From fragmented plant-floor data to unified operational intelligence across facilities.

Client context

A manufacturing group operating three production facilities with a combined workforce of approximately 800 employees, producing precision components for industrial and automotive customers.

Business challenge

Operational data is siloed across facility-specific systems. Plant managers compile weekly and monthly reports manually. Cross-facility comparison is not possible. Quality incidents are tracked per-facility with no visibility into systemic patterns.

Constraints & complexity

• Heterogeneous data sources across facilities (different MES, ERP versions)
• OT/IT connectivity and security constraints for sensor data
• No existing enterprise data warehouse or integration layer
• Requirement for near-real-time data for production monitoring dashboards
• End users (plant managers) needed simple interfaces, not complex BI tools

Appxerbia approach

Appxerbia will run a data landscape discovery across all three facilities, mapping data sources, quality, and latency. We will design a unified data architecture with appropriate ingestion approaches for each source type, build the integration and transformation pipelines, and then iteratively develop the dashboard and analytics layer with direct input from operations and quality teams.