Legacy System Modernization with Real-Time Dashboard Integration for Manufacturing Operations

A manufacturing company relying on an outdated desktop-based control module faces difficulties integrating modern features, hindering real-time data access, remote monitoring, and quick responsiveness. Existing legacy code and architecture impede system modernization efforts and slow down process improvements.

A large-scale manufacturing enterprise specializing in precision medical treatments, requiring modernized control systems for production monitoring and management.

• Develop a web-based control and monitoring dashboard with real-time data updates to improve oversight of manufacturing processes.
• Achieve a reduction in onboarding time for new operators from three days to six hours through user-friendly interfaces and streamlined workflows.
• Enable remote access and control capabilities, supporting distributed management and quick issue resolution.
• Improve data visualization and structuring to facilitate faster decision-making and problem identification.
• Ensure the new system supports future feature expansion via modern coding standards and scalable architecture.

• Real-time data visualization dashboards for monitoring production metrics and system status.
• Web access compatibility via standard browsers, supporting remote operation.
• Intuitive, responsive user interface aligned with company branding standards.
• Implementation of real-time communication protocols (e.g., WebSocket, WebRTC) for instant data updates.
• Customizable data visualizations and structured representations of process parameters.
• Secure user authentication and role-based access control to safeguard sensitive data.

• Legacy control modules and device interfaces for data extraction
• Existing process management and analysis platforms
• Authentication and authorization systems for secure access
• Data storage solutions for historical data logging and reporting

• System must support real-time dashboards with minimal latency, targeting sub-second update intervals
• High availability with 99.9% uptime
• Secure data transmission and user authentication mechanisms
• Scalable architecture to accommodate future system feature growth
• Smooth update deployment process with minimal operational disruption

The implementation of a modern, real-time control and monitoring dashboard will significantly enhance operational efficiency, enabling faster decision-making and remote management capabilities. The solution aims to reduce training time for new staff from three days to six hours, decrease system response latency, and support rapid feature integration. These improvements are expected to lead to increased productivity, reduced industrial incidents, and a strengthened competitive edge in the manufacturing sector.