Automotive Components Manufacturing
From Japanese
The client is a long-established automotive components manufacturer, operating in Vietnam for nearly three decades. With a workforce of over 2,000 skilled employees and a modern factory equipped with advanced production lines, the company supplies high-precision interior and filtration systems for major global automakers. By applying world-class quality management and lean manufacturing principles, the client has built a strong reputation for reliability, safety, and continuous innovation. As a Tier-1 supplier in the global automotive supply chain, the company plays a vital role in supporting the consistent quality and operational excellence of its international partners.
Building a centralized system to monitor production status across 6 assembly lines (9–26 workstations each).
Automating data collection and daily reporting to replace manual logbooks.
Implementing a real-time alert system to detect and notify abnormalities instantly.
Enabling downtime recording and root cause analysis for continuous improvement.
Optimizing overtime management through accurate production data tracking.
Unifying KPI dashboards and performance reports across shifts and lines.
Before implementing NxFactory’s solution, several issues limited productivity and traceability:
Manual production reports were time-consuming and error-prone.
No integrated system to visualize line status or shift progress in real time.
Downtime and errors were not systematically recorded, delaying problem resolution.
Maintenance coordination was reactive, often leading to prolonged recovery times.
Overtime planning relied on estimates, resulting in labor inefficiency.
Lack of standardized data made it difficult for managers to compare line performance and optimize resources.
To address these challenges, NxFactory implemented a Smart Manufacturing Monitoring System designed to digitalize production management and ensure end-to-end visibility across all assembly lines.
Real-time Line Monitoring: Supervisors can track the status of each workstation and production progress in real time, enabling faster response to any disruption.
Automated Data Capture: Eliminated manual input by collecting data directly from terminals and sensors, ensuring accuracy and transparency.
Downtime & Error Tracking: NxFactory’s alert system identifies the top 10 causes of downtime, helping teams act proactively to reduce unplanned stoppages. This minimized idle time and improved overall line efficiency.
Digital Reporting: Production reports, OEE metrics, and performance dashboards are generated automatically, helping management make data-driven decisions.
Overtime Optimization: The platform calculates overtime needs based on actual production progress, improving labor allocation and cost efficiency.
Unified Performance Dashboard: Centralized dashboards allow leaders to compare productivity, defect rates, and machine utilization across all lines.
6
Production lines unified under a single monitoring system
26
Workstations per line connected and synchronized in real time
Overtime reduced almost completely within 6 months
Centralized and Transparent Data Management: A unified monitoring system improved visibility, responsiveness, and traceability across all production lines. Managers gained access to consistent real-time dashboards for OEE, DLE, and production performance tracking.
Maximize Efficiency: Production data automation and real-time alerts significantly reduced manual errors and unplanned downtime. Within 6 months, overtime was almost completely eliminated while maintaining delivery schedules.
Enhanced Connectivity: All 6 production lines and 9–26 workstations per line were fully connected and synchronized, enabling standardized operations and unified data flow across departments.
Real-time Alerts & Predictive Response: NxFactory’s real-time alerts and predictive analytics helped teams detect issues early, allowing quick root-cause analysis and proactive maintenance for stable productivity.