BI & Data Analytics
Unlocking predictive insight for metal production lines with IoT-powered analytics.
About Client
Our partner worked with a metal producer modernizing its foundries with connected sensors. Their teams needed a unified way to understand production health across furnaces, casting lines, and material handling systems.
Challenge
The plant generated high-volume telemetry from IoT sensors monitoring temperature, vibration, throughput, and energy usage. Yet insights were siloed, engineers spent hours reconciling spreadsheets while line supervisors lacked predictive visibility into bottlenecks or equipment drift.
How We Helped
We designed event-driven data pipelines that normalized sensor feeds, trained predictive models to flag anomalies, and launched executive and operator dashboards. The solution mapped copper flow end-to-end, highlighting stations most likely to impact yield before issues surfaced on the shop floor.
Impact
Teams now prioritize maintenance based on model-driven alerts, focusing on the processes with the highest risk to throughput. The analytics platform cut time-to-insight from days to minutes and keeps leadership aligned on where to invest to protect output.
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