Project Description
ORIGINAL SITUATION
Our client, a Food Manufacturing Facility was operating with an unstable IT infrastructure, hindering accurate data collection, and slowing the analysis process.
THE CHALLENGE
Because of the inability to collect real-time production data, the facility was running inefficiently, unable to correctly monitor inventory levels, production rates and quality control metrics.
Additionally, the instability of the IT systems meant that downtime was a regular occurrence, causing disruptions to daily operations, and causing inconvenient delays in reporting.
OUR SOLUTION
Firstly, we conducted a thorough assessment of the existing IT infrastructure to identify the weaknesses and bottlenecks.
We then implemented a robust IT infrastructure upgrade. This included server consolidation, network optimisation, and redundancy measures to ensure consistent levels of stability and reliability.
Following the upgrade, our team deployed Industrial Internet of Things (IIoT) sensors across production lines. These capture real-time data on equipment performance, product quality, and inventory levels.
From that point, we integrated data collection systems with a centralised Manufacturing Execution System (MES) for streamlined data analysis and reporting.
THE OUTCOME
Our actions resulted in the achievement of a stable and resilient IT infrastructure with reduced downtime, ensuring continuous data collection and system availability.
The client now experiences enhanced data visibility and accessibility which facilitates informed decision-making, leading to improved production planning and resource allocation.
Additionally, real-time monitoring of production processes enabled proactive maintenance, reducing equipment breakdowns and optimising overall equipment efficiency (OEE).
The Food Manufacturing Facility now operates with streamlined inventory management and quality control processes, resulting in reduced waste, improved product consistency, and increased customer satisfaction.
