Integrated IoT and Business Intelligence Platform for Manufacturing Optimization

The client faces difficulties maintaining continuous and reliable reporting during major system transitions such as ERP rollouts. Additionally, there is a need to optimize production line maintenance costs, minimize downtime, and reduce product warranty claims through improved analysis and monitoring of manufacturing processes.

A large-scale manufacturing company specializing in creating high-quality industrial products with multiple operational sites and a focus on innovation and efficiency.

• Implement a self-service Business Intelligence platform enabling continuous and ad hoc reporting across multiple regions and departments.
• Develop an IoT-enabled predictive maintenance system to reduce production downtime, lower maintenance costs, and improve product quality.
• Centralize key operational metrics and KPIs in a unified system with mobile, online, and real-time access.
• Leverage sensor and production data to identify process inefficiencies, optimize manufacturing parameters, and improve final product quality.
• Achieve measurable outcomes such as reduced downtime, decreased warranty claims, and enhanced analytics flexibility.

• Self-service dashboards with interactive, customizable visualizations for diverse user roles.
• Centralized data model combining sales, finance, procurement, and manufacturing KPIs.
• Mobile and web-enabled reporting for instant access to critical metrics.
• Integration with IoT sensors for capturing temperature, vibration, environmental parameters, electric currents, and other machine data.
• Predictive models utilizing neural networks, decision trees, and survival models to forecast maintenance needs and product quality issues.
• Data processing and storage architecture based on cloud platforms with in-memory models for high performance.
• Ability to track product journey from production to customer, facilitating end-to-end analysis.

• Manufacturing execution systems (MES) and IoT sensor data streams for real-time monitoring.
• Enterprise resource planning (ERP) systems for financial and operational data synchronization.
• Business analytics systems for consolidated KPI analysis.

• High scalability to support multiple regions and increasing data volumes.
• Real-time data processing to facilitate immediate decision-making.
• Strong security protocols to protect sensitive operational and business data.
• High system availability and reliability to ensure continuous reporting during critical operations.

The deployment of an integrated IoT and BI platform is expected to significantly reduce production downtime, lower maintenance costs, and decrease warranty claims. The system will enable more agile and informed decision-making, leading to improved product quality, increased operational efficiency, and a competitive advantage in the manufacturing sector.