Deploying machine-level production and downtime monitoring across manufacturing lines at Dr. Reddy's Laboratories to improve OEE visibility and operational coordination.
Controlytics deployed a production and downtime monitoring system across manufacturing lines at Dr. Reddy's Laboratories. The system provides machine-level performance and OEE visibility, enabling operations and maintenance teams to identify downtime patterns, track micro-stoppages, and conduct more structured production reviews using real-time data rather than manual shift reports.
Limited visibility into machine-level performance and downtime across manufacturing lines
Machine-level OEE data was not available in real time. Performance assessments relied on end-of-shift reports, delaying identification of production inefficiencies.
Brief, recurring stoppages across manufacturing lines went unrecorded, accumulating into significant productivity losses over time without any structured tracking mechanism.
Without shared real-time data, coordination between operations and maintenance teams was reactive, with downtime causes often identified after the fact.
Production reviews were conducted using manually compiled reports, limiting the accuracy and timeliness of data available for decision-making.
Machine-level monitoring system delivering real-time production and downtime data
Continuous monitoring deployed across manufacturing lines, capturing production output, machine states, and downtime events at the individual machine level.
Real-time OEE metrics available across all monitored lines, providing immediate visibility into availability, performance, and quality indicators.
Automated detection and logging of brief stoppages that previously went unrecorded, enabling teams to quantify and address recurring issues.
Data-driven production reviews replacing manual shift reports, enabling both operations and maintenance teams to work from the same real-time dataset.
Phased rollout across multiple manufacturing lines
Production and downtime monitoring deployed across multiple manufacturing lines at Dr. Reddy's Laboratories.
Rolled out across multiple lines with phased expansion planned for additional production areas.
Improved visibility, coordination, and data-driven decision-making across production
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