Smart Manufacturing Intelligence
Manufacturing
Rubber Parts Manufacturer
PLC-driven manufacturing analytics improving productivity and process adherence
Objectives
The objective was to capture and centralize process parameters from multiple moulding machines across the manufacturing floor. The goal was to improve operational visibility, enhance productivity, ensure SOP compliance, and enable end-to-end traceability.
Solutions
We studied PLC connectivity protocols across multiple vendors and developed custom communication adapters to extract critical process parameters. The data was normalized and stored in a centralized database for structured analytics. Live operational dashboards were created for shop-floor teams, along with supervisory and management views for productivity and compliance tracking. Integration touchpoints were built to enable batch-level traceability across production cycles.
Benefits
- Unified machine data visibility: Integrated data from multiple PLC vendors, improving plant-level visibility by 70%.
- Real-time production dashboards: Reduced manual reporting efforts by 60% and improved decision response time by 30–40%.
- Improved process adherence: Increased adherence to defined SOP parameters by 20–25% through live monitoring and alerts.
- Reduced material wastage: Lowered raw material wastage by 15–20% via continuous process parameter optimization.
- PLC DATA INTEGRATION
- INDUSTRIAL IOT ADAPTERS
- MANUFACTURING ANALYTICS