Matics > Case Studies > Tetro Factory's Efficiency Improvements

Tetro Factory's Efficiency Improvements

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 Tetro Factory's Efficiency Improvements - IoT ONE Case Study
Technology Category
  • Analytics & Modeling - Predictive Analytics
  • Analytics & Modeling - Real Time Analytics
  • Application Infrastructure & Middleware - Data Exchange & Integration
  • Application Infrastructure & Middleware - Data Visualization
  • Functional Applications - Enterprise Asset Management Systems (EAM)
  • Functional Applications - Manufacturing Execution Systems (MES)
  • Functional Applications - Remote Monitoring & Control Systems
Use Cases
  • Factory Operations Visibility & Intelligence
The Customer
About The Customer
The Challenge

Tetro factory had the following challenges: - Controlling the production flow, tracing mistakes and optimizing performance. - Running a fully integrated knowledge-based business with systems that work seamlessly together. - Centralizing manufacturing production data into one system that can be viewed and analyzed from a single-point-of-entry. - Pinpointing in real-time which stations are compromising production and what can be done to restore and improve efficiency. -Implementing preventative maintenance and ensuring minimum downtime. - Monitoring energy consumption and optimizing material consumption per product.

The Solution

Tetro factory implemented the LeaderMES system to tackle the aforementioned challenges. The LeaderMES system with its plug-and-play modules were deployed across the production floor became instrumental to Tetro's operational success and long term vision of a fully visible, connected and knowledge-based factory. Being open and flexible, LeaderMES was configured to integrate with Tetro's internal business intelligence and validation systems to meet its specific traceability and analysis requirements. LeaderMES gave Tetro full visibility of their floor operations and material management enabled the team to monitor and track the entire plant's day-to-day operations and resource usage in real time. It also enabled predictive maintenance that reduced unplanned downtime.

Data Collected
Asset Status Tracking, Energy Consumption Rate, Fault Detection, Operation Performance, Production Efficiency
Operational Impact
  • [Cost Reduction - Overall]
    Real-time monitoring of resource consumption helped the firm to save costs.
  • [Efficiency Improvement - Production Uptime]
    Predictive maintenance reduced costly unplanned downtimes.
  • [Data Management - Data Collection]
    Accumulating manufacturing data allows the firm to manage their "SWOT (Strengths, Weaknesses, Opportunities & Threats) process" to maximize advantages and reduce risks.
Quantitative Benefit
  • In less than a month of using the LeaderMES system, the firm's overall energy efficiency improved by more than 30%.

  • Time to market was also reduced by 25%.

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