Case / 001 · Industrial operations
From manual ledgers to a real-time factory operating system.
A textile hub was losing raw material it could not trace and running on production data two days old. We connected the looms to a live system without stopping the floor.
The problem
- Raw material leakage of 15%, traced back to manual ledger entry.
- Production data lagged the floor by 48 hours, so decisions were made on yesterday's numbers.
- Machines were working; the systems around them were not.
The system
FactoryOS, a focused micro-app for the production floor, fed by IoT current sensors fitted to the existing looms. Shift logging became automatic, so the record of what each machine did no longer depended on someone writing it down.
The architecture
- Looms (Existing machines)
- Current sensors (Non-intrusive IoT)
- Shift logging (Automated capture)
- FactoryOS (Micro-app)
- Control tower (Live floor view)
The implementation
- IoT current sensors installed on looms, with no production downtime
- FactoryOS micro-app for the production floor
- Automated shift logging in place of manual ledger entry
- Real-time floor dashboard for supervisors and management
The outcome
Production data went from two days old to effectively live, and material that used to leak through manual records is now accounted for.
- Production data latency: 48h → 0.2s
- Material saved: $240k / yr
Capabilities used
- Industrial Systems
- Automation
- Software Systems
- Process Engineering