Background
The customer supplies several domestic OEMs with strict batch traceability requirements. Production progress was recorded on paper by shift leaders and keyed into ERP later, creating more than a day of lag. Quality incidents required manually combing paper route cards, typically taking two to three days.
Solution
- Machine connectivity: 260 machines onboarded, including 60 legacy machines retrofitted with capture terminals, supporting OPC UA and Modbus
- Core MES: work orders, operation reporting, batch management, quality inspection, equipment ledger
- Traceability: a five-dimensional chain — batch, operation, machine, operator, inspection record
- Analytics: OEE, downtime cause classification, automatic anomaly alerts routed to owners
Outcomes
- Production data latency reduced from over a day to under five minutes
- Traceability time cut from 2-3 days to under three minutes
- OEE improved from 61% to 74%
- Paper route cards eliminated, saving roughly RMB 460,000 a year in printing and data entry