Business Overview
A global leader in ODM Plus solutions, serving industries such as Aerospace & Defense, Communications, Energy & Industrial, Healthcare, and Transportation, operates multiple state-of-the-art facilities specializing in Printed Circuit Board Assemblies (PCBAs) for mission-critical applications — from home appliances to aircraft systems.
Operating in the electronics manufacturing sector demands exceptional precision, strict compliance, and continuous quality improvement. The chip manufacturing process is highly capital-intensive and technologically complex, requiring world-class manufacturing systems and meticulous data documentation at every stage.
Recognizing that real-time data intelligence could dramatically improve production performance and customer satisfaction, the organization partnered with Logesys to design and deploy a centralized, automated, and insight-driven analytics ecosystem.
Business Objectives
The project aimed to:
- Reinforce and optimize existing data pipelines for reliability and seamless integration.
- Eliminate dependence on manual MIS reporting and enable real-time performance tracking.
- Create a “Production Cockpit” with live visibility into Plan vs Actuals, Yield Analysis, and customer order tracking.
- Empower predictive and real-time decision-making through advanced Power BI dashboards.
- Standardize data flows across geographically dispersed manufacturing units using modern Azure services.
Scope of Work
Logesys designed a future-ready solution encompassing:
- Centralized Data Pipelines: Unifying data from multiple manufacturing units.
- Real-Time Data Ingestion & Transformation: Implemented using Azure Data Factory and SQL Database.
- Automated Dashboards & Reporting: Developed in Power BI for operational, planning, and forecasting insights.
- Predictive Analytics Capabilities: Enabling better production scheduling and resource allocation.
The solution was tailored to consolidate data from multiple control tables and operational databases into a single, reliable data warehouse — ensuring a single source of truth across all locations.
Challenges & Solutions
Challenge 1: Pipeline Failures and Data Loss
Legacy pipelines frequently failed, leading to delays and incomplete reports.
Solution: Strengthened pipeline architecture and implemented automation via Azure Data Factory, reducing dependency on manual intervention and ensuring high data reliability.
Challenge 2: Manual MIS & Inconsistent Reporting
Excel-based reporting slowed decision-making and introduced errors.
Solution: Migrated to automated, interactive dashboards in Power BI, delivering instant access to accurate performance data.
Challenge 3: Distributed Databases & Complex Integration
Multiple databases and inconsistent formats made consolidation difficult.
Solution: Designed a control-table-based ingestion strategy to standardize and integrate all operational data into the centralized SQL Database.
Challenge 4: Need for Real-Time Performance Metrics
Operational leaders lacked live visibility into production KPIs.
Solution: Built a Production Cockpit with real-time Plan vs Actuals, Yield, and order tracking — enabling rapid corrective action.
Technical Solution
- Azure Data Factory: For building, orchestrating, and automating pipelines between multiple manufacturing units.
- SQL Database: Centralized repository for all transactional and incremental manufacturing data.
- Power BI: For dynamic visualization, forecasting, and decision-support dashboards accessible across devices.
The system was designed to minimize latency, reduce data loss, and deliver near real-time insights for mission-critical operations.
Results
The transformation delivered measurable operational and strategic value:
- Robust Data Pipelines: Significantly improved reliability and timeliness of data updates.
- Advanced Reporting: Predictive analytics and real-time dashboards enhanced planning and resource optimization.
- Standardized Processes: Consistent KPIs and benchmarks across all manufacturing units.
- Real-Time Visibility: Instant access to production performance metrics accelerated decision-making.
- Reduced Manual Effort: Automated workflows freed up valuable resources.
- Improved Efficiency: Early detection and resolution of bottlenecks reduced downtime and waste.
- Cost & Time Savings: Better forecasting minimized excess inventory and quality issues.
Conclusion
Through the strategic implementation of Azure Data Factory, SQL Database, and Power BI, the manufacturing operation transitioned from fragmented, manual processes to a centralized, automated, and insight-driven architecture.
The result: enhanced production visibility, improved operational agility, and a strong foundation for future scalability and innovation in mission-critical PCBA manufacturing. With real-time insights now driving every decision, the organization is well-positioned to lead the next wave of growth in global electronics manufacturing.