Plant Floor Information System for a Leading US-Based Manufacturer
Overview
The client needed a reliable, real-time factory floor monitoring system to reduce unplanned downtime, ensure product quality, enable traceability, and seamlessly integrate production data with enterprise systems like MES and ERP
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Challenges
No real-time production data visibility
Frequent unplanned downtimes
Disconnected systems reducing quality and efficiency
Solution
- Deployed PFIS with Ethernet-based Data Acquisition Card and Gateway
- Enabled real-time data collection from industrial equipment
- Implemented predictive maintenance using continuous sensor data analysis
- Detected potential equipment failures for proactive maintenance scheduling
- Monitored product quality in real time with automatic deviation alerts
- Maintained detailed traceability logs for compliance and recalls
- Integrated with MES, ERP, and PLM systems for seamless data flow
- Improved production planning and operational efficiency through system synchronization
Outcomes
- Reduced unplanned downtime by up to 30% through predictive maintenance
- Improved product quality with 20% faster response to deviations and defects
- Achieved 100% traceability compliance, enabling quicker audits and streamlined recalls
