Connected Production Telemetry and Digital Quality Transformation
CYVERRA designed and implemented an end-to-end digital operations ecosystem connecting multi-site shop floor telemetry with enterprise planning systems. The modernisation unified production line tracking, automated scrap reporting, and accelerated quality verification cycles across four facilities.
Mid-tier European industrial equipment manufacturer
- -42%
- Quality inspection cycle time
- -34%
- Scrap and rework volume
- -28%
- Unplanned line downtime
- +19%
- Overall equipment effectiveness (OEE)
The Challenge
The manufacturer operated four production facilities with disparate legacy programmable logic controllers (PLCs), proprietary machine interfaces, and fragmented data silos. Shift supervisors relied on manual paper logs and end-of-day spreadsheet reconciliations to capture line output, cycle times, and scrap volumes, creating an 18-to-24 hour latency in operational visibility. Quality assurance processes were disconnected from real-time line telemetry, meaning tolerance deviations and calibration drifts were often detected only during post-assembly destructive testing. This delay caused significant batches of work-in-progress (WIP) inventory to be scrapped or routed for costly manual rework. Furthermore, the disconnect between plant-level operations and central ERP planning prevented accurate capacity scheduling. Procurement teams lacked granular consumption data, resulting in safety-stock bloating and frequent changeover delays on high-mix assembly lines.
Our Approach
CYVERRA architected an event-driven digital manufacturing platform designed to bridge the operational technology (OT) and enterprise IT divide. Edge gateway appliances running containerised protocol adaptors were deployed across all assembly lines, standardising legacy PLC signals via OPC UA and MQTT without disrupting ongoing production schedules. Telemetry data was ingested into an enterprise event streaming backbone that normalised machine states, throughput metrics, and environmental parameters in real time. CYVERRA implemented automated quality-gating rules that flag dimensional anomalies directly on operator terminal touchscreens, triggering automated line-stop workflows before out-of-spec batches propagate downstream. To close the enterprise loop, bidirectional integration pipelines were established with the client's ERP core. This enabled dynamic work order dispatching, real-time bill-of-materials decrementing, and continuous overall equipment effectiveness (OEE) dashboards tailored for plant managers and executive leadership.
The Outcome
The transition to real-time telemetry and digital quality controls delivered immediate operational efficiencies across all manufacturing sites. Shift reporting latency dropped from 24 hours to sub-second visibility, empowering shift leads to address machine bottlenecks and micro-stoppages as they occurred rather than post-shift. Early defect containment workflows substantially reduced scrap and rework overheads, while accurate line telemetry improved production scheduling accuracy. Cross-plant operational transparency also enabled unified standard operating procedures and informed strategic capital equipment investments.
Technology used
- Azure IoT Edge
- OPC UA
- MQTT
- Apache Kafka
- PostgreSQL
- Kubernetes
- Grafana
- Node.js
Consolidating our plant-floor telemetry into a single digital operational plane eliminated our reporting lag and drastically improved shop-floor accountability.