42
Machines Connected
+20%
Productivity
−30%
Downtime
100%
Live Visibility
Project Overview
Industry
Automotive Manufacturing
Production Lines
3 Lines
Client Type
Brownfield Upgrade
Deployment Time
3 Weeks
Machines Connected
42 Machines
Background
Project Context
Hero MotoCorp operates high-volume automotive manufacturing lines where even short stoppages can significantly impact output and delivery schedules.
The existing production lines lacked real-time visibility into machine performance, making it difficult to identify bottlenecks, track Overall Equipment Effectiveness (OEE), and respond quickly to production issues. Manual data collection led to delayed insights and reactive maintenance approaches that impacted productivity.
The objective of this project was to improve real-time visibility across existing machines—without disrupting production or replacing equipment.
Pain Points
Challenges We Addressed
Key obstacles that were preventing optimal production performance
The Problems
1
Manual Data Collection
Manual production reporting caused delays in decision-making
2
Limited Real-Time Visibility
Limited real-time visibility for supervisors and management
3
Reactive Maintenance Approach
Response time to machine issues was inconsistent
4
Legacy Equipment Integration
Breakdown reasons were unclear or captured late
Our Approach
The Opus One Solution
Opus One was deployed as a modular solution combining industrial hardware with cloud-based software—integrated seamlessly into the existing production setup.
Software Capabilities
Live OEE monitoring across all machines
ANDON alerts at machine level
Automatic downtime reason capture
Shift-wise and line-wise dashboards
Hardware Deployed
Edge Controllers
Connected directly to machines for real-time data acquisition.
ANDON Call Points
Physical interfaces for operators to log status or request help.
Secure Data Transmission
Wi-Fi-based connectivity ensuring reliable cloud syncing.
Implementation
How Opus One Product Works in Hero MotoCorp
Opus One delivers real-time production visibility and OEE insights across manufacturing lines through smart hardware, Wi-Fi connectivity, and integrated ANDON systems.
Install Across Production Lines
Opus One OEE devices are installed on CNC machines and critical production equipment across Hero MotoCorp’s manufacturing lines using a non-intrusive retrofit approach.
- Panel or machine-side mounting
- Designed for high-volume automotive environments
- No changes to existing machine controllers
Connect to Plant Network
Opus One OEE devices are installed on CNC machines and critical production equipment across Hero MotoCorp’s manufacturing lines using a non-intrusive retrofit approach.
- Panel or machine-side mounting
- Designed for high-volume automotive environments
- No changes to existing machine controllers
Capture Machine & Operator Data
Opus One OEE devices are installed on CNC machines and critical production equipment across Hero MotoCorp’s manufacturing lines using a non-intrusive retrofit approach.
- Panel or machine-side mounting
- Designed for high-volume automotive environments
- No changes to existing machine controllers
Monitor, Alert & Optimize
Opus One OEE devices are installed on CNC machines and critical production equipment across Hero MotoCorp’s manufacturing lines using a non-intrusive retrofit approach.
- Panel or machine-side mounting
- Designed for high-volume automotive environments
- No changes to existing machine controllers
“The biggest advantage was real-time visibility without changing our existing setup. The system was adopted quickly across shifts.”
