Manufacturing
Case Studies

Automotive Manufacturing

Featured

Leading Automotive Manufacturer — MES Implementation for Rockwell Automation

Delivering Multi-Functionality MES for a Rockwell Automation Implementation QAS leveraged its manufacturing and technology expertise to deliver a Manufacturing Execution System (MES) solution with mu

62% → 85%

OEE (Overall Equipment Effectiveness)

68% → 96%

Production Planning Accuracy

Baseline → ~35%

Unplanned Downtime (Predictive Maintenance)

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Tyre & Rubber Manufacturing

Featured

Leading Tyre Manufacturer Transforms Shop Floor with MES & Industry 4.0 Digitalization

Delivering Multi-Functionality MES for a Rockwell Automation Implementation QAS leveraged its manufacturing and technology expertise to deliver a Manufacturing Execution System (MES) solution with mu

64% → 87%

OEE (Overall Equipment Effectiveness)

40% → 97%

Real-Time Production Visibility

65% → 99%

Batch Traceability & Genealogy Accuracy

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Healthcare Waste Management / Environmental Compliance / BMW Treatment Facility Operations

Medical-Waste Solution Platform — End-to-End BMW Treatment Facility Operations Management

Fragmented Operations Across a Complex Regulatory Landscape Bio-Medical Waste Treatment Facilities operate under the strict oversight of the Bio-Medical Waste Management Rules, 2016 — meaning every

Baseline → –90%

Compliance Deadline Miss Rate

75% → 99%

Waste Collection Reconciliation Accuracy

5 days → Real-Time (auto-triggered)

Invoice Processing Time

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Power Generation / Renewable Energy / Utilities & Substation Infrastructure

61 PV Plants & 22 Substations — Legacy SCADA Migration to N3uron on Microsoft Azure

A Legacy SCADA System Limiting Visibility Across 61 Plants and 22 Substations Before this migration, the client operated 61 PV plants and 22 substations on a legacy centralized cloud-based SCADA syst

~0 → 3 live (of 83 total)

Sites Migrated to N3uron

Centralized only, no local HMI → Full local + centralized visibility

Real-Time Monitoring Coverage

Baseline → Standardized via templates

Plant Integration Time (per site)

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Digital Signage / Retail & QSR Technology / Manufacturing Facility Management

Centralized Digital Signage Platform — Scalable Foundation for Multi-Plant & Multi-Location Franchise Rollout

Fragmented Signage Management Across Multiple Locations Organizations operating across multiple plants, stores, or franchise outlets — from manufacturing facilities to QSR chains like pizza and fas

2-3 days → Same day

Content Update Time Across Locations

Baseline → –70%

Screen Downtime (Health Monitoring)

Baseline → –45%

Licensing Cost per Location

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Life Sciences / Medical Device Manufacturing

Medical Device Industry Leader — First-Ever FTPS MES Implementation for Mass Spectrometry & Capillary Electrophoresis

An Unsolved Problem: FTPS Had Never Been Implemented for Medical Devices Before this engagement, no MES implementation had successfully deployed FTPS (Rockwell) functionality for the medical device i

Baseline → Fully audit-ready-Data

FDA Compliance Audit Readiness

70% → 99.5%

UDI Traceability Accuracy

Baseline → ~65%

Quality Management Risk Incidents

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Life Sciences / Pharmaceutical Manufacturing

Leading Life Science Manufacturer — MES with FTPS-Driven Regulatory Compliance

Regulatory Complexity Demanding Digitized, Auditable Systems Life science manufacturing operates under some of the strictest regulatory requirements of any industry — where digitizing the system is

6 hrs → 45 min

Batch Record Review Time

8% → 1.5%

Non-Conforming Batch Rate

Baseline → –74%

Manual Data Entry Volume

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CPG (Consumer Packaged Goods) Manufacturing

CPG Manufacturer — Material Baggage Verification & Continuous Process Monitoring MES

Quality Determined by Process Parameters, Not Just Final Inspection For this CPG manufacturer, product quality is strictly determined by process parameters — meaning material baggage verification b

60% → 100%

Material Verification Coverage

65% → 90%

OEE (Overall Equipment Effectiveness)

9% → 1.5%

Batch Quality Rejection Rate

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CPG (Consumer Packaged Goods) — Food & Beverage Manufacturing

Leading Ice Cream Manufacturer (USA) — Cloud-Based CRM on Ignition Platform

Manual Vendor Ordering Limiting Growth for a Leading Ice Cream Manufacturer Before this CRM deployment, this leading ice cream manufacturer in the USA relied on manual or disconnected processes for v

4 hrs → 20 min

Vendor Order Processing Time

82% → 99%

Order Accuracy Rate

35% → 95%

Real-Time Inventory Visibility

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Semiconductor & Electronics Manufacturing

Leading Semiconductor & Smartphone Charger Manufacturer — Custom MES Solution

Precision Manufacturing Demands in Semiconductor and Charger Production This market leader in semiconductor and smartphone charger manufacturing operated in one of the most precision-sensitive produc

78% → 96%

Yield Rate

3 hrs → 15 min

Defect Detection Time

72% → 99.5%

Traceability Accuracy

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Automotive Manufacturing

Leading Automotive Manufacturer — Database Performance Optimization & Issue Resolution

Database Slowdowns Threatening Production Decision-MakingA leading automotive manufacturer encountered database slowdowns, data retrieval failures, and system inconsistencies, affecting production tra

8 Sec → 0.2 Sec

Application-to-Database Response Time

24% → 1%

Data Retrieval Failure Rate

Baseline → +65%

Query Execution Efficiency

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Electric Vehicle (EV) Manufacturing — Two-Wheeler

Leading Indian EV Bike Manufacturer — Comprehensive MOM/MES Solution

A Leading Indian EV Bike Plant Needed a Unified MOM/MES Foundation A leading Indian EV bike plant required a robust MOM/MES solution to streamline production, real-time monitoring, and SAP integratio

3 hrs → 15 min

Real-Time Alarm Response Time

22% → 1.9%

SAP-MES Data Sync Errors

65% → 97%

Workforce Shift Scheduling Accuracy

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Electric Vehicle (EV) Manufacturing

Overseas EV Manufacturing Plant — Custom Manufacturing Information System (MIS)

Scaling Real-Time Intelligence Across a Global EV Manufacturing Operation Before this Manufacturing Information System (MIS) deployment, this overseas EV manufacturing plant faced a challenge common

66% → 89%

OEE (Overall Equipment Effectiveness)

35% → 96%

Real-Time Shopfloor Data Visibility

68% → 99%

Order Genealogy Traceability Accuracy

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Automobile Manufacturing

Multinational Automobile Manufacturer — Unified HRMS for Workforce Digitalization

Fragmented HR and Admin Functions Across a Multinational Manufacturing Workforce Before this HRMS deployment, HR and admin functions operated as separate, disconnected systems across the client's aut

70% → 98%

Employee Data Accuracy

5 Days → 1 Days

Payroll Processing Time

21 Days → 9 Days

Recruitment-to-Onboarding Cycle Time

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