Business Impact
- $2.3M annualized savings via scrap & unplanned downtime reduction.
- 16% improvement in Overall Equipment Effectiveness (OEE).
- Alert lead time increased from minutes to hours for critical assets.
Challenge
Fragmented historian systems and batch ETL delayed insight delivery. Quality issues were detected post‑production, driving rework and warranty exposure.
Solution
- Edge gateway normalizing PLC / sensor feeds into a unified streaming bus.
- Time‑series enrichment & feature generation (rolling stats, vibration spectra).
- Predictive maintenance models (anomaly detection + survival analysis).
- Real‑time quality classification integrated with MES for proactive routing.
- Operations dashboard with drill‑downs, alert rationale & model confidence.
Architecture Highlights
- Event streaming backbone + schema registry.
- Feature store for temporal aggregations & model reuse.
- Model registry & CI/CD promoting retrained models w/ rollback gates.
- Edge inference for latency‑sensitive alerts.
Outcomes
Unified platform accelerated new use case onboarding (energy optimization, predictive quality) cutting development cycle times by 45%.