Power BI Implementation For A Casting Manufacturing Industry

Problem Statement

Our client relied on a manual and fragmented reporting system, which caused delays in decision-making and operational inefficiencies, ultimately affecting performance. They approached Aegis for a solution and highlighted the following challenges:

• Data was dispersed across ERP systems, inventory tools, and production floor sensors.
• No live insights into raw material usage or production output, causing delays in adjustments.
• Manual processes introduced errors and consumed time.
• Difficulty identifying wastage patterns led to increased material costs.
• The existing setup struggled to handle growing production data.

Objectives

• Centralization of all data sources into a unified platform.
• deploy real-time data tracking and dashboards.
• Automate reporting processes.
• Analyze wastage patterns and optimize resource allocation.
• Develop and implement a scalable system to handle increasing data demands.

Outcomes

The Power BI solution delivered substantial improvements:

• Reduced delays by 40% through real-time insights and improved decision-making speed.
• Optimized material usage and minimize wastage by 30%.
• Enhanced system capacity to support 50% more data growth.
• Freed up 60% of managers' time by automating reporting and improving their productivity.

Conclusion

Aegis successfully developed and deployed a Power BI-based analytics platform for the casting manufacturing client. This solution enhanced visibility, optimized resource utilization, and reduced wastage, empowering the client to achieve greater operational efficiency and cost savings.

Future Implications

The Power BI solution lays a foundation for smart manufacturing, advanced analytics, and global expansion.

• Incorporating predictive models for wastage reduction.
• Scaling dashboards for multi-plant operations.
• Leveraging AI and IoT for predictive maintenance and workflow optimization.