Industry 4.0 IIoT MES Platform & SAP Cloud ERP Integration
Connected 5,000+ plant floor IIoT sensors into a cloud MES predictive maintenance platform, preventing $1.2M in annual unplanned factory downtime.
articleExecutive Overview
Titan Composites manufactures high-precision aerospace components across three automated facilities. Equipment breakdowns on critical autoclave pressure vessels created multi-day production halts.
warningThe Operational & Technical Challenge
Legacy SCADA machines operated in isolated silos. Plant managers lacked visibility into vibration and temperature anomalies until machines suffered catastrophic failure.
Unplanned Outages
Equipment failures caused costly factory downtime and scrapped expensive raw materials.
Manual Inspection Delays
Technicians manually checked gauge logs once per shift, missing early warning indicators.
ERP Data Isolation
Production counts were manually keyed into SAP ERP at end-of-day, delaying order fulfillment.
architectureDevEngine Engineering Solution & Orchestration
DevEngine designed a hybrid edge-to-cloud Manufacturing Execution System (MES) utilizing MQTT protocols, AWS IoT Core, and computer vision quality inspection.
Key Technical Deliverables
- check_circleEdge MQTT telemetry streaming over 5,000 sensor feeds in real-time.
- check_circleComputer vision AI camera inspection detecting sub-millimeter component defects in real-time.
- check_circleBi-directional SAP ERP integration for automated work-order tracking and material decrementing.
- check_circleRole-based plant floor tablet UI for technicians with automated SMS maintenance alerts.
"DevEngine connected our 30-year-old machinery into a modern cloud platform. We caught three major bearing failures before they caused production halts."
David Kowalski
VP of Manufacturing Engineering, Titan Composites Tech
Technologies Deployed
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