Manufacturing Execution System (MES) Digital Transformation
SteelWorks Manufacturing needed to modernize their production floor operations to achieve Industry 4.0 standards. Their legacy systems were causing production bottlenecks, quality inconsistencies, and lack of real-time visibility into manufacturing processes.
Technology Stack
The powerful technologies that made this project possible
Project Overview
SteelWorks Manufacturing needed to modernize their production floor operations to achieve Industry 4.0 standards. Their legacy systems were causing production bottlenecks, quality inconsistencies, and lack of real-time visibility into manufacturing processes. We implemented a comprehensive Manufacturing Execution System (MES) that connects all production equipment, monitors real-time performance, and provides predictive maintenance capabilities. The system includes quality control automation, inventory tracking, and compliance reporting for ISO standards.
Challenges
Integrating with 20-year-old legacy machinery and PLCs
Real-time data collection from diverse equipment types
Maintaining production uptime during system implementation
Training floor workers on digital systems
Ensuring compliance with safety and quality standards
Coordinating between IT and operational technology teams
Our Solution
Developed custom industrial IoT gateways for legacy equipment integration
Implemented OPC-UA protocols for standardized machine communication
Built progressive rollout strategy with minimal production disruption
Created intuitive touchscreen interfaces for shop floor workers
Integrated with existing ERP and quality management systems
Established real-time monitoring dashboards for production managers
Results & Impact
25% increase in overall equipment effectiveness (OEE)
60% reduction in unplanned downtime
40% improvement in product quality metrics
50% faster response time to production issues
30% reduction in inventory waste
Full ROI achieved within 15 months
Project Details
Project Showcase
Visual highlights from the implementation
