Scalable Cloud Data Platform for Real-Time Manufacturing Operations

One large manufacturing group was burdened with inconsistent reporting, varied data sources, and a poor ability to identify production issues. So much time was soaked up with manual spreadsheet consolidation that it took hours per day, and managers were stuck with no real end-to-end line-of-sight for plant health or throughput. They were looking for scalable cloud solutions that would unify information and absorb steam from plant-wide streaming along with modern production requirements. Vortunix has come up with a cloud data platform that is precisely designed for real-time manufacturing, showing the potential for future growth—performance, reliability, and cloud computing technology combined in an integrated form in the manufacturing industry.
Vortunix stepped in to deliver a phased, multi-cloud migration strategy without disrupting critical operations.

Here’s how we helped:

1. 1.Unified Control Center: Implemented a Snowflake-driven single command layer that quickly aggregates data from over 250 machines and equipment streams through our cloud-based manufacturing software deployment.
2. 2. Instantaneous Data Feeds: Used streaming pipelines via Apache Kafka and AWS Kinesis to provide real-time analysis of output status, vibrations, and temperatures, giving site managers real-time insight into operation per shift.
3. 3. Smarter Safety Nets: Implemented integrated predictive monitoring systems to identify performance deviations prior to them causing downtime.
4. 4.Dynamic Resource Use: Adopted a serverless architecture, cutting infrastructure costs by 35% while keeping performance fluid during production peaks.

1. 65% Reduction in time taken for manual reporting
2. 18% Improvement in productivity effectiveness because of continuous visibility
3. ₹9 Lakhs Saved Per Month With predictive alerts avoiding downtime
4. A centralized cloud-based data platform that brings together production figures, downtime history, and quality data into one operational hub.
5. Zero Disruptions in capacity expansion at locations

1. 1.Live Production Dashboard: Developed in Power BI + Snowflake to support rich visualization of real-time manufacturing performance metrics.
2. 2.Smart Alert Automation: Real-time anomaly detection for early intervention using Airflow and AWS Lambda
3. 3.Serverless Data Infrastructure: Apache Kafka + AWS Glue + S3 + Lambda for cost-efficient, elastic processing of millions of telemetry events daily
4. 4.Early-Stage Predictive Analytics: Implemented machine learning models to forecast maintenance needs and optimize production scheduling.
5. 5. High Availability & DR setup via cross-region backups and autoscaling