The challenge
A mid-sized auto-component manufacturer ran four plants across Maharashtra and Gujarat. Each plant had its own SCADA system and reporting was a manual weekly Excel exercise. Leadership couldn't see plant-level OEE in real time, and unplanned downtime was costing roughly ₹2 crore per quarter.
What we did
- Audited the OT environment at each plant; cataloged 240 PLCs across vendors (Siemens, Allen-Bradley, Mitsubishi)
- Designed an OT-to-IT data layer using AWS IoT Greengrass at the edge and AWS IoT Core in the cloud
- Built a unified OEE dashboard in Grafana with role-based views (operator → plant manager → CEO)
- Implemented network segmentation between OT and IT per IEC 62443
- Trained on-site IT teams to handle Tier-1 issues independently
Results
- Real-time OEE visibility across all four plants within 11 weeks of kickoff
- 60% reduction in unplanned downtime within 6 months (from preventive alerts triggered by sensor data)
- ₹1.2 crore in saved downtime per quarter (verified by the client's CFO office)
- Internal IT team trained to run the platform without ongoing DivergeiX involvement
Tech stack
AWS IoT Greengrass AWS IoT Core Lambda Timestream Grafana Terraform Python
