacturing - SH10 In the current system, preventive maintenance (PM) schedules are tracked manually, and predictive maintenance (PdM) insights—if any—are not centralized. This leads to missed schedules, unplanned breakdowns, and reduced equipment reliability. A digital application is needed to manage PM/PdM schedules and generate timely, automated notifications for maintenance teams, improving machine uptime and resource planning. A web application that: 1) Customizable scheduling (daily, weekly, hourly run-time based) 1) Frontend: React / Angular / Flutter for app |
SH11 | Digital Application for Product Layout Inspection – Plan vs Actual Tracking |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/15/ Digital Application for Product Layout Inspection – Plan vs Actual Tracking - SH11 In the machining and quality control process, product layout inspection is a critical step to verify that components conform to dimensional and design specifications. Currently, inspection records—including plan vs actual dimension comparisons—are maintained manually in paper formats. This leads to difficulties in data retrieval, analysis, and audit readiness. A digital application is needed to record, compare, and store layout inspection results, improving traceability, accuracy, and compliance with quality standards. A web based application that: 1) Support for multiple product types and drawing revisions 1) Frontend: React / Angular for web |
SH12 | Water Monitoring and Replenishment Tracking System for Achieving Water Positivity Standards |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/16/ Water Monitoring and Replenishment Tracking System for Achieving Water Positivity Standards - SH12 To move toward water positivity, an organization must monitor its water consumption, reduce wastage, and implement replenishment measures such as rainwater harvesting, wastewater recycling, and recharge pits. Currently, water consumption and replenishment efforts are tracked manually or through fragmented systems, making it hard to assess water balance and plan improvement actions. A unified digital platform is required to monitor water usage across the facility, track water-saving and recharge initiatives, and report against water-positive benchmarks. A digital solution that: 1) Integration with digital water meters or flow sensors at source and end-use points 1) IoT-enabled water flow meters |
SH13 | AI-Driven Carbon Net Zero Tracking and Optimization System for Manufacturing Operations |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/17/ AI-Driven Carbon Net Zero Tracking and Optimization System for Manufacturing Operations - SH13 Sakthi Auto Component Limited is committed to achieving Carbon Net Zero by 2040 across its operations. However, existing systems lack the ability to measure, analyze, and reduce emissions at a granular level. There is an urgent need for a digital solution that can monitor real-time carbon footprints across different departments (melting, machining, dispatch, etc.), recommend actionable emission reduction strategies, and track the effectiveness of interventions over time. The system should also support carbon offset integration and reporting aligned with global sustainability frameworks. A comprehensive digital platform that: 1) Must support multi-department emission tracking 1) Frontend: React / Angular |
SH14 | Automated Tooling Management and Digital Daily Inspection Recording System |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/18/ Automated Tooling Management and Digital Daily Inspection Recording System - SH14 In the machining shop, effective tooling management is crucial to maintain quality, productivity, and machine health. Currently, tool issue records, condition tracking, and daily inspection reports are maintained manually—leading to human error, missed inspections, and lack of traceability. A digital system is required to manage tooling inventory, track tool life, and auto-record daily tooling inspection results for traceability, compliance, and predictive maintenance. A tooling management solution that: 1) Support for multiple tool types and tool crib categorization 1) Support for multiple tool types and tool crib categorization |
SH15 | Automated Pattern History Monitoring and Tooling Revalidation Trigger System |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/19/ Automated Pattern History Monitoring and Tooling Revalidation Trigger System - SH15 In the foundry, each pattern used for casting has an associated Pattern History Card that tracks its usage, wear, and maintenance cycles. Currently, these cards are updated manually based on production records, and the process of sending revalidation requests to the Foundry QA department is also manual—resulting in missed schedules, delayed validations, and compromised casting quality. A digital system is required to auto-update pattern history based on actual production data and automatically notify the Foundry QA team when tooling revalidation is due. An application / digital system that: 1) Integration with production log or ERP system for daily part count 1) Frontend: Angular / React Web Application |
SH16 | Digital Tracking System for New Product Development (NPD) Sample Records |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/20/ Digital Tracking System for New Product Development (NPD) Sample Records - SH16 "In the New Product Development (NPD) process, multiple product samples are created, tested, and validated across stages—pattern making, trials, machining, inspection, and customer feedback. Currently, these sample records are maintained manually, which leads to issues in version tracking, delayed feedback loops, and difficulty in traceability. A digital system is needed to monitor the lifecycle of each sample with real-time updates, approvals, and documentation for faster and error-free product development. A digital platform that enables: 1) Unique ID assignment for each sample product 1) Frontend: React / Angular for web, Flutter for mobile |
