The Challenge
A leading automotive parts manufacturer operated scattered CNC machines and legacy assembly lanes lacking central communication channels. Operational teams were unable to track real-time machine efficiency, resulting in unplanned downtime and high tooling failure scrap rates.
Our Solution & Engineering Approach
We deployed edge gateway bridges running custom OPC-UA connectors that secure and model machine metrics. The telemetry flows into a centralized Kafka pipeline, analyzing Machine OEE, thermal thresholds, and mechanical vibrations via custom analytics engines.
Key Achievements
Standardized data telemetry across 80+ legacy and modern CNC machines.
Configured real-time OEE dashboards displaying device-level cycle details.
Implemented predictive maintenance alerts for early spindle wear detection.
“The OPC-UA integration gave us full visibility into our assembly lines. We can now react to spindle failures before they occur, saving thousands in scrap metal costs daily.”