Production Planning & IoT Dashboard for an Auto-Parts Manufacturer
Tier-1 automotive component manufacturing conglomerate operating 6 production facilities and over 1,200 heavy CNC milling and stamping machines.
The Challenge
Plant managers lacked real-time visibility into machine status, line velocity, component defect trends, and overall equipment effectiveness (OEE). Heavy reliance on manual shift-end spreadsheets delayed corrective actions and caused costly unplanned machine downtime.
- Disjointed legacy stacks preventing automated continuous delivery.
- Manual, high-friction operational workflows causing scaling bottlenecks.
- Lack of real-time monitoring and unified telemetry across critical nodes.
The Architecture & Solution
Deployed hardened industrial IoT edge gateways running OPC-UA collectors to ingest high-frequency telemetry directly from CNC and stamping PLCs.
Engineered an enterprise cloud ingestion and time-series data pipeline in Azure handling millions of sensor data points per minute.
Built a unified web-based production dispatch and scheduling suite directly synchronized with SAP ERP for material orders and work instructions.
Created dynamic live shop-floor dashboards displaying real-time OEE metrics, line cycle bottlenecks, and predictive thermal wear warnings.
Delivered ruggedized tablet web interfaces allowing shop-floor machine operators to log scrap codes and trigger instant maintenance support.
This system was delivered by a dedicated cross-functional Hious squad operating on continuous integration pipelines, automated regression suites, and 24/7 SLA infrastructure telemetry.
The Results & Long-Term Impact
Reduction in unplanned machine downtime within the first 6 months
Improvement in on-time delivery rates across 6 production facilities
Paperless digital shift tracking replacing manual clipboards and spreadsheets
Reduction in scrap rate through early-warning vibration anomaly alerts
Following rollout, the client continues to scale without major rework or technical debt, leveraging Hious modular components and continuous monitoring frameworks.
Project Architecture
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