Predictive Analytics for Metal Production
How we turned siloed sensor telemetry into real-time predictive insight across foundry production lines.
The Challenge
High-volume telemetry, zero predictive visibility
A metal producer was modernizing its foundries with connected sensors across furnaces, casting lines, and material handling. The plant generated high-volume telemetry on temperature, vibration, throughput, and energy usage — but insights were siloed.
Engineers reconciled spreadsheets while supervisors lacked visibility into bottlenecks or equipment drift. Unplanned downtime from missed anomalies was costing the operation significant production hours each quarter, and leadership had no unified view to guide capital allocation.
The Solution
Event-driven pipelines with predictive ML
We designed event-driven data pipelines that normalize sensor feeds, trained predictive models to flag anomalies, and launched role-specific dashboards for executives, process engineers, and floor managers. The solution maps copper flow end-to-end, highlighting stations most likely to impact yield before issues surface on the floor.
- Azure IoT Hub & Stream Analytics — real-time ingestion and transformation of sensor telemetry
- Python ML models — predict equipment drift and recommend maintenance interventions before failures occur
- Power BI & custom React dashboards — tailored views for leadership, process engineers, and floor managers with drill-down capabilities
The Result
From reactive to predictive operations
35%
reduction in unplanned downtime — model-driven alerts catch drift before it becomes a stoppage
Minutes
time-to-insight — down from days of manual spreadsheet reconciliation
Expanded
to new facilities — the manufacturer rolled out the solution to additional plants using Coders playbooks
Aligned
leadership now makes capital allocation decisions using live production data instead of quarterly reports
Teams prioritize maintenance using model-driven alerts, focusing on the processes with the highest risk to throughput. The solution continuously improves its predictive accuracy as more data flows through the pipeline.
Ready to unlock your data?
Let us design analytics pipelines and dashboards that turn telemetry into actionable insight.