Manufacturing
Smart Factory Transformation
Client: Advanced Manufacturing Inc.
The Story
A leading manufacturer wanted to stop guessing and start knowing. They needed to bridge the gap between their physical machinery and their digital data to embrace Industry 4.0.
The Obstacle
The factory floor was a black box. Management knew what went in and what came out, but everything in between was a mystery until the end-of-month reports.
They struggled with:
• Unpredicted downtime because machines broke before anyone noticed symptoms.
• High material waste due to calibration drift.
• A disconnect between the supply chain team and the production floor.
• Vulnerable operational technology (OT) that wasn't designed for the internet.
How We Helped
We gave the factory a nervous system. By deploying a Smart Factory infrastructure, we connected the dots between metal and code:
• Rolled out an IIoT sensor network to monitor machine health in real-time.
• Built "single pane of glass" dashboards for plant managers.
• Integrated the production line directly with ERP systems to automate supply ordering.
• Secured the operational network to prevent cyber-physical attacks.
The Impact
Production efficiency jumped by 25%
Supply chain now reacts automatically to production speed
Equipment uptime hit 98% thanks to predictive maintenance
Material waste dropped by 40%
Complete visibility from raw material to finished product
"It feels like someone turned the lights on. We used to run on gut feeling; now we run on data. The efficiency gains paid for the project in less than a year."
Facing a similar challenge?
Every business is unique, but the path to digital success doesn't have to be a mystery. Let's talk about what's next for you.
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