Operations Dashboard for Perth Manufacturing Plant
Live production tracking dashboard for a manufacturing plant with 3 production lines. We replaced whiteboards and shift handover spreadsheets with real-time visibility across the factory floor. Key results: 40% reduction in production downtime Real-time OEE tracking across 3 lines 25% improvement in on-time delivery $280k annual savings from efficiency gains
Perth Manufacturing Company
The Challenge
A Perth manufacturing plant running three production lines was tracking output on whiteboards and passing information between shifts in spreadsheets. Machine downtime was not recorded properly so nobody knew the real cost. Production managers were making decisions based on gut feel because they could not see live data. Quality issues were discovered too late, and on-time delivery kept slipping because they could not accurately predict when orders would be ready.
The Solution
We built a real-time operations dashboard connected to sensors on each production line. Large wall-mounted screens on the factory floor show live output rates, OEE (Overall Equipment Effectiveness), downtime events, and quality metrics. Production managers see their lines on tablets. The plant manager sees the whole picture with trend analysis and AI-integrated alerts for anomalies. Automated shift reports replace manual handovers.
Technologies Used
Our Approach
Factory Assessment
2 weeksSpent time on the factory floor understanding how each production line works, what data the machines already capture, and what gaps needed IoT sensors.
Dashboard & Alert Design
2 weeksDesigned factory floor displays, manager views, and executive summaries. Set up alert thresholds with the production team so notifications are useful, not annoying.
Integration & Build
10 weeksConnected machine sensors via MQTT, built the real-time data pipeline with WebSockets, and developed the dashboards with drill-down from plant level to individual machines.
Factory Rollout
3 weeksInstalled floor displays, trained operators and managers, and ran a two-week parallel period comparing dashboard data to manual records for accuracy validation.
We used to find out about problems an hour after they happened. Now we see them in real time on the big screen and react immediately. Our downtime has dropped dramatically and we can actually tell customers when their orders will be ready — and mean it.
Results & Impact
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