Unified shop-floor operations & OEE telemetry across 9 production plants
Connecting plant machinery, raw inventory, and dispatch into one real-time dashboard.
- Client
- Auto-Components Manufacturer
- Tier-1 Automotive Component Supplier
- Location
- Sanand & Pune
- Timeline
- 16 weeks to pilot plant launch, 8 weeks for rollout across remaining 8 units
- Headline result
- 9 Plants
- Connected into one unified view
Overview
A premier automotive parts manufacturer operated 9 factories across western and northern India, with each unit maintaining isolated legacy spreadsheets and standalone ERP modules. Management had zero real-time visibility into machine downtime, batch bottlenecks, or inventory scrap. Nexasoft engineered a custom shop-floor operations platform connecting IoT machine telemetry with production schedules and ERP ledgers.
The challenge
- Each plant reported production numbers 24 to 48 hours late via manual Excel logs.
- Unplanned machine breakdowns halted assembly lines without automated maintenance alerts.
- High excess buffer inventory kept at each plant due to inaccurate consumption forecasts.
- Difficulties meeting stringent audit traceability requirements from OEM automakers.
What we built
- Deployed IoT edge gateway telemetry to collect real-time machine uptime, stroke counts, and power draw.
- Developed an intuitive touch-friendly shop-floor interface for line operators and shift supervisors.
- Engineered automated predictive maintenance triggers and OEE (Overall Equipment Effectiveness) analytics.
- Integrated end-to-end QR code tracking from raw coil receipt through stamping to dispatch palleting.
Results
- Factories and 140+ assembly lines connected in real time
- 9
- Reduction in excess raw inventory holding through JIT synchronization
- 45%
- Increase in Overall Equipment Effectiveness (OEE) within 6 months
- 14%
- Batch-level component traceability compliant with automotive OEM audits
- 100%
Architecture
- React dashboard with real-time WebSocket telemetry updates.
- Go microservices ingestion pipeline processing 25,000 sensor telemetry events/sec.
- TimescaleDB for high-speed time-series analytics and PostgreSQL for enterprise business logic.
- Local edge offline caching allowing plants to operate even during local internet disruptions.
“For the first time in 20 years, our executive leadership can see the exact output of any plant in Gujarat or Maharashtra right from their phone. Nexasoft made our shop floors truly intelligent.”
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