Cutting Losses, Boosting Throughput: How Digital Twin–Enabled OEE Monitoring Transformed Glass Manufacturing Efficiency
Client
A leading glass windows manufacturing company specializing in high-precision glass cutting and assembly for industrial and commercial projects.
Business Need
The company was struggling with high glass wastage during the cutting process, resulting in increased production costs and poor utilization of raw materials. Frequent equipment downtime and low productivity slowed production schedules and negatively affected profitability. What the company lacked was real-time visibility into equipment performance to identify the root causes of inefficiencies, proactively reduce downtime, and minimize wastage through continuous improvement.
Solution
The manufacturer partnered with our team to implement a Digital Twin–enabled Overall Equipment Effectiveness (OEE) Monitoring solution. A network of smart sensors was installed across critical equipment on their cloud-based production platform to capture performance metrics—including availability, performance, and quality.
Sensor data fed into a Digital Twin model, which leveraged advanced analytics and machine learning algorithms to simulate equipment behavior and surface actionable insights.
Interactive real-time dashboards and reports empowered production teams to track bottlenecks, performance drops, and inefficiencies with full transparency. Additionally, a mobile application enabled technicians to receive instant alerts on downtime or abnormal variations, allowing rapid corrective action on the shop floor without waiting for manual inspections.
Benefits
- Improved Equipment Availability: Real-time insight into downtime patterns enabled the team to address root causes quickly, resulting in higher machine availability.
- Increased Productivity: Visibility into bottlenecks allowed optimized production workflows, boosting throughput across the glass cutting line.
- Enhanced Quality Control: Continuous monitoring helped detect defects early, reducing material waste and rework.
- Reduced Costs: Lower downtime and optimized equipment efficiency drove significant savings across maintenance, raw materials, and operational expenditure.