A leading discrete manufacturer operating CNC and robotic assembly lines wanted to modernize its production operations, reduce unplanned downtime, and improve OEE across multiple plants. PROLIM implemented a cloud-native smart factory platform on AWS, unifying machine sensor data, enabling real-time analytics, and deploying predictive maintenance models. The solution improved asset availability, optimized maintenance planning, and unlocked enterprise-wide operational visibility.
- Disconnected PLCs, SCADA, and MES data with no centralized analytics
- Frequent unplanned machine breakdowns impacting production throughput
- Limited visibility into OEE and performance trends
- Manual reporting; delays in root-cause analysis
- No scalable environment to run ML workloads across plants
PROLIM deployed an AWS-based industrial analytics and predictive maintenance platform, enabling real-time data processing and intelligent asset insights:
- AWS IoT Core & IoT SiteWise for secure machine connectivity and edge ingestion
- Kinesis Data Streams & Firehose for streaming telemetry processing
- Amazon S3 Data Lake with AWS Glue for ETL and metadata management
- Amazon SageMaker for predictive maintenance ML model development & deployment
- AWS Lambda for automated data transformation workflows
- Amazon QuickSight dashboards for OEE, downtime, and machine health insights
- IAM, KMS, CloudTrail for enterprise-grade security & governance
- Centralized production visibility across plants
- Real-time asset health monitoring and early fault detection
- Automated performance KPIs (OEE, cycle time, scrap trends)
- Scalable serverless architecture with reduced infra overhead
- Strong security, governance, and audit controls
- ~80% reduction in unplanned downtime
- 18% improvement in OEE within six months
- 90% ML model accuracy for anomaly detection and failure prediction
- 30% reduction in maintenance costs through condition-based servicing
- <5-minute latency for production KPIs and alerts
- Foundation created for enterprise-wide Industry 4.0 expansion on AWS
This project demonstrates how PROLIM, with its deep expertise in Azure IoT, analytics, and machine learning, can help discrete manufacturers modernize their operations and achieve Industry 4.0 readiness through intelligent predictive maintenance.
