Client Overview
A mid-sized precision manufacturing firm based in Europe, producing industrial components for aerospace and energy sectors. The company aimed to adopt Industry 4.0 principles to enhance visibility, flexibility, and productivity across its shop floors.
Our Approach
Key elements of our approach:
- Real-time data acquisition from CNC, PLC, and SCADA systems
- Deployment of IIoT edge gateways across all machinery
- Digital twin for critical production lines
- AI-based predictive models for quality and maintenance
Challenge
The client operated multiple legacy systems, lacking synchronization between departments and minimal use of real-time data. Major issues included:
Industry 4.0 Implementation
India
Key pain points included:
- Disconnected machines and siloed data
- Manual reporting across production lines
- No predictive maintenance or real-time visibility
- High machine idle times due to reactive planning
- Inability to meet increasing demand efficiently
Solutions Delivered
Smart Manufacturing Dashboard & KPI Engine
Live monitoring of OEE, downtime, quality, and throughput across connected shop floors.
End-to-End Machine Connectivity & Data Lake
Enabled OPC UA & MQTT integration, centralized access control, and unified data infrastructure.
AI-Powered Downtime & Quality Analytics
Deployed predictive models to identify root causes and minimize unplanned disruptions.
MES + ERP Integration with Digital Twin Simulation
Achieved real-time production sync and simulated workflows to eliminate bottlenecks.
Technologies Used
Business Impact / Results
The implementation of Industry 4.0 solutions brought transformational improvements:
What Our Clients Say
"QeMatic's RPA team transformed our manual loan processing system. What once took days now happens in hours. Their deep platform knowledge and process-driven approach helped us reduce turnaround time by over 60% while staying fully compliant."
“We engaged QeMatic to integrate AI with our existing automation efforts. The results were outstanding — predictive quality control and demand forecasting brought a new level of intelligence to our operations. They truly understand the future of automation."
"QeMatic's Time and Motion Study uncovered hidden inefficiencies in our patient onboarding flow. Their insights led to a 30% improvement in staff productivity and better patient experience. The free consultation alone was eye-opening."
Key Highlights (Summary Box)
| Metric | Before | After |
|---|---|---|
| System Visibility | Manual, Disconnected | Real-Time, Centralized |
| Downtime | 18% | Reduced to 9% |
| Production Planning | Spreadsheet-Based | MES-Driven & Agile |
| Decision Making | Reactive | Predictive & Data-Driven |
| Customer Order Fulfillment | 70% On-Time | 95% On-Time Delivery |