SH17 | AI-Driven Alloy Addition System Based on Spectrometer Results and Process Capability |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/21/ AI-Driven Alloy Addition System Based on Spectrometer Results and Process Capability - SH17 In the foundry process, alloying is a critical step to ensure the final chemical composition meets product specifications. Currently, alloy addition decisions are manually taken based on spectrometer readings and operator experience, which introduces variability and inconsistencies. There is a need for an AI-based system that automatically recommends or executes alloy additions by analyzing real-time spectro results and previous process capability data, ensuring faster, precise, and consistent metallurgical compliance. An intelligent system that: 1) Integration with spectrometer and furnace alloy feeding system 1) AI/ML: Python |
SH18 | Digital Documentation and Record Management |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/22/ Digital Documentation and Record Management - SH18 At Sakthi Auto, various departments maintain operational documents and records—ranging from production logs and inspection sheets to process control documents—using paper-based or semi-digital formats. A unified digital system is required to replicate and digitize all documents and records exactly as per existing workflows, ensuring seamless adoption without disrupting the current process logic. An electronic / digital documentation system that: 1) Must mirror the current process flow without major re-engineering 1) Frontend: Angular / React |
SH19 | Digital Project Management Tracker with Plan vs Actual Monitoring and Delay Escalation System |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/23/ Digital Project Management Tracker with Plan vs Actual Monitoring and Delay Escalation System - SH19 Currently, project activities across departments—such as new product development, tooling, maintenance shutdowns, or infrastructure projects—are tracked manually using spreadsheets or written reports. This results in limited visibility, delayed response to deviations, and lack of accountability. A digital project management application is required to monitor Plan vs Actual timelines of project milestones, with built-in auto-alerts and escalation triggers for delayed or overdue activities. A project tracking application that: 1) Multi-user access with role-specific views (Project Manager, Engineer, QA, etc.) 1) Frontend: React / Angular / Flutter |
SH20 | Innovative Reuse Ideas and Buyer Identification for Furnace Slag Generated in Foundries |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/24/ Innovative Reuse Ideas and Buyer Identification for Furnace Slag Generated in Foundries - SH20 "Furnace slag is a by-product of the melting process in foundries, often treated as industrial waste. However, it has latent potential for reuse in areas like cement manufacturing, road construction, brick making, and other value-added applications. Currently, there is no structured approach to identify innovative reuses or link slag generators with potential end users. The challenge is to explore creative reuse possibilities and identify external industries or buyers who can effectively utilize furnace slag, promoting a circular economy and reducing environmental impact. Innovative and implementable ideas that: 1) Must consider slag composition and safety/environmental standards Not applicable (idea and strategy-based submission preferred) |
SH21 | IoT and AI in Everyday Life |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/25/ IoT and AI in Everyday Life - SH21 Ideas focused on the intelligent use of resources for transforming and advancements of technology with combining the artificial intelligence to explore more various sources and get valuable insights. 1. Intelligent traffic management system 1. Integration with real-time sensor data and AI-based decision engines for automation Any relevant Tech Stack can be used |
SH22 | Green and Clean Technologies |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/26/ Green and Clean Technologies - SH22 Solutions could be in the form of waste segregation, disposal, and improve sanitization system. 1. Innovations pertaining to recycle/reuse of e-waste from energy sector 1. Must comply with environmental and safety standards for recycling or energy reuse Any relevant Tech Stack can be used |
SH23 | Agriculture, FoodTech & Rural Development |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/27/ Agriculture, FoodTech & Rural Development - SH23 Developing solutions, keeping in mind the need to enhance the primary sector of India - Agriculture and to manage and process our agriculture produce. 1. Help farmers monitor their crops more efficiently, reduce pesticide use, and improve overall farm efficiency. 1. Should support IoT-based field sensors, weather integration, and crop-specific advisory systems Any relevant Tech Stack can be used |
SH24 | Robotics and Drones |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/28/ Robotics and Drones - SH24 There is a need to design drones and robots that can solve some of the pressing challenges of India such as handling medical emergencies, search and rescue operations, etc. 1. Developments might save lives, increase efficiency in emergency rescue operations, and offer vital support during crises. 1. Must feature real-time control or autonomous navigation using GPS and AI/ML models Any relevant Tech Stack can be used |
SH25 | Renewable/ sustainable Energy |
Detail |
/events/sakthi_hackathon_1.0/hackathonregister/29/ Renewable/ sustainable Energy - SH25 Innovative ideas that help manage and generate renewable /sustainable sources more efficiently Create an effective and sustainable solution to reuse or recycle worn-out solar panels and E-Vehicle batteries, minimizing waste and maximizing the recovery of valuable materials for future use 1. Must include chemical/physical recovery processes that meet regulatory recycling standards Any relevant Tech Stack can be used |