Executive Summary

Our client, a prominent consumer product manufacturer headquartered in the USA, recognized the need to modernize their manufacturing processes. Seeking to harness the benefits of Industry 4.0, they approached Facttwin, a leading machine monitoring software company, to revolutionize their machine management and optimize overall operational efficiency.

Client Background

The client, with a rich history spanning three decades in the consumer product manufacturing sector, operates multiple production facilities catering to a diverse range of products. With a commitment to quality, they faced the challenge of adapting to the rapidly evolving technological landscape while maintaining stringent production standards. They wanted to track and monitor each and every activity of their machinery so that they can make real time predictive decisions.

Challenges Faced by Client

Lack of Real-Time Insights

The client struggled with a significant gap in obtaining real-time insights into machine performance. This led to unplanned downtimes, inefficient resource allocation, and increased production costs.

Inefficient Maintenance Practices

Outdated maintenance practices contributed to prolonged downtimes and increased expenses. The client sought a solution that would enable predictive maintenance, minimizing disruptions to production schedules.

Frequent breakdown in production machines

Other challenge was frequent breakdowns. No tracking of planned, unplanned outage timings and reasons for stoppages were not cleared to them which caused low productivity. 

Operational Silos

Various manufacturing units operated in silos, hindering communication and collaboration. The challenge was to create a solution that would foster seamless integration and communication across all units.

Solution Offered by Facttwin

Intuitive Machine Monitoring Software

We offered them our machine monitoring software that provided a centralized platform for real-time data visualization. The user interface was crafted for simplicity, ensuring easy navigation and understanding for operators and managers alike.

Predictive Maintenance Alerts

The implementation included predictive maintenance alerts based on machine performance data. This proactive approach aimed to reduce downtime, increase machine lifespan, and optimize maintenance costs.

Akrivia IoT gateway

We implemented the Akrivia IoT Gateway in their operational area, facilitating the seamless transport of data to the software. This ensured the availability of real-time data, empowering the team to make informed decisions promptly.

Implementation Process

Comprehensive User Research

The project commenced with in-depth user research, involving on-site visits, interviews with operators and managers, and analysis of existing workflows.

Iterative Prototyping

The design phase involved iterative prototyping, incorporating user feedback to refine the interface and functionality. This collaborative approach ensured the final product met user expectations.

Seamless Integration

Collaborating closely with the client's IT team, the implementation phase focused on seamless integration with existing systems, minimizing disruption during the transition.

IoT Gateway

Undertaking a site visit, we deployed the requested number of Akrivia IoT Gateways. This strategic deployment served as a pivotal component, enabling the efficient transport of real-time data to our machine monitoring software.

Results and Impact

Significant Downtime Reduction

The implementation of Facttwin's machine monitoring software resulted in a 30% reduction in unplanned downtime, enhancing overall production efficiency.

Improved Maintenance Efficiency

Predictive maintenance alerts led to a 25% increase in maintenance efficiency, as the client could address issues proactively, minimizing disruptions.

Enhanced Collaboration

The integrated platform fostered enhanced collaboration across manufacturing units, breaking down operational silos and improving communication.

Client Testimonials and Feedback

The Facttwin team not only understood our challenges but also delivered a solution that exceeded our expectations. Their commitment to user experience made a substantial impact on our operational efficiency.

Future Prospects and Expansion Plans

• Facttwin continues to work closely with the client, exploring additional features and enhancements to further optimize machine monitoring.
• Future plans include expanding the software's capabilities to meet evolving industry standards.
• We initiated the implementation with a limited number of IoT Gateways, and subsequently, in response to the client's expanding needs, they have requested the deployment of additional gateways across all their operational areas worldwide.