Case study
OEE improvement with real-time operational insights for a global high-strength fasteners and form parts manufacturer
01.22.2025
When a global high-strength fasteners and form parts manufacturer realized there was a lack of real-time production output tracking and reporting , they came to Belden. The experts at Belden delivered a solution that acquired and transmitted data from field devices into a cloud-hosted IIoT platform for proactive machine monitoring. With the right data and insights now in hand, the company was able to achieve reduced waiting times and improve on overall efficiency.
JUMP TO: Challenges | Solution | Results
Challenges
- Lack of real-time production output tracking and reporting
- Manual, time-consuming inventory counting process
- Difficulty in assigning skilled operators to higher value tasks
- Concerns about data privacy and labor union issues with camera-based solutions
- Perceived complexity in connecting operational technology (OT) data to cloud
Solution
- Sensor-based bolt counting system with high-resolution light grid sensor for accurate production tracking
- Secure OT to AWS connectivity via edge gateway for seamless data integration
- AWS IoT Greengrass for preprocessing operational data before sending to AWS IoT Core
- AWS Lambda functions for production KPIs and machine performance monitoring
- Mobile app and SAP ERP integration for real-time data access and order fulfillment
Results
- 2.5%-3.5% increase in operator time on higher value tasks due to proactive
- Optimized forklift routes and reduced waiting times
- Improved visibility for production planning and supply chain
- Reliable and secure solution with remote management, ensuring data privacy compliance
- Seamless OT data integration with cloud analytics, eliminating need for additional expertise
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