Factory-wide data integration

Overview

The Factory-Wide Data Integration project focused on connecting isolated systems and data sources into a unified, transparent production environment. The client operated multiple production lines and support systems that generated valuable data, but the information remained fragmented across separate platforms and departments.

The objective was to create a centralized data infrastructure that would enable real-time visibility, consistent reporting, and data-driven decision-making across the entire factory.

Client challenges

Before integration, the facility faced several data and coordination issues:

• Disconnected production, quality, and maintenance systems

• Manual data collection and inconsistent reporting

• Limited real-time visibility into factory performance

• Difficulty correlating data across departments and processes

• Delayed decision-making due to lack of reliable insights

Objectives

The primary objectives of the project were to:

• Create a single source of truth for factory data

• Enable real-time monitoring of production and operations

• Improve data accuracy and consistency across systems

• Support data-driven operational and management decisions

• Build a scalable foundation for future digital initiatives

Solution approach

A layered data integration strategy was implemented to connect machines, control systems, and business platforms. The solution was designed to be vendor-agnostic and compatible with both legacy and modern equipment.

Key components of the solution included:

• Centralized data platform for aggregation and normalization

• Standardized data models and communication protocols

• Real-time dashboards and performance indicators

• Secure and scalable architecture for future expansion

Implementation process

The project was executed through a structured and low-risk process:

• System Mapping & Data Audit
  Identification of all relevant data sources, formats, and integration points across the factory.

• Architecture Design
  Design of a unified data architecture aligned with operational and business requirements.

• Integration & Connectivity
  Connection of machines, software systems, and databases into a centralized platform.

• Data Validation & Visualization
  Verification of data accuracy and development of dashboards for real-time insight.

• Training & Knowledge Transfer
  Training teams to use integrated data tools for monitoring, analysis, and reporting.

Conclusion

The Factory-Wide Data Integration project eliminated data silos and created full operational transparency across the facility. By unifying systems and standardizing information flow, the client gained faster insights, improved coordination, and a robust digital foundation to support continuous improvement and future smart factory initiatives.