~100
Machines Connected
18%
Increased Productivity
25%
Reduced Downtime
100%
Digital Documentation
Project Overview
Industry
Automotive Manufacturing
Production Shift
Multiple Shifts
Geography
Vadodara, Gujarat, India
Machines Connected
~ 100 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
Distributed Monitoring
No centralized monitoring across plants and machines
2
Manual/Excel Data Management
Production, quality, and compliance data managed through Excel
3
Performance Delay
Delayed KPI reporting and reactive decision-making
4
Manual Quality Documentation
PFD, PFMEA, Control Plans, SOPs, and Quality Checklists maintained manually
5
Workflow Misalignment
Generic IoT platforms unable to align with manufacturing workflows
Our Approach
The Opus One Solution
Opus One was deployed as cusomized solution – MES Platform – Effy, combining industrial hardware with cloud-based software—integrated seamlessly with custom measurement and device integration. A centralised, IoT-enabled MES was deployed to digitise end-to-end manufacturing and quality processes.
Key Capabilities
Digital PFD, PFMEA, Control Plans, SOPs, and Quality Checklist
Real-time production and machine monitoring
Operator efficiency tracking and benchmarking
ANDON Breakdown Monitoring
Material movement
Task management
Plant and enterprise level KPI dashboards
Technologies & Capabilities
MES | IoT | Real-Time Analytics | Digital Quality Management | Manufacturing Intelligence
See it in action
Opus One Outcome
Opus One delivered real-time production visibility and OEE insights across manufacturing lines through smart hardware, Wi-Fi connectivity, and integrated ANDON systems.
Key Outcomes
- Shift from manual, reactive operations to data-driven manufacturing
- Strong alignment with automotive quality and compliance standards
- Scalable digital foundation ready for Industry 4.0 expansion
Architecture Diagram
Machines and utilities are connected via IoT gateways to Opus One
“The biggest advantage was real-time visibility without changing our existing setup. The system was adopted quickly across shifts.”
