Client Overview
A mid-sized manufacturing company based in Pune, India, producing precision-engineered components for the automotive and aerospace sectors. With over 300 employees and two manufacturing units, the company faced rising operational inefficiencies due to outdated systems and manual supervision across production lines.
Our Approach
Our strategy focused on:
- Deploying sensor-based real-time machine monitoring
- Implementing PLC-based automation for repetitive operations
- Integrating AI-powered defect detection via vision systems
- Centralizing production KPIs through live dashboards
- Creating automated alerts for downtime and threshold deviations
Challenge
The client was struggling with disconnected production processes and lack of real-time visibility into factory operations, which led to delays, higher rejection rates, and inconsistent throughput.
Industrial Automation
India
Key pain points included:
- Manual machine monitoring and data logging
- Frequent production halts due to unplanned downtime
- High human dependency in quality control
- Limited traceability in material movement
- No centralized dashboard for performance KPIs
Solutions Delivered
IIoT-Based Machine Monitoring System
Enabled real-time data capture from CNC and molding machines to track OEE (Overall Equipment Effectiveness) and downtime events.
Automated Quality Control with Machine Vision
Installed AI-based visual inspection systems to detect product defects with high accuracy and reduce manual error.
Centralized SCADA Dashboard
Deployed a unified SCADA interface to visualize machine status, process KPIs, and alerts for faster decision-making.
Automated Material Handling Integration
Integrated conveyors and PLCs with ERP to auto-track material movement, reducing manual interventions.
Technologies Used
Business Impact / Results
Qematic’s end-to-end industrial automation transformed factory operations with the following outcomes:
What Our Clients Say
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Key Highlights (Summary Box)
| Metric | Before Implementation | After Implementation |
|---|---|---|
| Production Throughput | 700 units/day | 950 units/day |
| Machine Downtime | 20% | 4% |
| Quality Inspection Accuracy | 78% | 96% |
| Real-Time Process Visibility | No | Yes |
| Manual Dependency | High | Low |
