CASE STUDY
Operational Visibility Across Multiple Plants
A Multi-Plant Enterprise Rollout of BayaSense
The Challenge
As the enterprise expanded, management faced a visibility and governance gap:
Each plant tracked KPIs differently
No standardized definition of utilization, downtime, or productivity
Consolidated reporting took days and involved manual data collation
Difficult to benchmark plants or identify best practices
Corporate leadership lacked a real-time, enterprise-wide view
The leadership team wanted a solution that could deliver fast, consistent visibility across all plants—without waiting for a full MES rollout.
Why BayaSense
BayaSense was selected as the enterprise-wide operational intelligence layer because it offered:
Rapid deployment across heterogeneous plants
Standardized KPI definitions with plant-level flexibility
Edge-first architecture suitable for varied network conditions
Centralized dashboards with role-based access
A scalable foundation that could later integrate with MES/ERP
Most importantly, BayaSense enabled speed without chaos—a controlled, repeatable rollout model.
Business Impact
Single source of truth for operations across all plants
5–7% improvement in average plant utilization
Faster identification of underperforming lines and shifts
Best practices replicated across locations
Reduced dependency on manual MIS preparation
Deployment Scope
Architecture Highlights
- Machine utilization and downtime tracking
- Shift-wise and daily production visibility
- Energy consumption tracking (plant and machine level)
- Unified KPI framework across all locations
- Edge devices deployed at each plant
- Secure edge-to-cloud data pipeline
- Centralized enterprise dashboards
- Plant-level views retained for local teams
Key Paramaters
KPI definitions
Reporting cycle
Plant benchmarking
Management visibility
Decision-making
Before BayaSense
Plant-specific
Weekly / monthly
Not possible
Fragmented
Lagging
After BayaSense
Enterprise-standard
Real-time
One-click comparison
Unified
Proactive
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: Manufacturing (multi-location enterprise)
Company Size: Mid-to-large enterprise
Footprint: 5 manufacturing plants across different geographies
Plant Characteristics:
- Varying machine mixes and production profiles
- Different levels of digital maturity across plants
Digital Landscape:
- No unified MES across all plants
- Plant-level reporting done independently
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.