One Dashboard. 200 Plants. Zero Blind Spots.
How we built an operational intelligence layer that transformed reactive firefighting into proactive decision-making
The Challenge
IndustraCorp operated 200 manufacturing plants across 3 countries, each running siloed reporting tools. Operations leadership had no live view of production output, equipment health, or anomalies — decisions were made on yesterday's exports.
Fragmented, Day-Old Data
Plant managers submitted manual Excel reports 24 hours after shift end. Leadership had no real-time picture of operations.
Undetected Equipment Degradation
Without sensor trend data, equipment failures were unpredictable — unplanned maintenance costs exceeded $2M annually.
No Cross-Plant Benchmarking
High-performing plants couldn't share operational patterns with underperformers due to incompatible data systems.
Our Approach
We built a multi-tenant analytics platform ingesting sensor streams from all 200 plants over WebSockets, normalising the data, and surfacing it through a role-based dashboard with anomaly alerting.
Unified Data Ingestion Pipeline
Designed an event-driven ingestion layer consuming PLC and SCADA sensor data streams, normalising disparate data schemas into a common model.
Real-Time WebSocket Dashboard
Built a React dashboard with live chart updates via WebSockets, showing OEE, throughput, and equipment health per plant and at aggregate level.
Anomaly Detection & Alerting
Implemented statistical threshold alerting with configurable escalation rules, delivering SMS and in-app alerts to the right personnel within seconds of detection.
Cross-Plant Benchmarking Module
Created a comparative analytics module allowing leadership to rank plants by KPI and identify improvement opportunities with drill-down capability.
The Outcome
Within 90 days of go-live, IndustraCorp saw measurable shifts in maintenance costs, downtime, and overall equipment effectiveness.
"For the first time in 20 years, I can walk into a board meeting knowing the exact state of every plant in our network. That's priceless."
Ready to achieve similar results?
Let's discuss how we can apply these learnings to your business.