Key Highlights
- OptiSol partnered with a global manufacturing enterprise to design and implement a centralized plant efficiency monitoring system.
- The solution automated report generation across multiple plants, replacing manual monitoring processes that were time-consuming and prone to errors.
- Real-time analytics provided managers with visibility into plant, stream, and shift-level performance metrics.
- The system empowered leadership to identify inefficiencies, track KPIs, and make faster, data-driven decisions.
Problem Statement
01
Data Silos: Manufacturing plants operated on different systems, making it difficult to collect and manage data centrally, leading to inconsistencies and delays in performance reporting.
02
Analysis Gaps: Data from multiple plants was unstructured and inconsistent, making it challenging to analyze, compare, and interpret results accurately for informed decision-making.
03
Visibility Issues: Managers lacked real-time insights into plant and shift-level performance, preventing them from identifying inefficiencies and resolving production bottlenecks promptly.
04
Manual Effort: The reliance on manual report generation consumed significant time, increased chances of errors, and made tracking KPI achievement and plant performance inefficient.
05
Problem Detection: Complex, un-visualized reports made it difficult to identify performance issues and patterns, which delayed corrective actions and affected overall productivity.
Solution Overview
01
OptiSol designed a centralized efficiency monitoring solution using .NET Core, Angular 8, Microsoft SQL Azure, and PRIME to automate performance tracking across multiple plants.
02
The system consolidated data from all plants and streams, ensuring accuracy, consistency, and real-time availability for managers to monitor performance effectively.
03
Automated report generation replaced manual tracking, providing detailed insights into plant, stream, and shift-level performance, reducing time and human error significantly.
04
The solution identified top-performing plants and streams, tracked KPI achievements across plants, and highlighted inefficiencies to help managers focus on improvement areas.
05
Real-time dashboards allowed managers to monitor performance trends, compare plant and shift productivity, and take data-driven actions to enhance efficiency and operational output.
Business Impact
About The Project
This success story highlights how OptiSol helped a global manufacturing enterprise improve plant efficiency and operational visibility. The client faced challenges in collecting, analyzing, and interpreting data from multiple plants and shifts. Manual reporting caused delays, inefficiencies, and inaccuracies. OptiSol developed a centralized plant efficiency monitoring system using .NET Core, Angular 8, Microsoft SQL Azure, and PRIME. The solution automated report generation, tracked KPIs, and provided real-time dashboards for plant, stream, and shift-level performance. This enabled managers to quickly identify inefficiencies, reduce downtime, and make informed, strategic decisions, leading to measurable improvements in productivity and operational efficiency.
Technology Stack
FAQs:
Why is centralized reporting important for manufacturing?
Centralized reporting ensures consistent, accurate data across plants, making it easier to compare, analyze, and act on performance insights.
How does automation improve plant monitoring?
Automation replaces manual report generation with system-driven analytics, reducing errors, saving time, and ensuring accuracy.
Can the solution track performance at shift level?
Yes, the system provides detailed reports for plant streams and specific shifts, allowing managers to pinpoint inefficiencies precisely.
How does this solution benefit plant managers?
Managers can access real-time dashboards, track KPI achievements, and quickly identify top-performing streams and plants.
Is the system customizable for different manufacturing setups?
Yes, the platform is flexible and can be configured to align with specific plant processes, KPIs, and reporting needs.
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Ken Kisner
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My experience has been incredibly positive. They were incredibly easy to work with, even with changing requirements.
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