Client: Major Tier-1 worldwide automotive manufacturer

Industry: Automotive production, quality, data management 

Focus: Traceability, data collection automation, system integration from assembly lines and process automation 

Technologies: Azure Cloud Services,.Net, Angular, SQL Server Analysis Services, Power BI

Duration:  ongoing development since 2018

The Challenge

Disconnected data, manual processes, and high audit risk

A leading automotive supplier with a European production plant was facing growing complexity on the shop floor — but had limited visibility into real-time data. Production insights were scattered across paper logs, standalone machines, and legacy systems. This caused:

• Time-consuming traceability for parts and process issues

• Manual reporting and inconsistent data collection

• High preparation effort for quality audits

• Limited confidence in data for operational decisions

The client needed a reliable, scalable way to capture and analyze production data in real time — and to trust it.

Our Solution

A single platform for traceable, trusted production data

We developed a modular web-based system that integrates data from machines, MES systems, and manual inputs. It provides one source of truth for production, maintenance, and quality teams.

Key capabilities include:

• Automatic data collection from PLCs and operator inputs
• Real-time traceability of serial numbers, batches, and events
• Audit logs for non-standard behavior and downtime
• Visual dashboards in Power BI for shop floor and management
• Role-based access and operator authentication via chip cards
• Scalable architecture — vendor-independent and easily expandable

The system was designed to be flexible, maintainable, and vendor-independent — allowing the client to adapt and expand it as needed.

Business Impact

Real-time control, faster decisions, and audit readiness

• Traceability time reduced from hours to seconds
• 70% less manual data entry and validation
• Clear audit trails aligned with compliance standards
• Increased operator discipline and data-driven improvement
• Full product “digital CV” from raw material to final packing
  

Today, the client can monitor machine performance in real time, compare historical trends, and act immediately on inefficiencies. What started as a tool for basic monitoring has become the backbone of their Industry 4.0 journey.