Enhancing Production Efficiency for an American Automotive & E-Mobility Supplier

Business Overview

A leading American supplier in the automotive and e-mobility sector was facing challenges with inefficient production monitoring and limited process traceability. The lack of real-time insights into machine performance, tool usage, and part-level traceability was impacting overall shopfloor efficiency and product quality.

Business Requirement

The client’s immediate need was clear:

• Implement a robust Process Traceability Solution to improve operational visibility and enable data-driven decision-making on the shopfloor.

Solution Deployed

Kripya’s CentralStage Industry 4.0 platform was implemented to digitize and connect their production environment. The solution integrated IoT software and hardware components, creating a connected and intelligent shopfloor ecosystem.

Key actions included:

• Connected & digitized 65 machines using CentralStage for real-time machine monitoring

• Installed 40 barcode scanners across critical checkpoints to capture process-level traceability data

• Integrated energy meters and sensors on key machines to enable real-time tool and machine condition monitoring

Results Achieved

The deployment of CentralStage delivered measurable improvements within months of implementation:

• 20% Increase in Shopfloor Productivity

  Real-time data access enabled better scheduling, reduced downtime, and faster issue resolution

• Enhanced Part & Process Traceability

  Barcode-enabled traceability across operations improved quality control and audit readiness

• 30% Improvement in Tool Life

  Sensor data and usage analytics allowed for predictive maintenance and optimized tool usage

Conclusion

By partnering with Kripya and leveraging the CentralStage platform, the client successfully transitioned to a smart manufacturing model, aligning with Industry 4.0 best practices. The solution not only addressed their immediate need for process traceability but also unlocked long-term gains in productivity, tool management, and operational visibility.

Technology Used:

• Kripya CentralStage Smart Factory Platform

• IoT Gateways & Barcode Scanners

• Energy & Machine Monitoring Sensors

• Real-time Dashboards & Analytics