Connecting Three Manufacturing Plants Through One Reliable Data Platform
Turning fragmented ERP, production, and quality data into a connected source of operational intelligence.
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About the Client
A precision components manufacturer operating across three facilities relied on spreadsheets, separate quality systems, and ERP data that often lagged behind shop-floor activity. Plant managers needed a reliable, unified view of production performance without disrupting existing manufacturing workflows.
The Challenges
Fragmented operational data and inconsistent reporting practices slowed production decisions and made performance comparisons across facilities difficult.
Plant managers spent hours consolidating reports instead of addressing production bottlenecks.
ERP data often failed to reflect shop-floor activity in time for daily production reviews.
Inconsistent reporting practices made it difficult to compare performance across all three plants.
Fragmented production and quality records delayed investigations and reduced confidence in operational data.
Our Solutions / Approach
We proposed a connected data platform combining automated integration, data standardisation, and production analytics to improve visibility across all three facilities.
Connected ERP, production, inventory, and quality data using Microsoft Fabric and Azure Data Factory.
Standardised operational records using Python and SQL, with consistent downtime categories and KPI definitions.
Developed Power BI dashboards for production attainment, machine downtime, scrap rates, and inventory discrepancies.
Introduced automated data-quality monitoring, role-based access controls, and clear ownership of reporting metrics.
Technologies Used
Microsoft Fabric
Azure Data Factory
Python
SQL
Power BI
Outcomes / Result
Targeted improvements across reporting efficiency, production visibility, data reliability, and quality investigations.
Under 1.5 hours
Target daily reporting effort per plant, down from 4 hours
Before morning review
Target production report availability, instead of the following day
Below 2%
Target unmatched production records, down from 8%
Same working day
Target quality issue investigation, down from 2-3 days
More consistent reporting
Standardised operational KPIs across all three facilities
Foundation for manufacturing AI
Reliable production data to support future predictive maintenance and anomaly detection use cases
Client Feedback
SyncOrigins helped us turn close from a fire drill into a managed process. We finally have visibility early enough to act.
VP Finance
Corporate Finance · Enterprise Client