Dataranya Solutions Pvt Ltd > Case Studies > Automotive manufacturer increases production throughput

Automotive manufacturer increases production throughput

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 Automotive manufacturer increases production throughput - IoT ONE Case Study
Technology Category
  • Analytics & Modeling - Edge Analytics
  • Analytics & Modeling - Process Analytics
  • Analytics & Modeling - Real Time Analytics
Applicable Industries
  • Automotive
  • Equipment & Machinery
Applicable Functions
  • Process Manufacturing
Use Cases
  • Factory Operations Visibility & Intelligence
  • Data Science Services
  • Hardware Design & Engineering Services
  • Software Design & Engineering Services
  • System Integration
About The Customer

An automotive components manufacturer of micro-motors

The Challenge

An automotive components manufacturer was facing lower productivity from a relatively new automated assembly line - production 43% lower than installed capacity; new plant, 3 years old. Plant runs 24 hours, 6.5 days a week.

Management is budgeting a 2nd assembly line driven by demand, but wants current productivity issues resolved.

The Solution

Dataranya installed a non-invasive system on a bottleneck machine to track factory operations 24x7, in real-time & remotely.

Pattern recognition algorithms, automated production reports & downtime phone alerts to stakeholders were other tools deployed.

Data Collected
Asset Availability, Asset Utilization, Downtime, Idle Time, Production Efficiency
Operational Impact
  • [Efficiency Improvement - Production Uptime]

    It was made evident that the factory can & has produced as per installed capacity. A recurring downtime pattern accounted for ~25% lower throughput.

    Key contributors were night-shift operations running for upto 2 hours less & day-shift starting upto 1 hour late everyday.


  • [Management Effectiveness - Real Time Information]

    With Dataranya's solution, the gap between the production throughput & the installed capacity was narrowed.

Quantitative Benefit
  • Resolved productivity issues, adding significantly to the top-line.

  • Historical production data to benchmark the 2nd assembly line's productivity after it commences operations.

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