Production Line Monitoring System

A precision manufacturing company with 8 production facilities needed real-time quality control infrastructure to reduce defect rates and maintain consistency across distributed operations.

The Challenge

Quality control was reactive and inconsistent:

• Defects discovered hours or days after production
• Manual inspection catching only 78% of issues
• No visibility into production line performance in real-time
• Quality standards varied across facilities

The company was experiencing 4.3% defect rate, resulting in £840,000 in annual waste and customer returns.

The Infrastructure Solution

Entrelix engineered a real-time quality monitoring infrastructure:

Sensor Integration Layer

Connected 240+ sensors across all production lines into a unified monitoring system. Every measurement—temperature, pressure, dimensions, timing—streams into the central infrastructure in real-time.

Automated Quality Detection

AI-powered analysis identifies defects and anomalies instantly. The system learns normal operating parameters for each production line and detects deviations before they produce defects.

Predictive Maintenance System

Infrastructure monitors equipment performance patterns and predicts failures before they occur. Maintenance is scheduled proactively rather than reactively, minimizing downtime.

Cross-Facility Dashboard

Unified operations view shows real-time performance across all 8 facilities. Quality metrics, production rates, and equipment status visible to operations leadership instantly.

Measurable Outcomes

Results after 9 months:

• 67% reduction in defect rate (from 4.3% to 1.4%)
• £685,000 annual savings in waste reduction
• Real-time defect detection vs. hours/days delay
• 43% reduction in unplanned equipment downtime
• Consistent quality across all facilities

Operational Transformation

The infrastructure fundamentally changed how the company operates. Quality control shifted from reactive inspection to proactive prevention. Production managers now make decisions based on real-time data rather than daily reports. The system has processed over 8 million production events with 99.94% uptime.