1. Overview
A leading automotive manufacturing enterprise operates multiple assembly plants nationwide, where production lines run continuously with thousands of sensors, robots, and production management systems (MES, SCADA, PLC).
To ensure smooth operation, the company identified the need to develop a centralized operation and monitoring system capable of detecting, predicting, and resolving issues in real time.
After evaluating several technology partners, the company selected BAP for its proven expertise in System Operations & Maintenance, DevOps, and AI-based Monitoring.
2. Challenges
Due to the large scale and high level of automation, the manufacturer faced several key challenges:
Difficulty in managing data from hundreds of IoT devices and multiple production lines.
Lack of centralized monitoring tools, resulting in delayed incident detection.
Inability to predict hardware failures or performance degradation before they occurred.
Unplanned downtime on production lines led to significant losses in output and cost.
The goal was to build a proactive, intelligent, and stable monitoring system that ensures Zero Unplanned Downtime in production.
3. Solution
The System Operations & Maintenance team at BAP collaborated with the client to develop a comprehensive Smart Operation System, including:
Comprehensive Monitoring Integration: Connected MES, PLC, and SCADA data via IoT Gateway to provide real-time visibility of production line status.
Predictive Maintenance Analytics: Applied Machine Learning to detect equipment anomalies before system failures occur.
Automated Incident Response: Built automated alert and resolution workflows to reduce response time.
Intelligent Operation Dashboard: Delivered an intuitive dashboard for real-time monitoring, analysis, and optimization.
Onsite & Remote Support Team: Implemented a hybrid DevOps model combining on-site maintenance with 24/7 remote support.
4. Technologies Used
Monitoring & Analytics: Prometheus, Grafana, Elastic Stack, Azure Monitor
Automation & CI/CD: Jenkins, Ansible, Docker, Terraform
AI & Predictive Maintenance: TensorFlow, Python ML, AWS SageMaker
Infrastructure: AWS EC2, Azure IoT Hub, Kubernetes
Security & Backup: CloudTrail, GuardDuty, automated snapshot backup
5. Results
0 minutes of unplanned downtime, ensuring continuous production line operation.
30% faster incident resolution with automated alerts and response workflows.
25% reduction in maintenance costs through early fault detection and proactive fixes.
Improved production efficiency and overall system performance.
