Real-Time Production Monitoring with IoT
How a leading automotive Manufacturer achieved 10-15% productivity boost and 90% reduction in manual effort through connected factory automation
Client Overview
A leading automotive die-casting manufacturer producing high- precision aluminium components at scale. With multiple machines running continuous operations, the leadership team required live production insights to reduce downtime, increase throughput, and meet customer delivery timelines consistently.
Key Challenges
Traditional manufacturing processes created significant operational blind spots that prevented optimal production efficiency and timely decision-making.
Manual Data Capture
Error-prone and delayed reporting process
Inconsistent Target Tracking
Deviations spotted only during review meetings
No Live Dashboards
Production monitored post-shift, issues found too late
No Breakdown Warnings
Machines failed before detection, causing unexpected downtime
Operator Accountability Gaps
No real-time performance checks or monitoring
GWC's IoT-Driven Solution
We deployed a Connected Factory Framework enabling automated live insights across the entire production floor.
IoT + Cloud Integration
- ✓IoT Core to ingest telemetry from machine counters
- ✓Low-latency device communication for continuous streaming
Real-Time Data Platform
- ✓GCP Cloud hosting pipelines and messaging services
- ✓Streaming into Real-time DB for dashboard updates within seconds
Full-Stack Production Monitoring App
- ✓React + Node.js application for supervisors
- ✓Live display of machine status (running, idle, breakdown)
- ✓Color-coded alerting for deviations
Target vs Actual Shift Insights
- ✓Automatic tracking of hourly & shift KPIs
- ✓Visual alerts for low-performing machines
Production Analytics Layer
- ✓Python + SQL data processing jobs
- ✓Operator productivity and part-rejection visibility
100% Automated Workflow
- ✓Zero manual effort required
- ✓Instant data capture and processing
Real Business Impact
Quantifiable improvements across key operational metrics, delivering measurable value to production efficiency and bottom-line results.
Reporting Latency
From delayed post-shift reports to instant live visibility
Downtime Transparency
Logged instantly with cause tagging and tracking
Productivity
Via faster intervention and proactive management
Manual Effort
Automated data capture eliminates manual logging
On-Time Delivery
Enhanced through live tracking and predictive insights
Response Time
Supervisors now react within minutes, not next day
Supervisors now react within minutes, not next day
Technology Stack
A robust, scalable architecture built on industry-leading technologies and best practices for mission-critical manufacturing operations.
Want results like this for your business?
Partner with GWC to accelerate your digital transformation and drive impact.
Schedule a Strategy Call
Download Case Study