Executive Summary
In a rapidly evolving manufacturing landscape, Webtech Industries, a leader in pharmaceutical leaflets and outserts, achieved a remarkable leap in efficiency, visibility, and intelligence all powered by CountWONDER®.
Within months, the company transformed its operations by implementing CountWONDER® OEE Insights, integrating it seamlessly with its custom ERP system, and then advancing to CountWONDER® AI Insights, which delivers intelligent production insights directly via WhatsApp — zero learning curve, 100% adoption.
Today, Webtech’s management and operators make faster, data-driven decisions effortlessly — setting a new benchmark for smart, connected manufacturing.
Company Overview
Webtech Industries, headquartered in Mahape, Navi Mumbai, India, is a trusted name in pharmaceutical printing known for precision, consistency, and innovation. With decades of experience and a reputation for delivering uncompromised quality, Webtech has continuously evolved to meet the dynamic needs of India’s regulated pharmaceutical market.
Recognizing the importance of digital transformation, Webtech began its journey to modernize production aiming to unify data, eliminate manual errors, and bring real-time visibility to every stage of manufacturing.
The Challenge: From Paper to Real-Time Intelligence
Before adopting CountWONDER®, Webtech’s daily production tracking relied heavily on manual logs and Excel sheets.
Operators filled out paper-based reports, supervisors compiled them manually, and managers waited hours to understand what went wrong the previous day.
As Director Ajay Chajjed described,
“Every evening, production reports came in as handwritten sheets. Managers spent hours compiling them, often realizing the next morning what could have been fixed the same day. We needed data that spoke instantly, not reports that arrived too late.”
The lack of real-time data made it difficult to identify recurring downtime, validate operator feedback, or make quick, informed decisions. Webtech needed a system that was powerful yet effortless one that simplified data capture, reduced reporting delays, and made insights instantly accessible across all levels of the organization.
The Solution: Introducing CountWONDER® OEE Insights
To address these challenges, Webtech implemented CountWONDER® OEE Insights, starting with a pilot project at its Mahape facility on two folding machines.
Within weeks, CountWONDER® began automatically tracking machine performance, downtime reasons, and shift-wise efficiency. Its clean, visual dashboards gave immediate visibility into where improvements were needed most.
When the first pilot results were presented to the board, the effect was instant.
“It was the Wow-Effect – the board could see the data in a very clear and credible way.” — Ajay Chajjed, Director, Webtech Industries
The pilot proved so successful that Webtech decided to expand CountWONDER® across all machines at its Mahape plant.
ERP Integration: One Source of Truth
To ensure data consistency and eliminate duplication, Webtech integrated CountWONDER® with its in-house ERP system.
This synchronization allowed job details such as job numbers, clients, and quantities to flow automatically into CountWONDER®, creating a seamless bridge between production planning and execution.
“After integration, operators no longer needed to enter job details manually. Everything flowed directly from ERP to CountWONDER® — it saved hours and eliminated mistakes.” — Kushal, Plant Manager, Webtech Industries, Mahape
With this integration, Webtech achieved a single, unified data ecosystem, where real-time production updates aligned perfectly with ERP-driven planning.
WhatsApp Reporting: Visibility at Your Fingertips
To enhance responsiveness and simplify access, Webtech adopted CountWONDER® WhatsApp Reporting an innovative communication feature that delivers live production data, shift summaries, and downtime alerts directly to managers and supervisors.
“Right from the start, CountWONDER® has been great! The support from the team has always been absolutely fantastic.” — Kushal, Plant Manager, Webtech Industries, Mahape
Now, without logging into a system or opening dashboards, leadership could monitor factory performance instantly anywhere, anytime.
Next Evolution: CountWONDER® AI Insights
After mastering real-time monitoring, Webtech took its next leap by implementing CountWONDER® AI Insights a layer of intelligence that converts raw machine data into predictive, actionable insights.
CountWONDER® AI Insights automatically analyzes performance trends to:
• Detect inefficiencies and hidden bottlenecks
• Predict downtime causes before they occur
• Recommend optimal speed and utilization improvements
• Deliver real-time performance coaching to the shop floor