Automotive electronics manufacturing
From Japanese
The client is a large-scale manufacturer specializing in wire harnesses and precision electronic components, operating a multi-factory system in Northern Vietnam. The company employs over 3,000 workers and technicians across four factories, each running high-volume production with more than 240 machines operating across multiple shifts. Their production environment includes dozens of assembly lines, semi-automated processes, strict quality checkpoints, and continuous operation requirements. As a Tier-1/2 supplier to global electronics and automotive brands, the client must maintain high equipment stability, accurate production data, and consistent cycle times across all plants. The size and operational complexity of the factories make real-time monitoring essential to ensure stable throughput, minimize downtime, and optimize workforce allocation.
Building a centralized monitoring platform for over 240 machines running across multiple shifts.
Real-time machine status tracking to replace manual checklists and delayed reporting.
Automatic downtime detection with accurate categorization for deeper analysis.
Standardizing performance data across plants to enable comparison and continuous improvement.
Enhancing workforce allocation by understanding true machine availability and workload.
Reducing unplanned stoppages to avoid production delays and delivery risks.
Before implementing NxFactory, the client encountered several operational bottlenecks:
No real-time visibility into machine performance, leading to slow response to stoppages.
Manual recording of machine status caused inaccuracies and inconsistent reporting.
Downtime causes were unclear, making root-cause analysis difficult.
Fragmented data across four factories hindered cross-site benchmarking.
Late detection of abnormalities resulted in prolonged machine stoppages.
Lack of centralized dashboards made it difficult for management to assess production health.
To address these challenges, NxFactory deployed a Smart Machine Monitoring System connecting all machines across four factories into a single, unified digital platform. The solution delivered real-time visibility, automated data collection, downtime analysis, and consolidated reporting — enabling the client to operate with higher stability and efficiency.
Real-Time Machine Status Monitoring : NxMES continuously tracks the running, idle, and error states of all 240+ machines, allowing supervisors to instantly identify abnormalities and take quick corrective actions.
Automated Downtime Detection & Categorization : Every machine stoppage is automatically captured and assigned a downtime reason, eliminating manual logging and enabling accurate root-cause analysis.
Centralized Data Platform for 4 Factories : All factories share one unified monitoring system, ensuring consistent data flow, standardized KPIs, and seamless cross-site comparison.
Production Loss & Efficiency Tracking : The system calculates loss time, cycle time, and performance trends to highlight hidden inefficiencies and support continuous improvement initiatives.
Real-Time Alerts & Operator Notifications : Supervisors and technicians receive instant notifications when a machine stops, reducing reaction time and improving equipment availability.
Standardized Daily & Shift Reports : Reports for each shift, each machine, and each factory are automatically generated, ensuring accuracy and eliminating reporting delays.
4
Factories centrally monitored
12%
Downtime reduction
240+
Machines fully connected
Centralized and Transparent Data Management : A unified monitoring platform enhanced real-time visibility, responsiveness, and traceability across all four factories. Managers gained access to consistent dashboards for machine status, downtime reasons, cycle-time deviations, and performance trends, enabling faster decision-making and accurate cross-plant benchmarking.
Maximize Efficiency : Automated data capture and instant downtime alerts significantly reduced manual errors and unplanned stoppages. Machine availability improved, and overall downtime dropped by more than 12% after deployment, stabilizing takt time and maintaining production continuity across shifts.
Enhanced Connectivity : Over 240 machines across four factories were fully connected and synchronized, enabling standardized reporting, consistent production data flow, and seamless coordination between departments. Shift handovers improved with accurate, real-time operational information.
Real-Time Alerts & Predictive Response: NxMes alert system enabled early detection of abnormalities and supported proactive maintenance. Rapid root-cause visibility minimized recurring issues, reduced micro-stoppages, and strengthened overall operational stability.