Transforming Shopfloor Efficiency for a Billion-Dollar Automotive & E-Mobility Supplier

Client Profile

A leading American automotive and e-mobility component supplier, serving global OEMs with high-performance, precision-engineered products. With a strong innovation focus, the company operates advanced manufacturing facilities across the U.S. and globally.

Business Challenge

The client faced a critical challenge on the production floor:

• Limited visibility and manual monitoring machines led to low operational efficiency.

• Lack of real-time process traceability made it difficult to track production deviations or part history.

• Tool wear and failure were going unnoticed, leading to frequent breakdowns and unplanned downtime.

To stay competitive and scalable, the company needed an immediate digital solution to bring process traceability, machine monitoring, and predictive insights to their shopfloor.

Kripya’s Solution: Centerstage-Powered Digital Shopfloor

Kripya deployed a robust IoT-based Smart Manufacturing solution tailored to their production needs. Key components included:

• Connected & Digitized 65 Machines using Kripya’s Centerstage platform.

• Installed 40 Barcode Scanners for real-time Part and Process Traceability.

• Integrated Energy Meters and Machine Sensors to monitor performance, usage, and health metrics.

• Combined IoT Hardware and Software to deliver end-to-end shopfloor visibility.

Results & Business Impact

The transformation delivered tangible operational improvements within a short span

• 20% Increase in Shopfloor Productivity

  Real-time insights and machine status tracking enabled proactive decision-making.

• Enhanced Part and Process Traceability

  End-to-end visibility of each production step, ensuring compliance and faster root-cause analysis.

• 30% Improvement in Tool Life

  Early detection of wear patterns led to optimized usage and reduced tool-related failures.

• Energy Optimization

  Continuous energy monitoring identified inefficiencies, leading to informed consumption strategies.

Conclusion

By digitizing its shopfloor operations with Kripya’s Centerstage platform, the client took a significant leap toward Industry 4.0 adoption, unlocking efficiency, traceability, and sustainable performance across operations.