Smart Factory Robotics Orchestrator

Client
Automotive Supplier
Industry
Manufacturing
Services
Engineering
Case Study Cover

The Challenge

The factory was rigid. Changing products took days of reprogramming. Quality defects were found only at the end of the line.

Client Overview

A Tier-1 automotive supplier needed to switch to 'lot size one' production without losing the efficiency of mass manufacturing.

High precision
Just-in-Time
Legacy PLCs
Quality critical

Solution Components

Universal Connector

Middleware translation layer speaking to Kuka, Fanuc, and ABB robots.

Vision QC

cameras spotting defects in welding/paint immediately.

Dynamic Scheduling

Re-routing parts to available cells if a robot needs maintenance.

Challenges & Risks

1

Protocol Hell

Every robot brand spoke a different proprietary language.

2

Latency

Vision checks had to happen within the 2-second cycle time.

Key Impact

12%
increase in first-pass yield
25%
reduction in changeover time for new products
Full
traceability of every part's manufacturing history
Return
on Investment (ROI) achieved in 9 months

The Solution

We implemented an IIoT orchestration layer. It treats robots as software objects, allowing flexible production lines. Computer vision inspections at every step catch errors instantly, preventing scrap.

Tech Stack

C#.NET CoreAzure IoT EdgeOPC UAInfluxDB
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