Case Study

Sustainable & Smart Factory Operations 

See how Petrus designed connected factory operations by bringing all stakeholders to sustain and increase efficiency and reduce CoPQ

About the Client

The client is an AS9100D certified aerospace component manufacturer having tie up with major global OEMs & Tier 1’s in the US, Europe, and various divisions of Indian defense & research organizations.  Have expertise in delivering components across engine, structure & structural assembly, and composites from their 16000 sq. meter facility located in south of India

Problem Statement

The client’s metallic division embarked on a digital transformation journey to achieve seamless dissemination of machine & process intelligence to all stakeholders for optimal collaboration & timely intervention. They wanted to identify avenues for value creation to increase and sustain production efficiency, save time & effort spent on non-value activities.


Petrus with their detailed 4 weeks assessment, prepared a project plan to digitize and transform the way operations are done on their floor. The solution is to bring all the key stakeholders their 50+ machines, 150+ Operators, Tool crib team, Maintenance team, Quality team, & RM Stores team into a scalable centralized platform to provide a real-time view on Air time Vs Cut time, Machine availability ratio, machine load ratio, Planned vs actual production data.


      • Deployed centralized smart manufacturing platform, connected 50+ machines using edge boards & add-on sensors for CMS, connected quality devices

      • Developed and deployed rich HMI for operators to refer to technical details and key in contextual machine data for correlation

      • Provided app to all stakeholders to ensure material availability & collaboration

      • Customized reports, and dashboards with real-time alerts for timely insights and actions

    Sustainable Value Delivered


    Reduction in Cost of Poor Quality 


    Improvement in Real-time OEE

    1.5 hrs

    Time saved from NVA per operator per day