Industry: Automotive & Electronics Manufacturing
Tech Stack: National Instruments LabVIEW, Edge AI Vision, PLC Interfacing, REST APIs, PostgreSQL
Deployment: On-site Edge Computing & Secure Enterprise Integration
Turn your existing automotive & electronics equipment into smart assets — without costly replacements.
Upgrade legacy machines into Industry 4.0 smart assets without costly replacements. Our Edge IIoT solution integrates LabVIEW, Edge AI Vision, PLC Polling, REST APIs, and secure databases to deliver paperless operations, eliminate human error, enable real-time monitoring with instant alerts, and maximize ROI by extending machine lifespan — transforming your factory to be smarter, faster, and safer.
Impact Metrics at a Glance
- 100% Elimination of Manual Data Logging
- 0% Human Data Entry Errors
- Real-Time OEE & Alarm Visibility
- High ROI via CapEx Preservation (No New Machinery Required)
The Challenge: The Legacy Data Gap
On modern production floors, data is key to operational efficiency. However, the client faced a common industrial dilemma:
- High Capital Barrier: Essential shop-floor machines were fully functional mechanically, but lacked built-in networking capabilities. Replacing them with modern connected machinery would require multi-million-dollar CapEx investments.
- Manual Overhead: Operators were required to manually audit machine statuses, analog gauges, and cycle times, writing down logs every 10 minutes across multiple lines.
- Data Latency & Human Error: Paper-based logging created data delays, risk of transcription errors, and prevented management from seeing real-time bottlenecks or sudden equipment failures.
Our Solution: Non-Invasive IIoT Architecture
We engineered a non-invasive Edge IIoT data extraction platform that captures machine data without interrupting active production or voiding legacy machine warranties.
Legacy PLC / Analog Display –> Edge Vision & Signals –> LabVIEW Analytics Engine –> Enterprise Database & Dashboards
Key Solution Highlights
1. Multi-Modal Data Extraction
- Direct PLC Memory Polling: Extracted cycle metrics, part counters, and machine alarms directly from legacy PLC memory registers.
- Edge Machine Vision: For machines with locked PLCs or analog gauges, installed industrial vision cameras paired with OCR/pattern recognition to digitize physical displays into actionable software data.
2. Edge Processing & Analytics (LabVIEW Engine)
- Built custom, highly robust LabVIEW edge applications to process raw machine signals locally.
- Handled real-time data filtering, error checking, signal validation, and Pokayoke (error-proofing) logic at line side.
3. Enterprise Integration & Real-Time Dashboards
- Unified edge data from diverse machine types into standard data payloads.
- Streamed real-time data securely via REST APIs and database connectors to centralized Executive Dashboards and DENSO internal networks.
Business Impact & Results
- Operational Efficiency: Shifted operators from manual paper auditing to high-value technical tasks, optimizing shop-floor workforce utilization.
- 100% Data Integrity: Replaced manual transcription with direct digital validation, guaranteeing accurate historical logs for audit and quality tracking.
- Instant Anomaly Detection: Real-time dashboard updates allow engineering teams to respond instantly to line stoppage or cycle time degradation.
- Extended Asset Lifespan: Turned existing machinery into smart connected assets, achieving Industry 4.0 capability at a fraction of new equipment investment.
Have Legacy Machinery on Your Shop Floor?
Upgrade your production line to a Smart Factory without replacing your machinery.
Contact our IIoT and Automation Engineering team today for an on-site technical survey.