Type
Manufacturing Process Optimization
Objective
A leading manufacturing company planned to increase its production by taking full advantage of the best technologies in downtime reduction and improvement of general performance of the operations. In other words, the main goal was to make sure the integration of their legacy systems with modern cloud solutions would provide real-time data access and smoothen the operations.
Technologies
.NET, AWS and SAP
Country
United States
Project Attributes
Engagement Model
Dedicated Team Engagement
Duration
8 months
App Users
Production managers, IT staff, and operational teams
Challenges
- Integration with the Legacy System: “The manufacturing systems of the client were
outdated and incapable of integrating with modern technologies, due to which they
caused a lot of fragmentation in data and ineffective processing. - Siloed Data: The critical data was scattered amongst a variety of systems; it also made
access to real-time information and data-driven decision-making very difficult. - Inefficient Operations: The case also illustrates dependence on manual processes,
limited automation, which translated to more hours of down time, low productivity, and
enhanced cost of operations. - Limited scalability: The existing infrastructure was not in a state to handle the
operational expansion needs of the growing business.
Solutions
- Custom .NET Applications: The design, development, and deployment of custom .NET
applications that extended the system to increase usability. It was intended for smooth
integration within the current SAP ERP system, along with AWS infrastructure. - AWS Cloud: Integrated AWS cloud into the customer’s business by migrating data and
applications to assure scalable cloud resources. Developed different AWS services for
data storage, real-time analytics, and automated solutions of backup storage to ensure
high availability and disaster recovery. - SAP Integration: The integration of SAP into .NET applications and AWS infrastructure
for data centralization and operational smoothing was done. Real-time data interchange
between the manufacturing process and the ERP system was enabled, hence increasing
visibility and control. - Automation and Analytics: Deployed automation and advanced analytics to monitor
manufacturing processes and predict the needs for maintenance, thus optimizing
resources. This led to a tremendous improvement in the operational efficiency and
reduction of downtime. - Scalability Solutions: We designed a scalable AWS infrastructure for the ever-growing
business needs of the client and one that could be easily scaled up according to future
requirements
Results:
- Smoothened Processes: Improved operational efficiency by 30% and reduced lots of manual interventions.
- Reduced Downtime: It resulted in a reduction of 25% in downtime through proactive maintenance and automation, hence allowing for more production hours.
- Improved data access: With real-time access to data, the decision-making powers of the system improved and resulted in a 20% increase in productivity.
- Savings: Operational costs went down 15% due to minimal human labor and proper use of resources.
- Flexible Infrastructure: It helped provide a new AWS-based infrastructure that could meet any variance in operations for achieving growth objectives of the client.
Conclusion:
The integrated solution by Adorebits in .NET, AWS, and SAP transformed the client’s manufacturing operation. Not only did this project cater to the objectives of the client, but it positioned the client as an industry leader in manufacturing innovation by applying modern technologies for better performance and efficiency.