CASE STUDY
Brownfield Digital Transformation for MSMEs
How BayaSense helped an MSME with mixed-vintage equipment achieve real-time operational visibility and fast ROI—without a traditional MES.
The Challenge
The client wanted to improve productivity, energy efficiency, and decision-making, but lacked answers to basic operational questions:
Which machines are actually utilized—and when?
Where is time being lost due to idle or unplanned downtime?
How much energy does each machine really consume?
Which problems repeat shift after shift?
Without reliable data, decisions were reactive and experience-driven, limiting scalability and competitiveness.
Why BayaSense
BayaSense was selected because it is purpose-built for brownfield environments:
Non-intrusive deployment on legacy and modern machines
Edge-first architecture with minimal shop-floor disruption
Protocol-agnostic data acquisition
Cloud dashboards without heavy IT dependency
Ability to start with BI and evolve toward AI over time
Most importantly, BayaSense delivered visible value within weeks—not months.
Business Impact
6–8% improvement in machine utilization
12–15% reduction in idle energy consumption
Faster identification of chronic downtime issues
Improved shift discipline and accountability
Management confidence to scale digital initiatives
Deployment Scope
Architecture Highlights
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Machine status monitoring (Run / Idle / Down)
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Machine-level energy monitoring
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Shift-wise and daily operational dashboards
Edge devices connected to selected machines
Sensors and signals captured without modifying machine logic
Secure edge-to-cloud data flow
Web dashboards for supervisors and management
Key Paramaters
Visibility
Downtime tracking
Energy insights
Reporting
Decision-making
Before BayaSense
Manual estimates
Not available
Monthly utility bills
Paper / Excel
Reactive
After BayaSense
Real-time dashboards
Categorized & time-stamped
Machine-level data
Automated
Data-driven
Building a Future-Ready Digital Foundation
With BayaSense in place, the client now has a scalable digital backbone to:
Add quality and process parameters
Introduce predictive insights using AI
Integrate or augment a future MES
Support customer audits with data-backed evidence
Progress toward zero-defect manufacturing
Client Snapshot
Industry: Precision engineering / Auto components
Company Size: MSME
Shop Floor Reality:
CNC machines + conventional machines (10–20 years old)
Multiple OEMs, mixed controls
Digital Baseline:
No MES
Manual shift & energy reporting
Key Takeaway
Industry 4.0 doesn’t have to start with new machines or massive IT projects.
BayaSense enabled this MSME to digitize a brownfield shop floor, unlock real operational intelligence, and build a future-ready roadmap—with low risk, low disruption, and fast ROI.