End-to-end MES integration bringing real-time visibility to 12 production lines.
A mid-size manufacturer had 12 production lines running on a mix of legacy PLCs, manual data entry, and disconnected systems. Leadership had zero real-time visibility into production performance.
We built a modern manufacturing execution layer that unifies data from all equipment while respecting the reality of legacy infrastructure.
Deployed edge gateways to extract data from 47 machines across 8 different protocols (OPC-UA, Modbus, MQTT, serial) without disrupting production.
Built a streaming architecture handling 50,000+ data points per second with sub-second latency from sensor to dashboard.
Created a live digital representation of the factory floor showing machine states, throughput, and quality metrics in real-time.
Added predictive maintenance alerts and automated root cause analysis for downtime events.
"For the first time in 20 years, I can see exactly what's happening on every line from my office. That visibility alone has transformed how we run this plant."
Let's explore how we can bring clarity to your operations.
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