40% Higher Productivity.
Zero New Machines.
How a High-Volume Zippers Manufacturer Eliminated Breakdowns and Stabilized Cycle Time—with zero production downtime during deployment.
01 // THE CHALLENGE
Reactive Firefighting
Operating in a high-volume, fast-paced discrete manufacturing environment, the factory struggled with chronic productivity losses and operational variability.
Run-to-Failure
Mechanical wear went undetected until components failed—triggering costly, unplanned downtime and emergency repairs.
No Cycle Visibility
Micro-stoppages and performance deviations were invisible until the end of the shift, making real-time intervention impossible.
Reporting Blindness
Reliance on handwritten logbooks prevented accurate root-cause analysis of bottlenecks and throughput instability.
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Non-Invasive Predictive Intelligence
Niotek deployed HORUS Predict as a high-frequency intelligence layer on top of existing control systems—without installing new sensors.
Predictive Analytics (No More Surprises)
Advanced analytics continuously monitored component health and performance drift. Maintenance teams now receive early warnings before failures occur.
Cycle-Time Optimization
High-frequency machine event data (stamping, cutting, assembly cycles) was captured to reveal micro-stoppages and station-level bottlenecks.
Real-Time OEE Visibility
Manual logbooks were fully replaced. A unified dashboard now calculates Availability, Performance, and Quality in real time—across all shifts and lines.
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From Reactive to Proactive
Within four months, the factory transitioned to a data-driven operating model—unlocking hidden capacity.
| Metric | Before HORUS | After HORUS | Impact |
|---|---|---|---|
| Productivity | Low Baseline | +40% Higher | Bottleneck Optimization |
| Maintenance Strategy | Reactive (Fix-Fail) | Proactive | Fault Detection |
| Unplanned Downtime | High / Frequent | Significantly Reduced | Early Warnings |
| Cycle Stability | Untracked | Measured & Stable | Deviation Analysis |
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Discrete Mfg Focus
Analytics optimized specifically for high-speed stamping and assembly operations.
Non-Invasive
Connected directly to existing PLCs and counters with zero deployment downtime.
High-Freq Analytics
Real-time signal processing enabled instant detection of anomalies and performance drift.
Future-Ready
Machine-level digital models are ready for simulation and advanced optimization.
"We stopped fixing broken machines. We started preventing them from breaking."
This project demonstrated that predictive maintenance is the fastest, lowest-risk path to measurable ROI in brownfield discrete manufacturing.