Client is one of the group company among top 5 automotive companies in India having More than 6 decade of successful business operations with Revenues in excess of USD ~6 billion. Sold over 90 million two-wheelers with Extensive rural coverage ~100,000+ villages.

Client has multiple plants operated a manual data tracking system with teams dedicated to collecting machine production data and punching it to the SAP manually. This manual tracking was prone to significant errors and was time-consuming, requiring lot of hours per day.

There was regularly a full day between the point of data collection and the point when it was ready for consumption. This meant that the data was no longer actionable; many events had passed, and there was no longer anything that could be done to prevent or remedy any issues.

Client installed the Hiotron Smart Machine Monitoring (SMM) System on 57 of its fully robotics HPDC (High pressure die casting) machines at multiple plants locations and displayed Hiotron dashboards on TVs across the shop floors to showcase real-time machine performance.

10 Inch Tablets were also mounted at each machine for operators to share feedback on downtime and quality. When a job fell behind production goals and the color of the tile changed on screen, text notifications were sent to managers to act immediately.

This connectivity, real-time data collection, and analysis gave Client instant visibility into the realities of the shop floor. The transformation was so quick that the team was still acclimating to the monitoring system when actionable insights became available.

For Client, there was an obvious and immediate benefit in understanding downtime, production count and machine utilization. As the Hiotron platform continued to deliver results, Client realized tremendous improvements in the first year of deployment.

Hiotron platform enabled Client to understand what’s happening in real-time and respond to problems immediately. This increased machine OEE by 20 % in the first year. As OEE increased, client found hidden capacity within its machines and gained an average of 768 extra operating hours per machine.

The ability to identify and solve problems as they occurred also led to improved quality measures. Client began to focus more proactively on quality, and quality managers became more intimately involved in the system. And because operators used the tablet interface to classify rejections in real-time, managers could respond immediately, eliminating the paperwork required for non-conformance.

Client’s initial investment in Hiotron platform was returned within only 3 months (90 days) of using the software, and the company saved INR1.09CR. in its first year of machine monitoring.