Work·Internal Tools·Capability showcase

Factory production analytics

Live production line telemetry collapsed into KPIs the shift manager can act on — OEE, downtime reasons, scrap — without an SAP rollout.

The Problem

Mid-size factories generate millions of data points per day from PLCs and SCADA, then run the business off a paper shift report and a feeling. The signal is there; the system isn't.

The Approach
  1. 01

    Ingested PLC / SCADA streams over MQTT + OPC-UA into TimescaleDB with the right downsampling for KPI queries.

  2. 02

    Built OEE (availability × performance × quality) live, per line and per shift, with downtime reasons captured by operators on a tablet.

  3. 03

    Designed comparison views — this shift vs last shift, this week vs last week — so improvement isn't anecdotal.

  4. 04

    Implemented scrap tracking by reason code, not just totals, so root-cause work has data behind it.

  5. 05

    Built management views in Grafana for the boardroom and a clean operator UI for the floor.

“Factories don't need more dashboards. They need one dashboard the manager actually steers from.”

The Outcome
  • ●

    Shift managers act on the line in minutes, not the next morning.

  • ●

    Recurring downtime causes become visible and fixable.

  • ●

    Boardroom KPIs are the same numbers the floor sees — no two truths.

  • ●

    ROI is measurable within a quarter.

Millions of points/day
Data ingest
Live
OEE refresh
Operator-captured
Downtime reason data
Removed
Reporting effort
Stack
Next.jsPythonTimescaleDBGrafanaMQTTOPC-UA
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