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Manufacturing

Finding the constraint from the doorway

Textile processing group202418 weeks

Three plants across two countries

31%
Faster fault localisation
6 → 2 wk
Engineer onboarding
17%
Modelled throughput gain from relayout

The challenge

Three plants, twelve dashboards each, and a plant manager who could tell you every machine's OEE but not, on a bad shift, which one was actually constraining output. New engineers took six months to learn the material flow.

How we approached it

We scanned all three floors, aligned the existing CAD layouts to the scan — they were out by up to 400 mm in places — and bound every asset to its OPC-UA tags. The overlay defaults to WIP rather than OEE, because inventory piling up in front of a machine is the fastest visual signal of a constraint.

What we delivered

  • Terrestrial scan of three floors, registered to survey control at ±18 mm
  • OPC-UA tag binding for 340 assets across the three plants
  • WIP, OEE, alarm and utilisation overlays with a 30-day scrub
  • Discrete-event layout model calibrated on six months of telemetry
“The scan settled arguments we had been having for eleven years about where things actually are.”
— Plant Head, Surat

More work

Other projects

Figures on this page are illustrative composites, not audited client metrics, and the client is unnamed by design. They indicate what this kind of engagement is worth measuring — not what it is guaranteed to return.

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