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Global Manufacturing Intelligence: Real-Time OEE and SPC Powered by IIoT and Cloud Integration

Global Manufacturing Intelligence

A leading global beverage manufacturer operating a network of concentrate production facilities across Europe, Asia, Africa, and North America. The client maintains stringent quality and efficiency benchmarks and has a strong focus on digital transformation across its global operations. The client aimed to gain real-time visibility into production efficiency and process control across its global network of concentrate production plants.

Challenge:

The client faced critical visibility and consistency gaps across its global concentrate production plants. They needed a unified digital layer to overcome challenges such as:

  • Lack of real-time insights into Overall Equipment Effectiveness (OEE)
  • Inconsistent process control, especially around ingredient weight variation (SPC)
  • Non-standardized shop-floor practices across multiple sites
  • A multilingual, multi–time zone environment requiring remote-first deployment with minimal on-ground support

Solutions

  • Real-Time OEE Monitoring: Continuous capture of machine and line performance metrics to compute OEE at plant and enterprise level.
  • SPC on Ingredient Weights: Integration of inline measurement systems with automated alerts for statistical anomalies to ensure product consistency.
  • Multilingual, Global UI: Unified user experience across sites with support for English, French, Mandarin, and Hindi, enabling ease of adoption.
  • Cloud-Native & Big Data Architecture: Scalable, secure platform leveraging modern cloud infrastructure and big data frameworks for high availability and performance.
  • 100% Remote Deployment & Support: Entire solution was rolled out, configured, and supported remotely—demonstrating efficiency, agility, and adaptability in distributed industrial environments.
  • Agile Delivery Model: Global teams collaborated using Agile methodology, enabling flexible prioritization, incremental releases, and continuous user feedback.
  • DevOps Integration with Microsoft Azure DevOps: Seamless integration with Azure DevOps enabled automated CI/CD pipelines, efficient code management, and streamlined global deployments.

Benefits

  • Standardized Global Operations: Unified metrics and process governance across continents improved transparency and decision-making.
  • Enhanced Quality Control: Real-time SPC allowed early detection of deviations in ingredient weights, reducing waste and improving compliance.
  • Scalable, Future-Proof Design: Modular architecture and cloud-first approach ensured easy expansion, integration, and long-term viability.
  • High Adoption & Usability: Multilingual support and intuitive dashboards ensured smooth onboarding across diverse user groups.
  • IT/OT Integration Excellence: Deep integration between operational technology (shop floor) and cloud IT systems ensured seamless data flow and reliability.
  • Reduced Rollout Time & Cost: Fully remote deployment minimized travel, logistics, and installation overheads—accelerating time-to-value.

Knowledge Where It Counts

This engagement reinforced a core principle of global manufacturing digitalization: technology creates value only when it meaningfully connects people, processes, and plants.

By delivering a unified, cloud-first, multilingual platform across regions, the program transformed fragmented operations into a connected, data-driven ecosystem.

With real-time OEE visibility, automated SPC, strong IT/OT integration, and remote-first deployment, the initiative proved that scalable, compliant digital transformation is achievable—even in highly distributed environments.

Paired with modern engineering practices like Agile delivery, CI/CD, and big-data architecture, the solution drove accuracy, adoption, and long-term sustainability.

In essence, it demonstrates how the right mix of technology, usability, and operational discipline unlocks standardization, transparency, and excellence across global manufacturing networks.

Tools & Technologies Used

  • Cloud & Infrastructure: Azure Cloud, Azure Kubernetes Service (AKS), Azure Data Lake
  • Application Frameworks: .NET Core, Microservices Architecture
  • Data & Analytics: Azure Databricks, Azure Synapse, Stream Analytics, Power BI
  • IIoT & Integration: OPC UA, MQTT, Edge Gateways, IT/OT Connectors
  • DevOps & Delivery: Azure DevOps, CI/CD Pipelines, Docker, Kubernetes
  • Security & Compliance: Azure AD, Role-Based Access Control (RBAC), Encryption Standards
  • Frontend & UX: Angular / React, Responsive Industrial UI Components