At AeroFlexx, innovation is a mindset that drives every part of our operations. Our commitment to continuous improvement recently led us to implement a new strategy for enhancing visibility into our converter line, a vital part of our manufacturing process.
We were facing a major challenge: critical production data on our high-speed converter line was stuck in siloed systems, leaving operators with limited visibility and slowing real-time decision-making. Traditional HMI screens were too small and restrictive, forcing staff to rely on delayed reports or even cellphone photos to analyze performance.
To overcome this, we partnered with Factory Systems, which deployed its FS.IoT platform to securely capture data from PLCs, sensors, and vision systems, and FS.Net to centralize and normalize the information in the cloud. This data was then brought to life through FS.Display dashboards, giving operators and managers across the plant — and even across the globe — instant access to live performance metrics.
Immediate, far-reaching result
The results were immediate and far-reaching. The company quickly reduced downtime, improved shift-to-shift accountability, and accelerated issue resolution thanks to transparent, real-time insights. The solution proved easy to scale, allowing us to expand visibility across multiple lines worldwide with minimal effort. Beyond immediate benefits, the integration positioned AeroFlexx for long-term growth, enabling predictive analytics, continuous improvement initiatives, and future ERP and MES system integrations. As Vice President of Quality Veronica Sebald noted, the project wasn’t just an upgrade — it established a smart manufacturing foundation designed to evolve with AeroFlexx’s global expansion.