IIOT – Transforming Manufacturing with Real-Time Data

A world-renowned pharmaceutical company sought to revolutionize its manufacturing processes by identifying product issues at the earliest possible stage.

Key challenges included:

• The excessive costs associated with fixing problems after distribution, which were significantly higher than fixing them during manufacturing
• The need to optimize waste and improve cost efficiency
• Managing over 30 manufacturing sites, each with 15,000 devices generating significant data throughput
• The need for continuous system operation and control
• Implement a machine learning (ML) model to consistently recommend optimal parameters

• Identify product problems early to avoid costly fixes after distribution
• Improve waste reduction strategies to reduce estimated costs
• Streamline the management of extensive device networks across multiple locations
• Ensure continuous system control and monitoring
• Leverage ML for continuous parameter optimization

C&F deployed a comprehensive IIOT data integration system, initially tailored for the US market and then replicated in the UK, Germany, Russia, Japan and Australia. The solution included:

• Azure IoT Edge with IoT Hub: This facilitated the collection and cloud transmission of data for immediate action, with pre-processing capabilities at the edge
• On-site action triggering
• Advanced logic enabled the system to initiate responses based on real-time data without human intervention
• Database Replication: A robust system that replicated data from local databases to the cloud, ensuring data consistency and availability

Strategic implementation led to breakthrough improvements:

• Real-time analytics: The system enabled near real-time processing and analysis of data, enabling immediate insights and automated actions
• Increased resilience: With offline support features such as a local event broker and stateful store, the system ensured consistent operations even during network disruptions
• Enhanced security: The unidirectional edge-to-cloud connection adhered to strict security protocols, essential in the sensitive pharmaceutical sector
• Operational Simplification: Centralized cloud management enabled streamlined operations, minimizing manual intervention
• Cost-effective model: Usage-based pricing and low onboarding costs provided an economically viable solution