An Automotive Tier 1 supplier faced difficulties optimizing asset utilization due to a lack of transparent data on machine performance. As production volumes grew, the need for additional capacity became critical, but without insights into existing asset usage, planning for new investments was impossible. The factory, equipped with a mix of legacy and modern machines, faced these challenges:
Impact
Within 8 months, the factory transitioned from manual processes to a fully connected ecosystem:
- All critical assets streamed real-time data to the cloud, offering complete transparency on utilization and downtime.
- The solution enabled insights at the plant, production line, and asset levels.
- The customer achieved an 18% improvement in OEE, avoiding significant capital expenditure on new machinery.
- Flexibility increased to adapt to dynamic market conditions, resulting in an extension of the solution to three additional factories in just two months.
Key Deliverables
- Private Smart Factory Instance: Built on Microsoft Azure with a RAMI 4.0 architecture.
- AAS Standards: Centralized data for plants, machines, lines, and assets.
- Real-Time Machine Connectivity: Continuous streaming every second.
- IIoT Gateway Deployment: Seamlessly integrated with legacy and modern machines.
- OEE Application Enablement: Comprehensive monitoring and analytics.
- Downtime Reporting: Pareto charts and actionable insights.
- Alerts and Notifications: Proactive measures for maintenance and downtime reduction.
- Team Training: Empowering the local workforce to configure additional assets independently.