Challenge

Disconnected Systems Causing Downtime and Inefficiency
A precision manufacturing company faced inefficiencies caused by siloed production, maintenance, and procurement systems. Shop-floor supervisors had to manually track material shortages, machine downtimes, and maintenance logs.

When a production line stopped, identifying root causes took hours because machine data and inventory details lived in separate spreadsheets. The company lacked predictive insights — maintenance was reactive, and costly downtime frequently disrupted deliveries.

Management sought a centralized digital system to improve visibility, predict failures, and unify operational data without replacing existing machinery.

Solution

ERPNext + Azure-Powered Predictive Analytics
Wilco deployed ERPNext hosted on Microsoft Azure, connecting it to IoT data streams for production tracking. The system unified inventory, scheduling, and procurement with real-time machine status.

We built Power BI dashboards using Azure Data Services, which collected sensor data and maintenance logs to train predictive models for machine failure patterns. The solution alerted engineers of potential equipment issues before they caused downtime.

Integration with existing warehouse and procurement systems allowed the company to automate material replenishment and improve supplier coordination.

Impact

Data-Driven Factory Transformation

• Production downtime reduced by 25% through proactive maintenance alerts.
• Inventory optimization improved material availability by 40%.
• Centralized visibility enabled real-time performance tracking across shifts.
• The plant became a model for digital transformation within its corporate group.