Smart Factory Transformation for a Leading Indian Shaft Manufacturer

Business Requirement Overview

A prominent shaft manufacturing company in India sought to modernize and optimize its production process using Industry 4.0 technologies. Their primary objective was to increase efficiency, reduce operational costs, and enhance product quality. The key requirement was to deploy a Process Traceability Solution that could provide real-time visibility and control across the shop floor.

Solution Provided by Kripya CentralStage

Kripya’s CentralStage Smart Factory Platform was selected for its comprehensive capabilities combining AI/ML, IoT, and Industrial Analytics. The platform enabled end-to-end digitization and real-time monitoring of critical manufacturing operations.

Key Implementations:

• Digitization of 65 Machines & Systems

  IoT hardware and software were deployed across machines and devices to ensure seamless real-time data capture and visibility.

• Barcode-Based Traceability

  40 barcode scanners were installed to track and trace components at every stage of the manufacturing process.

• Energy & Sensor Integration

  Machines were connected to energy meters and sensors to monitor performance, energy consumption, and tool usage in real time.

• AI/ML-Based Production Analytics

  Data collected was analyzed using CentralStage’s built-in AI/ML models to generate actionable insights, optimize production processes, and enhance decision-making.

Business Impact & Results

• Improved Productivity

  Real-time visibility helped reduce machine downtime, streamline operations, and improve overall shop floor efficiency.

• Significant Cost Savings

  Optimized resource allocation and predictive insights led to measurable reductions in operational and energy costs.

• Enhanced Tool Life

  Real-time monitoring enabled the manufacturer to better manage tool usage, leading to reduced replacement frequency and extended tool lifespan.

• Complete Process Traceability

  Continuous monitoring and traceability across all processes improved defect detection and resolution, leading to superior part quality and regulatory compliance.

Conclusion

With the deployment of Kripya CentralStage, the shaft manufacturer successfully transitioned toward a data-driven smart factory model. The solution delivered measurable improvements in productivity, traceability, cost efficiency, and tool management, making it a benchmark case of Industry 4.0 success in the Indian manufacturing sector.