Production Visibility System for a Mid-Sized Manufacturer
SunAlgo delivered a practical plant-operations dashboard that improved visibility across production, maintenance, and leadership without requiring a disruptive rip-and-replace program.
Overview
A manufacturer had data scattered across machines, spreadsheets, and ERP reports. Leaders were often learning about downtime or throughput issues after the fact, which made it difficult to respond quickly or improve line-level performance.
Challenge
- • Production reporting lagged behind actual plant conditions by hours or days.
- • Line supervisors and leadership lacked a shared view of downtime, throughput, and recurring bottlenecks.
- • Existing systems could not support the level of operational visibility the business wanted without custom work.
Approach
- • Prioritized a pilot around a few critical lines and built a unified dashboard for near real-time operational visibility.
- • Integrated plant signals and business-system context so teams could see production issues in a more useful operational frame.
- • Focused the rollout on practical decision support rather than overly ambitious Industry 4.0 storytelling.
Outcomes
- • Improved response time for downtime events and recurring performance issues.
- • Made production reviews more concrete by replacing delayed spreadsheet reporting with shared operational visibility.
- • Created a credible path to expand plant analytics without overcommitting to a large transformation program upfront.
Related Case Studies
Explore adjacent case studies from similar delivery contexts to see how we approach product, platform, and modernization work.
Workflow Automation Platform for a Scaling B2B SaaS Company
Rebuilt a brittle internal-and-customer workflow platform so the team could onboard larger customers without adding operations headcount.
Embedded Finance Infrastructure for a Mid-Sized Lending Platform
Modernized core lending APIs and underwriting workflows so the platform could support higher volume and new distribution partners.
Care Navigation Platform for a Multi-Location Healthcare Group
Launched a patient-facing scheduling and follow-up experience that reduced call-center load and improved appointment completion.