Automotive Component Manufacturer
- Downtime Reduction
- 38%Downtime Reduction
- Increase in Production
- 26%Increase in Production
- Quality Improvement
- 22%Quality Improvement
The Challenge
Breakdowns and rejects were holding back output on two lines.
Plants are asked to raise output, hold quality and cut cost at the same time. Supply shocks arrive with no notice. Machines log plenty through the PLC, but little of it reaches the person planning the next shift.
What We Built
We added failure alerts on key motors and camera checks at final inspection, across two plants.
Predictive Maintenance
Flag a failing motor or bearing days before it stops the line.
Quality Inspection
Cameras check each part on the line and mark the bad ones.
Production Optimisation
Better schedules, less changeover time, more output from the same plant.
Supply Chain Intelligence
One live view of stock, orders and supplier promises.
The Outcome
Higher Productivity
More output from the same plant and the same shift pattern.
Cost Optimisation
Less scrap, less overtime, fewer rush orders for spares.
Improved Quality
Fewer rejects and less rework, so dispatch holds steady.
Data-Driven Decisions
Numbers your team trusts, ready by the start of each shift.
