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Manufacturing

Manufacturing

IoT 4.0, predictive maintenance, and factory-floor intelligence at scale, where OT meets IT and every percentage point of OEE is money.

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81%
Defect Escape Reduction
67%
Less Unplanned Downtime
62→81%
OEE Improvement
<10ms
Edge Inference
USE CASE SCENARIOS

Real problems. Real deployments.

Each scenario follows the same arc: the challenge as the customer lived it, the solution as we built it, and the outcome as they measured it.

01

100% In-Line Quality Inspection

VP Manufacturing, Electronics OEM

The Challenge
Manual sampling inspection caught defects after entire batches were built. By the time a solder fault was found, 4,000 boards had shipped with the same flaw, and the recall cost more than a year of inspection salaries.
The Solution
Computer vision QC deployed at 12 AOI stations: every board inspected at line speed, defect classification in under 10ms at the edge, and instant line-stop triggers when fault patterns emerge.
The Outcome
Defects caught at board one, not board four thousand. The recall budget became an R&D budget.
Defect escape rate down 81% · throughput up 12%
Built WithSmart Factory PlatformComputer VisionEdge AI
02

Predicting Machine Failure 72 Hours Out

Plant Director, Auto Parts Manufacturer

The Challenge
240 CNC machines ran on calendar-based maintenance: healthy machines got serviced unnecessarily while others failed mid-shift. Every unplanned stop cascaded through the JIT delivery schedule.
The Solution
A vibration and thermal sensor network fed ML models trained on each machine's failure history, predicting bearing and spindle failures 72+ hours ahead, with work orders auto-generated into the CMMS.
The Outcome
Maintenance became a scheduled event, not an emergency. The JIT schedule finally held.
Unplanned downtime down 67% · maintenance cost down 35%
Built WithPredictive MaintenanceIoT SensorsMES Integration
03

Real-Time OEE for Every Line Manager

COO, Food & Beverage Group

The Challenge
OEE was calculated monthly, in a spreadsheet, three weeks after the fact. By the time leadership saw a problem line, the losses were already booked, and nobody could say which shift, which SKU, or which machine.
The Solution
OT/IT convergence piped PLC data into the ERP in real time: live OEE per line on the floor displays, automated shift handover reports, and drill-down from plant level to individual station.
The Outcome
Line managers started fixing problems during the shift they happened in.
OEE improved from 62% to 81% in 6 months
Built WithSmart Factory PlatformOPC-UA IntegrationLive Dashboards
04

GMP Serialisation & Track-Trace

Quality Director, Pharmaceutical Manufacturer

The Challenge
New serialisation regulations demanded unit-level traceability from raw material to pharmacy shelf. The existing paper-plus-Excel system would have needed 14 new hires just to keep up.
The Solution
An IoT-based serialisation platform assigned and tracked unique identifiers at every packaging stage, aggregation, warehousing, shipping, with GMP-compliant audit trails generated automatically.
The Outcome
Full regulatory compliance without the hiring spree. Recalls went from days to minutes.
Serialisation cost down 40% · full GMP compliance
Built WithTrack & TraceIoT 4.0Compliance Automation

Facing a similar challenge in Manufacturing?

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