FerroCore
A production-floor analytics dashboard turning machine sensor data into actionable insight.
Timeline
4 months
Industry
Manufacturing
Tech Stack
<5 min
Downtime Detection
54
Machines Monitored
+75%
Defect Visibility
Overview
FerroCore operates a mid-scale metal fabrication plant with machines instrumented for sensor output but no way to visualize it. We built a real-time production dashboard consolidating machine uptime, throughput, and defect data.
The Challenge
Plant supervisors relied on end-of-shift paper logs to understand machine downtime, meaning production bottlenecks were only identified a day after they occurred, if at all.
The Solution
We connected existing machine sensor feeds through an MQTT ingestion layer into a time-series pipeline, surfaced through a live dashboard. Supervisors see per-machine uptime, throughput trends, and defect-rate alerts as they happen, with drill-down views per production line.
Key Features
- Real-time machine uptime and downtime tracking via MQTT ingestion
- Per-line throughput trend charts with shift comparisons
- Automated defect-rate alerting above configurable thresholds
- Historical drill-down by machine, shift, and operator
- Exportable shift reports for management review
- Role-based views for supervisors versus plant management
Results
- Cut average time to identify a production bottleneck from a day to minutes
- Reduced unplanned downtime through earlier anomaly detection
- Replaced end-of-shift paper logging with automated data capture
- Improved defect-rate visibility across production lines
Gallery
“We used to find out about a bottleneck the next morning. Now the supervisor gets an alert on the floor while it is still happening.”
