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AvailabilityManufacturing

Manufacturing Performance Monitoring Suite

A monitoring suite that consolidated sensor, alarm, and production data into dashboards for daily manufacturing performance reviews.

Automated smart factory line representing manufacturing performance monitoring.
Sensors Monitored
200+
Auto-Updates
Daily
Visibility
100%

Client context

A suite of data-driven monitoring tools provided real-time visibility into manufacturing performance, equipment health, and operational inefficiencies.

The solution integrates equipment states, sensor signals, alarms, and production logs into intuitive dashboards enabling proactive decision-making.

Problem

  • +Limited visibility: Teams lack insights into equipment degradation.
  • +Reactive maintenance: No early warning indicators leads to unplanned downtime.
  • +Data silos: Equipment data exists in separate systems preventing benchmarking.

Approach

  • +Inefficiency Time Analysis: Tracks and categorizes non-productive time.
  • +Normalized Performance Dashboard: Compares actual vs. baseline performance.
  • +Sensor Trend Analysis: Visualizes 200+ sensors to detect drift.
  • +Alarm Root Cause Tracker: Links inefficiency events to specific alarms.

Measured result

  • +Daily operational use by management for decision making.
  • +Procedure improvements (e.g., cleaning frequency optimized based on data).
  • +Proactive maintenance enabled by sensor thresholds rather than fixed intervals.

Next step

Have a similar operational constraint?

Bring the current baseline, target, and available data. PrismaWerk will help define the first measurable pilot.

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