Empowering Production and Sustainability with Digital Transformation

Client Summary :

Our client, a leader in the aluminum
die cast industry with over 20 years of
experience, employs more than 1500
professionals. To stay competitive
and embrace modern manufacturing
trends, they sought to digitize
operations, enhance productivity, and
reduce their environmental impact
through Industry 4.0.

Industry:

Aluminium Die Cast Manufacturing

Challenges:

System Integration: Balancing new IoT systems with legacy equipment.
Data Accuracy: Ensuring real-time data accuracy for precise operations.
Change Management: Workforce training to adopt new technologies.

System Highlights :
The implementation of Industry4.0 solutions improved predictability, traceability, and sustainability through data-driven insights:

Predictability: IoT sensors enabled predictive maintenance, cutting machine downtime by 30% and improving OEE.
Traceability: Real-time tracking of orders, material availability,
production stages, and dispatch.
16 Loss Analysis: Tools to identify and reduce major manufacturing losses like downtime and defects.
Utility Monitoring: Reduced utility costs by 20% and water usage by 25%.
ERP Communication: Seamless communication and real-time
operational transparency.
OEE Monitoring: Advanced tracking of machine availability,
performance, and quality.
Zone-Specific Dashboards: 13 dashboards to monitor key operational zones.

Customer Feedback :

“The Industry 4.0 transformation has been a game-changer, improving efficiency, reducing downtime, and making us more sustainable. Instron Technologies has provided us with the tools to predict issues and trace every aspect of production.”

– Operations Manager, A2 Plan