Case Studies
Seven anonymous cases, each explained in terms of problem, solution, results and project boundaries.
All cases are anonymized; boundaries and replication conditions are detailed on each case page.
A Japanese-invested home appliance group: a decade of production line digitalization
Line status relied on people watching and shouting out; anomaly response lagged. Data from multiple machines was disconnected, and quality issues could not be traced to the step where they occurred.
Started with single-line LED visualization and expanded year by year to whole-line MES, motor assembly testing and facility energy management, with annual maintenance rolling to this day.
Anomaly response shortened from hours to minutes; test data archived automatically. The system evolves with the production line, and its health is quantifiable and assessable.
A well-known food company: dual-plant OEE and end-to-end traceability
Manual weighing errors or omissions meant food safety incidents; OEE losses could not be located, and traceability meant digging through paper records, taking days.
Real-time comparison and error-proofing on 13 electronic scales for ingredient weighing, with end-to-end traceability across man, machine, material, method and environment; the Japanese-convention OEE model line was proven on one line, then rolled out across both plants.
Ingredient error-proofing moved from experience-based to system-based; traceability moved from days of paper search to minutes by scanning, and OEE losses became transparent.
An automotive research institute and testing company: dual R&D and testing tracks
Test line commissioning depended on engineers being on site; test data was scattered and hard to reproduce; durability tests required rewriting software for every new machine model.
On the R&D side, OPC UA collection plus digital twin and remote commissioning; on the testing side, configuration-based CAN/LIN durability test bench software.
A substantial share of on-site commissioning moved to remote; test data recorded automatically and traceable; test bench software delivered in volume to multiple companies.
A chemical & tire group: large-scale SCADA and machine-networked MES
Chemical units suffered alarm floods, with real anomalies buried; tire curing required every mold and every cycle's curves traceable, and data during network outages had to be backfilled.
SCADA alarm engineering governance with nearly 80,000 variables; 366 curing presses networked in four tiers with MES, three-needle curve forward/backward traceability, outage backfill collection.
Alarm fatigue and missed-alarm risk significantly reduced; traceability moved from one or two days of record search to minute-level queries, and the solution has a replication record across multiple group sites.
A water utility: pump station remote monitoring and Industrial IoT (IIoT) gateway cloud connectivity
Pump stations are scattered and on-site staffing costs are high; failures were discovered only through complaints. Equipment brands and protocols were mixed, and operating data could not reach the cloud.
Industrial IoT (IIoT) gateway integration at a water treatment pump station: ModbusTCP data collection, MQTT cloud upload and device address table planning.
Pump station operating data reaches the cloud via the gateway and was confirmed by the project, providing a reference integration pattern for remote monitoring and future site replication.
A steel group and energy storage integrator: battery safety and energy storage EMS
Manual patrols cannot detect early internal-resistance degradation; energy storage safety is a prerequisite for grid-connection acceptance, and thermal-runaway early warning must arrive before smoke appears.
Formal solutions covering online UPS battery monitoring with three-tier alarms, three-layer BMS for energy storage, and fire-protection and power-cut linkage design.
The solutions span from cell-level monitoring to fire-linkage as a complete design, providing a design basis for condition-based maintenance and energy storage safety management.
A European foundry equipment maker: OEM bundled software going overseas
Whenever overseas-sold equipment failed, engineers had to fly out; outsourced factory-bundled software quality was unstable, and building an in-house team for multilingual, multi-market delivery was costly.
A 266-screen foundry line SCADA delivered with the equipment at home and overseas plants; the remote O&M client lets after-sales diagnose remotely first; trade-show demo systems delivered stably.
After-sales moved from mandatory on-site visits to remote diagnosis first; mature factory-bundled software lifts brand perception, and multilingual delivery eases the burden of building in-house teams.
Confirm whether these solution boundaries apply to your site
Tell us about your industry and site conditions to get a diagnosis and phased solution proposal.
Request an On-site Diagnosis