Tier-1 Supplier: 25% Reduction in Unplanned Downtime

25%

Downtime Reduction

RM 240k

ANNUAL COST SAVING

12 Weeks

Implementation

100%

Data Traceability

The Challenge

High rework rates due to late feedback.

Untracked micro-stops cumulative losses.
 
High rework rates due to late feedback.

The Shiftix Solution

✓ Real-time IIoT machine connectivity.

✓ Automated OEE dashboards visibility.

✓ Predictive QC alerts integrated with MES.

Week 1-2

Site Audit & Sensor Mapping

Mechanical constraints identification.

Week 3-6

OT-IT
Connectivity

Edge Gateway installation & PLC handshake.

Week 7-9

MES
Configuration

Workflow digitization & Dashboard setup.

Week 10-12

UAT & Team Training

Operator enablement and Go-Live.

Strategic Results at a Glance

4 Proof-of-Result Stories

Financial ROI · Plastics & Packaging
RM202,450
Recovered in 3 months via OEE monitoring
Recovering RM202,450 in Hidden Revenue
Identified 22% hidden downtime through real-time machine monitoring — without new machines or additional headcount.
Best for: Financial ROI & Cost Recovery
Read the full story
Audit Compliance · Electronics
99.8%
Traceability accuracy to pass international audit
Securing a Global Tier-1 MNC Contract
Achieved 99.8% traceability accuracy to pass a critical international audit — unlocking global supply chain access.
Best for: MNC Readiness & Global Expansion
Read the full story
Zero Defect · Automotive
4.5% → 0.2%
Reject rate drop via digital quality gates
Achieving Zero-Defect Production
Internal reject rates dropped from 4.5% to 0.2% through digital quality gates and real-time defect tracking on the floor.
Best for: Risk Mitigation & Quality Excellence
Read the full story
Legacy Modernization · Manufacturing
14 Days
100% of legacy machines connected to cloud
Transforming a 30-Year-Old Legacy Factory
Connected 100% of "dumb" machines to the cloud in just 14 days — no production downtime, no new hardware required.
Best for: Second-gen Legacy Modernization
Read the full story

System Architecture

Hardware-agnostic layer that sits between legacy PLCs and modern Cloud Analytics. No rip-and-replace needed.

MQTT / OPC-UA Protocols
Local Edge Processing
SQL Server / SAP Integration
PC 1

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