Case Studies
Manufacturing DX projects delivered remotely. Each case follows the structure: Problem → Solution → Results.
Rubber Manufacturing: 400-Machine SCADA System
Problem
A factory with 400 vulcanizing machines lacked real-time visibility into process data — temperature, pressure, cycle times — across all equipment. Skilled operators performed periodic walk-through inspections, resulting in delayed anomaly detection and limited data-driven improvement.
Solution
Designed and built a SCADA system collecting data from all 400 machines with 80,000 monitoring points, storing 5 million data rows daily in a time-series database. Implemented web-based real-time dashboards, historical trend analysis, and threshold-based alerting.
Results
- 70% reduction in anomaly detection-to-response time
- 50% reduction in inspection man-hours
- Enabled data-driven maintenance planning
- Captured maintenance expertise as institutional data
Tech Stack
PLC (Mitsubishi, Omron, Siemens), OPC UA, MQTT, InfluxDB, Grafana, Python, React
Remote Delivery Method
Customer's maintenance team handled on-site PLC network setup and OPC UA server deployment. ORPAON developed all data collection software, databases, and dashboards remotely. Weekly remote progress reviews ensured alignment.
Automotive Parts: Multi-Line OEE & Alarm Analysis
Problem
Multiple production lines lacked accurate OEE measurement and systematic alarm analysis. Improvement priorities were based on intuition rather than data.
Solution
Built an automated data collection infrastructure capturing equipment operation and alarm signals across all lines. Implemented OEE dashboards, Pareto downtime analysis, alarm frequency/duration analytics, and auto-generated shift reports.
Results
- 15% OEE improvement
- 40% reduction in unplanned downtime
- Data-driven improvement prioritization
- Enabled cross-shift performance comparison
Tech Stack
PLC data collection, Node.js, PostgreSQL, React, Apache ECharts
Remote Delivery Method
Customer's production engineering team provided equipment signal lists and PLC connections. ORPAON remotely developed data collection, database design, analysis logic, and UI. Two-week pre-validation on test environment before production cutover.
Packaging: Quality Traceability & Error Proofing
Problem
Risk of defective product escapes on the packaging line, with root cause investigations taking hours. Multiple material lots, operators, and equipment parameters made tracing complex.
Solution
Built a manufacturing history database keyed by product serial number, automatically linking material lots, equipment parameters, inspection results, and operator data. Implemented real-time error-proofing checks that detect parameter deviations, material mismatches, and incomplete inspections.
Results
- Zero defect escapes achieved
- Root cause analysis reduced from hours to minutes
- 80% reduction in audit preparation time
- Enabled lot-level quality trend analysis
Tech Stack
PLC, barcode reader integration, SQL Server, C#, WPF
Remote Delivery Method
Customer's quality team defined traceability requirements and installed on-site hardware (barcode readers). ORPAON remotely developed the database, application, and PLC integration logic. Only one on-site witness test was required.